MARS 2 Operating Table: Service Manual

MARS 2 Operating Table
Service Manual
This is a class I medical product according to Annex IX of the COUNCIL DIRECTIVE 93/42/EEC concerning
medical devices (MDD) of 14 June 1993.
The manufacturer declares that the essential requirements as stated in Annex I, MDD have been fulfilled, and
that the conformity assessment procedure required for class I products has been performed according to Annex
VII, MDD. This is documented by the CE sign.
TRUMPF Medizin Systeme GmbH

Postfach 24 44
D-07310 Saalfeld, Germany

Carl-Zeiss-Straße 5
Distribution Telephone +49 3671 586-0

Fax +49 3671 586-166
Technical Telephone +49 3671 586-172

Customer Service +49 3671 586-176
Fax +49 3671 586-175
We are constantly working on further developments.

Therefore, please understand that we must reserve the right to change the scope of the delivery in respect of
the form, equipment and technology at any time.
Reprinting, copying or translating this document, in whole or in part, is forbidden without the express written
permission of TRUMPF Medizin Systeme GmbH.
All rights under the copyright laws are expressly reserved by TRUMPF Medizin Systeme GmbH.
Within the bounds of the legal requirements, the manufacturer is only then responsible for the technical safety
characteristics of this apparatus if the maintenance, repairs and modifications to this apparatus are performed
by him or by someone appointed by him and in accordance with his instructions.
© 09/07 TRUMPF Medizin Systeme GmbH

This User Manual applies to the following sales units:
Designation Item no.

MARS 2.01 operating table 1 380 094
Cable remote control MARS 2 BM* 1 416 569

Cable remote control MARS 2 BE** 1 411 554
Cable remote control MARS 2 FA*** 1 409 407
IR remote control MARS 2 BM* 1 416 572
IR remote control MARS 2 BE** 1 411 553
IR remote control MARS 2 FA*** 1 409 406
Charging unit mobile 230 4 544 122
Charging unit mobile 115 4 500 122
Wall-fitting charging unit 230 4 544 123
Charging unit IR DVE 230 1 314 349
Charging unit IR DVE 115 1 283 947
Charging unit, panel mounted 1 220 519
* for Mars 2.01/2.02
** for Mars 2.03/2.05
*** for Mars 2.04/2.06
Service Manual MARS 2 1 435 274 - 09/07

The variants available for the operating table differ in the following properties:
Properties MARS variant

2.01 2.02 2.03 2.04 2.05 2.06
Tabletop height -Standard-
X X X X
Tabletop height -low-

X X
Tabletop with displacement

towards the head end X X X X X
(longitudinal displacement)
Travel mode can be set
X X
mechanically with pedal
Travel mode can be set
X X X X
electrically with control unit
Electrically driven running gear X X

Contents
Contents
1 Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4.1 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4.2 Protection against infection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4.3 Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.5 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 Preparatory work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1 Repair site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 Tools, measuring instruments, equipment . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 Operating table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 Emergency Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4 Repair Guide for the Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.1 Remove the power from the operating table . . . . . . . . . . . . . . . . . . . . . . 15
4.2 Internal power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.3 Metal covers (without membrane keyboard) . . . . . . . . . . . . . . . . . . . . . . 17
4.4 Metal cover with membrane keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.5 Head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.6 Expansion bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.7 Connection unit’s operating unit, head end . . . . . . . . . . . . . . . . . . . . . . 26
4.8 Connection unit’s operating unit, foot end (not MARS 2.01). . . . . . . . . . . 28
4.9 Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.10 Switching relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.11 Membrane keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.12 Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.13 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.13.1 Lifting motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.13.2 Trendelenburg motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.13.3 Tilting motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.14 Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.15 Toothed belt (main drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.16 Lifting unit limit switches, MARS 2.03 to 2.06 . . . . . . . . . . . . . . . . . . . . . 49
4.17 Trendelenburg limit switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.18 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.19 Energy chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5 Repair Guide for the Tabletop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

5.1 Plastic plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.2 Leg section gearbox (LS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.3 Leg section motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.4 Leg section toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.5 Leg section joint (LS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.6 Back section gearbox (BS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
5.7 Back section motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.8 Back section toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Service Manual MARS 2 1 435 274 - 09/07 1

Contents
5.9 Back section (BS) joint and its components. . . . . . . . . . . . . . . . . . . . . . . 80

