Replacing Double Gimbal Joints with Single Gimbal Joint (LCH)

HyLED 8600 Lighthead

 HyLED 8600 灯头双 C 臂改直臂 C 臂拆装工艺

1. 工具清单

序号 名称 规格 单位 数量
1 内六角扳手 1.5mm/2mm/2.5mm/3mm/4mm/5mm/6mm/8mm 套 1
2 十字螺丝刀 5mm 个 1
3 一字螺丝刀 3mm 个 1
4 卡簧钳 直头 个 1
5 套筒扳手 5mm 个 1
6 防静电手套 无 双 2
7 普通小剪刀 无 个 1

2. 物料清单

序号 物料编码 零件名称 单位 数量
1 006-000251-00 环形磁环 个 1
2 0091-20-100600 C 臂阻尼螺钉 个 2
3 0091-20-89861 C 臂平垫 个 1
4 032-000040-00 端面轴承 个 1
5 032-000048-00 卡簧 个 2
6 032-000266-00 滚针轴承 个 2
7 032-000313-00 不锈钢钢球 个 2
8 033-000292-00 旋转臂控压缩弹簧 个 2
041-017420-00 直 C 臂（中置、C81） 个 1
041-017420-01 直 C 臂（中置、DS193） 个 1
9
041-009965-00 直 C 臂（C81） 个 1
041-009965-01 直 C 臂（DS193） 个 1
041-009971-00 旋转臂控座装饰盖（C81） 个 1
10
041-009971-01 旋转臂控座装饰盖（DS193） 个 1
115-021293-00 旋转臂控座组件（C81） 个 1
11
115-021293-01 旋转臂控座组件（DS193） 个 1
12 030-000036-00 M3×12 十字沉头螺钉 个 2
0091-20-89865 C 臂装饰盖（C81） 个 1
13
043-005886-00 C 臂装饰盖（DS193） 个 1
14 M04-051043--- M5×10 十字沉头螺钉 个 2
15 041-009995-00 弹簧定位螺套 个 2
115-021294-00 直臂弹簧臂（中置、C81） 个 1
115-021294-01 直臂弹簧臂（中置、DS193） 个 1
16
115-005044-00 直臂弹簧臂（C81） 个 1
115-005044-01 直臂弹簧臂（DS193） 个 1
17 009-003353-01 24V 连接线 个 1

1-1
18 009-003354-00 SPI 连接线 个 1
19 009-004005-00 CCD 信号电源线 个 1
20 009-004006-00 中置 CCD 控制线 个 1
21 009-004026-00 灯头电源线 个 1
22 A90-000031--- 扎线带 个 6

3. 注意事项

 拆装开始前，必须保证天花板内提供的电源接线的所有电气连接都已被切断！

 拆、装灯头时，需要两人协同操作，注意轻拿轻放，保护好灯头。
 拆装灯头及臂控板，如需要触碰 PCB 板卡时，作业员须带防静电手套（作业员
双手先接触大地，再带防静电手套）且在洁净的环境下作业，以防静电损坏 PCB
板卡或弄脏灯头内部。

 拆手术灯过程中，保管好所有拆下的零部件，待后面重新组装时使用。

4. 具体步骤
4.1 将双 C 臂灯头从普通弹簧臂上拆下
1) 拆卸灯头时先将普通弹簧臂调整至水平限位处（先将弹簧臂按压至水平位置
后，使用 5 号内六角扳手斜插入弹簧臂右侧孔中，调节其中的内六角螺钉，顺
时针旋转到底，完成限位），然后专人扶住弹簧臂。

普通弹簧臂

5 号内六角
扳手

图 1

1-2
 2) 将固定弹簧臂铝圈的 M3×4 十字盘头螺钉拆下后，把铝圈向上推，将月亮型挡
片取下（注意将灯头向上拖以松开挡片，为防止灯头坠落，需两人一起操作，
小心轻放；拆卸灯头后缓慢放开弹簧臂至限位处，避免弹簧臂突然翘起，造成
人身伤害）。

