SERVICE MANUAL Shampaine® 5100B/5100E Surgical Table Getinge/Castle, inc. 7371 East Spartan Boulevard North Charleston, SC 29418 Phone: (800) 638-2427 USA Fax: (843) 552-0348 se GE TINGE [ea‘SERVICE MANUAL 350520 | Rev. A (1/31/96) New Manual | @ Rev. B (10/15/96) Headrest revised pages ix, 1-6, 1-7, 1-11, 5-4 Rev C (5/20/97) Logo change Related Publications: Installation Instructions. 350551 Owner and Operator Manual 350519 . Parts Catalog 360552 Gil Ob PB ‘Shampaine is a registered trademark of Getinge/Castle, Inc. Copyright © 1996 by Gatinge/Castle, Inc. DESCRIPTION OF SYMBOLS & NOTES IN MANUAL. The following symbols with related notes appear in this manual. “Warning” notes alert the user fo the possiblity of personal injury. “Caution” notes alert the user to the possibilty of damage fo the equipment. “Notes” alert the user to pertinent facts and conaltions. Getinge/Castle, Inc. assumes no liabilly for table performance when used with accessories desig \ by others tor use on Shampaine equipment, or damage resulting to Shampaine equioment resutting {rom the use of accessories designed by others. This manual contains proprietary information of Getinge, Castle, Inc. It shall not be reproduced whole or in part without the written permission of Getinge/Castle, Inc.Table of Contents 1. General Information 4-1 General Description ie 13 41.1 Power Supply... er wee 1S 1.1.2 Floor Lock System Seer eeeees 16 4-1.3 Headrest 7 16 411.4 Accessories and Options 17 1-2 Dimensions : Sent = : 18 1-3 Control Pendant 19 4-4 Footswitch Control (Optional) : wat 4-5 Manual Pump and Auxiliary Pendant ..... see HAZ 4-6 Emergency Service Switch. . a ee 1414 2. Principles Of Operation 2-4 Hydraulic System 2.1.1 Table Functions ‘ 244.2 Table Locking System... 2.2 Electrical System : 2.2.1 Power Entry Assembly. 2.2.2 Low Voltage Box 3A 2.2.3 Pendant Box 48 2-2-4 Auxiliary Pendant 5A 2.2.8 Control Pendant 6A 2.2 Footswiten 7A 2-2.7 Sensor Board 8A 2.2.8 Leg and Back Sensors, 3. Service Data Hydraulic System Schematic Diagram ‘ 32 Hydraulic System Component Locations ...... ++ : 34 Electrical System Schematic Diagram on 342 Electrical Component Locations : Sea ats Control Board 3A1U Component Location ........0000++ 3:22 CPU Board 441U Component Locations 3-26 4, Maintenance 4-1 Cleaning... oe "1.4 Chvome-Plated and Stainless Steel Parts 41.2 Painted Surfaces 4-1.3 Control Pendant 4-1.4 Conductive Items. : 4-1.5 Leather and Canvas ItemsTable of Contents (continued) 4-2 Periodic Maintenance : Becca 44 4-2.1 PC. Board Handling... eae 24d 4-3 Service Access. 45 44 Inspection... 4-4.1 Electrical System (Visual Check) 4-4.2 Hydraulic System Check : i. 48 4-4.3 Flexible Hydraulic Lines te 168 4-44 Fasteners and Retaining Cips .... pues 445 Clamps and Accessories orcas 49 4-46 Structural Integrity of Table ae 4-4, Situational inspections 49 45 Hydraulic Fluid Level Check 410 4-6 Electrical Safety Check a and 4-6.1 Ground Continuity Check : ; 4-10 4-6.2 Leakage Current Check ee 410 4 lbleton cease crest ae att 4-7.1 Upper Pivot Points ite . 414 472 Elevate Ram... aie 4-7.8 Kidney Elevator and Hydraulic Cylinder Pivot Pine 412 4.7.4 Lower Fivot Points a 1413 4-8 Rsturo To Level Calibration oo... 0s. nee) 48,1 Level Check voecteseteeeees aia 4-8.2 Calibration a 144 4-9 Travel Speed Adjustment Beaute Hf . oe 415, 49.1 Tit Speed Adjustment foe tteeeenen 416 4-9.2 Function Travel Times... : 416 4-10 Floor Feet Adjustment... 417 5. Trouble Analysis 5-1 General Instructions... feet teense BB 5-2 Fuse Replacement ee 156 5-3 Service Incicator 57 5-4 Troubleshooting Charts ae 1510 5-4.1 Pump Motor - : 1510 5.4.2 Table Functions : Bat 5-4.3 Footswitch a : : 1844 ‘5-4.4 Auxiliary Control Pendant . Ht 5-15 S45 Batteres 0... ee 5-4\8 Floor Lock System. cnn : 517 5.4.7 Electrical System as 5-19 5-48 Hydraulic System... 15:20 350520)e Table of Contents (continued) 5-5 Circuit Board Checks ae 5-5.1 Control Board 3A1U : 5-5.2 CPU Board 4M1U 5-5.3 Pendant Board Stee ae 5.5.4 Sensors - : aes “531 5-55 Interlock Switches . eee . 5-31 : 6. Repair And Replacement 6-1 Electrical System Components ee 62 6-1.1 Power Entry Assembly... 62 6-1.2 Low Voltage Box Assembly See 62 64.8 Control PC Board SATU... : 63 6-1.4 CPU PC Board 4A1U 63 6-1.5 Sensors 63 641.6 Floor Lock Switch ...... a 64 6-17 Auxiliary Control Drawer interiock Sth ee 6-1.8 Auxiliary Control Pendant oe 165 6-9 Batteries... eee Paes 6-2 Hydraulic System Components... .eceesececees 66 62.1 Check Valve Gartridge : 168 @ 6-2.2 Solenoid Valves . Saisie 67 6.2.3 Flow Control VaNves ..-....ee0sces : 68 62.4 Filer Replacement. 63 6.2.5 Valve Manifold Replacement cy 6-266 Litt Column Replacement... ent 6.2.7 Lift Column Rebuilding 612 62.8 Hydraulic Hoses 16-15 6-2.9 Underside of the Base Assembly = 616 62.10 Power Unit (Motor, Pump and Reservoir Assembly) 22-617 6-2.11 Manual Pump = beer 618 6-2.12 Tit Cylinder Replacement 622 He 6-2.13 Trendelenburg Cylinder Replacement .. . is 6-22 6-2.14 Table Top Series Cylinders 16-24 6.2.18 Foot Jacks ae 628 . 6-3 Removing Air (Bleeding) the Hydraulic System 6-36 63.1 Valve Manifold... : eat eae 63.2 Main Litt : ee eee 6-36 : 6-3.3 Power Unit and Manual Pump He wees . 6-36 634 Filing Hydraulic Lines... eee aoe 63.5 Filing Hydraulic Cylinders =... ‘i : 637 6-3.6 Bleeding Hydraulic Cylinders. -..... Eee woe 687 360520 vwi Figure 1-1 Figure 1-2, Figure 1-3, Figure 1-4. Figure 1-6. Figure 1-6. Figure 1-7. Figure 1-8, Figure 1-9. Figure 1-10. Figure 2-1. Figure 2-2, Figure 2-3. Figure 3-1 Figure 3-2, Figure 3-3, Figure 3-4, Figure 3-5, Figure 3-6. Figure 4-1, Figure 4-2. Figure 4-3. Figure 4-4, Figure 4-5, Figure 4-6. Figure 4-7. Figure 4-8, Figure 4-9, Figure 4-10, Figure 4-11 Figure 5-1 Figure 5-2, Figure 5-3, List of Figures ‘Shampaine §100B/5100E Surgical Table Power Entry Module Headrest . Dimensional Outiine Control Pendant... . Footswitch Control Manual Pump Auxiliary Control Drawer Auxiliary Emergency Pendant Service Switch : Hydraulic System Operation Floor Lock System Electrical System Block Diagram Hydraulic System Schematic Diagram Hydraulic System Component Locations Electrical System Schematic Diagram Electrical Component Locations Control Board 3A1U Component Locations ‘CPU Board 4A1U Component Locations Location of Access Panels Removing Base Covers Hydraulic Fluid Check Upper Pivot Points Elevate Ram ......, Kicney Elevator Rack ee Lower Pivot Points—Tit and Trend Lower Pivot Points—Base Flow Control Valve Tilt Flow Control Valves Floor Feet Adjustment Fuse Locations Service Indicator Diagnostic Code Display a 1-2 15 16 18 19 142 1413 1.13 14 34 < 312 314 3-22 3:26 47 “47 4-10 at 42 412 413 2413 415 415 447 | 56 | 57 | 350520'|Figure 6-1 Figure 6-2. Figure 6-3, Figure 6-4. Figure 6-5. Figure 6 Figure 6-7, Figure 68, Figure 69, Figure 6-10. Figure 6-11. Figure 6-12 Figure 6-13, Figure 6-14 Figure 6-15. Figure 6-16. Figure 6-17, Figure 6-18. Figure 6-19, Figure 6-20, Figure 6-21 Figure 6-22. Figure 6-23. Figure 6-24, Figure 6-25. Figure 6-26, Figure 6-27. Figure 6-28 Figure 6-29 Figure 6-30. Figure 6-31 List of Figures (continued) Power Entry Module Removal Low Voltage Box Removal Battery Replacement Check Valves Solenoid Valves. Flow Control Valves Manifold Fiter Blocking Main Lift Blocking Titt Frame Valve Manifold Removal Hose Guide Bracket Lift Column Mounting Hardware tt Rebuilding Hydraulic Line Clamps Power Unit Removal ‘Manual Pump Removal Pressure Relief Valve Adjustment Manual Pump Suction Line Valve Block Subassembly Piston and Body Subassembly Manual Pump Repair Parts Titt and Trend Cylinders Tilt Frame Table Top Cylinders : Foot Jack Locking System... Foot-End Rod End Removing F2 Line for Filing. HO Cylinder Replacement & Balancing RH Cylinder Replacement & Balancing LH Cylinder Replacement. . Bleeding Cylinders. 610 en Gt os 615 617 618 619 2619 6-20 6-21 26-21 6-23 6-23 6-27 6-28 + 6-30 631 6-32 6-34 8-35—IMPORTANT— ‘SPECIAL SAFETY INSTRUCTIONS WEIGHT LIMIT This table has a patient iting capacity of 500 Ibs, (227 kg) and a patient articulation capacity of 400 Ibs. (181 kg). Do not exceed these maximum loads in service Overloading may result in tipping of the table or failure of the table sections to move. Note that some positions put additional restrictions on patient weight. This table is specifically designed for use only as specified in the operator manual. Accessories provided by Getinge/Castle, Inc. are designed to per- form safely with the patient loads for which this table was designed ACCESSORIES DESIGNED BY OTHERS Getinge/Castle, Ino. assumes no liability for table pertor- mance or damage to Shampaine equipment resulting ‘rom the use of accessories that are designed, built and sold by other companies for use on other tables. PINCH POINTS Due to the variety of table positions attainable with this table, pinch or crushing points exist. The OR staff must be trained to ensure that fingers, hands, feet, elbows and other body parts of patient or OR personnel are not inserted into pinch points when the table is operated, Severe cutting or crushing injury may occur if any part of a patient or OR staff ‘member isin a table pinch point when the table function movement is initiated. Damage to table or object may occur it any foreign object, accessory, clamp, etc. is in a table pinch point when a table function movement is initiated, Pinch points include, but are not limited to: + kidney elevator to seat channels + kidney elevator to seat top + kidney elevator to back section + back section to side shields * leg section to side shields + leg section to column shield ‘+ leg section to base cover ‘+ back section link to seat channel + column shields to base cover + side shields to column shields (in tit) + floor feet to base cover + floor feet to floor * base cover to tloor ‘reated by the attachment of accessories. Always c' ‘This list is not ail inclusive because pinch points a that the patient and staft are clear of pinch points befor and while the table is in motion.TECHNICAL DATA Electrical Power Requirements 115 VAC, 50/60 Hz, 4A, Single-Phase or 220 VAC, 50/60 Hz, 2A, Single-Phase Table Top Radiolucent and conductive panels conform to 21 CFR subchapter J Radiation Control for Health and Safety Act of 1968 Dimensions Length 72-1(2" (88-3/8" with removable leg extension) 3 1842 mm (2245 mm with removable leg extension) Width 19-9/4" (21-3/4" with side rails) '502 mm (552 mm with side rails) Height 28" to 43° (711 mm to 1092 mm) Weight Approximately 700 tbs (318 kg) Range of Motion Trandelenburg Up to 25" Reverse Trendelenburg Up to 25° Lateral Tit Up to 18° right or left Back Section Adjustable 30° below horizontal to 90° above horizontal Kidney Elevator Extendible up to 2-1/2" (64 mm) Leg Section Adjustable 95° below horizontal to 70° above horizontal Headrest ‘Adjustable from 120° below horizontal to 120° above in 15° increments @ —_cratusnal sie 8° (203 mm) total Table Movement Limits In addition to the specified limits above, interference will occur when certain functions are combined to position the table, Unless stated as software controlled, limits must be controlled by the operator, Position of Function Resulting Function Limit Full reverse Trendelenburg (25° | Titttimited to 10° right or let Full tit (18°) right or left Reverse Trendelenburg limited to 20° Back section up over 25° Kidney elevator cannot be operated : (software contrclled) Kidney elevator fully extended Back section limited to 25° elevation : (oftware controlled) ‘Slide fully toward head section and leg section down 95° | Reverse Trendelenburg limited to 5° ‘Specifications are subject to change without notice.SHAMPAINE 5100B/5100E SURGICAL TABLE 1. General Information 350520 Section 1 — General Information 4-1 General Description 1-1.1 Power Supply 1.1.2 Floor Lock System TAB Headrest 62... eee e eee 11.4 Accessories and Options - 1-2 Dimensions 4-3 Control Pendant. a 7 4-4 Footswitch Control (Optional) at 1-5 Manual Pump and Auxiliary Pendant is cones tA 4-6 Emergency Service Switch ‘ wee teSHAMPAINE 5100B/5100E SURGICAL TABLE 1. General Information maven ore ADEA noma: OngEATON NENCATOR sue sevesse ——] SUDE FORWARD wert ———T 2, ag Ge oney ur -———] ——~ ronev cow | ~~ erisx x ———] ‘wonas postion | __— reverse posmion rico Fees ee RADIOLUCENT LEG PENDANT KIDNEY Les. ‘SECTION BOX ELEVATOR SECTION EXTENSION | (OPPOSITE SIDE) / FOOISWITCH contro: RECEPTACLE ENDANT r POWER ENTRY RECEPIACLE ] MODULE ‘AUXIUARY, : ‘CONTROL DRAWER 49 MANUAL, 1-1, SHAMPAINE 5100B/5100E SURGICAL TABLE @ LEFT SIDE VIEWSHAMPAINE 5100B/5100E SURGICAL TABLE 1. General Information GENERAL INFORMATION 4-1 GENERAL DESCRIPTION POSSIBLE EXPLOSION HAZARD: DO NOT operate this table in the presence of flammable anesthetics. The Shampaine 5100B and 5100E are designed for use in non-hazardous anesthetizing Jocations, POSSIBILITY OF TIPPING: Overloading _may resull in tipping of the table or failure Of the table sections to move, DO NOT exceed these maximum loads in service: «+ Patient liting capacity is 500 tbs. (227 kg). This means the Table Up, Trendelenburg, and Reverse Tren: delenburg functions will operate with a ‘500 lb, patient positioned on the table. + Patient articulation capacity is 400 Ibs. (181 kg), This means that a 400 [b. patient can be moved into any of the standard procedural positions. * Section lift capacity of 300 Ibs. (136 kg) located 13 in. (330 mm) from the pivot point. This applies to both the Back Up and Leg Up function. ‘The Shampalne 51008 is a battery-powered, hydraul- cally-positiones, full-function major surgical table. The 51008 is a mains-powered (AC) table with backup bat- tery (for operation of the controls only) to be used with the manual foot pump. ‘Table positioning is controlled by eight solenoid valve ‘assemblies mounted in the base and operated by @ con- ‘rol pendant, See section 1-3 for a description of the ‘contro! pendant. Hydraulic pressure for the cylinders is provided by an electric motor-driven pump or a manual foot pump In addition to the standard table functions, the control pendant provides two special features: Retum to Level and Patient Orientation. The Return to Level feature automatically moves the table to a horizontal level posi tion, The Patient Orientation feature adjusts all tunctions relative to the patient's position on the table (normal or reversed), For safety, the START/STOP function on the control pendant must be pressed to activate the pendant before selecting a table function.SHAMPAINE 5100B/5100E SURGICAL TABLE 1. General information ‘The base is a steel-fabricated weldment fitted with stain- less steel upper base covers, a painted stee! iower base ‘cover, and telescoping stainless steel column shields, The tabletop consists of back, kidney, seat, and leg sec- tions. They are constructed of cast stainless steel chan- nels and electrically-conductive, X-ray permeable pan- els, The side rails are made of stainless steel, The head- rest and leg extension are also made from the same materials. The tabletop and leg extension are fabricated from a radiolucent, conductive material conforming to the Radiation Control for Health and Safety Act of 1968 (21 CFR Subchapter J). To prevent discoloring, this materi- al should be kept clean and dry. ‘lucent panels from nicks and scratches. Scratches more than .008 in. (127 microns) deep may appear on X-rays. Damaged or scratched panel should be replaced if X-ray quailty is affected. A ‘The tabletop and leg extension are fitted with a match- ing set of conductive, raciolucent pads which conform to NFPA 99. Veloro tapes hold the pads in place. If pad replacement becomes necessary, use Shampaine pads to ensure X-ray compatibility. Cleaning instructions are outlined on a tag attached to each pad. If the patient is reversed on the tabletop, the seatback section pad can be reversed to close the perineal cutout in the seat section end provide an opening for the secondary perineal cutout in the back section.‘SHAMPAINE 5100B/5100E SURGICAL TABLE 1. General Information 1-11 POWER SUPPLY This table does not have a mains switch: the ON/OFF switch disconnects the bat- tery and control circuits only. Disconnect power source at the appliance inlet or unplug the power cord. ‘The 5100B is powered by two series-connected 12 VDC, 24 Amp:Hour batteries, The table may be operat- ‘ed with or without the power cord connected to an AC outlet. The 8100E is mains-operated. The backup battery only provides power for the control pendant, control circuits and solenoid valves. If AC power is interrupted, the manual pump must be used to provide hydraulic power. * The green pilot lamp will be lit when AC power is pre~ sent, ‘The voltage selector allows the table to be operated from either a 115V or 230V power source. When selecting the line voltage, be sure the correct fuses are installed: 4 AMP for 115Y, 2 AMP for 230V. +The On/Off switch is used to disconnect the battery and control circuits. The On/Off switch must be ON (i) to recharge the batteries. Recharge the batteries at least ance a week (e.g., over a woekend or overnight). To prolong battery operation ite, turn OFF (0) the Or/Oft switch when not in use (except when recharging the batteries). ‘+The ground stud provides an equipotential grounding point. Se uence Fen se SAMA paupnse oan in FIGURE 1-2. POWER ENTRY MODULE 350520 15‘SHAMPAINE 5100B/5100E SURGICAL TABLE 1. General information 1-1.2 FLOOR LOCK SYSTEM ‘The floor lock system consists of three hydraulically- operated floor feet. The floor fest are controlled by the ‘control pendant. ‘The table functions will not operate unless the floor feet are extended (locked). When the feet are retracted, the table rests on four swivel casters. If electrical power is interrupted, the floor feet can be unlocked by pressing the FEET UNLOCK switch on the auxiliary pendant while operating the manual foot pump. See section 1-5 for auxiliary pen- dant operating procedure. 1-1.3 HEADREST The headrest is rated for a maximutn Joad of 100 ibs, This 100 tb. load must distributed over the first 6° of the haat rest (5° from pivol). if loaded at the of the headrest, the load must be | ‘creased so that the torque at the pil does not exceed 500 in-ibs. When moving the table, do not ay excessive force against the headragt Excessive force can damage the I ability of the headrest, which might re in patient injury. ‘The headrest can be installed at either end of the table. In the normal patient orientation, the headrest is installed at the end where the power entry module and ‘manual pump pedal are located. To remove the headrest, loosen the locking screws located on each side of the table on the underside of the ‘back section (or leg section). Slide the headrest out gt the dovetail slots. Reinstall the headrest in rever order. Back SECTION oe Locking SCREW FIGURE 1-3. HEADREST | 16SHAMPAINE 5100B/5100E SURGICAL TABLE 1. General Information Support the headrest while raising or lowering as it wil fall freely when the ratchet is released. ‘The headrest can be latched in any position from 120° below to 120° above horizontal in 15° increments. To raise it, pull on the lever located on the right rear side of the headrest. The ratchet will lock the assembly in the selected position when the lever is released. ‘To lower the headrest, release the ratchet by pulling out ‘on the release lever on the rear of the headrest 1-1.4 ACCESSORIES AND OPTIONS ‘See the Owner and Operator Manual for a description of the following accessory items: * radiolucent leg extension + Xray cassette holder * transfer support (optional) See section 1-4 for a description of the optional footswitch control.‘SHAMPAINE 5100B/5100E SURGICAL TABLE 1. General Information 1-2. DIMENSIONS Refer to Figure 1-4 for table dimensions. 