5.10 Back section strut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5.11 Energy chain (not MARS 2.01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.12 Locking unit (not MARS 2.01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.13 Distributor board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.14 Longitudinal displacement (LD) microbutton (not MARS 2.01) . . . . . . . . . 93
5.15 OR adapter sensor MARS 2.01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5.16 OR adapter sensor (not MARS 2.01) . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.17 Leg section (LS) end sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.18 Back section (BS) end sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5.19 Leg section reference sensor (LS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5.20 Back section reference sensor (BS). . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5.21 Leg section (LS) -35° sensor (not MARS 2.01) . . . . . . . . . . . . . . . . . . . . 111
6 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
6.1 Inclination sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
6.2 Leg section (LS) end sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
6.3 Back section (BS) end sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
6.4 Leg section reference sensor (LS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6.5 Back section reference sensor (BS). . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6.6 Leg section (LS) -35° sensor (not MARS 2.01) . . . . . . . . . . . . . . . . . . . . 120
7 Repair Guide for the Running Gear . . . . . . . . . . . . . . . . . . . . . . . . 121

7.1 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
7.2 Mains socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
7.3 Power supply fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
7.4 Battery fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
7.5 Castor with locking device MARS 2.01/2.02 . . . . . . . . . . . . . . . . . . . . 126
7.6 Castor with locking device MARS 2.03/2.05 . . . . . . . . . . . . . . . . . . . . 128
7.7 Front castor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
7.8 Rear castor MARS 2.01/2.02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
7.9 Rear castor MARS 2.03 to 2.06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
7.10 Brake Bowden cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
7.11 Directional travel Bowden cable MARS 2.01/2.02 . . . . . . . . . . . . . . . . 138
7.14 Directional travel switch cable MARS 2.03/2.05. . . . . . . . . . . . . . . . . . 145
7.15 Foot lever MARS 2.01/2.02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
7.16 Rest cam MARS 2.01/2.02. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
7.17 Gas-filled spring device MARS 2.01/2.02 . . . . . . . . . . . . . . . . . . . . . . 151
7.18 Jacking up switch MARS 2.01/2.02. . . . . . . . . . . . . . . . . . . . . . . . . . . 153
7.19 Jacking up switch cable MARS 2.01/2.02 . . . . . . . . . . . . . . . . . . . . . . 155
7.20 Jacking unit MARS 2.03 to 2.06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7.21 Hall sensor circuit board MARS 2.03 to 2.06 . . . . . . . . . . . . . . . . . . . . 161
7.22 Travelling drive MARS 2.04/2.06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
7.23 Toothed belt travelling drive MARS 2.04/2.06 . . . . . . . . . . . . . . . . . . . 167
7.24 Drive roller MARS 2.04/2.06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
7.25 Travelling drive motor MARS 2.04/2.06 . . . . . . . . . . . . . . . . . . . . . . . 170
7.26 Gas-filled spring device MARS 2.04/2.06 . . . . . . . . . . . . . . . . . . . . . . 171
2 Service Manual MARS 2 1 435 274 - 09/07

Contents
8 Lubrication Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

8.1 Tabletop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
8.2 Column. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
8.3 Running gear MARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
9 Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

Contents

Important Information
1 Important Information
1.1 General information
Repairs may only be carried out by TRUMPF service technicians or
by persons trained and authorized by TRUMPF.
Please follow these instructions exactly, and follow all the specified
repair steps. We would be grateful to receive any corrections to the
description of the repair or suggestions for improving the efficiency
of the repair.
Only perform those repairs and settings described in these
instructions, or those which you have been trained to do. Repairs
not described in these instructions may only be made after
consultation with TRUMPF Technical Customer Service or by
TRUMPF themselves.
Unauthorized and provisional repairs are not permitted, even if a
customer asks for them. All applicable laws, legal regulations and
standards must be observed and complied with.
Only use original spare parts specified by TRUMPF as spare parts.
Replace all defective parts and those which are not clearly in good
working order with original spare parts, including those parts
going beyond the repair order.
After repairs have been completed, return all cables to their
original positions, make sure that there are no points where cables
are subject to shear stresses or crushing. After every repair, check
all electrical connections again against the circuit diagram before
making a functional test. A functional check/test must be made
after all repairs and settings as required by these instructions or
applicable standards. Check the positions of the cables again
during and after motion sequences.
Only hand the device over to the customer after it has been
tested and found to be in full working order. The handover
must be made in writing with confirmation by the customer.
The functional condition must be demonstrated to the
customer.
Please refer to the user manual for the intended use and operation
of the operating table.
Please contact our Technical Customer Service in Saalfeld if you
have any questions or suggestions.
Technical Customer Service
Carl-Zeiss-Str. 5
07318 Saalfeld, Germany
Telephone +49 3671 586-172