普通弹簧臂
铝圈

M3×4 十字
盘头螺钉
月亮型挡片

灯头

图 2 图 3

4.2 普通弹簧臂换直臂弹簧臂
 中置灯头
1) 使用 3mm 内六角扳手将 4 个 M5×12 内六角沉头螺钉拆下，用 5mm 内六
角扳手将 2 个阻尼螺钉从延伸臂上拆下，将普通弹簧臂从延伸臂上拆下，
拆开弹簧臂与延伸臂之间的线材连接端子。
2) 将直臂弹簧臂（115-021294-00 或 115-021294-01）按照上述相反顺序装在
延伸臂上。

M5×12 内六角沉 延伸臂

头螺钉，另一侧
还有 2 个螺钉
拆开线材连接端子
阻尼螺钉，
另一侧还有 1 个 普通弹簧臂
阻尼螺钉
3)
图 4 图 5

 非中置灯头
1) 使用内六角扳手将 4 个 M5×12 内六角沉头螺钉和 2 个阻尼螺钉从延伸臂
上拆下，将普通弹簧臂从延伸臂上拆下；将固定滑环止转座上的 2 个
M3×25 十字小盘头螺钉旋出，将滑环公端从弹簧臂内拔出。
2) 将直臂弹簧臂（115-005044-00 或 115-005044-01）按照上述相反顺序装在
延伸臂上。

1-3
 M5×12 内六角沉 M3×25 十字小
头螺钉，另一侧 盘头螺钉
还有 2 个螺钉
将滑环公端从
阻尼螺钉， 弹簧臂内竖直
另一侧还有 1 个 拔出
阻尼螺钉
普通弹簧臂
图 6 图 7

4.3 拆卸双 C 臂灯头

1) 拆卸插座固定盖或者手柄轴。
 中置灯头
a. 拆中置摄像头：用手拧下固定中置摄像头的 3 个滚花螺钉后，竖直向上拔
出中置摄像头约 20mm 后，将摄像头取下。

取下滚花螺钉后，
竖直向上拔出中
置 摄 像 头 20mm
后取下

滚花螺钉

图 8 图 9

b. 拆插座固定盖：用 2.5mm 内六角扳手取下 4 个 M4×16 内六角螺钉，卸下

插座固定盖拆开线材连接端子，用十字螺丝刀取下 M4×8 十字盘头组合螺
钉，取下插座固定盖接地线。

插座固定盖
接地线
M4×16 内六
角螺钉
M4×8 十字盘
头组合螺钉

插座固定盖 拆开线材连
接端子

图 10 图 11

1-4
 图 12

 非中置灯头
a. 按压取下消毒手柄，取下 2 颗 M3 胀紧螺钉和弹簧垫，取下消毒手柄内
把。

2 颗 M3 胀紧螺
钉+ 弹簧垫

按压取下消
消毒手柄内把
毒手柄外把

图 13 图 14

b. 取下 3 个 M4×12 沉头螺钉，取下遮挡盖。

M4×12 沉头螺
钉

遮挡盖

图 15

c. 取下 4 颗 M4×20 十字沉头螺钉，取下手柄轴。

1-5
 4 个 M4×20 十
字沉头螺钉

手柄轴

图 16 图 17

2) 翻转灯头，取下螺钉孔的硅胶塞，拆下后罩顶盖上的 3 个顶盖螺钉帽及 3 个
M4×12 十字沉头螺钉，取下后罩顶盖；将 12 个硅胶塞取下，拆下灯后罩上的
12 个 M3×16 十字槽盘头螺钉。