72 -—— 829mm) Ww l. EG soar EXTENSION] 86" (2184) 2843" (711-1092men) FIGURE 1-4, DIMENSIONAL OUTLINE RIGHT SIDE VIEW'SHAMPAINE 5100B/5100E SURGICAL TABLE 1. General Information e 1-3. CONTROL PENDANT All table functions are controlled by a hand-held pen- dant. The floor feet must be locked to operate the pen dant functions. This ensures that the table will not roll while being positioned. ‘The control pendant plugs into the lett side of the recep: tacle box on the lift column shieid. eae pole a Los DRAWER OPEN INDICATOR NORMAL: ORIENTATION INDICATOR. BACK DOWN TABLE DOWN, e rrenoetensuRs ——] SLIDE REVERSE ———] TUT LEFT ————] KIONEY UP ———] FLEX RETURN TO LEVEL 7 NORMAL POSITION . UNLOCK FLOOR ———~] FEET START / STOP Before positioning the table, be sure the correct table orientation is selected (as indicated by the NORM or REV indi- cator). Improper orientation will result in reverse functioning and potential patient injury. __— TABLE UP INDICATOR REVERSE ORIENTATION INDICATOR LEG DOWN REVERSE ‘TRENDELENSURG SLIDE FORWARD ———— Tur RIGHT REFLEX REVERSE POSITION Lock FLOOR FEET BATTERY INDICATOR ‘ e FIGURE 1-5, CONTROL PENDANT 350520 19‘SHAMPAINE 5100B/5100E SURGICAL TABLE General Information CONTROL PENDANT INDICATORS DWR (yellow)—Auxiliary Control (auxiliary pendant) drawer is open. SERV (red)—Control malfunction. Use auxiliary pen- dant and manual foot pump to complete procedure, then call for service. NORM (green)—Normal patient orientation is select ed. In normal orientation, the patient's head is at the end of the table with the manual foot pump. REV (yollow)—Reverse patient orientation is select- ed. The back and leg, and trend and reverse trend funetions are reversed on the pendant. UNLOCK (yellow)—Floor feet are raised (table unlocked). LOCK (green}—Floor fest are lowered (table locked). Battery (5100B)—Iindicates status of battery: Green—Full charge. Pump motor is operational Yellow—Low charge. Pump motor is operational, but batteries should be charged at the first opportunity Red ((lashing)—Recharge battery. Pump motor is shut off and manual foot pump must be used. Red (steady}—Auxiliary pendant must be used. Recharge battery immediately! Battery (5100E) Indicates AC or battery operation: Green—AC power is present. Red (flashing}—Battery backup mode. Electric pump is shutoff and manual foot pump must be used, Red (steady)—Auxiliary pendant must be used. Recharge batteries immediately! Battery backup mode is intended for ‘emergency use only. Recharge the bat- teries after power is restored (51008). The battery sensing circuit has a built-in protection circuit that prevents the bat- tery from being fully discharged: If the red battery indicator goes off, plug the table into an AC outlet to recharge and reacti- vate the pendant. CONTROL PENDANT FUNCTIONS * Back Up/Back Down—Raises and lowers the be section, + Table Up/Table Down—Raises and lowers the & table top. + Leg Up/Leg Down-—Raises and lowers the leg sé tion. + TREND/REV TREND (Trendelenburg}—Tilts tt contire table top about the transverse axis. + SLIDE FORWARD/SLIDE REVERSE—Shifts th entire table top with respect to the lift column. | «TILT LEFT/TILT RIGHT—Tits the entire table top about the head to foot axis. + KIDNEY UP/KIDNEY DOWN—Raises and lowers the kidney elevator. + FLEX/REFLEX—Retlex combines the back up funo- tion with Trendelenburg to form a "V". Flex combines the back down function with reverse Trendelenturg to form an inverted *V" | + LEVEL—Moves the table back into a horizontal level position. + ORIENT TABLE—Selects normal (NORM) or reverse (REV) patient orientation, ‘+ FLOOR LOCK/UNLOCK—Raises (unlocks) or (locks) the floor feet. + START/STOP—Turns the control pendant on and off. The pendant will be backlit when activated. The pendant will automatically shut olf after 20 seconds if table function Is nai selected. OPERATING SEQUENCE 1. Press STARTISTOP to activate pendant 2, Press FLOOR LOCK to lower the floor feet. 3. Press ORIENT TABLE—NORM or REV to select patient orientation. | 4, Press and hold function key until table is in desired position, 5, Press LEVEL to return table to horizontal position.@ SHAMPAINE 5100B/5100E SURGICAL TABLE 1. General information 1-4 FOOTSWITCH CONTROL (Optional) POSSIBILITY OF INJURY: Improper ori- entation ofthe table may result in reverse functioning and cause patient injury Verify patient orientation (NORM or REV) ‘on control pendant before operating footswitch. PINCH POINT: A pinch point exists between the lowered leg section and the base cover when the table top is lowered, tilted right oF left, or moved in reverse Trendelenburg. Severe cutting or crushing injury may ‘occur ifa finger, toe, foot, ele. is caught in the pinch point when a table function is initiated. If fluid drainage is anticipated to come in contact with the footswitch, itis suggest fed that the footswitch be protected by enclosing it with a clear disposable footswitch bag (Cat. No. S-4005-FSB). Take care when using the tit function with the leg section in the down position {0 avoid colliding with the base cover. The footswitch control is used for OB/GYN, cystoscopy, and urologic endoscopic procedures where the surgeon |s seated at the pelvic end of the patient. FIGURE 1-6. FOOTSWITCH CONTROL Plug the footswitch control into the receptacle on the underside of the Pendant Box. (On the control pendant, select the desired orientation: normal or reverse (patient reversed on table with pelvis, located aver alternate perineal cutout in back section). ‘Once the correct orientation is selected, the TRENDE LENBURG footswitch will always lower the patient's head and the TILT LEFT/TILT RIGHT footswitch will move the table relative to the surgeon's left oF right. To operate the footswitch control, the fioor feet must be locked. To operate the table, select the desired function and direction of movement, and depress the appropriate side of the rocker switch. Depressing the opposite side of the rocker will reverse the direction of travel Releasing the rocker switch will stop table movement. Itis not necessary to remove the pendant contro! when operating the footswitch control ‘The footewitch will not operate if: ‘the batteries are iow, as indicated by the red battery indicator on the contro! pendant. the AUXILIARY CONTROL drawer is open. Operating the footswitch and contro! pen- dant simultaneously will not cause @ table maitunction, except that if opposing funetions (such as table up and table down) are actuated simultaneously, the first switch selected will override its oppo- site function. 950520 11‘SHAMPAINE 5100B/5100E SURGICAL TABLE 1. General Information 1-5 MANUAL PUMP AND AUXILIARY PENDANT ‘The foot-operated manual pump provides hydraulic power when the electric motor-driven pump is shut ‘down. The manual pump must be used when the the red battery indicator is lt or the auxiliary pendant is used, ‘The footswitch can also be operated with the manual Pump. To position the table, operate the footswitch in he normal way and have another person operate the manual pump pedal PEDAL RELEASE \ FIGURE 1-7. MANUAL PUMP ‘To operate the manual pump: 1 Pull the pedal out until it snaps into the extent position, For best results, depress the foot-operated pur pedal completely, making full stokes, atthe ratel pt about one stroke per second. WW To cetract the pedal inthe stored poston, moi tary ul down on the pedal relate, then push pecanSHAMPAINE 5100B/5100E SURGICAL TABLE 1. General Information The auxiliary pendant can be used if the main control Pendant becomes inoperative. The auxiliary pendant is located in a drawer, marked AUXILIARY CONTROL, on. the left side of tne base. To remove the auxiliary pen- ant, pull on the finger pull tab and slide the drawer open. FIGURE 1-8, AUXILIARY CONTROL DRAWER, When the auxiliary pendant is being used (drawer open), the main pendant will not function. ‘The auxiliary pendant is yellow to avoid confusion between it and the main control pendant. When the drawer is open, the control circuit automatically switch- es from the main control pendant to the auxiliary pen- dant, The auxiliary pendant bypasses the main control circuit and operates the hydraulic solenoid valves direct- ly from the batteries. Hydraulic power is supplied by the manual pump. The auxiliary pendant does not have the flex, reflex, or level functions. it does have the feet unlock function, which can be used to mobilize the table in the event ‘of a main pendant problem. “Toner ue IfS BI —aney sow money uP If Thr vert Tt ST ar rica tate ue — 118 TABLE DOWN tec UP tec Down sec vp——Ha Gt ——eack Down TREN NBURG —[7& EH—REVERSE TREND FEET UNLOCK 7 FIGURE 1-9, AUXILIARY PENDANT To position the table using the auxliary pendant: 1. Extend the manual pump pedal, 2. Remove the auxiliary pendant. 8. Press the desired function key while operating the manual pump, nore The auxiliary controt pendant will tune tion regardless of whether the fioor feet are locked or unlocked. If the floor feet are unlocked, the table may roll when the ‘manual pump is operated. The auxiliary pendant is hard-wired tor normal patient orientation. 360520 113SHAMPAINE 51008/5100E SURGICAL TABLE 1. General Information 1-6 EMERGENCY SERVICE SWITCH Asservice switch is located behind the base cover near the manual pump pedal. This three-position (Table Up/Olt/Feet Up) may be used in conjunction with the manual pump to unlock the floor feet or raise the litt ‘column when power is not available through the table's power supply. The service switch wires the battery directly to one of the hydraulic solencids. FIGURE 1-10. SERVICE SWITCH 2 hapten ihyartes—| 4, Release the momentary switch when the floor feet are retracted. To raise the itt column: 1, Extend the manual pump pedal 2. Hold the momentary switch in the right position 3, Pump the manual pump with your hand. 4, Release the momentary switch when the table top has been raised.SHAMPAINE 5100B/5100E SURGICAL TABLE 2. Principles of Operation Section 2 — Principles of Operation 2-1 Hydraulic System : cece 7 22 2-1.1 Table Functions . 22 2-1.2 Table Locking systern 22 . 2-2 Electrical System Bae 26 22.1 Power Entry Assembly 2A. eee . we BB 7 2-2.2 Low Voltage Box 3A . See eee a 2-2.3 Pendant Box 48 7 26 2:2.4 Auxiliary Pendant 5A cai seer 2 BS 2-2.5 Control Pendant 6A 7 26 2-2.6 Footswitch 7A, 7 . 7 26 2-2.7 Sensor Board 8A Saisie 26 2-2.8 Leg and Back Sensors freee pee 26SHAMPAINE 5100B/5100E SURGICAL TABLE 2. Principles of Operation PRINCIPLES OF OPERATION 2-1 HYDRAULIC SYSTEM See Figure 3-1 for hydraulic system schematic diagram. 24.1 TABLE FUNCTIONS POSSIBILITY OF INJURY: Keep the hydraulic system free trom contamina- tion. Patient or staff injury could result from hydraulic maifunetion. Hydraulic systems are extremely sensi- tive to particulate contamination. All ‘maintenance work requiring disassembly of the hydraulic system must be done in an area free from sources of contamina- tion. If allowed to enter the hydraulic sys~ tem, contaminates will cause maifunction of valves and flow controls. All hydraulic repair must be performed only by quali- fied, experienced technicians know!- edgeable in contamination prevention methods. The primary source of power is a hydraulic pump driven by an electric motor. A foot-operated pump is included for the backup system. ‘The valve manitold contains eight solencid valve assem- blies for controlling all functions of the table. Pressurized ‘olf enters the hydraulic manifold and is routed to sole noid vaives. The solenoid valves direct the oil to cylin- ders to obtain a selected table action. Cylinder movement Is controlled via two (one for ‘ft) plot-operated check vaives for each function. WI 1a function is selected, the pressure of the incoming) will open the check valves allowing oil to fiow into ‘out of the cylinder. At all other times the check valve are closed, thereby focking the cylinder(s) in position. ‘The hydraulic feet are locked in the same manner. Cylinder speed is controlled via variable flow contra} valves, 24.2 TABLE LOCKING SYSTEM The table is immobilized by three hydraulic cylinders that raise and lower the tloor lock feet. These cylinders are series-connected for synchronous movement of all three feet, Mechanisms are uliized to drive the two foot fend cylinders but the head end cylinder is attached directly to the foot. Extended and retracted positions of the floor lock feet are sensed electrically for control interlock and visual display purposes. ‘The floor lock system includes a pressure relief val This vale is set at the factory and should not requir adjustment unless it is disturbed. The relief valve is located on the hydraulic manifold and should be set for 2000 psi ‘The feet should extend or retract in 4 to 6 seconds. This travel rate can be adjusted if necessary (see section 4-9), | The floor lock system is ilustrated in Figure 2-2. |‘SHAMPAINE 5100B/5100E SURGICAL TABLE 2, Principles of Operation 5) VALVE 0 — sabmN Tice | ee | FLOORLOCK er | Semeins BATTERY. ‘CHARGING at OPERATION ee . FIGURE 2-3. ELECTRICAL SYSTEM BLOCK DIAGRAM 350520 27SHAMPAINE 5100B/5100E SURGICAL TABLE 2. Principles of Operation NOTES | eSHAMPAINE §100B/5100E SURGICAL TABLE 3. Service Data Section 3 — Service Data Figure 3-1. Hydraulic System Schematic Diagram ee 32 Figure 3-2. Hydraulic System Component Locations : a4 Figure 3-3. Electrical Schematic Diagram B12 Figure 3-4. Electrical Component Locations aa ceed Figure 3-5. Controt Board 3A1U Component Locations cee 3-22 7 Figure 3-6. CPU Board 4A1U Component Locations «2.2.2... 00eeee0+ 6-26 350520 34SHAMPAINE 5100B/5100E SURGICAL TABLE. 3. Service Data mae P< f. % IT 50 PSI | crackins | | ro [EE 1425 ps1 NOWINAL ee CONTROL MANIFOLD 1-2 Si CRACKING FIGURE 9-1, HYDRAULIC SYSTEM SCHEMATIC DIAGRAM (Sheet 1 of 2)SHAMPAINE 5100B/5100E SURGICAL TABLE 3. Service Data FORWARD SLIDE REVERSE TREND. ENDELENBURG i : \ TRENDELENBUR i L DENOTES LOWER t MANIFOLD FITTING TABLE SSSR e@ FIGURE 3-1. HYDRAULIC SYSTEM SCHEMATIC DIAGRAM (Sheet 2 of 2)‘SHAMPAINE 5100B/5100E SURGICAL TABLE 3. Service Data i BACK CYLINDER X Nt = — je * @ 4 KIDNEY ELEVATOR: LEG CYLINDER CYLINDER LEET_SIDE VIEW ORME HOSES ND MOST FING REMED FOR CLARET : ELECTRICAL ROUTING - RIGHT SIDE i | (Sheet 1 of 8) FIGURE 3-2. HYDRAULIC SYSTEM COMPONENT LOCATIONS. 9508‘SHAMPAINE 5100B/5100E SURGICAL TABLE 3. Service Data e LEFT SLIDE CYLINDER C L T a o i G : [i Til ° + t + 7 TILY/TREND EN: BACK POSITION ‘SENSOR | PC BOARD aes TILT CYLINDER _TRENDELENBURG CYLINDER LEG POSITION (HIDDEN) SENSOR i I RIGHT SLIDE 380620-L CYLINDER TOP VIEW HYDRAULIC HOSES Slide Forward © Back Cylinder crossover Slide Reverse D Right Slide Cylinder Leg Cylinder crossover E Left Slide Cylinder Kidney Cylinder crossover. F_~—_—Slide Cylinder crossover, . FIGURE 3-2. HYDRAULIC SYSTEM COMPONENT LOCATIONS. (Sheet 2 of 8) 950520 35‘SHAMPAINE 5100B/5100E SURGICAL TABLE 3. Service Data weos70-w WY VWiEW D~D HYDRAULIC HOSES 4 Leg Down A Leg Cylinder crossover 6 Back Down B Kidney Cylinder crossover 9 Slide Forward Back Cylinder crossover 11 Kidney Up FIGURE 3-2, HYDRAULIC SYSTEM COMPONENT LOCATIONS. (Sheet 3 of 8)‘SHAMPAINE 5100B/5100E SURGICAL TABLE 3. Service Data MEW A-A HYDRAULIC HOSES (See Sheet 8) 3 Leg Up A. Leg Cylinder crossover F1 Feet Up 5 Back Up B Kidney Cylinder crossover F2 Feet Down 10 Slide Reverse 12 Kidney Down C Back Cylinder crossover FH Head to R Foot crossover FC R Foot to L Foot crossover FIGURE 3-2, HYDRAULIC SYSTEM COMPONENT LOCATIONS (Sheet 4 of 8) 350520 a7IE 5100B/5100E SURGICAL TABLE Data (ene: A “Ti T fol Wr 4 | oz, \ VIEW B—B roux wos: coe | ead VIEW _C~C ro nw. vost 90 Sse Hee FRONT VIEW HYDRAULIC HOSES 4 Trendelenburg 9 Slide Forward 2 Reverse Trendelenburg 10 Slide Reverse 3 Leg Up 414 Kidney Up 4 Leg Down 42 Kidney Down 5 BackUp 43 TiltRight | 6 Back Down 14 TitLett : FIGURE 3-2. HYDRAULIC SYSTEM COMPONENT LOCATIONS (Sheet 5 of 8) 2 =SHAMPAINE 5100B/5100E SURGICAL TABLE ISE BOXES REMOVED i LARITY 3. Service Data HYDRAULIC HOSES 4 Trendelenburg 2 Reverse Trendelenburg 3 LegUp 4 Leg Down 5 Back Up 6 Back Down 9 Slide Forward 10 Slide Reverse 11 Kidney Up 12 Kidney Down 43° Tilt Right 14 TitLett FIGURE 3-2. HYDRAULIC SYSTEM COMPONENT LOCATIONS (Sheet 6 of 8) 950520SHAMPAINE 5100B/5100E SURGICAL TABLE 3. Service Data ONTROL ‘eon Poor MANUAL PUM ce Ly ue uM MANIFOLD: CYUNDER \ | rower | UNIT (PuMP,woroR! AND RESRVOIR) x PUMP PRESSURE LINE TO 1AIPS To 3AiuIP? TO SA1UIP6 _DETAIL °F-F” 2A25 » ” DETAIL “E-E 2AGND e 1a1d— PUMP AND BarrenY sarutP — CONTROL PC BOARD PIN [FUNCTION PIN [FUNCTION 1 Pump Voltage 1 Battery Charge 2 __ | Battery Voltage (switched) 2___ [No connection 3 Battery Sense 3 [Pump 4 __ [Battery Sense 2A1J — LOW VOLTAGE BOX 5__ | Solenoid Power PIN [FUNCTION 6 Controls Power 1 ‘RAAT Primary (L1) 7 ‘Auxiliary Pendant Power (fused) 2__[2AtT Primary (Selector 18-2) | Auxiliary Pendant Power 3__[2AiT Primary (Selector 18-3) 9 | Solenotd Power (tused) 4_ | 2aiT Primary (12) 5 | Ground : 6 | Ground e@ FIGURE 2-4, ELECTRICAL COMPONENT LOCATIONS. (Sheet 4 of 8) 350520 a7SHAMPAINE 5100B/5100E SURGICAL TABLE 3. Service Data cout. || aus So 8 rar FIGURE 3-4, ELECTRICAL COMPONENT LOCATIONS. (Sheet 5 of 8)SHAMPAINE 5100B/5100E SURGICAL TABLE 3. Service Data ne view "BB © (To POWER ENTRY BOX, 2AiP) FROW SA1U6P1 = FROM SAIUGPS 2 FROM 2AITRED FRow sarusPa — FROM SaGNO FROM SATTRED 2 FROM SatUeP3 — pera e “sac, 2A1P — POWER ENTRY ASSEMBLY 3A1U6P — CONTROL BOARD PIN FUNCTION PIN FUNCTION 1 2A1T Primary (L1) 1 Ground 2 2A1T Primary (Selector 1 $-2) 2 Charge Relay (2K-O) 3 BAIT Primary (Selector 1 $-3) 3 Charge Relay (2K-NO) 4 ‘ANT Primary (L2) 4 Act 5 Ground 5 Ace 6 Ground 6 Charge Relay (2K-NC) 115V: Terminals 1-2, 3 -4 connected 2K-NO: Fast charge via 17 nore] 290 Terinas 2-9 connected Nor 2K-NC: Siow charge via R15 e@ FIGURE 3-4, ELECTRICAL COMPONENT LOCATIONS (Sheet 6 of 8) 350520 319‘SHAMPAINE 5100B/5100E SURGICAL TABLE 3. Service Data ELECTRICAL ROUTING - RIGHT SIDE (OR NOSES MO MOET Fas OED FoR LARTH et BAT FoR ALC ROWTM) FIGURE 3-4. ELECTRICAL COMPONENT LOCATIONS (Sheet 7 of 8) 3-20 0520SHAMPAINE 5100B/5100E SURGICAL TABLE 3. Service Data A rocru pss omh nf. Other Hydraulic (O} ose DOO eres: | TO 3AlU4P sae 60 pee (4.0) emoved Head of Table. o = A ©) : ‘Tie-Wraps verano Somat To 4atuaP @ FIGURE 3-4, ELECTRICAL COMPONENT LOCATIONS. (Sheet 8 of 8) 350520SHAMPAINE 5100B/5100E SURGICAL TABLE 3. Service Data AUXILIARY PENDANT PENDANT BOX 2 FLOOR LOCK AND AURILIARY. CONTROL Is AND, BATTERY PUMP vt CHARGER 6. n eee) esp ss0s000 3A1U6P/J6 — POWER SUPPLY AND. 3A1UP/J1 — BATTERY AND PUMP BATTERY CHARGER PIN [FUNCTION PIN [FUNCTION 1 Battery Charging Voltage 1 Ground 2 No connection 2 Charge Relay 2K-C 3 Pump 3 Charge Relay 2K-NO | 4 Battery Sense Voltage 4 ACI ui 5 Solenoid Power 5 AC2 lB 6 Controls Power 6 Charge Relay 2K-NC 7 Emergency Pendant Power (fused) + 8 Emergency Pendant Power 9 Solenoid Power (fused) | FIGURE 3-5. CONTROL BOARD 3A1U COMPONENT LOCATIONS 322 35052 e' ee | ae‘SHAMPAINE 5100B/5100E SURGICAL TABLE 3, Service Data 3A1U2P/J2 — EMERGENCY PENDANT 3A1U3P/J3 — SOLENOIDS PIN _| FUNCTION PIN | FUNCTION 1 Trendelenburg 1 Trendelenburg 2 Reverse Trendelenburg 2 Reverse Trendelenburg 3 Leg Up 3 Leg Up 4 Leg Down 4 Leg Down 5 Back Up 5 Back Up 6 Back Down 6 Back Down i Table Up 7 Table Up 8 Table Down 8 Table Down 9 Slide Forward 9 Slide Forward 70 | Slide Reverse 10 _| Slide Reverse 4 iney Up 1 Kidney Up. 12___[ Kidney Down) 12___[ Kidney Down 73__[TiltRight 13__[ Tilt Right 14__| TiltLett 14 ___| TiltLott 15 Interlock 15 Feet Up 16___[ Feet Up 16 | Feet Down 7 Ground 18 [ No connection 3A1U4P — PENDANT BOX PIN _| FUNCTION 1 Ground S3A1USP/J5 — FLOOR LOCK AND 2 Ground AUXILIARY CONTROL SWITCHES 3 +12V PIN | FUNCTION 4 SCLK 1 ‘Aux Control Interlock © S$ MOS! 2 ‘Aux Control Interlock NO 6 MISO 3 ‘Aux Control Interlock NC is Enable 4 Floor Lock NO 8 Battery Status 5 No connection é Floor Lock C 350520 3-23‘SHAMPAINE 5100B/5100E SURGICAL TABLE 3. Service Data Function Priority e When a function is selected (either by pressing START/STOP then the function key on the pendant, or pressing function switch on footswitch), that function has. priority over any other function with which it conticts. ‘Two functions which are independent in operation may be operated simultaneously by pressing START/STOP, then the functions desired, FUNCTION CONFLICTING FUNCTION | Table Up Table Down Back Up Back Down Back Up (normal orientation) Kidney Up Leg Up (normal orientation) Kidney Up Leg Up Leg Down Trendelenburg Reverse Trendelenburg Kidney Up Kidney Down Flex Reflex Kidney Up Reflex 1 @ Slide Forward Slide Reverse Floor Lock Floor UnlockSHAMPAINE 5100B/5100E SURGICAL TABLE 3. Service Data NOTES 350520 3-25SHAMPAINE 51008/5100E SURGICAL TABLE 3. Service Data st 000000) [oooccc0n 9 afo-aB-o HI ol zo fH] 122-0 ks 60-0 DIAGNOSTIC ‘CODE DISPLAY ost 2 a 1] o-oo g Ve ©. o —E + ot Eel] 3 o> 0-0 8S g ole 5 2\s 516 a ols ge & §€ Sls [5 get 8 2) Blslelelsl? ae 0000000 9} Slalsjmlels a 90000000 2 5/8) a/3\°/2 oc & bl Z18/e)22)ydraultc tines and result in faite of the hydraulic system. DO NOT attempt to clean this table in automatic cart washing equioment. Use of high pressure water guns could lead to an electrical malfunction and must be avoided, The use of quaternary-type disinfectants without immediate rinsing may result, alter an extended period of time, in cor. rosion of painted and plated table com- ponents. Rinse all surlaces which come ‘into contact with this type of disinfectant 4-11 CHROME-PLATED AND STAINLESS STEEL PARTS Use of iodophors wil cause staining. Failure to thoroughly dry surfaces after cleaning and disinfecting may result in staining. Chrome-plated and stainless steel parts should be wiped weekly with a clean, damp cloth. When cleaning stainless steel, never wipe the material ina circular motion. Always make the cleaning strokes in the same straight direction as the grain of the metal ‘After cleaning, the surface should be rinsed with clean water and dried, Strong bleaches and disinfectants that are left on the ‘material for prolonged periods may corrode or pit the surface ofthe metal The best clearing agent for stain} less steel Is a mild detergent It stubborn stains persist, they should be removed with ‘@ mild cleanser such as Bon-Ami, or a non-chlorinated, non-abrasive cleanser. Rub in the direction of the grain. Exterior surfaces should be regularly wiped clean with mild detergent solution and wiped dry with a soft, lint free cloth, | Care should be taken to avoid exposing the table ta excessive moisture. Flooding, fogging, or steam clean- ing is not recommended, Plaster, blood, etc.,if allowed to remain on the table for a long period of time, will require special cleaning to ba removed. A 5% acetic acid solution or white vinegar ig especially good. i Stahinganaszlraon of aig can b cored) cleaning with a good commercial coloring compound, such as Acme White tinh, and then butfing the surface by hand. Frequent application of paste wax will maintain the appearance and resist stains To disinfect exterior surfaces, use a quaternary ammo: niuin or similar type disinfectant compound according t the manufacturer's directions for use. Rinse with wate and wipe dry with a soft lint-free cloth. 