+49 3671 586-176
Fax +49 3671 586-175

1.2 Explanation of symbols

Important information in this repair manual is marked with
symbols and keywords.
Keywords such as DANGER, WARNING or CAUTION indicate
the level of danger involved. The symbols emphasise the message
visually. Additional symbols can indicate injury hazards or danger
to life and limb.
The measures to prevent danger arising must be implemented
without fail.
DANGER
Danger to life and limb (for example electric
shock)!
Notice indicating an immediately impending hazard which will
cause death or serious injuries if the appropriate precautionary
measures are not taken.
WARNING
Danger to life and limb!
Notice indicating an immediately impending hazard which may
cause death or serious injuries if the appropriate precautionary
measures are not taken.
CAUTION
Risk of injuries (for example a risk of crushing)!
Notice indicating a possible hazard which may cause slight or
moderately severe injuries or property damage if the appropriate
precautionary measures are not taken.
CAUTION
Risk of material damage.
Notice indicating a possible hazard which may cause property
damage if the appropriate precautionary measures are not taken.
NOTE
Useful additional information and tips
TEST
Performance of functional tests, measurements and tests.
ENVIRONMENT
Notes concerning disposal in ways which do not harm the

environment.

1.3 Liability
TRUMPF Medizin Systeme GmbH SHALL ONLY BE LIABLE for
reliable and faultless function of the operating table IF
• installation, modifications and repairs have been done by
TRUMPF service technicians or by persons authorized by
TRUMPF.
• the operating table is used for the intended purpose as
described in the user manual.
1.4 Safety instructions
1.4.1 General information

• Clothing must be worn in such a way that it cannot get caught
in machinery etc. Button or roll up the sleeves of shirts and
jackets. Tie long hair together or tie it up. Tuck the ends of
scarves, ties and shawls into the clothing or secure them. Loose
clothing can be a source of danger.
Wear protective goggles when doing work that could endanger
the eyes (e. g. soldering work, removing springs or securing
devices under tension, knocking pins and similar parts in and
out).
• Do not perform any actions that could endanger persons or
could render the device a source of danger.
• Casings and other parts of devices that are removed during
work must be put in a safe place. Always put tools and
dismounted parts in places where no one could trip or fall over
them. Any nuts, bolts or other small parts that fall into column
modules must be removed.
Keep the area around the device clean and tidy during and
after repair work.
• After finishing the work, replace or renew all protective devices,
such as:
- covers
- cable binders, cable holders
- cable shieldings
- ground and potential equalization connections
- ground connections.
Check that the potential equalization and grounding lines
have been connected according to the currently valid
standards.
• Only use solid rosin flux for brazing work.
• Bolts and screws with an M4 or larger thread must be fixated
with medium strength screw fixing lacquer (red).

1.4.2 Protection against infection

• Danger of infection in the entire hospital.
Comply with all safety measures, rules of conduct and
hygiene requirements. Comply with the requirements of
the medical facility for protection against infection.
• Only perform maintenance and repair work on disinfected
operating tables. The disinfection is carried out by the medical
facility.
• Only perform work in the operating area with the
corresponding authorization.
• Consult a doctor immediately any health problems occur. Tell
your doctor that you have been working in hazardous areas,
even several months later.
Preventative measures
• Ask your doctor about possible hazards and protective
measures against them in your work as a service technician.
• After obtaining medical advice, have yourself inoculated
against hepatitis B.
Have a booster inoculation every 3 to 5 years. The incubation
period for hepatitis B ranges from one to six months.
1.4.3 Environmental protection

• Materials must be disposed of in an environmentally
compatible way, and in accordance with the nationally
applicable disposal guidelines.
• Comply with the recycling obligations for dismounted
components, in particular for:
- batteries
- circuit boards
- cables

1.5 Glossary
The following terms and abbreviations are used in this repair
manual:
BS Back section
LS Leg section
SS Seat section
LD Longitudinal displacement
SP Spare part
IR Infrared
RC Remote control
He
ad
Head end Back section joint end (battery

Ri
en
gh
d
ts
id
compartment)
e
Foot end Leg section joint end (power socket)

Le
ft
sid
Fo
e
ot
en
Right side Side of operating table without

d
membrane keypad
Left side Side of operating table with membrane
keypad

Preparatory work
2 Preparatory work
2.1 Repair site
Read Section 1 “Important Information” from page 5.
Be aware of the hygienic conditions at the place of work, and
consult the responsible doctor in cases of uncertainty about
protection against infection.
Only make repairs if your protection against infection is assured.
2.2 Tools, measuring instruments, equipment
Tools Basic equipment:

- Set of mechanic’s tools
- Hot-air gun (hair dryer)
- Battery screwdriver
Special tools:
- Pin remover
- Open-jawed spanner 10 (ground)
Measuring TRUMPF Medizin Systems measuring instruments (specifically for

instruments servicing the MARS)
- Feeler gauge 0.2 mm/narrow
- Mulco SM4 strand tension gauge
Equipment - Adhesive Scotch Weld 110DP

- Instant adhesive
- Cable binders
- Medium strength screw fixing lacquer
- Fixing lacquer for sensors
- Double-sided adhesive tape
- Wooden spacer (for working on lifting motor)
- Spirit of wine (degreaser)
- Spindle grease (order from TRUMPF Medizin Systeme GmbH)
- Wooden spacers 3 mm
- Screw clamp (for working on the MARS gas-pressure spring
2.03/2.04/2.05/2.06)