12 个硅胶塞+M3×16 3 个顶盖螺钉帽
十字槽盘头螺钉 +M4×12 十字沉头螺
钉

飘带手柄 后罩顶盖

图 18

3) 拆下 4 个 M3×8 十字沉头螺钉，取下板卡导热片和导热硅胶；取下插接线扣，
并将这些线材理顺，方便后面从灯头中抽出。

4 个 M3×8 导热硅胶
十字
沉头螺钉

导热片

图 19 图 20

4) 将灯头翻至正面，取下蓝色飘带手柄（图 18 示），取下 3 颗 M3×12 盘头带垫

螺钉，取下透明玻璃面板和白色遮盖板，将线材从灯后罩中抽出，待后面从灯

1-6
 头中抽出（注意用小剪刀剪开连接磁环间线材与灯后罩的扎线带，将套在线材
上的磁环取下）。

M3×12 盘头带
垫螺钉

剪开扎线带

白色遮盖板

图 21 图 22

5) 将连接灯头和双 C 臂间的阻尼螺钉拆下。

阻尼螺钉

双 C 臂装饰盖

图 23

6) 将双 C 臂装饰盖从 C 臂上拆下（用十字螺丝刀钻破装饰盖），拆下的装饰盖须
废弃。

图 24

1-7
 7) 使用卡簧钳将 2 个卡簧从 C 臂中取下，缓缓取出双 C 臂，连同线材从灯头中
一起抽出（将拆下的卡簧和线材需废弃，须两人一起操作，小心轻放）。

卡簧
线材

图 25

8) 拆双 C 臂臂控板：取下臂控板后壳的 4 个 M3×8 组合螺钉，取下臂控板后壳。

M3×8
组合螺钉

臂控板后壳

图 26

触摸臂控板 按键臂控板

图 27 图 28

9) 拆开插接线扣。对于选配了触摸控制面板的灯头来说，取下固定 CPU 模块的

2 个 M2.5×6 十字盘头螺钉，取下 CPU 模块；用套筒扳手取下板卡上挡住臂控
板前壳固定螺钉的 2.5×7 螺柱螺钉。按键臂控板无 CPU 模块，拆开插接线扣
即可。

1-8
 CPU 模块

2.5×7
M2.5×6 螺柱螺钉
十字盘头螺钉

图 29 图 30

10) 拆下 6 个固定臂控板前壳的 M3×8 十字盘头螺钉，取下臂控板（拆下的臂控板

零部件需保管好，待后面使用） 。

M3×8 十字
盘头螺钉

图 31 图 32

4.4 组装直臂 C 臂灯头

1) 开始组装直 C 臂（041-017420-00 或 041-017420-01 或 041-009965-00 或
，在手术灯柱头上依次放上 1 个端面轴承（032-000040-00），
041-009965-01）
和 1 个滚针轴承（032-000266-00）
，将直 C 臂装在柱头上（需装配到位，没有
空隙，若有空隙，则说明圆柱销没有装到位，重新安装）。

圆柱销
到位 未到位
柱头

端面轴承

滚针轴承

图 33 图 34

1-9
 2) 在 直 C 臂 的 另 一 端 将 1 个 滚 针 轴 承 （ 032-000266-00 ） 和 1 个 平 垫
（0091-20-89861）依次套在插入直 C 臂的手术灯柱头前端上，再使用 2 个新
卡簧（032-000048-00）将直 C 臂与柱头固定（卡簧需放入柱头上卡簧槽内） 。

滚针轴承
新卡簧
平垫

2 个新卡簧
图 35 图 36

3) 穿线。
 中置灯头
a. 将新的信号电源线（009-004005-00）从直 C 臂前端（与弹簧臂连接端）
穿入到灯头内部，再将新的灯头电源线（009-004026-00）从直 C 臂前端
穿出直 C 臂，待后面与臂控板连接。
b. 将新的 SPI 连线（连臂控板，009-003354-00），新的中置 CCD 控制线（连
臂控板，009-004006-00）
、新的 24V 连接线（连臂控板，009-003353-01）、
穿入灯头内。 （同拆卸过程相反，注意 24V 连线上装上磁环后，在磁环两
端用扎线带（A90-000031---）固定在灯后罩上，避免磁环在手术灯使用过
程中晃动。）

直 C 臂前端
信号电源线

灯头电源线

连臂控板

图 37

1-10
 SPI 连线，从灯后罩右开
24V 连线，从灯后罩左
口处穿入灯后罩内；待
开口处穿入灯后罩内；
后面连接灯后罩板卡
待后面连接灯后罩板卡

信号电源线

中置 CCD 控制线

图 38

 非中置灯头
a. 灯头电源线（700 大 C 臂线材）已安装好并穿出直 C 臂，没有信号电源
线）。
b. 只需将 SPI 连线（连臂控板，009-003354-00）、24V 连接线（连臂控板，
009-003353-01）穿入灯头内。
4) 将旋转臂控座组件（115-021293-00 或 115-021293-01）穿过线材安装在直 C
臂上。

旋转臂控座
组件

图 39

5) 将直 C 臂和旋转臂控座组件的孔位对准以后用 1 个 M5×10 十字沉头螺钉

（ M04-051043--- ） 将 旋 转 臂 控 座 组 件 固 定 在 直 C 臂 上 ； 将 两 个 钢 球
（032-000313-00）放在图示的孔中。