4-1.2 PAINTED SURFACES Painted surfaces should be wiped weekly with a damp, clean, soft cloth and frequently washed with a mild and water solution to remove persistent staina| Application of paste wax will reduce staining and he preserve the surface luster. Harsh cleansing powd should not be used on painted surtaces. 3508SHAMPAINE 5100B/5100E SURGICAL TABLE 4. Maintenance Ce 4-1.3. CONTROL PENDANT Clean with Formula 409 or equivalent cleaner. Do not use solvents or keypad graphics and case may be dam- aged. 4-1.4 CONDUCTIVE ITEMS Conductive cushions, pads, wristlets, and belts can be kept clean by washing, immediately ater staining, with mild soap suds. If stains are persistent, the use of a soft- bristled brush with mild soap suds or detergents will usually remove the siain. It is important that stains be removed as soon as possible, The cushions and other accessories must be clean in order to maintain conduc- tivity 4-1.5 LEATHER AND CANVAS ITEMS Leather goods may be washed with mild soap and water followed by an occasional application of Neatsfoot oil or ‘saddle soap to keep the leather soft and pliable. Canvas straps may be scrubbed with a soft-bristled brush and detergents or washed in an automatic washer. 350520 43SHAMPAINE 5100B/5100E SURGICAL TABLE 4, Maintenance 4-2 PERIODIC MAINTENANCE Regularly scheduled preventive maintenance and inspection is essential for continued reliable operation, The following schedule lists the minimum requirements to maintain the table in a serviceable condition, Consult NFPA 99—Health Care Facilities for more detailed information covering suggested test methods. A. leakage current meter and a power cord resistance tester are required to perform any electrical repairs or maintenance checks. Test equipment designed specifically for conducting these tests is available from domestic manufacturers, ‘The use of such equipment is essential to ensure per- sonal safety and reliable test results ELECTRICAL HAZARD: Instructions provided with test equioment must be fol lowed exactly or an electrical safety haz- ard to personnel or patients could result a 4-2.1 P.C. BOARD HANDLING \ The table contains printed circuit boards that should ‘not be handled without proper grounding with an ESD wriststrap. The user must be connected via the wrist strap to earth ground prior to any maintenance actions that involve P.C. boards. A wriststrap with @ 10 meg chm protective resistor is recommended. Table 4-1. RECOMMENDED MAINTENANCE SCHEDULE (Tem NORMAL PERIOD PROCEDURE (see Section No.) Inspection: 1. Electrical safety (visual check) | Monthly aad 2. Hydraulic system operation Quarterly 442 3. Flexible hydraulic lines Annually 443 | 4, Fasteners and retaining clips Annually 444 5, Clamps and accessories Annually 445 6. Structural integrity of table Annually 446 7. Situational As required 447 Hydraulic Fluid Level ‘Semi-annually, or whenever 45 leakage Is suspected or ‘components have been replaced. Electrical Safety 4. Ground continuity ‘Semi-annually 4-6.1 and NFPA 99 2. Leakage current ‘Semi-annually 4-6.2 and NFPA 99 Lubrication: 1. Upper pivot points, Quarterly ATA 2 Elevate ram Quarterly 472 3. Lower pivot points Semi-annually 474 4, Kidney elevator Annually 473 . ‘Component Replacement: 1. Batteries Expected battery ite is greater 619 than § years 2. Valve manifold filter Every 5 years 623 44‘SHAMPAINE 5100B/5100E SURGICAL TABLE 4. Maintenance e 4-3 SERVICE ACCESS Table 4-2. SERVICE ACCESS (Refer to Figures 4-1 and 4-2) ‘ACCESS AREA COMPONENTS EXPOSED REMOVAL METHOD Lateral fairing Hoses Remove screws, then lift and pull lateral fairing. Fitting on slide cylinders Lett inner and outer fairing. | Left leg cylinder and track cap screws | Remove screws and rotate ‘outer fairing upward and put! out Left back cylinder and track cap screws | Pull inner fairing down and out. Lett kidney elevator mechanism and cylinder Hoses Right inner and outer fairing | Right leg cylinder and track cap screws | Remove screws and rotate outer fairing upward and pull out. Leg position sensor cable Pull inner fairing down and out. Right back cylinder and track cap screws e Back position sensor cable Right kidney elevator mechanism and cylinder Kidney elevator switch Hoses Seat pane! Lateral firing and tit frame cover areas | Pry out plugs. Remove fasteners and panel. NOTE: New plugs (Fart No. 8062200) may be required. Tit frame cover Hose coils, See also “Flexible Bellows” Tit cylinder Remove screws, then pull tit frame ‘cover toward head end, away from od end of Trendelenburg cylinder angle to free clips. Main pivot assemblies for tit and Trendelenburg Leg and back position sensors e ae 350520 454, Maintenance ‘SHAMPAINE 5100B/5100E SURGICAL TABLE Table 4-2. SERVICE ACCESS (Refer to Figures 4-1 and 4-2) ACCESS AREA COMPONENTS EXPOSED REMOVAL METHOD Column fairing doors and shields Trendelenburg cylinder Hose boxes Lift column Removal of outer shield frees bottom of flexible bellows. Allows removal of base cover Outer Door: Remove screws and bars and spacer. Pull door down to free clips. Intermediate Door: Remove screws, pull door up to free clips. Inner Door: Remove screws, pull door up to free clips. Remove screws to free other column fairings. Flexible bellows Provides more access to tilt cylinder for removal, etc. Hoses Remove door, then screws and bars and fairing. Raise lower ‘edge of bellows. The bellows cannot be removed from the table, Upper base cover Power unit (electric motor, pump and reservoir assembly) Power entry assembly Low voltage box assembly ‘Solenoid valve manifold Hydraulic hoses and connections Floor lock system and floor feet Manual pump Remove screws at bottom of inner ‘column fairing and door. Remove screws on side of base cover. Lift up fairing and slide half of base cover toward head end of table, the other half toward foot of table,SHAMPAINE 5100B/5100E SURGICAL TABLE 4, Maintenance e LATERAL FARING a ant erteane oven th tannin Se FLEXIBLE ~ any pe poon ait: BASE COVER AND SHIELDS @PIECES) e FIGURE 4-1, LOCATION OF ACCESS PANELS, RIGHT SIDE OF TABLE we, _—'NNE® COLUMN FAIRING E COVER (FOOT END) “STEP (1) @ FIGURE 4-2. REMOVING BASE COVER, 950520 47‘SHAMPAINE 5100B/5100E SURGICAL TABLE 4, Maintenance 4-4 INSPECTION 4-41 ELECTRICAL SYSTEM {Visual Check) Conduct a monthly visual inspection to ensure the phys- ical integrity of the control pendant, footswitch, pendant cord and plug, power cord and attachment plug. Any damage to these components requires replacement before further use. 4-4.2, HYDRAULIC SYSTEM CHECK ‘This inspection can be conducted in conjunction with lubrication of pivot points. 1. Operate each table function to ensure that it will per- form to specifications. 2. Check for functions that bind or do not operate in a ‘smooth manner, components that drift after position- ing, or components that operate when that funetion is not selected. 3. Consult the troubleshooting chart (see section 5) to determine the cause of any malfunction detected. 4. Check leg and back position sensor cables for secure mechanical connection and centering on cylinders. 4-4.3 FLEXIBLE HYDRAULIC LINES da ‘This inspection can be conducted in conjunction with lubrication of the kidney elevator mechanism. POSSIBILITY OF INJURY: The use of unauthorized substitute materials or pro- cedures could result in the impairment of the safety or reliabiliy of the table and the possibilty of injury to personnel or patients, Any hydraulic fine found to be damaged in any way must be replaced. Replacements must be completed in strict compliance with the requirements of Figure 3-2, 41. Remove inner and outer right- and left-hand fairings and lateral faitings. 2. Lower upper and intermediate column shields, hose ox covers, and tilt frame cover. 3, Inspect each hydraulic line for abrasions, interference with other components, proper attachment and rout ing (see Figure 3-2) and for leakage. Any interter- ences or other sources of abrasion must be eliminat- ed. Check each line for any nicks, blisters, distortion, Jacket abrasion, or other damage. Ater three years of service and every three years there- after, itis recommended that a more searching inspec- tion be made of the hydraulic system components 0 include disassembly and inspection of any component which appears to have deteriorated in performance oF reliability during the time in service. 4-4.4 FASTENERS AND RETAINING CLIPS This inspection can be conducted in conjunction with the inspection of flexible hydraulic lines. 1. Remove inner and outer right- and left-hand fairings. 2. Lower upper and intermediate column shields. 8. Check that the following fasteners and retainers are in place and securely tightened: a. Caster to base cap screws (under table). b. Head-end floor foot cylinder aitachment screws (2), | ¢. Foot-end floor foot cylinder pivot screws (2), roq ‘end pins (2), and linkage screws (4). 0. Adjustable feet and set screws €. Motor mounting bots. {. Manual pump mounting bolts (3). pedal bolts (2) ump linkage set screw and trunnion bar screws 2) 9. Column to base bolts. hh. Column to main support plate cap screws. 1. Trendelenburg eylinder mounting block to. main support plate cap screws. * Titt cylinder mounting angle to tit frame “| screws. k. Column key retaining screws. |. Cylinder roller track to Hrame cap screws (4 places), i 48 o 350520)‘SHAMPAINE 5100B/5100E SURGICAL TABLE ‘4. Maintenance 1m.Cylinder anchor 1 Htrame cap screws. 1, Tilt pivot to tit frame roll pin ©, Trendelenburg pivot pin lock nut p. Tilt oylinder clevis bot 4, Trendelenburg cylinder clevis bot f. Siderail to side channel attachment cap screws (all sections). s. Top to siderail cap screws (all sections) 1. Seat section to H frame cap screws, U, Block and shaft assembly to H frame cap screws. \, Back ang leg sections clevis pin set screws. 4-45 CLAMPS AND ACCESSORIES Annually inspect siderail clamps and accessories for wear, deformation, deterioration or any other damage which could impair their functions. 4. Make certain that all clamps can be securely tight- ened and will hold attachments reliably. 2. Check that teeth on clamps with adjustable positions are inact and will prevent rotation of accessories which are intended for use with them, 3. Inspect threaded parts for damage, burrs or evidence of stripping, 4-4.6 STRUCTURAL INTEGRITY OF TABLE 1. Check the structural components of the table for signs of damage, fallure or fatigue. 2. Inspect castings for cracks, especially in areas around bolt circles, clevis pins, intersections and webs. 3, Inspect structural welds on the H frame and tit frame for cracks, separation or rust. 4. Check radiolucent panels for cracks, especially around fasteners. 5, Test headrest locking mechanism and check for signs. of contamination 4-4.7 SITUATIONAL INSPECTIONS Situational inspections should be conducted immediate- ly whenever any of the following occurs: POSSIBILITY OF INJURY: Do not use an apparently damaged table. The table ‘must fee taken out of service and the cause of the maifunction determined and corrected before further use. 1. An oll leak is observes. 2. There is a noticeable change or degradation in table or accessory performance (e.g., no movement, drit- ing). 3. There is an unusual noise during table operation. 950520 49SHAMPAINE 51008/5100E SURGICAL TABLE 4. Maintenance 4-5 HYDRAULIC FLUID LEVEL CHECK ‘The pump and cylinders do not require lubrication due to the self-lubricating qualities of the hydraulic fluid. The enclosed reservoir design eliminates the need for changing fluid. Check fluid level semi-annually as follows: 1. Remove base cover and reservoir cap, 2. Lower table to minimum height of 28" (711 mm). 3. Visually check fluid level. Fluid fevel should be approximately 3/4'-1* below the top of reservoir with lit in lowest position. 4, Itnecessary, add Shampaine hydraulic fluid (Part No, ‘A032384) unti fluid level reaches the correct level, POSSIBILITY OF INJURY: Use of substi- lute hydraulic fluids may damage compo- BNING] nents or cause injury due to component failure, restavoR = FIGURE 4-3, HYDRAULIC FLUID CHECK 4-6 ELECTRICAL SAFETY CHECK Conduct regularly scheduled maintenance and safety Inspections to ensure that damage has not occurred ‘which would render the equipment electrically unsafe, Due to the impacts and abuse to which heavy equip: ment s subject during shipping, the tests outlined below must be performed prior to placing the equipment int) service. ‘The ground continuity and leakage current should be checked semi-annually 4-61. GROUND CONTINUITY CHECK Check the ground continuity between exposed exterior conductive surfaces of the table and the ground pin of the attachment plug. The resistance should not exceed 0.10 ohms, Tables are checked during manufacture to ensure thal this resistance is 0.1 ohm or less. The radiotransiucent top and pads, although conductive, have much higher resistance values and should not bd Included in this check. ' 4-6.2, LEAKAGE CURRENT CHECK Check the leakage current with the table connected to @ ground receptacle of known value. Leakage current Should be measured with the table grounded and with the ground connection open. The maximum allowable leakage current is 100 yA. i Tables ate inspected during manufacture to ensu leakage current values of 90 WA or less with an ope ‘ground and reversed polarity. Leakage current shot be nearly zero (not more than 5 yA) with the ground Connected in operating and non-operating modes. 4-10‘SHAMPAINE 5100B/5100E SURGICAL TABLE 4. Maintenance 4-7 LUBRICATION 4-7.1 UPPER PIVOT POINTS 1, Raise back and leg sections to maximum elevation. 2. Lubricate upperback and leg link clevises, hydraulic cylinder roller and clevises, and section pivot points with several drops of light machine oil. All of these points will be accessible with the sections raised fully. 3. Lubricate slide cylinder clevis pins and back and leg section hinge pins. 4, Cycle each section several times to distribute the lubricant, I the pivots are contaminated and gummed up, the mechanism should be NoTEP>] Gisassembles, cleaned and reassem- bied using Lubripiate_anti-corrosive grease #107, Getinge/Castle Part No. 302841, 350389-T FIGURE 4-4. UPPER PIVOT POINTS 350520 att‘SHAMPAINE 5100B/5100E SURGICAL TABLE 4, Maintenance 4-7.2 ELEVATE RAM +. Remove the upper and intermediate and lower col umn shield screws. 2. Lower the shields. 3, Extend the iit to the maximum height, 4. Apply grease (Getinge/Castle, Inc. Part No. RO36137, ‘or Amoco No. 2EP) where the rams telescope into the oylinders. Coat the cylinders. 5. Cycle the ram several times to distribute the lubricant. 6. Lightly coat the telescoping suriaces and keyways with a thin coat of grease. 7. Cycle the ram again several times. 8, Reinstall the column shields. 350589-¥ FIGURE 4-5, ELEVATE RAM LUBRICATION 4-7.3 KIDNEY ELEVATOR AND HYDRAULIC CYLINDER PIVOT PINS 1, Remove inner and outer right- and left-hand fairings. 2. Lubricate the exposed rack teeth and horizontal and vertical surtaces of the racks with Lubriplate #107. 3. Lubricate inner and outer rack pinion bushings = 3 If the mechanism is contaminated or gummed up, it should be disassem! Cleaned, and reassembled usi Lubriplate anti-corrosive grease #1 Getinge/Castle Part No. 302841. Kidney elevator hydraulic cylinder clevis pins with eral drops of light machine oil. 4, Raise the kidney elevator to expose any area of rack which was inaccessible at step 2, and lubricate these areas of the rack. 5. Cycle the kidney elevator several times to distribute the lubricant. 6. Lubricate the pivot pins at the fixed ends of hydraulic cylinder with several drops of light machi cil. (A total of eight places.) 7. Reinstall inner and outer right- and left-hand fairings. KIDNEY ELEVATOR RACK INSIDE. GEAR BLOCK OUTSIDE GEAR | BLOCK | (2 | LEG 350389-H1 CYLINDER FIGURE 4-6. KIDNEY ELEVATOR RACK‘SHAMPAINE 5100B/5100E SURGICAL TABLE 4. Maintenance 4-7.4 LOWER PIVOT POINTS 1. Use slide function to move tabletop toward leg end as far as possible. Raise back and leg section to ‘maximum elevation. 2. Remove the two-piece tit frame cover (see section 4-3), 3. The tit and Trendelenburg pivots are lubricated through oil passages drilled through the top of the tit frame over each pivot pin. Lubricate with light machine oil 4, Lubricate Trendelenburg and tilt cylinder clevis and ‘trunnions with light machine oil. HOSE CROSSOVER "AREA mr cvuNDER TREND — GYLINDER FIGURE 4-7. LOWER PIVOT POINTS — TILT AND TREND. 5. Cycle both functions independently to distribute lubricant, 6. Lubricate the hose crossover area with 2EP Grease, Part No. R036137. 7. Remove the intermediate and lower column shields and remove the base cover. 8. Inthe base locking mechanism, lubricate all linkage pivots with several drops of light machine cil 9. Lubricate all pedal and linkage pivots in the manual pump with several drops of light machine ol. 10. Lubricate the manual pump spring with 2EP. Grease, Part No. R036137. 11. Cycle each mechanism to distribute the lubricant, 350380-¥ FIGURE 4-8, LOWER PIVOT POINTS — BASE 350520 43.‘SHAMPAINE 5100B/5100E SURGICAL TABLE 4, Maintenance 4-8 RETURN TO LEVEL CALIBRATION 4-8.1 LEVEL CHECK 1, Raise the kidney elevator. 2, Raise the back section. 3. Press the LEVEL function on the contro! pendant, Verity that the kidney lowers, followed by the back section returning to the horizontal position, 4. Repeat steps 1 and 2 for Back Down, Leg Up, Leg Down, Trendelenburg, Reverse Trendelenburg, Tilt Left and Tilt Right 5. Using a level, check the table for levelness from head to foot, 6. Check the table for levelness from side to side. 7. If table is not level in either direction, proceed with calibration, 4-8.2 CALIBRATION When making fine adjustments, use the. auxiliary control pendant and manuat foot pump for more precise control 1. Verity the kidney elevator is fully down, 2. Verity the back and leg sections are even with the ‘seat section. | fcr eg # poet sons table top should be resting flat on each of the three sections (back, seat, and leg). 3, Using an angle-finder level, check the table for lever ness from head to foot. Reposition the Trendelenburg function if necessary, 4. Check the table for levelness from side to side,| Reposition the tit function as necessary. 5. Repeat steps 3 and 4 to ensure the table is level with+ in 1 degree of horizontal in both directions. 6. Check the leg and back sections for levelness. The leg and back sections should be within 1 degree of horizontal with respect to the seat section. Reposition as necessary. 7. Remove the cover from the Pendant Box Assembly 8. Press and hold (for 1 second) switch S1 on the CPU Board. The current position of the table sections will be stored in memory. 9. Check the calibration by raising and lowering individ- ual table sections, then pressing LEVEL to return the table to the horizontal position. Recheck table with a level Specttication is =1° with respect to cali- brated level position. ana‘SHAMPAINE 5100B/5100E SURGICAL TABLE 4, Maintenance 4-9 TRAVEL SPEED ADJUSTMENT See Figure 3-1 for hydraulic schematic. ‘The floor lock system, it system, back, lag, kidney, slide and Trendelenburg table functions each have one adjustable flow contro! valve. These are adjusted by loosening the jam nut, rotating the stem slightly with a hex wrench, then tightening the jam nut. Tightening the jam nut takes up play in the stem threads, moves the stem slightly and thus affects the previous setting. ‘Therefore, travel time must be verified after the jam nut has been tightened. The adjustment affects travel time in both directions. The tit system has two adjustable flow control vaives, fone on each side of the cylinder. One is beside port 13, ‘on the manifold and the other is located on the side of the base channel. See Figure 4-10. 5030944 MANIFOLD FIGURE 4-9. FLOW CONTROL VALVE wa 3505898 FIGURE 4-10. TILT FLOW CONTROL VALVES 4-9.1 TILT SPEED ADJUSTMENT These vaives must be adjusted to nearly the same positions. 4. Loosen jam nuts, turn both stems inward until they lightly contact the seats, then back #14A out approxi mately 1/2 turn, Back #14A out until desired speed is achieved. 2. After jam nuts are tightened and travel times are ver- ified, check for proper ttt position locking 3, Raise the back section and begin with table tited left side down. 4, Activate Tilt Right and while top is moving, pull to right on back Section during most of the till travet range. 5, Release buttons and alternately push and pull side- ‘ways on the back section. 