Preparatory work
2.3 Operating table

Always prepare the operating table according to the following
work steps before starting repair work:
1. CAUTION
Danger of infection!
Before beginning work, obtain confirmation from the
medical facility, that all the necessary measures for
protection against infection have been taken.
2. Remove all section segments and accessories from the
tabletop, and put them in a safe place.
3. Return the operating table to the zero position.
4. Return all tabletop adjustments and joints to their zero
positions.
5. CAUTION
Risk of tipping over!
Brake the operating table.
Brake the running gear (MARS 2.01/2.02) or jack up the
operating table (MARS 2.03/2.04/2.05/2.06).
Do not make any changes to the position of the operating table
during repair work unless they are expressly specified.

Preparatory work

Emergency Operation
3 Emergency Operation
Various electronic components used for operating table control
(e. g., the processor) have a redundant design in order to improve
the availability of the operating table. A failure in a processor will
be detected by the control, and the table will automatically switch
to emergency mode.
The EMERGENCY OPERATION indicator will flash red, and
the FAULT indicator will show a steady red light.
IDuring emergency operation, all positioning movements are

carried out at half the speed, and an audible signal will be heard
during every travelling motion.
CAUTION
Danger of collisions.
Limit switches will not be monitored. Do not move to any extreme
or limit position.
The emergency mode may also be activated manually in an

emergency if the operating table shows any untypical behaviour,
e. g., when certain positioning movements cannot be performed
or are overly restricted due to a sensor failure.
To do so, press both the ON and the EMERGENCY OPERATION
+ buttons on the column keypad at the same time for approx.
10 seconds. Several short audible signals will be heard until the
emergency mode is acknowledged by a long beep. The
EMERGENCY OPERATION indicator flashes red continuously.

Emergency Operation

Remove the power from the operating table
4 Repair Guide for the Column
4.1 Remove the power from the operating table

1. Disconnect the power supply cable from the mains supply.
2. Switch off the operating table (remote control).
CAUTION
Risk of injury from the capacitor voltage.
All LEDs on the membrane keyboard must be out.
5
1
2
4 5
3
Figure 1 Running gear - battery compartment

1 Cover battery compartment 4 M3x6 countersunk screw
2 Cover plate 5 Fuse
3 Battery
3. Carefully remove the cover from the battery compartment [1] on the running gear, and
put it down in a safe place.
4. Remove the cover plate [2] (4 countersunk screws [4]), and put them down in a safe
place.
5. Remove and safely put down the both battery fuses [5].
6. Disconnect the positive connectors from the both batteries [3].

Internal power supply
4.2 Internal power supply
5
1
2
4 5
3

1 Battery compartment cover 4 M3x6 countersunk screw
3 Battery
1. Reattach the positive connectors to the both batteries [3].

2. Insert both battery fuses [5].
3. Mount the cover plate [2] (4 countersunk screws).
4. Put the battery compartment cover [1] on the running gear.

Metal covers (without membrane keyboard)
4.3 Metal covers (without membrane keyboard)

1. Prepare the operating table (see section 2.3 “Operating table” page 11).
2. Raise the column to its highest position.
CAUTION
1
3
2
5
Figure 3 Cladding
1 Metal cover without membrane keyboard 4 Other cladding components
2 Metal cover with membrane keyboard 5 M3 countersunk screw
3 Expansion bellows (shown in gray)
5. Unscrew the two topmost metal covers [1]/[2] from each other (4 countersunk
screws [5]).
6. Lift the expansion bellows’ edge [3]; remove the metal cover without the membrane
keyboard [1] (3 countersunk screws on the top edge) and store safely.
CAUTION
Risk of injuries!
When removing the upper metal cover, there is a possibility that the remaining
cladding components are already unhooked and slip downwards!
7. Unhook the remaining cladding components [4] and guide them downwards.
8. Remove the metal covers from outside, segment by segment (each one: 4 countersunk
screws; lowermost metal cover: 6 countersunk screws).
9. Assemble the new metal covers, segment by segment, starting from the inside towards
the outside.
10. Guide the remaining cladding components [4] upwards and hook them into place.

Metal covers (without membrane keyboard)
11. Mount the metal cover without membrane keyboard [1] (3 countersunk screws at the
upper edge and 4 countersunk screws).
12. Connect the power supply, and switch the operating table on.
TEST
Check the column functions.