1-11
 M5×10 十
字沉头螺钉

钢球

图 40

6) 将弹簧定位螺套（041-009995-00）和弹簧（033-000292-00）固定在直 C 臂上。

弹簧定位螺套
+ 弹簧

图 41

7) 安装 2 个 C 臂阻尼螺钉（0091-20-100600）。

C 臂阻尼螺钉

图 42

8) 使用 2 个 M3×12 十字沉头螺钉（030-000036-00）将旋转臂控座装饰盖
（041-009971-00 或 041-009971-01）安装在旋转臂控上。

1-12
 M3×12 十字沉头螺钉

旋转臂控座装饰盖

图 43

9) 与拆卸过程相反，将前面拆下来的 LED 臂控板前壳安装在旋转臂控座组件上，

用 6 个 M3×8 组合螺钉固定，理顺线材。
 触摸臂控板（SPI 连线上加套磁环）

臂控板接地线
环形磁环
（006-000251-00）
CPU 模块
橙
白 中置 CCD 控制线
红 （中置摄像头用）
黑
黄 SPI 连线

图 44

 按键臂控板

中置 CCD 控制线
橙 （中置摄像头用）
白
红
SPI 连线
黑
黄

图 45

10) 参照拆卸过程，装上臂控板后壳。

1-13
 M3×8
组合螺钉

臂控板后壳

图 46

11) 参照拆卸过程（与拆卸过程相反），将灯头中的线材理好后放上遮盖板和透明
玻璃面板，使用 3 颗 M3×12 盘头带垫螺钉固定（为避免压坏玻璃面板，螺钉
仅需打到刚好压到玻璃面板即可，不要打紧）；装上飘带手柄。

M3×12 盘头
带垫螺钉
飘带手柄

遮盖板

图 47 图 48

12) 将灯头翻至背面参照拆卸过程（与拆卸过程相反） ，装上插接端子、导热硅胶，

盖上板卡导热片（避开电容），整理好线材（为防止板卡温度过高烧坏 SPI 连
线，SPI 连线不能压在板卡上），并用 4 颗 M3×8 十字沉头螺钉将板卡导热片
固定紧。

24V 连线
M3×8 十字沉
头螺钉
导热硅胶
避开电容

导热片
SPI 连线

图 49 图 50

1-14
 13) 参照拆卸过程（与拆卸过程相反），用 12 颗 M3×16 十字槽盘头螺钉从后罩顶
端将飘带手柄锁紧，用 3 颗 M4×12 沉头螺钉将后罩顶盖安装在灯后罩上。用
12 个硅胶塞将所有的飘带手柄锁紧螺钉孔塞住，用 3 个顶盖螺钉帽将后罩顶
盖上的安装螺钉孔塞住。

12 个硅胶塞+M3×16 3 个顶盖螺钉帽
十字槽盘头螺钉 +M4×12 十字沉头螺
钉

图 51

14) 安装中置摄像头或者消毒手柄。
 中置灯头：参照拆卸过程（与拆卸过程相反），用 1 个 M4×8 十字盘头组
合螺钉固定插座固定盖上的接地线；将插座固定盖上的线材端子与灯头内
的信号电源线、CCD 控制线端子相连；用 4 个内六角螺钉将插座固定盖
固定在灯头上（注意，固定盖上的定位孔朝向灯的直 C 臂）。竖直插上中
置摄像头（注意对正插座固定盖上的定位孔），拧紧滚花螺钉。

中 置 CCD
M4×8 十字盘头组合
控制线
螺钉，固定接地线

信号电源线

图 52

1-15
定位孔朝向
手术灯柱头

图 53 图 54

 非中置灯头：按照拆卸的相反顺序安装手柄轴，遮挡盖，内手柄及消毒手
柄。

4.5 将直臂灯头安装至直臂弹簧臂
1) 将直臂灯头安装至直臂弹簧臂。
 中置灯头
a. 连接弹簧臂与直 C 臂里面的线材端子，将直 C 臂插入弹簧臂，并推到底。
b. 旋转圆环护套到相应的位置，安装好 2 个卡槽螺钉和 1 个阻尼螺钉。
c. 安装好 C 臂装饰盖（0091-20-89865 或 043-005886-00）。