6. If the flow control valves are incorrectly adjusted, there will be excessive play in the tilt system. This play will disappear after tit has been reactivated in both directions without any sideways pulling Readjustment is necessary if this situation occurs, I air is in the system, the play will not disappear after tt has been reactivated, 380820 415SHAMPAINE 5100B/5100E SURGICAL TABLE 4. Maintenance 4-9.2, FUNCTION TRAVEL TIMES The following times are obtained with cool oll and, ‘except for the slide function, the slide centered Increased running of the motor increases the oll tem- perature, and subsequently the function speed Minimize motor operation prior to and during speed tests and adjustments. Retest speeds when oil has ‘cooled down to ambient temperature. ‘An emoty table, table with 60 Ibs. (27 kg) on fog and on back, and 120 Ibs. (54 kg) on feg and on back should all give times within these ranges. The following times are for full travel in one direction. ‘Travel times should be checked and agjusted while run- ning on AC power, ie., when the table is plugged in. ‘Table 4-3. FUNCTION TRAVEL RATES Table Function Travel Time (seconds) Trendelenburg 20-26 Reverse Trendelenburg 20-26 Back Up 20-36 Back Down 20-36 Leg Up 20-30 \ Leg Down. 20-30 Kidney Up 7-13 Kidney Down 7-13 | Tilt Right 14-26 Tilt Lett 14-26 Slide Forward 10-14 Slide Reverse 10-14 Table Up 18-22 Table Down 17-27 Lock Floor Feet 4-6 Unlock floor Feet 4-6 a6SHAMPAINE 5100B/5100E SURGICAL TABLE ‘4. Maintenance 4-10 FLOOR FEET ADJUSTMENT (PAD HEIGHT) ‘The table is equipped with hydraulic floor feet. A span- ner wrench, if available, can be used to adjust the height of the foot pads to the floor. Check the adjustment as, follows: 1. Unlock the floor lock feet. Move table to a flat level suriace. 2. With all feet fully raised and the table resting on the casters, adjust each foot to provide 5/6" (16 mm) floor clearance, 3, Insert the wrench pin into the hole provided in the foot. Rotate foot clockwise to lower, counterclockwise to raise. The set screw in each foot can be loos- ened with an Allen wrench to permit eas- ler rotation of the foot (but this is not required because of the nyion plug) nove The head end eylinder rod has @ through hole in it. necessary, insert along, thin too! (nail, piece of dri rod, fong end of an Allen wrench, etc.) into the hole to hold the cylinder rod stationary while adjust- ing the floor feet. SPANNER ‘Ween FIGURE 4-11, FLOOR FEET ADJUSTMENT‘SHAMPAINE 5100B/5100E SURGICAL TABLE 4. Maintenance NOTESSHAMPAINE 5100B/5100E SURGICAL TABLE 5. Trouble Analysis eee Trouble Analysis 5-1 General Instructions cece Gee. 5-2 Fuse Replacement 56 5-3 Service Indicator 57 5-4 Troubleshooting Charts =... : wees : 5-10 : 5-4.1 Pump Motor S10 5-4.2 Table Functions att 5-4. Footswitch apace) ieee een eld 5-4.4 Auxiliary Control Pendant : 2 BIS 5-4.5 Batteries . : 546 5-4.6 Floor Lock System ee 517 5-4.7 Electrical System a ee 5-19 5-48 Hydraulic System... 5-20 6-5 Circull Board Checks... 7 5-30 5-6.1 Control Board 3AIU. 2... 5-30 5-5.2 CPU Board 4A1U ae cette ee B80 e 5-5.3 Pendant Board Ee . +. 8-30 5-54 Sensors... 531 5-55 Interlock Switches ....--...2eeeee ee ee 531SHAMPAINE 5100B/5100E SURGICAL TABLE 5. Trouble Analysis TROUBLE ANALYSIS Prior fo troubleshooting, obtain as much details from user on how, when, where the problem occurred. Then inspect the table visually, and if appropriate, obtain a functional baseline prior to proceeding. 5-1 GENERAL INSTRUCTIONS 1. Before removing any covers or shields, review the electrical system and hydraulic system schematic diagrams in Section Service Data, 2. The power cord receptacle, batteries, pump motor, solenoid valves, auxiliary pendant, and service switches are protected by fuses. All fuses, except the battery and service switch fuses, are accessible with- ‘out removing the base cover. See section §-2 for fuse locations and ratings. 3, The SERV indicator on control pendant and digital display on the CPU Board can be used to assist in isolating certain contro! circuit malfunctions. See sec- tion 8-3 for diagnostic codes, 4. Follow the troubleshooting flowchart (Figures 5-4.and 5-5) to isolate the problem, then refer to the trou- bleshooting tables in Section 5-4. The troubieshoot- ing tables are organized as follows: + pump motor ‘+ table functions + footswitch + auxiliary control pendant + batteries + floor lock system + electrical system + hydraulie system 52SHAMPAINE 5100B/5100E SURGICAL TABLE 5. Trouble Analysis Troubleshooting Checklist Plug power cord into AC outlet. Does green pilot lamp light? Replace fuses 2A1U1F and 2F in power cord receptacle (see page 5-7). (After verifying AC to table) ‘Turn ON/OFF switch ON. Is START/STOP button on control pendant backlit? ‘Check connection at pendant box, try another pendant, replace battery fuse 1ATF (see page 5-7). ‘Are batteries charged? If battery indicator is red, plug power cord into AC ‘outlet to recharge. (Pump motor will not operate when red indicator is it and table is not plugged into AC) Are floor feet locked? If yellow UNLOCK indicator is lit, press LOCK to lower floor feet. (Table functions will not operate it floor feet are raised.) Aux pendant will operate. ls AUXILIARY CONTROL drawer open? It yellow DWR indicator is lit, close drawer. (Auxiliary pendant overrides main pendant when drawer is open.) Is red SERV indicator lt? Remove pendant box cover and note diagnostic code (see page 5-9) Does pump motor run when function is pressed? Replace pump fuse 2A3F (see page 5-7). ‘Are all table functions inoperative? Replace solenoid power fuse 2A1F (see page 5-7). Does auxiliary pendant work? Replace emergency power {use 2A2F (see page 5-7). 10. Reler to troubleshooting tables for specitic problems.SHAMPAINE 5100B/5100E SURGICAL TABLE 5, Trouble Analysis Troubleshooting Table compet | rem = Motor runs but appears to be overloaded. 510 Motor repeatedly blows fuse. 5-10 Pendant Batteries Batteries inoperative 5-16 ~| Floor Lock System | Motor runs but floor feet will not extend. SAT | Motor runs but for feet wil not retract. BAT | | Excessive leakage current. 5-19 | 54 ‘350520SHAMPAINE 5100B/5100E SURGICAL TABLE 5. Trouble Analysis SS ‘COMPONENT PROBLEM PAGE Electrical System | Motor runs when pressing level, but table will not level. 5-20 Back section not leveling properly. 5-20 Loss of power when in full tit or trend, 5:20 Loss of power when table is fully descended. 5-20 Hydraulic System | Motor runs, but inadequate hydraulic power available. 5:20 ‘Motor runs, but selected table function(s) do not operate properly. 5:20 External leakage of hydraulic oil visible on floor beneath base. 5:22 External leakage of hydraulic oil visible form under tabletop area. 5-23 Positional drift in slide, Kidney, leg, back, tit, or Trendelenburg. 5-23 Jerky motion of a table section. 5-23 ‘Warped table top section - back, leg, or kidney elevator. 524 ‘Table section won't hold position with power off 5:25 Play in table section when power is off, 5:26 Table will not lower (main lift) 6.27 Table loses elevation. 5:28 Table will not elevate (motor is running). 5-29 Table will not elevate to full height (43°) 5-29 Table will not stop when descending. 5-29SHAMPAINE 5100B/5100E SURGICAL TABLE 5. Trouble Analysi: 5-2 FUSE REPLACEMENT POWER ENTRY MODULE \ POWER INPUT. 2AWUIF & 2F SOLENOID POWER 2A1F EMERGENCY. POWER 2A2F PUMP 2A3F-— BATTERY qAIF So FIGURE 5-1. FUSE LOCATIONS Seceroow FUSE RATING CIROUITS PROTECTED Power cord receptacle 4 ANP (250¥) ‘AC power input 2AIUIF & 2F 2 AMP (250V) (ollot lamp will be off \ Solenoid power 2At 4 AMP (250V) Solenoid valves ! | Emergency power 2A2F 4 AMP (250V) Auxiliary pendant | Pump 2A3F 42 AMP (250V) Pump motor Battery 1A1F 15 AMP (32V) Batteries Service Switch 1A2F 2 AMP (250V) Service Switch 56 350520SHAMPAINE 51008/5100E SURGICAL TABLE. 5. Trouble Analysis 5-3 SERVICE INDICATOR © heres seAVindicetoron he corto! pendent indicates The CPU Boar, located inthe Pendant Box, contains a a faut concition has occurred, All table functions willbe digital display that provides a diagnostic code when the inoperable from the control pendent or footswitch. The SERV indicator is i auxiliary pendant and service switch can stil be used provided that the battery is not completely discharged. When the control software is operating properly and the pendant is plugged in, and the AUXILIARY CONTROL drawer is closed, the decimal point of the digital display will lash once per second. Swi ge BEREER cau wae eel (21 seavyce 1 Reset i INDICATOR e a ‘35052007 a e FIGURE 5-2. SERVICE INDICATOR E Sse FIGURE 5-3. DIAGNOSTIC CODE DISPLAY Prior to replacing components listed in corrective action, the following items should be checked: 1.All wire harnesses, especially the ‘main /O to CPU harness. blown battery fuse " when the table is 2. Baitery Fuse — will give @ Code plugged into AC. 3. Batlery Charge Slate — Low batteries an indicate various faults, even when plugged in. 350520 57SHAMPAINE 5100B/5100E SURGICAL TABLE 5. Trouble Analysis Table 5-1 CPU BOARD DIAGNOSTIC CODES CODE | FAULT CONDITION ‘CORRECTIVE ACTION il VO communications error ‘a. Check connection between CPU board and Control Board, Replace CPU Board. ©. Replace Control Board, 2 Reserved = 3 | Battery overcharge" 2. Check battery fuse. b. Check battery chargeistate. ¢. Replace Control Board. 4 Battery sense failure a. Check battery fuse 1A1F. b. Cheok battery connections. ¢. Gheck connector J1 on Control Board, 4. Check battery voltage. 5 Watchdog error Replace CPU Board. | 6 ROM error Replace CPU Board 7 RAM error Replace CPU Board 8 or blank*| Fatal error Check for power to CPU Board. f not present, replace CPU. | ” Contro! Pendant not present ‘a. Plug Control Pendant into Pendant Box receptacle. b. Check connector cable between Pendant Box receptacle and CPU Board. . Replace Control Pendant b Control Pendant not functioning Replace Control Pendant. c | Return to level malfunction a. Check Sensor Board (see Section 5-5) and replace if detective. | . Check position sensors (see Section 5-5) and i replace if defective | ©. Check sensor harnesses for pinched/cut wires. 4. Replace CPU Board. on AUXILIARY CONTROL drawer open | Close AUXILIARY CONTROL drawer, , “SERV indicator will not be lit when these codes occur “decimal point wil not lash | "See procedure on following page 58 950520‘SHAMPAINE 5100B/5100E SURGICAL TABLE. 5. Trouble Analysis PROCEDURE FOR ENABLING A. 5100B WITH DEAD BATTERIES OR AN OPEN BATTERY FUSE if a 51008 table's batteries are dead, or it the 15A bat- tery fuse is open, the table will be inoperable via battery power as well as when itis plugged into a 115V AC out- tet A problem is created if this failure occurs when the table is locked to the floor and the-column is fully descended. ‘The base cover must be removed to access the batter- jes the floor jacks to move the tabie. Ifthe table top is in the fully descended position, the column covers must be removed prior to removing the base covers. This is a time consuming task, and is even more time consuming if the leg oF back sections are in their full down positions. Using the following procedure, the table can be made to respond to pendant commands and positioned for ser- vicing if the batteries are very low or dead, or ifthe bat- tery fuse is open: 1. Tum the mains switch off at the base. 2, Plug the table into the AC outlet and connect your {grounding wrist strap to the table's ground stud or to 2 point with a good ground, 3, Remove the CPU Board Cover. 4, Remove the J4 connector. The J4 connector is the center connector on the right side of the CPU. 5, Remove the #8 baitery status wire from the connec tor. This is the white wire at the top of the connector. ‘To remove the wire, depress the small locking tab for the #8 pin on the side of the connector, and pull the pin and wire out of the connector. 6. Plug the J4 connector into the CPU board, 7. Turn the mains switch on. 8 The table should now respond to pendant com mands. The battery status indicator on the pendant should be a constant rad. 4 the table fails to respond to pendant ‘commands, cycle the mains switch one ‘or more times. 9. Once the problem that caused the failure is correct ‘ed, secure power, remove the J4 connector from the CPU board, insert the #8:wire back into the J4 con- rector, reinstall, and resume operation.SHAMPAINE 5100B/5100E SURGICAL TABLE 5. Trouble Analysis 5-4 TROUBLESHOOTING CHARTS 5-4.1. PUMP MOTOR A A locked rotor condition could draw over 60 Amps of current. When applying a #24 VDC power supply to the motor, be sure to connect 2 20 Amp overload pro- tection device in the test circuit. DO NOT connect batteries directly to pump. PROBLEM POSSIBLE CAUSE REMEDY 1. Motor does not run or does not come up to speed. Pump motor fuse blown. Check fuse 2A3F. Replace with 2 Amp fuse if blown, Motor overheated. Allow motor to cool down for 20 to 30 minutes until protector automatically resets, Apply +24 VDC across motor terminals. (See Caution above.) if motor hums but does nat start: > Rotor may be locked. I motor does not come up to speed: > Motor is defective, Replace power unit (see Section 6-28) Replace power unit (see Section 6-28) 2. Motor runs but appears to be overioaded ‘Check current draw with ammeter. Maximum current draw should be 11 Amps (DC) at full load. Full current load is excessively high, Replace power unit (see Section 6-28), 3, Motor repeatedly blows pump fuse or AC input fuses. | ‘Check current draw with ammeter. ‘Maximum current draw should be 11 Amps (OC) at full load. Full current load is excessively high. Replace power unit (see Section. 6-28), 510 350520SHAMPAINE 5100B/5100E SURGICAL TABLE 6, Trouble Analysis 5-4.2 TABLE FUNCTIONS PROBLEM POSSIBLE CAUSE REMEDY 44, Motor runs but all table functions do not operate. Solenoid power fuse blown. Check fuse 2A1F, Replace with 4 Amp fuse if blown. Disconnect P3 from Control Board. If +24 VOC is not present at JB when function is activated: > Detective auxiliary contro! interlock switch Mf +24 VDC is present at J3 but none of the table functions move: > Solenoid ground lead loose or open. Check continuity of switch $2 (erminals 1 and 2 should be closed when drawer is closed). Replace if defective. Check for defective ground lead or loose terminal. Repair or replace {ground lead fo manifold. 8. Motor starts running when power cord is plugged in Detective Control Board. land pendant Is not activated. | Defective CPU Board. Replace Control Board. Replace CPU Board,SHAMPAINE 5100B/5100E SURGICAL TABLE 5. Trouble Analysis PROBLEM POSSIBLE CAUSE REMEDY 6. All pendant functions work ‘except one, Press inoperative funotion key. 1 motor does not activate Detective pendant Try another pendant. Replace pendant if defective Disconnect P3 from Control Board. If ¥24 VDC Is not present at J3 when | function is activated: > Detective Control Board, It +24 VOC is present at J3 when function is activated but solenoid does not operate: > Open in wire harness or loose pin, Loose solenoid lead at terminal > Cortoded solenoid terminal, > Open in solenoid coll (see below). > It 24VDC is present at coil and coil is not open. Replace Control Board. Check wire continuity, replace or = repair. Tighten terminal Clean terminal or reptace solenokd coil Bad solenoid spool, replace ~ solenoid. Connect a DC voltmeter in parallel from ground (lead #17) to solenoid terminal. Press function and check for +24 VDC. If no voltage is present: > Broken solenoid lead or wire. Replace solenoid coil or harneser Disconnect solenoid I solenoid terminal. M ance between coil and ground ‘screw on manifold. Wt Ris not 28-32R. > Detective solenoid coi. Replace solenoid coil 512 960520SHAMPAINE 5100B/5100E SURGICAL TABLE 5. Trouble Analysis PROBLEM POSSIBLE CAUSE REMEDY 7. Solenoid appears to operate properly but table function does not move. Move solenoid with its lead to a vaive that is operating properly. Press function key and observe table movement. M table moves satistactoriy, relay and ‘solenoid coils are working properly > Contamination in valve spo}, flow control, or check valves. ‘See hydraulic system problems. 8, Table function starts running automatically when control pendant is activated but function is not pressed. Detective Control Pendant. Detective Control Board, Detective CPU Board. Try a different pendant. Replace pendant if defective, Replace Control Board. Replace CPU Board, Locos Check solenoid coils for functions that are moving when not activated If 24V is not present Defective solenoid valve. f 244 is present: Check for shorts in wire hamess from J3 to coils. If short exists: > Bad harness. Defective Control Pendant. > Defective Control Board, > Defective CPU Board. Replace solenoid valve. Replace harness. Try a different pendant. Replace pendant if detective. Replace Control Board. | Replace CPU Board.SHAMPAINE 5100B/5100E SURGICAL TABLE 5. Trouble Analysis 5-43 FOOTSWITCH PROBLEM POSSIBLE CAUSE ener 7 10. Footswitch malfunctions or will not operate. Try same function on pendant. If pendant operates satistectoriy: Loose or open footswitch connection. > Contamination or obstruction under footswitch pedal > Detective footswitch (water in switching or penetrating coating on PC Board). Detective CPU Board. Check connections at footswitch receptacle and J2 on CPU Board in Pendant Box. oe Clean and reassemble, Repair or replace footswitch. Replace CPU Board. 514SHAMPAINE 5100B/5100E SURGICAL TABLE. 6. Trouble Analysis 5-44 AUXILIARY CONTROL PENDANT PROBLEM POSSIBLE CAUSE, REMEDY 11. All auxiliary control pendant functions inoperative. Emergency power fuse blown. Defective auxiliary control interlock switch. Check the display on the CPU Board; a “a” wil be displayed when the drawer is open. Manual pump not providing pressure. Check for pressure output at pump. If no or low pressure check pump, Batteries are discharged. ‘Check fuse 2A2F. Replace with 4 Amp fuse if blown, Check switch $2 tor continuity (terminals 1 and 3 should be closed when pendant drawer is open). Replace if defective: Remove, disassemble, and inspect manual pump and pressure line check valve (see sections 6-2.9). Plug power cord into AC outiet to recharge batteries, 12, All auxiliary control pendant functions work except one. ‘Try same function on main Controt Pendant. i main pendant operates satistactoriy: > Defective auxiliary pendant. It same function does not operate on ‘main control pendant > Detective solenoid. Replace auxiliary pendant. See problem 6.‘SHAMPAINE 5100B/5100E SURGICAL TABLE 5. Trouble Analysis 5-4.5 BATTERIES PROBLEM POSSIBLE CAUSE REMEDY 13. Batteries inoperative. Battery fuse blown, Loose connection. Battery life expired or marginal Cheok fuse 1A1E Replace with | 15 Amp fuse if blown. Check connector 1P on Power Entry Assembly and J1 on Controt Board in Low Voltage Box, and at batteries. : See problem 16. 1 14, Battery charger inoperative, Line fuse blown. (Green pilot lamp roti.) Detective Control Board, i} Check fuses 241U1F and 2F. Replace with 4 Amp (250V} or 2 Amp (250V) if blown. Replace Control Board. Disconnect 6P from Control Board. Check for AC voltage between P-3 and 6P-1, if voltage is not present: > Detective battery charging circuit Replace 1/0 Board or Low Voltage Box. 16. Batteries won't hold charge. Battery charger defective. | Replace UO Board or Low | Voltage Box. Check date code on batterie: Mover 5 years old: > Battery life may have expired Replace batteries, Recharge battery for 24 hours, then unplug power cord. Measure battery voltage under no load condition, ‘and while operating one solenoid with auxiliary contro! pendant. If voltage drops more than 0.5 V: > Battery life is expired. Replace batteries, 516 350520‘SHAMPAINE 5100B/5100E SURGICAL TABLE 6, Trouble Analysis 5-46 FLOOR LOCK SYSTEM PROBLEM POSSIBLE CAUSE REMEDY 16. Motor runs but floor feet will_| not extend. No movement at ail. Solenoid power fuse blown. Check fuse 2A1F. Replace with 4 Amp fuse if blown. "Remove lead and measure resistance of solenoid, Replace if shortened. ‘Check for +24 VDC between solenoid terminal 16 and ground while activating floor lock. Wt no voltage is present: > Detective Control Board > Broken solenoid lead, > Shortened solenoid coil.” If +24 VDC is present: > Detective solenoid coll. Open Coil. If resistance is open, replace coil > Solenoid valve is stuck. > Check valve Ft stuck closed. Roliove pressure at F1 swivel by loosening and tightening. Replace Control Board. Repair or replace solenoid lead. Replace solenoid. Replace solenoid coll. Replace solenoid valve (see Section 6-2.2) It feet lock, replace F1 check valve and O-rings. 17. Motor runs but floor feet will not retract. No movement at al Solenoid power fuse blown, ‘Check fuse 2A1F. Replace with 4 ‘Amp fuse if blown. “Remove lead and measure resistance of solenoid. Replace it shortened. Check for +24 VDC between solenoid terminal 16 and ground while activating floor lock. If no voltage is present: > Defective Control Board. > Broken solenoid lead. > Shortened solenoid coil.” If +24 VDC is present: > Detective solenoid coll, Open coil, I resistance is open, replace coll > Solenoid valve is stuck. > Check valve F2 stuck closed. Relieve pressure at top of head foot via bleed screw and tighten. > Temperature relief valve stuck ‘open in manifold Replace Control Board, Repair or replace solenoid lead. Replace solenoid Replace solenoid coil Replace solenoid valve (see Section 6-2.2) If fet lock, replace F2 check valve and O-rings. 