Metal cover with membrane keyboard
4.4 Metal cover with membrane keyboard

3. Remove the power from the operating table (see section 4.1 “Remove the power from
the operating table” page 15).
3
2
7
5
6
Figure 4 Cladding
1 Metal cover without membrane keyboard 5 MEMBRANE KEYBOARD flat ribbon cable
2 Metal cover with membrane keyboard 6 Electronics
3 Expansion bellows (shown in gray) 7 M3 countersunk screw
4 other cladding components
4. Unscrew the two topmost metal covers [1]/[2] from each other (4 countersunk
screws [7]).
5. Lift the expansion bellows’ edge [3]; remove the metal cover without the membrane
keyboard [1] (3 countersunk screws on the top edge) and store safely.
CAUTION
Risk of injuries!
When removing the upper metal cover, there is a possibility that the remaining
cladding components are already unhooked and slip downwards!
6. Unhook the remaining cladding components [4] and guide them downwards.
7. Take note of where the flat ribbon cable has been laid!
Remove the MEMBRANE KEYBOARD flat ribbon cable [5] from the electronic unit [6].
8. Remove the metal cover with membrane keyboard [2] (3 countersunk screws at the
upper edge).
9. Install the new metal cover with membrane keyboard.
10. Make sure that the flat ribbon cable is in its original installation position!
Connect the flat ribbon cable MEMBRANE KEYBOARD [5].

Metal cover with membrane keyboard
13. Connect the batteries (see section 4.2 “Internal power supply” page 16).
TEST
Check the column functions using the membrane keyboard.

Head cover
4.5 Head cover

2. MARS 2.02 to 2.06
Move the tabletop carefully up to the head end stop.
CAUTION
Figure 5 Head cover

1 Pad 4 Head cover
2 Plastic plate 5 M4 fillister-head screw
3 M8 ball-head
5. Pull pad [1] off the seat section, and put it down in a safe place.
6. Unscrew the plastic plate [2] (4 ball-heads [3]), and put them down in a safe place.
7. NOTE
Do not let any parts fall into the column.

Remove the head cover [4] (4 fillister-head screws [5]), and put them down in a safe
place.
8. Do not jam or damage the expansion bellows.
Place the new head cover [4] carefully on the tabletop.
9. Screw tight the head cover [4] (4 fillister-head screws [5]).
10. Remount the plastic plate [2] on the seat section (4 ball-heads [3]).

Head cover
11. Press the pad [1] onto the 4 ball-heads [3].

TEST

Expansion bellows
4.6 Expansion bellows

3. MARS 2.02 to 2.06
7 6
1
3 10 12
11
9
2
4 8
Figure 6 Expansion bellows

1 Metal cover without membrane keyboard 7 Head cover
2 Metal cover with membrane keyboard 8 M4x6 fillister-head screw
3 Expansion bellows (shown in gray) 9 Frame
4 Other cladding components 10 M6x20 machine screw
5 Pad 11 Bearing support (tabletop)
6 Plastic plate 12 M8x20 machine screw
5. Open the column (see section 4.3 “Metal covers (without membrane keyboard)”
page 17, work steps 5. to 7.).
6. Open the tabletop (see section 4.5 “Head cover” page 21, work steps 5. to 7.).
7. Unscrew the bellows from the tabletop (8 fillister-head screws [8]).
8. Unscrew the frame [9] from the bellows (12 nuts).
9. Note the positions of the cables and the pin configuration!
Press the expansion bellows downwards, separate all cable connections to the tabletop
and release the tabletop for removal.
10. Unscrew the tilting motor from the tabletop (4 machine screws [10]).

Expansion bellows
11. CAUTION
Risk of injury on account of the heavy weight.
Support the tabletop and lift it up from the column with at least 2 people!
Remove 8 machine screws [12] from the bearing block (tabletop) [11]; lift the tabletop
from the column and place it safely on an even surface.
14
13
14
3
Figure 7 Expansion bellows

3 Expansion bellows 13 Bellow frame
9 Frame 14 Bellow holder
12. Take note of the mounting position of the bellows!

Carefully remove the expansion bellows [3] with the expansion bellows holder [14] and
frame [9] upwards from the column.
13. Unscrew both expansion bellows holders [14] from the expansion bellows frame [13]
on top of the expansion bellows [3] (15 fillister-head screws) and store safely.
14. Remove frame [9] from the expansion bellows [3] and install on the new expansion
bellows. Make sure that the frame [9] is sitting correctly in the expansion bellows’ edge!
15. Make holes on the expansion bellows at the spots needed for fastening.
16. CAUTION
Danger of damaging the bellows!
Work with caution and don’t use any tools with sharp edges!
Assemble both expansion bellows holders [14] with expansion bellows frame [13] on
top of the expansion bellows (15 fillister-head screws).
17. Put the bellows back into its original position!
Pull the new bellows carefully over the column head.
18. CAUTION
Lift the tabletop with at least 2 people, and support it during assembly!
Lift the tabletop onto the column and install it on the bearing block (tabletop) [11]
(8 machine screws [12]).