直臂弹簧臂 直C臂
插上线材连接端子

C 臂装饰盖

图 55

圆环护套

卡槽螺钉，旋转
圆环护套 180°，
安装另一侧卡
槽螺钉

图 56

1-16
 C 臂装饰盖

阻尼螺钉 图 57

 非中置灯头
a. 将直 C 臂插入弹簧臂，并推到底。
b. 旋转圆环护套到相应的位置，安装好 2 个卡槽螺钉和 1 个阻尼螺钉。
c. 安装好 C 臂装饰盖（0091-20-89865 或 043-005886-00）。
2) 恢复网电，打开手术灯检查是否工作。

1-17
空白页
 How to Replace Double Gimbal Joints with Gimbal Joint (LCH)

for HyLED 8600 Lighthead

1. Tools needed

No. Tool Type Qty

1 Allen key 1.5mm/2mm/2.5mm/3mm/4mm/5mm/6mm/8mm 1 set
2 Philips screwdriver 5mm 1
3 Flat-bladed screwdriver 3mm 1
4 Circlip pliers Straight tip 1
5 Socket wrench 5mm 1
6 Antistatic gloves / 2 pairs
7 Knife / 1

2. Bill of materials

No. P/N Description Qty

1 006-000251-00 Magnetic core 1
2 0091-20-100600 Braking screw for gimbal joint 2
3 0091-20-89861 Plain washer for gimbal joint 1
4 032-000040-00 End bearing 1
5 032-000048-00 Circlip 2
6 032-000266-00 Needle rolling bearing 2
7 032-000313-00 Steel ball 2
8 033-000292-00 Spring 2
041-017420-00 Gimbal joint (LCH, for integrated camera) 1
041-017420-01 Gimbal joint (LCH, for integrated camera) 1
9
041-009965-00 Gimbal joint (LCH) 1
041-009965-01 Gimbal joint (LCH) 1
041-009971-00 End cover for control panel seat assembly 1
10
041-009971-01 End cover for control panel seat assembly 1
115-021293-00 Control panel seat assembly 1
11
115-021293-01 Control panel seat assembly 1
12 030-000036-00 Cross recessed countersunk head screw, M3×12mm 2
0091-20-89865 End cover for gimbal joint 1
13
043-005886-00 End cover for gimbal joint 1
14 M04-051043--- Cross recessed countersunk head screw, M5×10mm 2
15 041-009995-00 Spring screw cover 2
115-021294-00 LCH spring arm (for integrated camera) 1
16 115-021294-01 LCH spring arm (for integrated camera) 1
115-005044-00 LCH spring arm 1

2-1
 115-005044-01 LCH spring arm 1
17 009-003353-01 24V connection cable 1
18 009-003354-00 SPI connection cable 1
19 009-004005-00 Camera signal and power cable 1
20 009-004006-00 Control cable of integrated camera 1
21 009-004026-00 Lighthead power cable 1
22 A90-000031--- Cable tie 6

3. Safety instructions

 Make sure the mains supply has been disconnected before replacing the
gimbal joints.

 It is recommended the lighthead be removed/installed by 2 persons. Be sure

to hold the lighthead. Otherwise, it may drop down.

 Be sure to wear the antistatic gloves if touching the PCB. Otherwise, the
lighthead may malfunction.

 Be sure to keep the removed components well for later reinstallation.

4. Steps
4.1 Remove the lighthead with double gimbal joints from the standard spring arm.
1) Press the spring arm down to the horizontal position and insert a 5mm Allen key
into the adjusting hole as the figure below shows. Turn the Allen key clockwise
to the utmost position.

2-2
 Standard spring arm

5mm Allen key

Figure 1

2) Remove the M3×4mm cross recessed pan head screw fixing the sleeve. Slide
the sleeve up and remove the securing segment and carefully remove the
lighthead.

 To remove the securing segment, slightly push the lighthead upwards. It is

recommended the lighthead be removed by 2 persons.

 Be sure to place some foam or pads under the removed lighthead.

Otherwise, the glass may be damaged.

 Ask an extra helper to hold the spring arm and slightly release the spring
arm to the horizontal position after the lighthead is removed. Otherwise, the
spring arm may jump up suddenly and cause personal injury.