2 Remove and inspect spring and ‘O-ring, Replace as necessary and reset to 2000 psi External leak in fiting or cylinder hydraulic system problem, Examine components in floor lock system for hydraulic fluid.SHAMPAINE 5100B/5100E SURGICAL TABLE 5. Trouble Analysis PROBLEM POSSIBLE CAUSE REMEDY 18. LOCK indicator does not light when floor feet are extended, Detective floor lock sense switch, or 1loor feet not extending completely. Detective Contro! Pendant (if UNLOCK turns on. Lock indicator ‘comes on when power is cycled) Detective Control Board, Check continuity of $1 (should be closed when feet are locked). Replace if defective. Check for proper tab engagement. Check floor feet system (see item 20). Activate “lock’. If the motor runs= {for approximately 2 seconds, the pendant is defective. Replace pendent. Replace Control Board. 49. UNLOCK indicator does not light when floor feet are retracted, Detective floor lock sense switch. Floor feet not retracting completely. Detective Controt Pendant (if LOCK tums off) Defective Control Board (if LOCK stays on). ‘Check continuity of S1 (should be ‘open when feet are unlocked). Replace if defective, Check tloor feet system (see item 20), Replace Control Pendant Replace Control Board. 20. Floor feet hydraulic: symptoms: a) Fest lock, then table drifts down. All 3 feet drift ‘eveniy. Drifting may be intermittent, b) Feet lock, head foot drifts down. Right and left at foot end of table stay locked, ) Feet lock, head foot stays locked, right and left feet at foot of table dit, lack light goes out. 4) Feet lock, head foot and Fight foot stay locked, left foot does not stay locked. External leak in F2 line to head oylinder. Check valve leaking Internal leak at head foot. Internal leak at right foot, External leak at right foot cap end, Internal leak at lett foot. External leak at right of left foot Repair leak. Replace valve and O-rings. Replace head foct. Replace right foot. Repair leak. 7 Replace lett foot Repair leak. 518‘SHAMPAINE 5100B/5100E SURGICAL TABLE 5, Trouble Analysis .7 ELECTRICAL SYSTEM PROBLEM POSSIBLE CAUSE REMEDY 21. Pilot lamp not lit when power cord is plugged into live outlet. > Line fuses blown, > No power to table, Check fuses 2A1U1F and 2F. Replace with 4 Amp (115V) or 2 ‘Amp (230V) fuses if blown, ‘Check power cord and room breaker. 22. Excessive leakage current. Check leakage current for normal and reversed polarity with ground closed. If leakage current is greater than 1 A | but less than 100 yA: Table not grounded properiy if leakage current is greater than 100 pA > Possible detective transformer. Check ground continuity between ‘ground pin on plug and base frame. If reading is greater than 0.1 ohm, check for loose ground terminal i pplug and ground screw on frame for a cut cord. Tighten terminal or replace cord, Replace Low Voltage Box. 23, Electrical interference on ‘monitoring equipment Unplug power cord. > 1f electrical interference (60 Hz noise) disappears: > Table ground and monitoring ‘equipment ground not a same potential ‘Connect monitoring equipment ground to same ground system as table. 24, Line fuses blow when table is plugged in. Unplug power cord from electrical outlet. Connect an ohmmeter or continuity tester between the ground pin and hot or neutral blades on the plug, If continuity exists between line voltage conductor end ground: > Insulation breakdown or short between live conductors and metal parts. This can be caused by a cut wire, ive terminal touching metal, tc. Isolate problem with ohmmeter or continuity checker. Replace defective components as required. Recheck electrical system.SHAMPAINE 5100B/5100E SURGICAL TABLE. 5. Trouble Analysis, PROBLEM POSSIBLE CAUSE REMEDY 25, Pressing level causes the ‘motor to run but the table does not level. Kidney switch not activating, Remove CPU cover. I kidney elevator feedback is +5V, switch is not engag: ing or bad. Remove tight side cover. Check for switch engagement. Bend tab to engage when elevator is Fotracted. if engaging, check switch operating & check wiring, 26. Back section not leveling properly. Sensor cable caught in right side shield. Elevate back and examine under table top for sensor cable catching sideshield. Remove side shield and move cable. 27. Loss of power when in full tit or trend. Pinched wire under table top. If the table can be made operational when bringing to level via aux. pendant and foot pump, a pinched cable is probable ‘cause. Remove seat section and inspect wiring for pinch points, cut or broken wiring. Replace as required 28. Power loss when table is fully descended. | ‘Cuvpinched communication cable between VO and CPU. Remove cover and inspect com- munication cable. If cut/pinched, replace. §-4.8 HYDRAULIC SYSTEM i checking the hydraulic pressure, do not continuously run the pump motor for more than a minute or two after the table function has reached its mechanical lit. This will cause the oll to heat up beyond | a] the normal operating temperature range. i PROBLEM POSSIBLE CAUSE REMEDY 29. Motor runs, but inadequate hydraulic power available. Install pressure gauge in P line at pump. Run table function to its mechanical limit. (See caution above). It gauge reads less than 1400 psi: > Roliet valve set too low. Adjust relief valve to 1425 psi. > Relief valve stuck open or defective. No improvement when reset. Replace relief valve. ~ > Pump bad. Replace power unit (see Section 6-2.8) 5-20 350520SHAMPAINE 5100B/5100E SURGICAL TABLE 6, Trouble Analysis PROBLEM POSSIBLE CAUSE REMEDY 30, Motor runs, but selected table function(s) do not operate properly. Check solenoid valve operation (see problems 4 and 6). i solenoid valves operate: > Low oil supply. > External oil leak at fitting. External oil leak at component or hose, > Clogged oil fiter (attects all functions). > Variable flow control valve out of adjustment. > Foreign matter in solenoid valve prevents complete closing/opening. > Foreign matter in variable flow control vatve. > Defective flow control valve. > Leakage across solenoid spool due to defective external (cage) seals. > Detective solencia valve. Check oil level in reservoir (see Section 4-5); add oll as necessary. Tighten or replace fitting. Repair or replace component or hose as applicable. Remove filter element, clean cavity and install new element and seal (see Section 6-2.3) Readjust tlow control (see Section 49). Remove, examine, clean and reinstall or replace valve (see Section 6-2.2). Replace seals as necessary. Remove valve, examine, clean and install flow contro! valve. Replace if it cannot be cleaned (see Section 6-2.2), Replace tlow control valve. Remove and examine solenoid valve from manifold (see Section 6-2.2). Replace external seals. Replace solenoid valve. 350520 521‘SHAMPAINE 5100B/5100E SURGICAL TABLE 5. Trouble Analysis $s PAOBLEM POSSIBLE CAUSE REMEDY e St Ederral leakage o Romovecotumn shige ara base hydraulic oil visible on floor | cover. Examine for source of leak. Deneath base Block up tale o pt couse leakage visible at a fitting: Loose or damaged fiting Tighten or replace fitting {leakage along hose: : > Hose damaged, Replace hose (see Section 6-2.8). : |W leakage at manifola: Loose valve or filter Check for tightness. I tight, remove and replace defective vaive fitting. Sol. valve torque = 30-32 fribs. Wf column shows external leakage: > Damaged piston ring(s). Rebuild or replace lift assembly | (see Section 6-2.5 and 6-2.6). if large amount of oil coming from | resent vent when it lowered e > Reservoir overrilleg. Check reservoir level with litt down (see Section 4-5), > Detective seal or loose reservoir. | Tighten reservoir nut. if leaX persists, replace pump and motor assembly (see Section 6-2.8) 522 350520SHAMPAINE 5100B/5100E SURGICAL TABLE 5. Trouble Analysis @ [Prose | PossiBLe CAUSE REMEDY 2, Extemal leakage of | Remove side faring, tt frame cover hydraulic ol visible from | or column firings as applicable. Under tabletop area 1 eakage visible a fiting: : > Loose or damaged fitting. Tighten or replace as applicable. I leakage at a cylinder rod oF joint: ~ Detective cylinder Replace cylinder 33, Positional drt in slide, Check valve leaking internally. Remove from manifold, examine kidney, leg, back, tit, or valve, cavity, and O-ring seals and Trendelenburg replace (see Section 6-2.1)- Ar in hydraulic system. Repair and bleed system (see Section 6-3.) External or internal leak in cylinder. | Replace fitting(s) or cylinders). 34, Jerky motion of a table Air in system Repair and bleed system (see Section 6-3.3) section. e Detective check valve Remove ang replace check valve (See Section 62.1). Speed control setting out of ‘Check and reset function speed adjustment at flow control valve (see Section 49), Mechanical obstruction. ‘Search for and remove obstruction. Air in the hydraulic system indicates that the hydraulic system integrity has been compromised. Air can ‘only enter the system if the hydraulic fluid level is tow enough so that the oil pickup tube pulls air into Note] ine puma ora breakin a hydraute Ine allows hid to escape followed by pulling arn who roving in the opposite direction. Air is most likely introduced by improperly trained personnel replacing cylinders or cracking hydraulic lines. IT 1S VERY UNLIKELY THAT AIR IN THE SYSTEM IS THE CAUSE OF A : HYDRAULIC PROBLEM. IT 1S MOST LIKELY THAT A LACK OF FLUID OR A VALVE FAILURE IS CAUSING A HYDRAULIC PROBLEM. 350520 5:23‘SHAMPAINE 5100B/5100E SURGICAL TABLE 5. Trouble Analysis PROBLEM POSSIBLE CAUSE REMEDY 35. Warped table top section— back, leg, or kidney elevator, ‘Observe section at various positions in travel range. able is warped: ‘> External leak at oylinder, fting or hose in crossover system, > Excessive temperature difference between that during adjustment bleeding and ambient temperature where warping is observed. > Air in crossover system. This problem can be identified by observing table movement—one side will move immediately, followed by the other side after a ‘small delay, depending on the amount of airin the system (like walking up steps), Internal leak across a cylinder piston, > Improper amount of oil in cross cover line due to personnel error. | balance, adding or subtracting oil Repair leak and replace compo- nent as necessary. Fil and balance system (see Section 6-3.3). Allow to sit in O.A. environment for 24 hrs. It warping persists then in crossover system, (This must be done in a temperature envi- ronment similar to the operating room.) Bleed and balance system, (This is very unikely ever the cause of warping,) Replace bad cylinders and balance system. ‘Add or subtract oll in crossover line, balance system. tis bes to examine the section in a horizontal postion when warping is observed. Determining i the lef oF right side ofthe section (referenced tothe head of the table) it higher, along with examining th hydraulic schematic, Fig. 3-1, can be useful when determining hydraulic fluid in the crossover line. 19 there is not enough or an excess of 528 950520SHAMPAINE 5100B/5100E SURGICAL TABLE 5. Trouble Analysis SSS PROBLEM POSSIBLE CAUSE REMEDY 36. Table section won't hold position with power off Jerk the section back and forth and/or apply more weight to it.I no external leaks. > Faulty check valve in manifotd > Contamination in manifold > Internal cylinder leak. > If section continues to move for a short time after motor turns otf. Remove and replace check valve (see Section 6.2.1), Use new O-rings. Remove check valve and check Inside manifold cavity using small light and mirror. (Manifold should be inspected and cleaned when replacing O-rings). Purge oil that is drifting. Replace cylinder(s). Replace solenoid valve. Check for external leakage from ‘manifold to applicable cylinder(s) If oll leakage is visible: > Trace oil leak to source, Tighten or replace fitting, hose ‘seal or component as applicable.‘SHAMPAINE 5100B/5100E SURGICAL TABLE 5. Trouble Analysi PROBLEM POSSIBLE CAUSE REMEDY 87. Play in table section when power Is off [Apply reversing force to section, ‘observe for eylinder piston movement. Look for mechanical play, frst at each Pivot, etc, 1" play observed, piston rod moving: > External oil leak > Air in system, > Internat jeak across cylinder piston. Wf play observed, piston rod not moving: > Loose or worn parts at connection. Tighten or replace fitting, hose, seal or component as applicable. Bieed System (see Section 6-33), Replace cylinder. Tighten loose parts of replace worn parts. 5-26 350520‘SHAMPAINE 5100B/5100E SURGICAL TABLE 5. Trouble Analysis — @ | proce POSSIBLE CAUSE REMEDY 38, Table will not lower Press Table Down. (see Note 1) Possible eccentric load on table. | Activate slide to bring lead over center of lit. Check for obstruction and grease Ii, tighten keys. > Electrical problem at solenoid vaive. | See problems 4 and 6. > Ram galled in oylinder. Remove column shields and inspect lit ram. If galling is evident, replace (see Section 6-2.5) Rock table top (back to leg) while pressing Table Down. It table begins to descend: > Ram needs lubrication Remove column shields and lubricate ram. > Ram galled. Inspect ram. It galling is evident, e replace (see Section 6-2.6). > Solenoid or check valve stuck Rlemove and replace check valve and O-rings (see Note 2), Remove, examine and clean solenoid valve. Reinstall or ropiace. NOTES: 4. IHtable lowers partially, the problem is not electrical and is probably in the litt or covers. 2. I replacing check valve with fit elevated, the lift must be biocked up prior to removing hydraulic tine #7 from the : manifold 350520‘SHAMPAINE 5100B/5100E SURGICAL TABLE 5. Trouble Analysis PROBLEM POSSIBLE CAUSE REMEDY @ | 39, Table loses elevation Press Table Up, then release. (see Note below), It table drops rapidly, slowly or | intermittently: > Check vaive stuck open. Remove and replace check valve in manifold (see Section 6-2.1) Detective litt seals. Replace lift column seals and tubes (see Section 6-2.5). | : Remove column shields and base cover, Inspect for leakage. Block up or tip if necessary. Uf fitting is leaking: > Loose fitting, Tighten fitting. If leakage continues, replace fitting and/or hose. It hose is leaking: > Defective hase. Replace hose (see Section 6-2.6). e i it external leakage at down side of it: | | > Piston ring or cylinder and piston | Rebuild lt (see Section 6-2.6)-~ must be replaced. oii, or if ois being squeezed up between HTD] ine incor, the it rogues reouleng — new pistons & seals. i | if the clear vent (scavenger) line is full of | 5:28 350520‘SHAMPAINE 51008/5100E SURGICAL TABLE 5. Trouble Analysis Be sure lft is all the way down prior to checking oil level > Solenoid valve not operating properly. > Mechanical obstruction. PROBLEM POSSIBLE CAUSE REMEDY 40. Table will not elevate (motor | if no external leakage: is running). > Low oil level. Check reservoir oil level (see Section 4-5) and bleed lift (See Section 6-3.2) after filing. See problems 4 and 6, Check and remove obstruction. I lift is galled, must replace. 41. Table will not elevate to full height (43"). Press Table Up until litt stops. It itt won't elevate full height: > Low oil level (see Caution above). > Mechanical obstruction. Check oil level and fil. AW oil as necessary (see Section 4-5) and then bleed lift column (see Section 6-3.2) fo remove any air drawn into itas a result of the low level condition. Check and remove obstruction. It lit is galled, must replace. ‘42, Table will not stop when descending, Press Table Down, then release. If table continues to descend: > Check valve sticking or obstructed by foreign matter. > Solenoid valve not returning to neutral position. Remove, replace check valve {see Section 6-2.1) and O-rings. Replace solenoid valve. 350520SHAMPAINE 5100B/5100E SURGICAL TABLE. 5. Trouble Analysis 5-5 CIRCUIT BOARD CHECKS 5-5.1 CONTROL BOARD 3A1U Refer to electrical schematic diagram, Figure 3-3 when checking Contro! Board. ore Check the operation of the Control Board as follows: 1. Check ali connectors on Control Board to ensure plugs are firmly seated, 2. Disconnect 3A1U6P from J6. 3. Using an AC volt meter or voltage tester, check for AC voltage between pins 4 and 5 of 6P. = If pilot lamp is tit but voltage in not present, trans- former 1T in the Low Voltage Box is detective. 4. Using a DC voltmeter, check for unregulated +24 VOC between pin 3 (+) and pin 1 (-) of 6P. @ If voltage is not present, rectifier bridge 1CR in the Low Voltage Box is defective, Reconnect SA1U6P to J6. Disconnect 31USP from JA. Using a DC voltmeter, check for +12 VDC at pin 3 of us. I voltage is not present, power supply circuit is detective—replace Control Board, 8. Check for battery sense voltage (+5 VDC or less) at in 8 of Ja, ‘= If voltage is not present, battery sense circuit is . 1. Remove base cover. 2. Unplug 381U2P from J2 on Control PC Board. 3, Note cord routing before removing cable ties. 4, Tip table on end (see Section 6-2.8) 5, Remove one track to remove auxiliary control drawer. 6. Remove strain relief bushing in back of drawer to remove pendant cord 7. Install new pendant in reverse order and route and secure cord in same manner as originally installed, 6-1.9 BATTERIES The batteries should be replaced every five years. 1. Unbuckle battery hold-down strap. 2. Disconnect battery wiring. 3. Connect replacement batteries as follows: a. Wire #23 to (+) terminal of 1BT. ', Wire #30 from (-) terminal of 1BT to (+) terminal of 2BT. . Wire #17 to (-) terminal of 287. 7 28T FIGURE 6-3, BATTERY REPLACEMENT 350520 65‘SHAMPAINE 5100B/5100E SURGICAL TABLE 6. Repair and Replacement 6-2 HYDRAULIC SYSTEM COMPONENTS. 6-2.1 CHECK VALVE CARTRIDGE Removal of a check valve cartridge wil remove the hydraulic lock normally held on a table function. Function movement can occur abruptly, causing damage or personal injury. Eliminate any hazard bby blocking or positioning the affected functions. This work must be completed in a clean area, Prior to removing a check valve, place the section having the valve replaced ina position that is the same for the valve being replaced. E.9., replacing the #5 back up check valve ~ place the back in the ful! "yp" position. Then secure the ‘back in this position using a cord or rope. The itt must be blocked as in Figure 6-8. ‘A brass O-ring removal tool is recommended when removing O-rings and check valves from the aluminum, manifold to prevent scratching of the O-ring sealing surfaces. Removal and Replacement 1. Remove the base cover, Odd-numbered cartridges are easily accessible from the top of the manifold. Access to even-numbered cartridges can be improved by placing the table on its side (see Section 62.7). 2. Access to the check valve is obtained by disconnect- ing the function hydraulic hose and removing the adapter fiting The adapter fittings are also orifices, and must be reinstalled in the correct foca- tion. The fiting with the larger hole is installed on the top of the manifold. t ‘more than one fitting is removed, mark them so that they can be reinstalled the same locations. This will aid obtaining the corect fitting orientations. 8, After removing the adapter fittings, remove the upper Orting and cartridge by hooking the exposed port with brass O-ring tool. Remove the lower O-ting. ~_ 4. Inspect the cartridge bore carefully for foreign matter. 5. Install a new inner O-ring and cartridge, noting that the cartridge is inserted so thet the longer section of the body is towards the outside of the manifold, Lubricate O-rings with hydraulic fluid rior to installation. Never reuse these O-rings! 6. Install the second O-ring on top of the cartridge. 7. Clean the locklite residue from the adapter and apply green locktite (609) around the adapter. Install and lighten adapter unt! it bottoms out on manifold. | 8. Reconnect the hydraulic hose and bleed the function (see Section 6-3). FLOW ADAPTER CONTROL, FITTING VALVE vee CHECK A it ok ME = ORINGS Tae SOLENOID VALVES FIGURE 6-4. CHECK VALVE ADAPTER FITTINGS, 350520‘SHAMPAINE 5100B/5100E SURGICAL TABLE 6. Repair and Replacement 6-2.2 SOLENOID VALVES This work must be performed in a clean area. The solenoid valves can be removed without disturbing the hydraulic lock on the table functions provided the check valve cartridges are functioning properly. Once a solenoid vaive is removed, the entire table will be disabled. Removal and Replacement 1 2. Remove the base cover (see Table 4-2). Disconnect the power cord from the base. Remove the tow voltage box. (Check that the solenoid leads are identiied (see dia. gram on low voltage box cover). f not, identity them now. Disconnect the leads to the solenoid valve coils {0 be replaced at the solenoid. Remove the retaining nut located on the end of the solenoid, Slide the solenoid coils and spacer off of the valve operating shatt Observe the effect on the wiring in the Jow voltage box to ensure that none of the connections are strained. if @ strain ‘occurs, disconnect the affected lead. Unscrew the solenoid valve body from the manifold and withdraw carefully. Inspect the valve bore care- fully for foreign matter, rough surfaces, scratches or other damage to valve seal surfaces, See Figure 6-5 {or location of solencid valve seals and seal suriaces. Inspect the solenoid valve seals for damage of any kind, A [te SOLENOID cons: f [tea LAL sson8aA 6 SOLENOID VALVE FIGURE 6-5. SOLENOID VALVE REMOVAL To reinstall the solenoid valve, reverse the installation procedure, noting the following: ‘a. Absolute cleanliness is essential. I reusing the old valve, solvent clean and blow dry with compressed alr. The valve bore must not be cleaned with cloths ‘which leave lint ». Lubricate the valve seals with hydraulic oil prior to assembly. Install the solenoid valve carefully to ‘avoid damage to the seals. It should thread into the manifold fully by hand. if not, determine the cause and correct it. A wrench shall be used ofly for final tightening of the valve to 30 to 32 ttlbs, Do not over tighten. ¢. Install the solenoid coils and spacer on valve oper- ating stem. Coils have a molded recess to fit the spacer and wil only install one way. However, the solenoids can be installed in reverse order. Check the solenoid lead numbers with the connection diagram on the outside of the low voltage box cover. Reverse the solenoids or the leads if neces- sary. The solenoid retaining nut should be torqued to 5 ft-lbs maximum. Do not over tighten. 