Expansion bellows
19. Assemble the tilting motor onto the tabletop (4 machine screws [10]).
20. Put the cables back into their original positions, and reconnect all cables to the
tabletop (see section 9 “Circuit Diagram” page 177). Fix the cables with cable binders
and plastic clips.
21. Screw the frame [9] of the expansion bellows tightly onto the column’s frame (12 nuts).
22. Screw the expansion bellows tightly onto the tabletop (8 fillister-head screws [8]).
Place the head cover [7] carefully on the tabletop, and screw tight (4 fillister-head
screws).
24. Remount the plastic plate [6] on the seat section (4 ball-heads).
25. Press the pad [5] onto the 4 ball-heads.
TEST

Connection unit’s operating unit, head end
4.7 Connection unit’s operating unit, head end

IR receiver 1 with RS485/232
3. Move the tabletop carefully up to the head end stop.
1
4
2 3
5
Figure 8 Connection unit’s OPERATING UNIT, head end

1 Head cover 4 M4x30 countersunk screw
2 Distributor board 5 IR gasket
3 Connection unit’s OPERATING UNIT
6. Take note of where the cables have been laid.

Remove the connection unit’s OPERATING UNIT plug from the distribution printed
circuit board [2], disconnect the leads, and remove the cable binder.
7. Unscrew the defective connection unit’s OPERATING UNIT [3] at the head end of the
column (2 countersunk screws [4]); pull out from the column head towards the outside
and remove.
8. Remove the IR gasket [5].
9. Feed in the new connection units OPERATING UNIT’s cable on the column head.
10. Pull a new IR gasket [5] onto the new connection unit’s OPERATING UNIT [3].
11. CAUTION
Ensure that the IR gasket is in the correct position!
Mount the new connection unit’s OPERATING UNIT [3] to the column head
(2 countersunk screws [4]).
12. Connect the cable leads of the new connection unit’s OPERATING UNIT to the plug.
13. Put the cables back into their original positions, and stick the connection unit’s
OPERATING UNIT plug in the corresponding distribution printed circuit board’s [2]
socket. Fix the cables with cable binders.

Connection unit’s operating unit, head end

screws).
15. Remount the plastic plate on the seat section (4 ball-heads).
16. Press the pad onto the 4 ball-heads.
TEST

Connection unit’s operating unit, foot end (not MARS 2.01)
4.8 Connection unit’s operating unit, foot end (not MARS 2.01)
IR receiver 2 with RS485/232
4
6
5
Figure 9 Connection unit’s OPERATING UNIT, foot end

1 Head cover 4 Connection unit’s OPERATING UNIT
2 Distributor board 5 M4x30 countersunk screw
3 Clamp plate 6 IR gasket

Remove the connection unit’s OPERATING UNIT plug from the distribution printed
circuit board [2], disconnect the leads, and remove the cable binder.
7. Remove the clamp plate [3] (2 countersunk screws), and put them down in a safe
place.
8. Unscrew the defective connection unit’s operating unit [4] at the foot end of the column
head (2 countersunk screws [5]); pull out from the column head towards the outside,
and remove.
9. Remove the IR gasket [6].
10. Feed in the new connection unit OPERATING UNIT’s [4] cable on the column head.
11. Pull a new IR gasket [6] onto the new connection unit’s OPERATING UNIT [4].
12. CAUTION
Ensure that the IR gasket is in the correct position!
Mount the new connection unit’s OPERATING UNIT [4] to the column head
(2 countersunk screws [5]).
13. Connect the cable leads of the new connection unit’s OPERATING UNIT to the plug.

Connection unit’s operating unit, foot end (not MARS 2.01)
14. Put the cables back into their original positions, and stick the connection unit’s
OPERATING UNIT plug in the corresponding distribution printed circuit board’s [2]
socket. Fix the cables with cable binders.
15. Mount the clamp plate [3] (2 countersunk screws).
screws).
18. Press the pad onto the 4 ball-heads.
TEST

Transformer
4.9 Transformer
4. Unscrew 2 countersunk screws from the very bottom of the metal cover.
Figure 10 Transformer
1 Metal cover 2 Transformer
5. Slide the metal cover [1] upwards and fix it securely to the column guide with the M6
retaining screw.
6. Loosen the 3 machine screws on the transformer base plate [2].
7. Move the mounting plate slightly into the direction of the lifting motor, and carefully lift
the entire transformer out from the screws.
8. Make note of the plug’s and cables’ installation position!
Disconnect all plugs from the transformer and remove all cables and cable binders.
9. Remove transformer [2].
10. Connect all plugs and cables to the new transformer (see section 9 “Circuit Diagram”
page 177).
11. Pay attention to the cables!
Set the new transformer’s mounting plate on the screws in the base of the column and
push it slightly away from the column (push into the screws).
12. Screw in the transformer [2] tightly (3 machine screws).
13. Put the cables back into their original positions. Fix the cables with cable binders.
14. Remove retaining screw from the column guide and slide the metal cover downwards.
15. Close the metal cover (2 countersunk screws).
TEST