Standard
spring arm
Sleeve
M3×4mm cross
recessed pan
head screw
Securing
segment

Lighthead

Figure 2 Figure 3

4.2 Replace the standard spring arm with the LCH spring arm.

 For a lighthead with an integrated camera,

1) Remove the 4 M5×12mm hexagon socket countersunk head screws with a

2-3
 3mm Allen key and 2 braking screws with a 5mm Allen key. Slightly remove the
spring arm from the swivel arm and disconnect the cable connectors.

4 M5×12mm hexagon
socket countersunk Swivel arm
head screws (2 screws
on the opposite side) 2 braking screws Disconnecting the
(1 screw on the connectors
opposite side) Standard spring
arm

Figure 4 Figure 5

2) Install the LCH spring arm (115-021294-00 or 115-021294-01).

 For a lighthead without an integrated camera,

1) Remove the 4 M5×12mm hexagon socket countersunk head screws with a

3mm Allen key and 2 braking screws with a 5mm Allen key. Slightly remove the
spring arm from the swivel arm. Remove the 2 M3×25mm cross recessed small
pan head screws fixing the cover and straight pull the 3-pole plug out.

M3×25mm
4 M5×12mm hexagon
cross recessed
socket countersunk
small pan head
head screws (2
screws
screws on the
opposite side)
Pulling the
2 braking screws 3-pole plug out
(1 screw on the
opposite side)
Standard

Figure 6 Figure 7 spring arm

2) Install the LCH spring arm (115-005044-00 or 115-005044-01).

4.3 Remove the horizontal and vertical gimbal joints from the lighthead.
1) Remove the connector assembly or the handle seat.

 For a lighthead with an integrated camera,

a. Loosen the 3 knurled screws and vertically pull the integrated camera
upwards by 20mm and then remove the camera.

2-4
Vertically pulling
the camera
upwards by
20mm

3 knurled
screws

Figure 8 Figure 9

b. Use a 2.5mm Allen key to remove the 4 M4×16mm hexagon socket screws
and remove the connector assembly. Disconnect the cable connectors and
use a Philips screwdriver to remove the M4×8mm cross recessed pan head
combination screw fixing the protective earth wire of the connector
assembly.
Protective earth
wire of the
M4×16mm connector
hexagon assembly
socket
screws M4×8mm cross
recessed pan head
combination screw
Connector
Cable
assembly
connectors

Figure 10 Figure 11

Figure 12

 For a lighthead without an integrated camera,

a. Press the button and remove the sterilizable handle. Use a 4mm Allen key

2-5
 to remove the 2 M3mm expansion screws with spring washers and remove
the central handle.

Removing 2 M3mm
expansion screws
Button
with spring washers Central handle

Figure 13 Figure 14

b. Use a Philips screwdriver to remove the 3 M4×12mm cross recessed

countersunk head screws and remove the central cover.

3 M4×12mm
screws

Central cover

Figure 15

c. Use a Philips screwdriver to remove the 4 M4×20mm cross recessed

countersunk head screws and remove the handle seat.

4 M4×20mm
cross recessed
countersunk
head screws

Handle seat
Figure 16 Figure 17

2) Carefully turn the lighthead upside-down. Remove the 3 screw caps and use a
Philips screwdriver to remove the 3 M4×12mm cross recessed countersunk
head screws. Remove the top cover.

2-6
 3) Remove the 12 screw caps and M3×16mm cross recessed pan head screws
around the lighthead.

12 screw caps 3 screw caps+M4×12mm

+M3×16mm cross cross recessed counter
recessed pan head sunk head screws
screws

Encircling handle Top cover

Figure 18

4) Remove the 4 M3×8mm cross recessed countersunk head screws. Remove the
metal plate and the black pads. Disconnect all the cable connectors connected
to the LED drive board.

4 M3×8mm
cross
Black pads
recessed
countersunk
head screws

LED drive
board
Metal plate
Figure 19 Figure 20

5) Carefully turn over the lighthead and remove the 3 encircling handles as Figure
18 shows. Remove the 3 M3×12mm cross recessed pan head screws with
washers and then remove the glass and the plastic cover. Cut off the cable ties
beside the magnetic core and pull out the cable connectors. Remove the
magnetic core for later use.