4. Bleed air from the manifold.first (see Section 6-31). Move to the function on which the valve was, replaced. Bleed the attected function according to paragraph 6-82 or 6-3.3. Check all functions for the presence of air, 350520 67SHAMPAINE 51008/5100E SURGICAL TABLE 6. Repair and Replacement 6-2.3 FLOW CONTROL VALVES 1. The flow control valves are similar to the solenoid valves in construction. They are accessibie from the top of the manifold. Set the function speed (see Section 4-9) upon replacement a. The tt system uses two flow control valves, one in the manifold, and one mounted remotely on the base between the valve manifold and the low volt= ‘age box. b. When replacing the flow control valves, they should be torqued to 30 to 32 ft-lbs. Do not over- tighten. FLOW ADAPTER CONTROL A | 8 rime VALVE, CHECK VALVE ADAPTER FITTING 35038942 VALV FIGURE 6-6. FLOW CONTROL VALVE REMOVAL 6-2.4 FILTER REPLACEMENT ‘The valve manifold is protected from system contami- ants by a 10 micron repiaceable element fiter. It is accessible by removing the cap. The filter should be replaced every tive years. the Na s503898S FIGURE 6-7. MANIFOLD FILTER Replacement 1. Remove the solenoid coils adjacent to the fier cap, 2. Unscrew the filter cap and withdraw the filter car- ‘ridge with a wire. 8. Check the cartridge bore for contaminants and clean it carefully. Do not allow contaminants into the pres ‘sure manifold (driling inside of fier bore). 4. Install a new cartridge into the bore. 5. Reinstall the cap. 6. Reinstall solenoid coils. | 7. Bleed the manifold (see Section 6-3.1). 68 350520SHAMPAINE 5100B/5100E SURGICAL TABLE 6. Repair and Replacement 6-2.5 VALVE MANIFOLD This work must be completed in a clean area. This should only be considered if there is 2 catastrophic manifold failure/problem. Components: can be replaced and should be replaced prior to replacing the entire manifold. Replacement 1, Remove the base cover (see Table 4-2) 2. Check that all solenoid electrical leads are labeled correctly (see diagram on Jow voltage box). If not, label them to enable installation 3. Check that all hydraulic hoses are labeled correctly (Gee diagram on low voltage box). If not, label them to enable reinstallation, 4. Raise the lift column fully. Install four wood blocks, 1" x 2" x 6-3/4" long, between the flanges of each lit stage, one on each side. Secure the blocks with cord oF wire. Lower the lft to trap the biocks between stages. Make sure the blocks are held in place ‘securely and will support the table, IM ne FIGURE 6-8. LIFT “if step 4 is not completed property, the lit will retract when line 7 is disconnected, limiting access end possibly causing personal injury. 6. Lower the back leg and kidney functions fully. This will prevent loss of oil when lines 3, 4, 5,6, 11 and 12 are disconnected. Retract the feet locks. 6. Install wood biocks between each end of the tit pivot bearn and the main support plate to prevent move- ment about the main plot when the Trendelenburg cylinder lines (1 and 2) are disconnected WOOD, Blocks 7 & ' _ 350589, FIGURE 6-9. BLOCKING TILT FRAME Fs 7. Immobilize the tit frame assembly with respect to the tit frame pivot beam by clamping wood or flat stock to the tit frame next to the tit pivot beam with C-clamps. 8. Have 15 clean 1/8" NPT pipe caps available to close lines as they are disconnected from the manifold ‘These caps will prevent contamination, loss of oil, and movement of the table top if the blocks installed in steps 4 and 6 become dislodged. 950520‘SHAMPAINE 5100B/5100E SURGICAL TABLE 6. Repair and Replacement 9. Disconnect the power cord from the base. Turn off the on/off switch. 10. Disconnect the solenoid leads, checking that the labeling matches the diagram on the low voltage box. 11, Disconnect the hydraulic hoses one at a time, cap ping the end of each hose. Check for labeling Correct any discrepancies. [ Rivals ea GOOOQOOOO FIGURE 6-10. VALVE MANIFOLD REMOVAL A Pay attention to the tabletop and hydraulic feet when disconnecting fines. Once each tine is alsconnected, there Is no longer a hydraulic lock on the cylinder supporting each table function. If table blocking shilts, the table may move abruptly causing personal injury. 6-10 12, Remove the four cap screws, and lift the manifold assembly clear of the base. 13, To reinstall the manifcld, reverse the disassembly steps. Bleed the table (see Section 6-3). It will be necessary to bleed all systems. Bleed the system, ‘one function at a time, in the following order: valve manifold, Trendelenburg, leg, back, table up/down, slide, kidney, tit, and floor locks. ze Remove the blocking before bleeding each function. Remove the blocking’on the function you are. working on only, leaving the others in place until you are ready to bleed that function. 350520SHAMPAINE 5100B/5100E SURGICAL TABLE 6. Repair and Replacement 6-2.6 LIFT COLUMN REPLACEMENT ore The fit column should only be replaced it the cylinders are galled or damaged. In- ternal leaks are not a reason to replace the lift column, Removal 1 hore Level table top and remove head rest and leg extension. Raise the table to full height, remove the column shields (see Table 4-2). Use two saw horses to support the tabletop. Lower the table over the horses to support the weight. Loosen the hose boxes. Loosen the hose guide bracket. ut cOLuMN FIGURE 6-11. HOSE GUIDE BRACKET Remove the four flat-head screws that fold the table- top to the lift column, Retract the lit Locate the fluid fine connections at the bottom of the lift column. Disconnect the hose fitting and remove the plastic tube from the barb fitting, The plastic tube can be dificult to remove and will require replacement if damaged or cut. 9. Remove six hex-head bolts, nuts, and lock washers. 10.Lift the entire lift column assembly from the base assembly. 11. Replace the lift assembly with a new factory tested unit. ee The lift assembly weighs 120 pounds (64 kg). Two persons will be required to handle it safely. A FIGURE 6-12, LIFT COLUMN MOUNTING HARDWARE 12, Reassemble the lift column assembly into the base in reverse order of removal. 19. Before replacing the column shields, remove the air from the lit column (see Section 6-3.2). 350520 611‘SHAMPAINE 5100B/5100E SURGICAL TABLE 6. Repair and Replacement =e FIGURE 6-13, LIFT REBUILDING 4 350520‘SHAMPAINE 5100B/5100E SURGICAL TABLE 6. Repair and Replacement 6-2.8 HYDRAULIC HOSES ey ‘The hydraulic hoses are of a high burst-pressure design ‘with swaged-end fittings Use only exact hose replacements meet- ing Getinge/Castle, inc. specifications. Unauthorized substitutions may cause system failure, resulting in severe patient ‘and operator injury. Replacement Replace hydraulic hoses if the PVC jacket is damaged the lines become kinked. fitting threads are damaged, or any other defect exists 2, Replace hydraulic hoses with hoses of the exact specified length. Verify length by comparison prior to installation. 3, Route hoses exactly as shown in Figure 3-2. ‘Assemble and tighten all ine clamps as follows: fa. Tighten the two hydraulic line clamps with the hydraulic lines completely filing the hose boxes at table low height. ». Tighten the two hydraulic line clamps after adjust- ing the hydraulic line running over the til beam so. thal they are free from binding against the tit cyin- der oF main support tug with the tabletop in full reverse slide This is necessary to prevent lines from being pulled tight in the hose boxes when the table is elevated or extra hose being pinched or abraded when the slide trame moves back and forth. HroRAUUe, UNE cues ‘5038980 FIGURE 6-14, HYDRAULIC LINE CLAMPS‘SHAMPAINE 5100B/5100E SURGICAL TABLE 6. Repair and Replacement 6-2.9 ACCESSING THE UNDERSIDE OF THE BASE ASSEMBLY Method 1 This method is recommended for examining the compo- ents under the base and lubrication of the casters. 1. Immobilze the table. 2. Level all the tabletop sections, then lower leg section 25 to 30 degrees, 3. Move the tabletop (in stide position) so that it is cen- tered on the elevate column, 4, From the lowest position raise the tabletop to highest position, 5. Remove the Jeg extension and the headrest. 6. Place corrugated board (3! x 3' area) or padding on tloor near the corner feet at the foot end of the base. Use two persons, one on each side of the table. Do not hold onto the fairing side covers on the table support frame, Hold by the siderails, one hand at the head end of the back section and the other hand at the center of the seat section, 7. Tilt the table toward the foot end until the leg section rests on the corrugated board. Ensure table is resting in a stable posi- tion and block if necessary to prevent table from falling. Instability may allow table 10 fall and cause injury to personnel and damage to table. 8. After work on the underside of the base is completed, lift the table back to the upright position, 6-16 Method 2 This method is recommended for replacing lower check valves and lift rebuilding: 4. Immobilize the table and lower It 2. Replace breather cap with solid cap on reservoir (if available); otherwise, wrap breather in towels. *. 8. Position for proper procedure (valve repl.) 4, Wrap power unit with towels. 5. Lay cardboard or mats, lengthwise on floor at left side of table. 6. Lay table down on side. Remove pendant cable or ensure that it doesn't become caught under table.'SHAMPAINE 5100B/5100E SURGICAL TABLE 6. Repair and Replacement 6-2.10 POWER UNIT (MOTOR, PUMP AND RESERVOIR ASSEMBLY) Removal and Replacement 1. Raise the table and place leg in up position 2, Disconnect the pressure line from the elbow on top of the pump, Cap the loose fine with a clean 1/8" NPT pipe cap to prevent leakage, contamination, and bleeding cifficulty. 3, Disconnect the return line from the elbow on top of the pump. Cap the loose line with a clean 1/8" NPT pipe cap to prevent leakage and contamination, Disconnect tine cord from base to pre- vent inadvertent connection to a power su source. 4. Remove vent ine from “d" port on power unit 5. Disconnect motor connector 1A1P from the power ‘entry assembly. 6. Disconnect the motor ground wire from ground stud. 7. Remove the 2 allen cap screws securing the pump to the base, 8, Remove the power unit, Iiting it over to the lett side of the base and place in drain pan or area to catch oil @. Remove foot pump source line from manifold, 10, Remove power unit and drain — return or discard old power unit Ifthe reservoir or power unit is held while securing the foot pump source line, the seal between the reservoir and pump ‘may come loose and allow oil to leak. Always hold the foot pump source line tube on the reservoir when tightening. 11. Install foot pump source line by holding source line tube on reservoir. Secure line, 12, Reinstall in reverse order, 18, Bleed by disconnecting the J3 solenoid connector at the control board and running the pump for approx: imately 1 minute by activating any function. This will force any air back to the reservoir via the reliet valve. RETURN UNE \ I~ escesune Indo" FIGURE 6-15. POWER UNIT REMOVAL 950520 617‘SHAMPAINE 5100B/5100E SURGICAL TABLE 6. Repair and Replacement 6-2.11 MANUAL PUMP Removal and Replacement 1, Tip table on end (see Section 6-2.7). 2, Remove outer pedal assembly by pulling it straight ‘outward. If assembly latches, pull release knob out ‘and withdraw pedal assembly. 3. Disconnect the pressure line-at the manual pump fitting. Disconnect the suction line at the reservoir filter fitting, 4, Remove three cap screws. 5. Remove the pump and pedal mechanism sub- assembly through the bottom of the base. 6. Reverse the above steps to install the pump and Pedal mechanism subassembly. 7. Tip table back onto floor feet. 8. Install the outer pedal holding the release knob out Until the end of the pedal bar passes. 9. Without operating any table top functions, prime the pump by operating the pedal until solid resistance is felt and no air bubbles are present in the foot pump source line. Pump for approximately 1 minute to force any air in the line out to the reservoir via the relief valve. 10. if the pump reliof valve has been disturbed, it must be readjusted (see next procedure). = A TO RELEASE PRESSURE UNE FITTING : FIGURE 6-16. MANUAL PUMP REMOVAL 618 350520‘SHAMPAINE 51008/5100E SURGICAL TABLE 6. Repair and Replacement 6-2.11.1 PRESSURE RELIEF VALVE ADJUSTMENT ‘The relief valve is set at the factory and should not need 10 be reset unless it is disturbed. To adjust, proceed as follows: 1. Remove upper base cover. Be sure pump is primed. 2, Remove pressure fine and connect a pressure gauge to the pump. WE ZB [L32oc3 abt FIGURE 6-17. PRESSURE RELIEF VALVE ADJUSTMENT 8. Through the hole in the base above the upper mount- ing screw, turn the stop screw to adjust pump output pressure, 4, Turn screw clockwise to increase pressure, counter clockwise to decrease pressure. Set the relief valve to 1400 to 1500 psi. Lock the stop screw with one drop of Loctite 242 (blue). 5, Remove gauge and reinsiali the pressure line. 6-2.11.2 FOOT PUMP SUCTION LINE REPLACEMENT 1. Remove the manual pump. 2. Remove four screws and remove the mount to gain access to the suction line fiting at the elbow. SUCTION LINE FIGURE 6-18, MANUAL PUMP SUCTION LINESHAMPAINE 5100B/5100E SURGICAL TABLE 6. Repair and Replacement 6-2.11.3 REBUILDING THE FOOT PUMP PRESSURE ~~ sueion. eeueh syste SrsTey e 1, Remove two screws to separate pedal linkage from haat the pump. 2. Remove four screws to separate the pump into its VY major subassemblies | eho 3. With the mount separated from the valve blok, the j suction hose can be removed from the valve block } = : 4, Valve Block Subassembly OF = a, Tho suetion check system consists of the eyelet, a : retaining ring and spring, 7 one SYSTEM os b. The output check system consists of the spacer, eo cartridge, and O-ring. a ‘i lomo 6. The pressure rolie! system consists of the tp, cw pg PRESSURE i (O-ring, stop screw, spring, and adapter plug. eee UNE i ' 4. Inspect all passages for foreign material and FIGURE 6-19, VALVE BLOCK SUBASSEMBLY examine suction check and relief seats for nicks and other impedections. The output check car i tridge must operate freely, @, Check poppet operation with a small diameter pin. e | Poppet must return to seated position smoothly and completely. f. Examine the check ball and relief tip for smooth- ness. Any defective items must be replaced. 5. Piston and Body Subassembly 1, Set on a table with piston rod and spring up. ’b. Immobilize piston rod with a 3/16" hex wrench in its upper end and loosen the trunnion bar. cc. Remove the hex wrench and compress the spring by pushing downward on the spring guide with the other hand unscrew and remove the trunnion bar. Slowly reduce force on the spring guide. 6-20 350520‘SHAMPAINE 5100B/5100E SURGICAL TABLE 6. Repair and Replacement FIGURE 6-20. PISTON AND BODY SUBASSEMBLY ‘Sudden release of the spring guide while the spring is compressed could allow the {guide to fy off and may result in injury to the service person or bystander. 4. Push the piston assembly through and out of the body. . Carefully clean alt parts and examine the bore and seals for scratches, nicks, ete. {. Replace parts if such problems are present. Because special tools and procedures are involved, Getinge/Castle, Inc. does not recommend field replacement of piston seat or piston rod seal. 6, Reassembie the applicable subassemblies and com plete pump by reversing the steps listed above. All Seals should be lightly lubricated with hydraulic oll before assembly. 7. Reinstall pump in table and check pressure relief valve (see Section 6-2.9), 950520 Repair Kits ‘A062850-52 — Body, Bearing & Rod Seal Assembly Includes: 1 Body 2 Seal 8 Bearing ‘A062850-51 — Seal Kit Includes: 4 O-Ring (2) 5O-Ring 6 O-Ring Refer to Parts Catalog for other repair part numbers. > 5 123 , OTE FIGURE 6-21. MANUAL PUMP REPAIR PARTSSHAMPAINE 5100B/5100E SURGICAL TABLE 6. Repair and Replacement ia 6-2.12 1 When replacing hydraulic cylinders, the section that attaches 10 the cylinder must be secured to a stationary object (e.9., table frame via rope) to prevent the sec- tion from moving and causing injury. TILT CYLINDER REPLACEMENT: Remove the 8 plug buttons form the seat section ‘The buttons can be pried out and reused, or punched out and discarded. Replacements can be obtained by ordering part number PO62200. Remove the 8 cap screws in the seat section. The ‘square nuts will drop into the x-ray channel below. Fiemove the seat section and put the screws and ‘huts aside for reassembly. Remove the 4 screws at the foot end of the table that seoure-the ill frame cover tothe frame, and slide the cover off. See Figure 6-23. TRENDELENBURG CYLINDER REPLACEMENT: 6-2.13 1, Remove the 8 plug buttons form the seat section. ‘The buttons can be pried out and reused, or punched out and discarded. Replacements can be obtained by ordering part number P062200. 2, Remove the 8 cap screws in the seat section. The square nuts will drop into the x-ray channel below. Remove the seat section and put the screws aad nuts aside for reassembly. 3. Remove the 4 screws at the foot end of the table that secure the tilt frame cover to the frame, and slide the cover off. See Figure 6:23. 4, Elevate the table, position in full reverse trendelen- burg, and tie it down, '5, Remove the lock nut and shoulder bolt securing the levis to the frame and retract the Trend. Cylinder. 6. Remove the upper column shield. 7. Remove the screws securing one of the hose boxes to the frame and lower the hose box (hoses inside). 8. Remove one of the brackets securing the trend cylinder to the frame, and remove the cylinder, hoses intact. 9. Remove the hydraulic lines from the old oytinder, ‘and fil and bleed the new cylinder using the steps in Section 6-3.5 and 6-3.6. 10. Retract the rod on the new Trend. cylinder and install in reverse order. 4. Activate tit right to obtain better access to the rod levis. Tie the table frame down so that it does not move after removing the cylinder. 5. Remove the locking nut and shovider bolt that ‘secure the clevis rod to the frame at the end of the tit cylinder. 6, Remove the upper column shield. 7. Tie the column boot up at the foot end of the table to access the tilt cylinder brackets. & Remove the 2 cap screws securing the tilt cylinder bracket to the frame and remove the brackel. See Figure 6-23. Only one bracket needs to be removed. 9. Remove the cylinder with both hydraulic lines attached. 10. Remove the hydraulic lines from the old cylinder, and fil and bleed the new cylinder using the steps in Section 6-35 and 6-3.6. The til cylinder has bleed screws for bleeding air. 11. Retract the rod on the new tit cylinder and install in reverse order. 6-22 950520SHAMPAINE 5100B/5100E SURGICAL TABLE 6. Repair and Replacement Hose cAgSSOVER : AREA {9 TILT CYLINDER ut Gs BRACKETS uber I ] TREND CYLINDER, TF 1 Lelie, sacar | |LT | Penne \ | | | wosenox “1 | e View FROM HEAD OF TABLE FIGURE 6-22. TILT AND TREND ‘Tur Bracket TO REMOVE TUT FRAME ‘COVER REMOVED FROM THIS END FIGURE 6-23. TILT FRAME 380520 6-23SHAMPAINE 5100B/5100E SURGICAL TABLE 6. Repair and Replacement 6-2.14 TABLETOP SERIES CYLINDERS - LEG, BACK, AND KIDNEY Ita table exhibits the symptom of the left side of a leg or back section being lower than the right side, the problem is most likely caused by a lack of fluid in the crossover fine, NOT AIR. This also holds true for a kidney elevator where the right side fs lower than the Jett side. This is because the leg, back, and kidney cylin. der pairs are in series. The FH cylinders for the leg and back, by moving out, pres- surize the LH cylinders to move out, For the kidney elevator, the LH cylinder ‘moves out and pressurizes the AH cylin- der, The hydraulic ine between series cylinder is called the crossover line. A lack of fluid in the crossover line will ‘cause the right cylinder to move out fur- ther than the left cylinder, causing the left side to be lower than the right side (ig. 1). The fluid in the crossover line must have either leaked out externally, or leaked past one cf the piston seals inter- nally. if you cannot isolate an external leak, an internal leak must be the cause. An internal leak can also manitest itselt by an excess of fluid in the crossover line. In this case, for the leg and back, the LH side will be higher than the RH side, and for the kidney, the RH side will be higher than the LH side. {f an internal teak is suspected, the following is a gener- al rule for determining which cylinder is teaking Leaking Section Higher Side cylinder Leg Lett Right Leg Right Left Back Left Right Back Right Left Kidney Lett Right Kidney Right Lett The following tests should also be run to verify that a cylinder is leaking internally 1. Level the section so that the lowest side is horizon- tal with the seat, 2. Load the section with at least 150Ibs on the end 3. Activate the uptunction for that section and move 2+ B inches. 