Switching relay
4.10 Switching relay

Figure 11 Switching relay

1 Metal cover 2 Switching relay
retaining screw.
6. Make note of the plug’s and cables’ installation position!
Disconnect all plugs from the switching relay and remove all cables and cable binders.
7. Unscrew the holding plate with the switching relay from the base of the column
(2 machine screws) and remove.
8. Connect all plugs and cables to the new switching relay (see section 9 “Circuit
Diagram” page 177).
9. Pay attention to the cables!
Place the holding plate with the switching relay in the base of the column and screw in
tightly (2 machine screws).
10. Put the cables back into their original positions. Fix the cables with cable binders.
TEST

Membrane keyboard
4.11 Membrane keyboard

3
2
7
5
6
Figure 12 Cladding
3 Expansion bellows (shown in gray) 7 Membrane keyboard
4 Other cladding components
4. Open the column (see section 4.4 “Metal cover with membrane keyboard” page 19,
work steps 4. to 8.).
5. Remove membrane keyboard [7] from the metal cover (glued).
6. Remove any glue residues from the metal cover [2] and degrease it.
7. Feed in the new membrane keyboard’s [7] flat ribbon cable [5] into the metal cover [2].
8. Glue in the new membrane keyboard.
9. Mount the metal cover [2] with membrane keyboard [7].
10. Make sure that the flat ribbon cable is in its original installation position!
Connect the flat ribbon cable membrane keyboard.
TEST
Check the column functions using the membrane keyboard!

Electronics
4.12 Electronics
NOTE
The electronic unit is always replaced in its entirety!
3
6
7
5
2 B 8
6 B
6
7 A
4
A
Figure 13 Electronics
3 Expansion bellows (shown in gray) 7 M4 machine screw
4 other cladding components 8 Nut M4
Remove all cable binders from the cables going to the electronic unit.
6. Label all plugs and cables on the defective electronic unit [6] and pull them out/
remove them.
7. Hold the electronic unit [6] securely! Remove 2 machine screws [7] and 2 washers from
the left side of the electronic unit.
8. Remove 1 nut [8] from the electronic unit’s rear panel.
9. Carefully pull out the electronic unit [6] downwards.
10. Remove the nut [8] with the washer from the defective electronic unit [6] and loosely
install it on the new electronic unit’s rear panel.
11. Insert the new electronic unit [6] and assemble it (tighten 1 nut [8] until it seizes, 2
washers and 2 machine screws [7]).
12. Put the cables back into their original positions, and connect all cables (see section 9
“Circuit Diagram” page 177). Fix the cables with cable binders.

Electronics
13. Mount the metal cover with membrane keyboard [2].

14. Make sure that the flat ribbon cable [5] is in its original installation position!
17. Transfer the IR code with the PC software.
TEST

Motors
4.13 Motors
4.13.1 Lifting motor

4. Slide the metal cover upwards and fix it securely to the column guide with the M6
retaining screw.
Figure 14 Wooden spacer

1 Wooden spacer 2 Lifting column
5. CAUTION
Risk of injuries!
Support the lifting column with an appropriate wooden spacer!
Put the wooden spacer [1] in the running gear and lower the column carefully until the
lifting column [2] sits on the wooden spacer.

Motors
6 8
5
Figure 15 Lifting motor

3 Lifting motor 6 M5 machine screw
4 Lifting motor holder 7 Toothed belt
5 M5 machine screw 8 Cap
7. Note the positions of the cables.

Remove all cable binders from the lifting motor [3], remove the plugs and the cable
(1 fillister-head screw, 1 washer, and 1 serrated lock washer).
8. Take note of the mounting position of the lifting motor!
Unscrew 4 machine screws [5] from the lifting motor holder [4] (lifting unit drive).
9. Move the holder slightly into the direction of the column and carefully lift out from the
screws.
10. Carefully pull out the lifting motor [3] from the toothed belt [7].
11. Carefully set the new lifting motor (lifting unit drive) [3] inside the toothed belt.
12. Make sure that the lifting motor is in its original installation position!
Place the holder [4] of the new lifting motor on the screws in the base of the column.
13. Remove the cap [8] that is on the side of the running gear and screw in 1 machine
screw [6] into the lifting motor holder [4] from outside. Set the toothed belt tension by
means of adequately turning the screw in or out.
14. Screw the lifting motor’s holder [4] tightly (4 machine screws [5]).
15. Unscrew the machine screw [6] on the side of the running gear again and insert the
cap [8].
17. Reattach the positive connectors to the both batteries.
18. Insert both battery fuses.
20. Lift the column slightly with the lifting unit and remove the wooden spacer.