2-7
 Magnetic core

M3×12mm
cross recessed
pan head
screws with
washers Cable ties

Plastic cover

Figure 21 Figure 22

6) Use a 5mm Allen key to remove the braking screw for the gimbal joint.

Braking
screw

Figure 23

7) Use a flat-bladed screwdriver to remove the end cover of the gimbal joint.

 Be sure to discard the removed end cover according to the local

regulations.

2-8
 Figure 24

8) Use a pair of circlip pliers to remove the 2 circlips from the shaft. Remove the
double gimbal joints with the connection cables.

Circlips
Cables

Figure 25

 Be sure to discard the removed circlips and cables according to the local
regulations.

9) Use a Philips screwdriver to remove the 4 M3×8mm combination screws fixing

the back cover of the control panel. Remove the back cover.

2-9
 M3×8mm
combination
screws

Back cover

Figure 26

Control board of
Control board
touch control
of control
panel
panel

Figure 27 Figure 28

10) For the control panel, disconnect the cable connectors. For the touch control
panel, remove the 2 M2.5×6mm cross recessed pan head screws fixing the
CPU module. Remove the CPU module and then use a 5mm socket wrench to
remove the M2.5×7+6-6 stud screw. Then disconnect all the cable connectors.

CPU module

M2.5×7+6-6
M2.5 ×6mm cross stud screw
recessed pan
head screws

Figure 29 Figure 30

11) Remove the 6 M3×8mm cross recessed pan head screws fixing the front cover

2-10
 assembly. Remove the front cover assembly.

 Be sure to keep the removed front cover assembly well for later use.

M3×8mm
screws

Figure 31 Figure 32

4.4 Reassemble the lighthead with a gimbal joint (LCH).

1) Put an end bearing (032-000040-00) and a needle rolling bearing
(032-000266-00) through the shaft. Install the gimbal joint (041-017420-00 or
041-017420-01 or 041-009965-00 or 041-009965-01) onto the shaft. Make sure
the gimbal joint is correctly installed. If the gap in the joint is so big, the round pin
is not properly installed. Reinstall the round pin.

Round pin
Joint: OK Joint: big gap

Shaft

End bearing

Needle
rolling
bearing
Figure 33 Figure 34

2) Put a needle rolling bearing (032-000266-00) and a plain washer

(0091-20-89861) through the front shaft. Fix the gimbal joint and the shaft with 2
new circlips (032-000048-00).

2-11
Needle rolling
bearing
New
circlips
Plain washer

2 new circlips

Figure 35 Figure 36

3) Guide the cables.

 For a lighthead with an integrated camera,

a. Guide the signal and power cable (009-004005-00) through the front part of
gimbal joint to the inner side of the lighthead.
b. Guide the lighthead power cable (009-004026-00) through the front part of
the gimbal joint to the front shaft end for connecting the control board.

Front part of
Signal and power cable the gimbal joint

Front shaft end

Lighthead power cable Lighthead

power cable to
connect with
control board

Figure 37

c. Guide the new SPI connection cable (009-003354-00), new control cable of
the integrated camera (009-004006-00) and 24V connection cable
(009-003353-01) through the front shaft end to the inner side of the
lighthead. Put the magnetic core upon the 24V connection cable and fix the
cable to the lamp housing hood with two cable ties (A90-000031---) beside
each end of the magnetic core.

2-12
 Opening
SPI connection
24V connection cable to cable to the right
the left opening opening

Cable ties
Signal and
power cable

Control cable of
integrated camera

Figure 38

 For a lighthead without an integrated camera,

a. There is no signal and power cable.

b. The lighthead power cable has been prewired.

c. Guide the new SPI connection cable (009-003354-00), 24V connection
cable (009-003353-01) through the front shaft end to the inner side of the
lighthead.
4) Guide all the cables through the control panel seat assembly (115-021293-00 or
115-021293-01) and install the assembly onto the gimbal joint.

Control panel
seat assembly

Figure 39

5) Align the holes on the control panel seat with the counterparts on the gimbal
joint. Fix them together with a M5×10mm cross recessed countersunk head
screw (M04-051043---). Place two steel balls (032-000313-00) as the figure
below shows.

2-13
 M5×10mm cross
recessed
countersunk
Steel balls
head screw

Figure 40

6) Place the two spring screw covers (041-009995-00) with the springs
(033-000292-00) into the desired positions.