4. Compare the resulting position of the section to the above table. 5. Asa final tost for an internal leak, move the suspect cylinder to its limit via its pressure line, e.9., Move the LH back or leg cylinder Down, and the RH back or {eg cylinder UP. Remove the crossover fiting and wipe clean, Activate the pressure line for the cylin- der in question. If cil comes out of the open ‘crossover fitting, the cylinder is leaking internally. Definitions: 1. Right (RH) and Left (LH) are referenced when standing al the head end of the table. This is the fend of the table that has the AC receptacle and the foot pump. This convention is for all table drawings, and procedures. 2. Pressure fitting and line: The pressure fitting and line are connected to the manifold. These are marked by numbers on the schematic and on the oylinders, 3. Crossover fitting and lines: The crossover fitting and lines connect one cylinder to another via the crossover fine. The fluid between these lines is cap- tive and never enters the manifold. These jines and fittings are marked by letters on the schematic and ‘on the cylinders. 4, LH-= Lett side of table; RH = Right side of table. Balancing is best performed by 2 people: ‘one to operate the hydraulics, and one to bleed the fines. iis best to tighten a hydraulic line white itis pressunzed with hydraulic fuid to prevent air entering the system. Filing cylinders for balancing via the table's hydraulic system requires @ brass coupling and two swivel ftings. : These are placed together so that a pressure hose from the manifold can be ‘mated to a crossover hose from the cylinder being filed. The part numbers to order are: (1) Coupling - 8052950, (2) Swivel Fiting - 8054332. 6-24SHAMPAINE 5100B/5100E SURGICAL TABLE 6. Repair and Replacement Bleeding and Balancing {1 the oylinder(s) are replaced, once they are filled with fluid and purged of air via section 6-3.5 and 6-36, or if the crossover line requires additional fluid due fo an external leak from the ‘crossover fitting, the following must be done to balance the cylinders. The oylin- ders must be mechanically disconnected from the table during bleeding to allow for tipping. {fa cylinder has been replaced, it must be positioned as described in the following steps for bleeding and balanc- ing. The cylinders must be positioned in the table so that the hydraulic lines can be properly connected. 4. Setup: Activate the “UP” function for the /eg or back ‘section that requires replacement or balancing, “Down’ for the kidney. Elevate the section unti itis approximately 15 degrees below its maximum limit. 2. Fill RH cylinder crossover section: Disconnect the section from its pivots. See Fig. 6- . Disconnect the hydraulic lines from the left cylinder and remove the fasteners securing the cylinder to the table as illustrated in Fig.6- This removes the LH cylin- der from the circuit and leaves the RH cylinder in the circuit. Place a coupling on the pressure line and pressurize until the air is purged from the coupling and connect to the crossover line (couple them together). Bleed the air by keeping the coupling loose and pressurizing from both sides of the loose fitting, .¢., activate the down function until oil runs out of the loose coupling, followed by the up function until oll runs out of the fiting. Tighten during the last ‘operation, Activate the "DOWN? (‘UP" for Kidney) function until the FH cylinder is almost fully retract- ‘ed, between 1-2" irom being fully retracted. (Extend the RH kidney rod until its almost fully extended, leaving 1-2"to full extension). See Fig.6- —_. The RH cylinder will now be retracted (extended for kid- ney), and the LH cylinder extended (retracted for kidney), leaving an excess amount of fluid in the ‘crossover line for bleeding and balancing. Remove the coupling and reconnect the lines to the LH cylin- der. Tighten the pressure line, and leave the crossover line slightly loose. 3, Removing air from the crossover side: With the LH cylinder crossover fitting cracked and the cylinder held do that the fitting Is elevated, activate the “UP” function (‘Down" for kidney), bleeding any air from the crossover line as in step 6-3.6. Stop bleeding when clear fluid runs-out and activate the “DOWN CUP" for kidney) function, bleeding any air from the cylinder, Tighten when clear fluid runs out. Be sure not to bleed too much fluid, or the process of filing will have to be repeated. 4, Removing air from the pressure side: Loosen the LH cylinder pressure=fitting and -activate the “DOWN function (*UP for kidney}, bleeding any air from the pressure line. Stop bleeding when clear fluid runs out, and activate the “Up” function (DOWN for kidney), bleeding any air from the oylin- der. Tighten the line. 5. Mechanical connection: At this can be secured to the table frame. 1, the cylinders, 6a, Balancing Leg and Back: At this point, the RH cytin- der will be almost fully retracted, and the LH cylin- der will be almost fully extended. Connect the left side pivot and activate the “UP" function until the section fully extends, Crack the fitting at the LH crossover line, activate the “UP function, and bleed fluid from the crossover line - the RH cylinder will start to extend. Bleed unti the RH link is very close to the point where it can be connected (Approx. 11/4"), At this point, tighten the crossover fitting. Pull the RH side of the section down with your hand, slightly warping the radiolucent top, and connect the pivot link to the RH side of the section with the roll pin (ubricate with grease). The right side of the sec- tion will now be lower than the left side, ~ ‘6b. Balancing Kidney: At this point, the RH oylinder will be almost fully extended and the LH almost fully retracted, Retract the kidney function until move- ment stops. Crack the LH crossover line and acti vate retract until the RK cylinder fully retracts (even with the left). At this point, tighten the fitting and stop the function. Reassemble the kidney elevator system. If the gears and rack will not line up, more fluid may have to be removed from the crossover. if this is required, bleed very small amounts until the system can be aligned. ‘The remaining steps are for the Back and Leg. 7. Check intial balance: Activate the “DOWN' function and bring the section down so that the RH side is level with the seat section - the LH side should be slightly higher. Place a straight edge on the RH side {rom the section being balanced to the seat section, 350520 6-25‘SHAMPAINE 5100B/5100E SURGICAL TABLE 6. Repair and Replacement eee eee eee : and move the section being balanced until the straight edge lies flat (See figure 2). NOTE: IF THE END OF THE SECTION STARTS TO WARP MORE THAN 1” DURING THE “DOWN” MOTION, CRACK THE LH FITTING TO PURGE A VERY SMALL AMOUNT OF OL OUT OF THE CROSSOVER LINE. TIGHTEN WHEN THE SECTION WARP IS. LESS THAN 1". Slide the straight edge over to the’ LH side. Crack the LH crossover fiting and lightly bush down on the left side of the section, bleeding oll from the LH crossover fitting until the LH side is approx. 1/8-1/4" higher than the RH side, Tighten the crossover fitting, 8. Articulate the section to fill any voids: Run the sec: tion fully up, fully down, and then bring the FH side level with the seat section 9. Check balance: Place a straight edge on the RH side from the section being balanced fo the seat section, and move the section being balanced until the straight edge lies fiat (See figure 2), Slide the straight edge over to the LH side. If the straight edge is less than 1/16" of being flat, the section is balanced - Proceed to step (12). If the section it not balanced, continue with the next step. 10. Open the crossover line at the LH fitting and push down on the LH side of the section until the straight edge is less than 1/16" of being fiat. Tighten the crossover fiting 11, Goto step (9) 112, Run the section through a complete up/down cycle and recheck balance. If all is satisfactory, check the reservoir oil level (1/2"-1" from top when the lift is down), Check all fittings for tightness, clean up allo residue, reassemble covers, and test and clean up the table, If during the bleeding, the LH side ever becomes lower then the RH side, TOO MUCH fluid has been removed from the ‘crossover, and the filing and balancing must be repeated. 6-26 360520‘SHAMPAINE 51006/5100E SURGICAL TABLE 6. Repair and Replacement 2 Fis. Lack Of Fuid In Crossover Line. RH Side a tended Farther Than LH Se. Tie The Secton “UP” When Pivots Are Removes Placement Of Siright Edge Back cmunen ictemtaht Z e; Disconnect Thi 7 Prot et Sere ‘On Bottom Of “ Disconnect This Una) For Back On Poot ForThe beg Each Sie «Te Seaton UP Gel bial Fasteners For bseety a <— HeaD eno Cylinder LeceN —p Cite Removal ry money Removal rUNDER LEVATOR Remove Kidney BlocksiBrackets And 10.2 RIGHT SIDE VIEW Gears For Kidney Elevator. (Raise Elovator If Accessing Leg Section } Coupling 4 aH ON _\ Fie.) FIGURE 6-24. TABLE TOP CYLINDERS‘SHAMPAINE 5100B/5100E SURGICAL TABLE 6, Repair and Replacement 6-2.15 FOOT JACKS (FLOOR LOCKING SYSTEM) The foot jacks are 3 hydraulic cylinders connected in series as illustrated in figure 6-25, They are sim- ilar to the leg, back, and kidney cylinders, except that there are 3 cylinders instead of 2, The cylinders are configured ina tipod system to compensate for uneven flors. One oylinder isa captive cylinder, ‘meaning that itis not directly connected tothe hydraulic manifold, butts movement is dependent ypon the two cylinders connected to it. To lock the table, the Head foot (HD) is pressurized by the F2 line from the manifold. As the head foot extends, it pressurizes the Right foot (RH) to extend, The right foot pressurizes the Left foot (LH) to extend. The right foot activates the interiock switch which sends a sig- ‘al to the controller thatthe table's locked. Only ater the table is locked can the table top functions be activated. To retract the feet, the system works in reverse, with the left foo! being pressurized By the maniold. in this system, the Right foot isthe captive cylinder. . HD Fe [Seater Gm Convo! — SEE Manito FH FL LH RH FC (Seake TV (Feat ABE (0.32 mm) [0.237 31mm FIGURE 6-25. FOOT JACK LOCKING SYSTEM 6-2.15.1. ISOLATING A FOOT JACK a PROBLEM: A foot jack problem’can manifest itself in a number of ‘ways, Among them are: ‘a. The floor lock light does not turn on, but the foot Jacks appear to be locking when activated. b. The floor lock light turns on, then goes off once the ‘motor stops running; drifting 's apparent, ©. The floor lock light does not turn on, and one or more foot jacks does not move when the locking system is activated, ‘One or more of the foot jacks cannot be retracted, or can only be partially retracted. ‘The floor lock light comes on, but the table wobbles: as if one or more of the foot jacks has not locked. The floor lock light is on, but the table can be pushed and moved, 6-28 ‘950520SHAMPAINE 5100B/5100E SURGICAL TABLE 6. Repair and Replacement 6-2.15.2 INITIAL ASSESSMENT OF A FAILURE: ‘The only way to property assess the failure is to remove the base covers and examine and/or measure the action of all three foot jacks. Mechanical and electrical prob- ems with the locking switch at the right foot can be eas- ily identified and corrected. Hydraulic problems with the locking require more testing and evaluation. This sec- tion addresses the initial assessment of @ problem that affects the ability to lock the table, and some simple measures to take prior to hydraulic disassembly of the foot locking system. 6-2,15.2.1. FOOT PAD ADJUSTMENT: ‘The table can be moved if tis pushed when the feet are locked and the lock light is on. The height of each foot ad should be checked first, The bottom of each foot ad 'should be 5/8” from the floor when the table is Unlocked and all feet are completely retracted. See sec: tion 4-10, 6-2.15.2.2. INTERLOCK SWITCH: ‘The table appears to be locked, but the lock light is off With the foot jacks extended, check to see if the inter- lock switch at the right foot is engaged. I itis, the prob- lem is electrical, If itis not, check the stroke of the right foot. If the stroke of the right foot is 1 11/32" +- 1/16 (see. 6-2,14.2.5 below), adjusting the switch bracket or sight- ly bending the tab on the switch is acceptable. If the stroke is less, ADJUSTMENT IS NOT THE SOLUTION: further investigation is required. 6-2.15. CHECK THE TIMING: fall feet are moving evenly, but it takes more than one Jock or unlock cycle to fully lock or unlock the table, the timing may be out of adjustment. It the feet are still mov- ing when the motor shuts off (full stroke has not yet been achieved), the speed may noed to be increased via the feet flow control valve. The feet should com- pletely lock and unlock in 4-6 seconds. See section 4- 9.2. 6-2.15.2.4 DRIFTING - ALL THREE. JACKS: If when activated to lock, all three foot jacks extend in unison, then drift down in unison so that the casters just touch the tloor, the problem is most likely an F2 check valve problem. This failure mode is usually intermittent. The key to determining this to be an F2 check valve problem is that all three feet drift evenly, and when acti- vated to unlock, they afftetract to specification. CYLINDER STROKE: Knowing the stroke of each foot jack is important when troubleshooting a foot locking problem. The stroke is defined as the distance that the cylinder rod moves. Take two measurements-between the same two points ‘on the rod of each foot jack, one extended and one retracted. Subtract the retracted from the extended 10, get the stroke. The stroke should be as noted below (+- 1/16"). If the stroke of any of the foot jacks is fess than specified, a problem exists that will require further inves. tigation 6-2.15.2.5, Stroke Rod Retracted Rod Extended (measured trom cylinder to end of rod) HD toot: 1” 156 25ie (25mm) RH foot: 1 11/2" 20/82 131/82" (1.83", 34mm) LH foot: 17/32" 24192 131/32" 1.28", 31mm) The RH and LH foot jacks are the same, but the stroke of each cylinder in a cor- rectly balanced foot jack system is differ cent. This is because the system is BAL- ANCED with all 3 jacks extended. When the feet are retracted, the oil in the cap end of the lett foot pushes on the rod end of the right foot. The right foot tully retracts, but the left foot cannot tully retract. This is because the volume of oll in the cap end of the left foot is greater than the volume in the rod end of the right foot. LE, the rod in the right foot takes up space: therefore, the left foot cannot push its tui! volume of oil into the right foot, preventing it from fully retract- ing. 4 6-2.15.3. EXTERNAL LEAKS - ore > ‘An external leak at any foot jack is easily isolated once the covers are removed (look for oil). An external leak at the head foot will show up as oil on the floor. An external leak at the right and left foot may not show up as oll on the floor because of the channel inside the base. External leaks can have the same symptoms of an internal leak, except that multiple unlock cycles will ot cause a foot to eventually lock or unlock. Replacement and balancing of a foot jack is determined by the location of the leak (see sections on replacement ‘350520 6-29'SHAMPAINE 5100B/5100E SURGICAL TABLE. 6. Repair and Replacement ee tensioner aU AE and balancing). The next section deals with isolating an internal leak if no external leak is found, 6-2.15.4. INTERNAL LEAKS: An internal leak is one where the hydraulic fluid bypass- €s the piston inside of a cylinder. Internal leaks manifest themselves in either driting or uneven movement of the 3 foot jacks. 6-2.15.4.1_ DRIFTING - HEAD FOOT: Ht the table locks to the floor, the lock light stays on, the head foot drifts or does not lft the table, and the tight and left feet lock and do net drift, an internal leak exists inthe head foot. The symptoms can vary, depending on the size of the leak. A large leak can cause the system to act as if the head foot piston is not there; Le., the right and eft feet will lock and the head foot pad may just touch the'fioor When retracting, aiMfeet should retract, ‘completely. A small leak can cause the head foot to slowly drift after liting the table, while the right foot and left foot stay locked. If this occurs, more than one unlock cycle may be required to fully retract the right and left feet 6. 15.4.2 DRIFTING - RIGHT FOO! It the head foot lifts the table off the floor, the right foot just touches the tloor, and the left foot lifts the table off the floor, there is an internal leak in the right foot. The table may appear to be locked, but the lock light will not turn on. As with an internal leak in the head foot, the ‘symptoms can vary, depending on the size of the inter- nal leak. A large leak can cause the system to act as if the right foot piston is not there; ie., the head fost and left foot wil lift the table off the floor, while the right foot ‘may just touch the floor. When retracting, all 3 feet ‘should retract completely. A small leak can cause the Tight foot to slowly drift alter locking the table, while the hhead foot and lett foot stay locked. if this occurs, more than one unlock cycle may be required to fully retract the head and leit feet. 6-2.15.4.3 DRIFTING - LEFT FOOT: I the head foot and right foot lift the table of the floor, ‘and the left foot does not, an internal leak exists in the left foot. The lock light will turn on. As with an internal leak in the right and head feet, the symptoms can vary, depending on the size of the internal leak. A large leak can cause the system to act as if the left foot piston is not there; j.e., the head foot and right foot will lift the table off the floor, while the left foot may just touch the floor. When retracting, all 3 feet should retract com- ietely. A small leakcan cause the left foot to slowly drift atter locking the table, while the head foot and right foot stay locked. If this occurs, more than one unlock cycle may be required to fully retract the head and right feet, 6-2.15.5 REPLACEMENT AND BALANCING: rior to replacing or balancing any of the foot jacks, all three must be mechanically disconnected from the table. Uniock (retract) the feet prior to disconnecting the feet from the table. If the feet will not retract, activate Unlock, and manually pry the feet up by placing a screw. driver under the foot pad of the foot that will not retract while the motor is running. The two cap screws that secure the head foct to the base are accessed by removing the gray base shield on the left side of the table. The left and right foot are disconnected by remov- ing the pin that secures the rod clevis to the cam (See figure 6-26). If the right of left foot requites replacement, the complete foot is removed via the nut and shoulder screw that secure the cap end of the foot jack to the base, If the pin securing the right or left foot clevis tots ‘cam cannot be removed due to the torque placed on it by the rod, the foot can be extended or retracted by acti- vating the lock or unlock function and tuning the on/off ‘switch off when the tod moves 1/4"to 1/2". If an internal leak is questionable, it can be verified using the proce- ‘dure in section 6-2.13. The next 3 sections are proce- ‘dures for replacing the foot jacks. If more than one foot jack requires replacement, balancing always starts with the eft foot and works backwards to the right foot, and then the head foct. Pivot FIGURE 6-26. FOOT-END ROD END. 6-30 350520SHAMPAINE 5100B/5100E SURGICAL TABLE 6. Repair and Replacement Filing, bleeding, and balancing foot jacks requires 2 people: one to operate the hydraulics, and one to manipulate the hydraulic cylinders and lines. Its best to fighten a hydraulic line while it is under pressure (0 prevent air entering the sys~ tem. Filling cylinders for balancing via the tabie's hydraulic system requires a brass coupling and two swivel fittings. These are placed together so that a pressure hose from the manifold can be mated to a crossover hose from the cylinder being filed. The part numbers to order are: (1) Coupling - B052950, (2) Swivel Fitting ~ 8054332, HEAD FOOT REPLACEMENT AND BALANCING: 6-2.15.5.1 When replacing ‘or balancing thevhead foot, an excess amount of hydraulic fluid is required between the head foot and the right foot to purge any air between the two when the head foot Is connected. Following are the steps in this process: 1. After disconnecting the feet from the table, activate lock and extend the feet (it possible). 