Spring screw
covers+ springs

Figure 41

7) Install the two braking screws (0091-20-100600).

Braking screws

Figure 42

2-14
 8) Use 2 M3×12mm cross recessed countersunk head screws (030-000036-00) to
fix the end cover for the control panel seat assembly (041-009971-00 or
041-009971-01).

M3×12mm screw

End cover for control panel

seat assembly

Figure 43

9) Install the front cover assembly to the control panel seat assembly by following
the disassembling instructions in reverse order. Fix the front cover assembly
with 6 M3×8mm combination screws and tidy all the cables.
 For the touch control panel, do not forget to put the magnetic core
(006-000251-00) upon the SPI connection cable.

Protective earth
wire of the control
Magnetic core
board

CPU module

Orange, Control cable of the

White, integrated camera
Red, (for the integrated
Black, camera use)
Yellow,
SPI connection cable
Figure 44

2-15
  Control panel

Control cable of

Orange, integrated camera

White, (for the integrated

Red, camera use)

Black, SPI connection

Yellow, cable

Figure 45

10) Fix the back cover with 4 M3×8mm combination screws.

M3×8mm
combination screws

Back cover

Figure 46

11) Tidy all the cables inside the lighthead and reinstall the plastic cover and the
glass. Fix them with 3 M3×12mm cross recessed pan head screws with washers.
To prevent the glass from being crushed, fasten the screws until they just reach
the glass. Do not tighten them. Install the 3 encircling handles.

2-16
M3×12mm cross
recessed pan
head screws with
Encircling
washers
handle

Plastic cover

Figure 47 Figure 48

12) Carefully turn the lighthead upside-down.

13) Connect the cable connectors. Place the black pads onto the frame positions
marked on the drive board. Tidy the cables and make sure the SPI connection
cable is not squeezed onto the control board. Otherwise, the cable may be
burned due to the temperature increase of the control board.
14) Install the metal plate and make sure the holes on the metal plate match the
capacitors. Fix the metal plate with 4 M3×8mm cross recessed countersunk
head screws.

24V connection M3×8mm cross

cable recessed

Black pads countersunk

head

Capacitor
SPI connection
cable
Metal plate

Figure 49 Figure 50

15) Fix the 3 encircling handles with 12 M3×16mm cross recessed pan head screws
and fix the top cover with 3 M4×12mm cross recessed countersunk head screws.
Insert all the screw caps.

2-17
 12 screw caps + 3 screw caps +
M3×16mm cross M4×12mm cross
recessed pan head recessed countersunk
screws head screws

Figure 51

16) Reinstall the integrated camera or the sterilizable handle.

 For a lighthead with an integrated camera, fix the protective earth wire with
a M4×8mm combination screw. Connect all the cable connectors and fix
the connector assembly with 4 hexagon socket screws. Finally install the
integrated camera and tighten it with 3 knurled screws.

Control cable of
Protective earth wire
integrated
camera

Signal and
power cable

Figure 52

Positioning hole
facing to the
shaft

Figure 53 Figure 54

2-18
  For a lighthead without an integrated camera, reinstall the handle seat,
central cover, central handle and sterilizable handle by following the
disassembling instructions in reverse order.

4.5 Reinstall the lighthead to the LCH spring arm.

1) Reinstall the lighthead to the LCH spring arm.

 For a lighthead with an integrated camera,

a. Connect the cables through the spring arm with those from the gimbal joint.
b. Insert the gimbal joint into the spring arm and make sure they are fully
engaged. Rotate the sleeve accordingly to install the 2 fixing screws and
the braking screw.
c. Install a new end cover for the gimbal joint (0091-20-89865 or
043-005886-00).

Gimbal joint (LCH)

LCH spring arm

Connecting cables

End cover
for gimbal
joint

Figure 55

Sleeve

Fixing screw

Figure 56

2-19
 End cover

Braking screw

Figure 57

 For a lighthead without an integrated camera,

a. Insert the gimbal joint into the spring arm and make sure they are fully
engaged. Rotate the sleeve accordingly to install the 2 fixing screws and
the braking screw.

b. Install a new end cover (0091-20-89865 or 043-005886-00).

2) Power on the mains supply and turn on the lighthead to check if it works.

2-20
This page is intentionally blank.
P/N: 046-007162-00(1)