2. Disconnect the F2 and FH lines from the head foot The tie wraps securing the lines together can be cut 0 that therfines can be pulled up and over the left side of the base for filing cylinders. See Fig. 6-27 Fill the new head foot using the F2 line as the pros- sure line as called out in 6-35. The head foot ‘should be lett retracted, which leaves the rod end of the head foot full of cil. See Fig. 6-28. Connect and tighten a coupling to the F2 hydraulic line and place the ond of the line in a bucket or a towel. Activate LOCK. When oil runs out of the coupling {all air removed), turn the on/off switch off at the base. ). This wil stop the pump from running its nor- mal 7 seconds. (For an E-Table, pull the AC power ‘input plug, or use the foot pump to lock). Connect the coupling to the FH hose, but do not tighten. Place the coupling over a bucket or towel, hold the loose end of the coupling up, and activate LOCK. Tighten the coupling when clear oil runs out of the line and allow the power unit to run. The right foot and lett foot will start to extend it they are not already extended, ‘This step removes any air from the end of the coupling. Hold the same coupling up, crack the fitting, and activate UNLOCK. This will push any air that isin the FH line out as the feet start to retract. Tighten the coupling when clear oil runs out. ‘Activate LOCK and fully extend the right and left Bring F2 Line Out From Foo! Jack FIGURE 6-27. REMOVING F2 LINE FOR FILLING CYLINDERS 350520 631‘SHAMPAINE 5100B/5100E SURGICAL TABLE 6. Repair and Replacement feet 10, Disconnect the coupling from the F2 and FH lines and reroute for connection to the head foot. 11. Connect and tighten the F2 and FH lines to their appropriate fitings on the filed head foot. 12, Take a measurement between the top of the foot ‘pad and the bottom of the cylinder block to be used in calculating the stroke. This measurement, added to 1", is the distance that the head foot needs to move. The head foot has two bleed screws that can be used to purge air and oil when balancing, 113. Position the head foot on its side (with hoses connected and tightened) so that the bleed screw at the rod end is point ing up. 14. Looserrthe bleed screw at the rod-end of the cylin der (side) and activate UNLOCK. Tighten when lear oll runs out. This purges air trom the FH line. 15. Loosen the same bleed screw and activate LOCK, Tighten when the rod moves the distance calculat- ed in step 12. This step purges air from the FH side Of the eyed an excess oto balance he clr yy der. 16. Place the head foot in its normai position. | 17. Loosen the bleed screw at the top of the foot and | activate LOCK. Tighten the screw when oil runs out | of the fiting. This step purges air from the F2 line. 18. Loosen the bleed screw atthe top of the head foot, activate UNLOCK. Tighten when clear oil runs out This step purges air trom the F2 side of the head foot : 49. Check all 3 feet for their proper stroke (+_1/16): Head Foot: 1" Right foot: 1 11/32" 7 Left foot: 1 7/32 20. Retract the foot jacks and reassemble in reverse order. When installing the base shield on the orate] 198s ofthe table, open the auxfary i drawer to prevent the base shield from “ocking’ the drawer closed. FIGURE 6-26, HEAD FOOT REPLACEMENT AND BALANCING (Foon 6 FR [Eonar j [Manifold El : | i [Head Foot Retrastes FH | SC . | ut RH | ect ft and Right if {Foot Extended 6-32 350520 |‘SHAMPAINE 5100B/5100E SURGICAL TABLE 6. Repair and Replacement ———— — 6-2.15.5.2 RIGHT FOOT REPLACEMENT AND BALANCING: “The right foot is a completely captive foot, meaning that it does not connect to the manifold. Replacement of the Tight foot requires removing air and balancing of both the FH and the FC crossover lines. Because both ‘crossover lines require filing, bleeding, and balancing, be sure that the failure necessitates replacement of the right foot. See fig. 6-29. 1. Disconnect the foot jacks from the table as called out in6-2.14.5, 2. Remove the clevis from the detective right foot and place on the new right foot. Remove the F1 pres- sure line from the left foot and using the UNLOCK function, fill the new right foot via 6-3.5. Position and leave the rod on the right foot extended 1/2” from its fully retracted position. Cover the fitings and set aside. 3. Remove the FC line at the cap end of the lett foot, ‘and connect the F'1 hydraulic line to this fing. The left foot cylinder rod should be ‘retracted; therefore, place the FH fitting Into a bucket or cover with towels 10 catch the hydraulic off that will flow out during the next step. 4. Activate UNLOCK, and extend the left foot 5. Reconnect the proper lines tothe eft foot: Ft to rod fend fting, and FC to the cap end fitting. 6. Remove the FH and FC hydraulic lines from the detective right foot, and connect them fo the newly filled right foot 7. At the head cylinder, remove the F2 and FH lines from the head foot 8 Connect a coupling to the F2 line, and activate LOOK. When oil runs out of the coupling (all air removed), turn the on/off switch off at the base. ) This wil stop the pump from running its normal 7 seconds. (For an E-Table, pull the AC power input plug, or use the foot pump to lock). 8. Connect the courting to the FH hose, but do not tighten 410, Place the coupling over a bucket or towel, hold the loose end of the coupling up, and activate LOCK. Tighten the coupling when clear oil runs out of the line and allow the power unit to run. This step removes any alr from the pressure side of the cou- pling (F2 tine). 41. Crack the same coupling and activate UNLOCK. Tighten the coupling when clear oil uns out, This removes air in the FH line at the coupling as the let and right feet retract a small amount. 12, 13, 14, Holding the FH fiting-at the right foot up, crack the fitting and activate LOCK. Tighten the fitting when clear oll runs out. This removes air in the FH line at the right foot. The right and left feet may extend a small amount. Holding the FH fitting at the right foot up, crack the fitting and activate UNLOCK. Tighten the fitting ‘when clear olf runs out. This removes air trom the FH end of the right foot. The right and left feet may retract a small amount. Holding the FC fitting at the left foot up, crack the fit. “ting and activate UNLOCK. Tighten the fitttag when 16. 16. 17. 18. 19. 21 clear oll runs out, DO NOT BLEED TOO MUCH OIL, FROM THIS LINE OR FILLING WILL HAVE TO BE REPEATED! (1-2 CCs af the most). This removes air from the FC side of the left foot. The left toot may retract a small amount. Holding the FC fitting at the left foot up, crack the fit- ting and activate LOCK. Tighten the fitting when clear oil runs out. DO NOT BLEED TOO MUCH OL. FROM THIS LINE OR FILLING WILL HAVE TO BE REPEATED! (1-2 CCs af the most). This removes air from the FC line at the left foot. The left foot may retract a small amount. Holding the FC fitting at the right foot up, crack the fitting and activate UNLOCK. Tighten the fiting when clear oil runs out. DO NOT BLEED TOO MUCH OIL FROM THIS LINE OR FILLING WILL HAVE TO BE REPEATED! (1-2 CCs at the most). This removes air from the FC line at the right foot. ‘The right and left feet may retract a small amount. Activate UNLOCK and retract the left and right feet. The right foot should retract completely (farther than the left foot). Take a measurement of the rod to the cylinder for calculating the stroke. Add this mea- surement to 1 11/32” to calculate how for the right foot needs to be extended. Holding the FC fitting at the right foot up, crack the fitting and activate LOCK. Tighten the fiting when the right foot extends the amount calculated instep 14. This removes air and oil from the FC side of the right foot and balances the rightrand lett foot. Holding the F1 fitting at the lett foot up, crack the fit- ting and activate UNLOCK. Tighten when clear oll runs out. This removes air from the F1 hydraulic line. - Holding the F1 fitting at the left foot up, crack the fit- ting and activate LOCK. Tighten when clear oil runs out. This removes air from the F1 fitting in the left cylinder. Check the stroke of the right and left feet by activat- ing Lock and Unlock and measuring each, Leave the right and left feet extended. The next steps install head feot and balance the complete 350520 6-33SHAMPAINE 5100B/5100E SURGICAL TABLE 6. Repair and Replacement system. They are same steps used when replacing the head foot. Remove the coupling from between the F2 and FH lines. If the head foot is not already retracted, fill the ew head foot using the F2 line as the pressure line as called out in 6-3.5. The head foot should be left retracted, which leaves the rod end of the head foot full of oil. Connect the F2 and FH lines to their appropriate fit- tings on the head foot. ‘Take a measurement between the top of the foot ad and the bottom of the cylinder block to be used 23. 24, 2s. 27. Loosen the bleed screw atthe rod end of the cylin- der (side) and activate UNLOCK. Tighten when clear oil runs out. This purges air from the FH line. Loosen the same bleed screw and activate LOCK. Tighten when the rod moves the distance caiculat- ¢ in step 12. This step purges air from the FH side of the oylinder and excess oil to balance the cylin- der. Place the head foot in its normal position. Loosen the bleed screw at the top of the foot and activate LOCK. Tighten the screw when oil runs out of the fiting. This step purges air from the F2 line 28. 29. in calculating the stroke. This measurement, added 31, Loosen the bleed screw at the top of the head foot, to 1", is the distance that the head foot needs to activate UNLOCK. Tighten when clear oll runs oul move. This step purges air from the F2 side of the head foot. The head foot has two bleed screws that 32. Check all 3 fee! for their proper stroke (+_1/16): can be used to purge air and oll when Head Foot: 1” balancing, Right foot: 111/82" Lett foot: 1.732 83, Retract the foot jacks and reassemble in reverse 26. Position the head foot on its side (with hoses con- order. ‘nected and tightened) so that the bleed screw at the rod end is pointing up. 2 FH I coins sy eae Reh foot reacted, fee TRH. Liou extended. FIGURE 6-29. RIGHT FOOT REPLACEMENT 6-34 350520‘SHAMPAINE 5100B/5100E SURGICAL TABLE. 6, Repair and Replacement 6-2.15.5.3 LEFT FOOT REPLACEMENT AND BALANCING: 1. Disconnect the foot jacks from the table as called out in 6-2.14.5. 2, Remove the defective lett foot from the table, 3. Remove the clevis from the defective left foot and place on the new left foot 4. Connect a coupling to the F 1 line, place into a buck- et or towel, and activate UNLOCK. When oil runs. out of the coupling (all air removed), turn the on/off switch off at the base. This will stop the pump from. running its normal 7 seconds. (For an E-Table, pull the AC power input plug, or use the foot pump to Nock) 7. Connect the coupling to the FC hose, but do not tighten. 8. Place the coupling over a bucket or towel, hold the loose end of the coupling up, and activate UNLOCK. “Tighten the coupling when clear oil runs out of the line and allow the power unit to run. This step removes any air from the pressure side of the cou- pling (F1 line), 9. Crack the same coupling and activate Lock. Tighten the coupling when clear oil runs out, This removes air that is in the FC line at the coupling as the head and right fest extend a small amount. 10. Activate UNLOCK ang fully retract the right foot and, hhead foot. Take a measurement between the end of the rod and the end of the cylinder body at the Tight foot to be used in calculating the stroke. Add this measurement to 1 11/32" to determine how for the rod in the right foot needs to move, . = HD Retracted 11. Remove the coupling from the F1 pressure line ang the FC crossover line. 42, Connect the F1 line to the rod end of the left cylin- der, and the UNLOCK function, fill the new cylinder via 6-3.5. Position and leave the rod on the left foot extended, 13. Connect the left foot to its proper tines, leaving the FC line loose, 14, Holding the FC fitfing of the left foot up, activate UNLOCK. Tighten the fitting when clear oil runs out. This removes air trom the FC side of the cylinder. 15. Keeping the FC fitting of the left foot up;-activate LOCK. Tighten the fitting when right foot's rod reaches the distance calculated in step 10. This ~ removes air and oil trom the FC line, and balances the left and right cylinders. See figure 6-30 16, Holding the F1 fiting at the left foot up, loosen the Ft fiting and activate UNLOCK. Tighten the fitting when clear oil runs out, This removes air from the F1 line. 17, Keeping the F1 fitting at the left foot up, loosen the F1 fitting and activate LOCK. Tighten the fitting when clear oil runs out. This removes ait from the F1 side of the left foot cylinder. 48. Check all 3 feet for their proper stroke (+_1/16) Head Foot: 1” Right foot: 1.11/32". Left foot: 1 7/32 19. Retract the foot jacks and reassemble in reverse order. FH FC RH Retracted FIGURE 6-30, LEFT CYLINDER BALANCING 350520 6-35‘SHAMPAINE 5100B/5100E SURGICAL TABLE 6. Repair and Replacement 6-3 REMOVING AIR (BLEEDING) FROM THE HYDRAULIC SYSTEM This section examines how to remove air from the vari- us parts of the hydraulic system. This is required when @ hydraulic component is replaced or repaired, or when the integrity of the system is broken. When bleeding a hydraulic system, its important to remember that an air Dubble wil rise to the highest point in the area of its loca~ tion, Airis removed from the system by providing a path ‘ut of the system and pushing it out wth hydraulic pres~ sure, whether it be via the relum line in the manifold, or aan open swivel iting. When purging air from the hydraulic sys- tem, itis best to purge while under pres- ‘sure and tighten the component, line, or fitting while under pressure. This ensures that no backliling of voids with air can occur if a connection is left open ‘and the pressure is removed. hore Removing aris accomplished by pushing the air out via hydraulic pressure, which causes the system to loose some oil. Itis very important thatthe oll moved during bleeding is thoroughly cleaned up. HYDRAULIC MANIFOLD KEPNER CHECK VALVES AND MANIFOLD FITTINGS: 6-3.1 63.4.1 Ia check vave is replaced, the air introduced into the system can be removed by pushing it into the return end of the manitold and back out to the reservoir. This is accomplished by positioning the section that requires, valve replacement in the full position forthe valve being replaced. £.g.; replacing the # § back-up check valve requires the back to be in a full “UP” position prior to replacing. Alter replacement of the valve, run the back {rom full up to full down. This is push any air from the area of the check valve back to the return end of the ‘manifold and back to the reservoir, 6-3.1.2 SOLENOID VALVES: Prior to replacing a solenoid valve, position the section for the valve to be replaced so that the side of the cylin- der that is attached to the fitting on the top of the mani- fold is retracted. E.g., replacing the back section sole- oid requires that the back section is fully retracted. ‘Once the valve is replaced, loosen the top swivel fitting al the manifold for the affected function, and activate so that the top fiting és pressurized from the manifold. E.g. for the back section, crack the # 5 swivel on the manifold land activate back up. Allow air to escape from the fitting and tighten under pressure (while the motor is running). Air will be purged from the high end of the solenoid via the swivel fiting; air at the low end of the solenoid will be purged through the return side of the manifold. FLOW CONTROL VALVES: 6-3.1.3 Alter replacing the valve, but prior to tightening it, acti- vate the function so that the top fitting on the manifold will be pressurized. This allows air to escape after being pressurized from below. This is followed by pressurizing {rom the other direction to assure that no air was pushed into the opposing line. After removing air form the ‘opposing line, the flow control valve can be tightened. Eqg,, replacing the back section flow contro! valve requires that the flow control be left loose and that the back up function be activated. Once clear oll is flowing, stop and activate back down. Once clear oil flows out during the activation of back down, tighten the valve. 6-3.1.4 FILTER: ‘After replacing the filter, do not tighten the iting. Activate a function with the fiting loose, and allow air and oil to be purged via the filter port. Tighten the fitting when clear oil runs out. 6-3.2 MAIN LIFT: After rebuilding or replacing the main lit, air is purged Via the bleed screw on the upper cylinder. The lift is run up/down to cycle oll and help push air back to the rager- \oir through the manifold. The remaining air is pushed out of the bleed screw while under pressure (table-up). 6-3.3 POWER UNIT AND MANUAL PUMP: Upon replacement, the power unit and manual foot pump are purged of air via the relief valve back tothe reservoir. After replacing a power unit, remove the J ‘connector at the LV box and activate any function for + ‘minute. This will run the pump and push any air in the pressure line through the relist valve back to the reser- voir. To purce ait from a manual pump that has been replaced, purp for 1 minute without activating any functions. This has the same effect as running the power unit. 6-3.4 FILLING HYDRAULIC LINES: Na hydraulic line is replaced, connect the line to its appropriate manifold fitting and pressurize the line until 6-36 350820‘SHAMPAINE 5100B/5100E SURGICAL TABLE 6. Repair and Replacement clear fluid runs out of the end that connects to the cylin- der. At this time, the line can be connected to the appro- priate cylinder for further bleeding. 63.5 FILLING HYDRAULIC CYLINDERS: lH @ cylinder requires replacement, the new cylinder ‘must be filled with oil prior to installing on the table and attempting further bleeding. To do this, attach a pres- ‘sure line (a line from the manifold) from the cylinder that was removed to the side of the new cylinder that requires filing. Attach it to the side of the eylinder, that when pressurized, will move the rod. E.g., I a cylinder is received with the rod retracted, connect the pressure line to the cap end of the cylinder. Leave the other end of the cylinder DISCONNECTED. Once the pressure line is connected, activate the function and pressurize the cylinder. Half of the cylinder will be filed with oi, and'the'other half wil be purged-of air as the piston moves out, Once the movement of the rod stops, remove the pressure line and install it on the other end. ff the cylinder. Position the fitting on the side that is full Of oil into a bucket or cover with towels, and pressurize until clear oll runs out of it. The eylinder is now ready for ‘connection and final bleeding/balancing. 6-3.6 | BLEEDING HYDRAULIC CYLINDERS: Anytime work is done that involves breaking a fitting at a cylinder, air enters the cylinder and it's associated hydraulic line to displace the oil that pours or drips out. To properly remove this air, an excess of hydraulic fluid must be available to push the air out under pressure. It seta on ofper via loose Faing o a Ait Babies yanmar the line to be" purged of air is a pressure line, excess fluid is available from the pump. If the line to be purged |s a captive crossover line between two series cylinders, ‘one or both cylinders must be overfilled to provide the excess oll needed to purge the air. Bleeding air from a cylinder is done at the swivel fitting, ‘The fitting is loosened and pressure is applied until clear Coil runs out of the fiting. The fiting is then tightened while under pressure. It is necessary to remove the cylinder from the table, or bleed a new cylinder prior to installing it on the table to-allow the necessary tipping required to remove air from the cylinder. ‘When a cylinder is connected to a hydraulic line, air can bbe trapped in 2 areas. One is in the cylinder, and the other in the hydraulic line. To remove the ait from each area, each fitting must be bled twice: Once while pres- surizing from inside the cylinder, and the other while pressurizing the hydraulic line. This is ilustrated in fig- ure 6-31 ‘To purge the air, the swivel fing that is opened-must be brought to the highest point for the cylinder being ser- viced. When purging air from inside the cylinder, tipped to allow the air bubble to move to the highest point (the swivel fiting). The cylinder is pressurized from the inside, and as the piston moves up, it “pushes” the hydraulc fluid toward the fiting and carries the air bubble with it, Once clear oil runs out of the fiting, the hydraulic ine (opposite direction) is pressurized and any ir in the line is pushed out of the fiting. Tie fitting is then tightened. The process is repeated for the opposite fitting if it was broken, | Aicexit FIGURE 6-31. BLEEDING CYLINDERS 350520 637