Motors

23. Mount the cover plate (4 countersunk screws).
24. Put the cover battery compartment on the running gear.
TEST

Motors
4.13.2 Trendelenburg motor
3. MARS 2.02 to 2.06
7 6
3 8
10
2
9
5
Figure 16 Cladding/Expansion bellows

1 Metal cover without membrane keyboard 6 Pad
2 Metal cover with membrane keyboard 7 Plastic plate
3 Expansion bellows (shown in gray) 8 Head cover
4 Other cladding components 9 M4x6 fillister-head screw
5 MEMBRANE KEYBOARD flat ribbon cable 10 Bellow frame
7. Unscrew the expansion bellows [3] from the tabletop (8 fillister-head screws [9]).
8. Unscrew the bellow frame [10] (6 machine screws).
9. Move the bellows [3] carefully down.
10. CAUTION
Risk of injuries!
Support the tabletop!
Prevent the tabletop from tilting. In order to do this, support the tabletop with a Mayo
instrument stand, for example!
11. Note the positions of the cables. Remove the Trendelenburg motor’s plug from the
electronic unit and release the Trendelenburg motor (MARS II Trendelenburg drive) for
removal.

Motors
12
13 14
11
Figure 17 Trendelenburg Motor

11 Trendelenburg bearing pin 13 Trendelenburg motor
12 Trendelenburg pin 14 Guidance
12. Remove 3 machine screws from each of the two Trendelenburg bearing pins [11].
13. Remove the Trendelenburg bearing pins [11] with a pin remover and store safely.
14. Remove the retaining ring and the washer from the Trendelenburg pin [12] (on the
main Cardan joint).
15. CAUTION
Risk of injuries!
Hold the Trendelenburg motor securely!
Pull the Trendelenburg pin [12] (with 1 washer and 1 retaining ring) out from the main
Cardan joint and store safely.
16. Remove Trendelenburg motor [13], two start-up disks on the main Cardan joint and
2 shim rings on the guide.
17. Insert the new Trendelenburg motor [13] with two start-up disks above on the main
Cardan joint and assemble (Trendelenburg pin [12] with 1 washer and 1 retaining
ring).
18. Insert the Trendelenburg motor [13] on the guide [14] with 2 shim rings and assemble
(two Trendelenburg bearing pins with 3 machine screws each).
20. Raise the bellows [3] carefully.
21. Tightly screw the expansion bellows [3] onto the tabletop (8 fillister-head screws [9]).
22. Mount the bellow frame [10] (6 machine screws).
screws).

Motors

26. Mount the metal cover with membrane keyboard [2] (3 countersunk screws at the
upper edge).
TEST

Motors
4.13.3 Tilting motor
3. MARS 2.02 to 2.06
7 6
3 8
10
2
9
5
Figure 18 Cladding/Expansion bellows

4 Other cladding components 9 M4x6 fillister-head screw
5 MEMBRANE KEYBOARD flat ribbon cable 10 Bellow frame
8. Unscrew the bellow frame [10] (6 machine screws).
9. Move the bellows [3] carefully down.
10. CAUTION
Risk of injuries!
Support the tabletop!
Prevent the tabletop from tilting. In order to do this, support the tabletop with a Mayo
instrument stand, for example!
11. Note the positions of the cables. Remove the tilting motor’s plug from the electronic
unit and release the tilting motor (MARS tilting unit - complete) for removal.

Motors
12
13
13
11
14
A
Figure 19 Tilting motor
11 Tilting unit pin 2 13 Tilting motor
12 Tilting unit pin 14 Guidance
12. Remove tilting unit pin 2 [11] below from the guide [14] (1 retaining ring and 1 washer)
and store safely.
13. Remove the retaining ring and the washer from the tilting unit pin [12] (on the main
tilting unit Cardan joint).
14. CAUTION
Risk of injuries!
Hold the tilting motor securely!
Pull the tilting unit pin [12] (with 1 washer and 1 retaining ring) out from the tilting unit
Cardan jointand store safely.
15. Remove tilting motor [13] and 2 buffer washers from the guide [14].
16. Insert the new tilting motor [13] above on the tilting unit Cardan joint and assemble
(tilting unit pin [12] with 1 washer and 1 retaining ring).
17. Insert the tilting motor on the guide [14] with 2 buffer washers and assemble (tilting pin
2 [11], 1 washer and 1 retaining ring).
19. Raise the bellows [3] carefully.
21. Mount the bellow frame [10] (6 machine screws).
screws).

Motors
25. Mount the metal cover with membrane keyboard [2] (3 countersunk screws at the
upper edge).
TEST

Spindle
4.14 Spindle
3. MARS 2.02 to 2.06
5
6
7
1 3
Figure 20 Cladding
4 Other cladding components
6. Remove the metal covers from outside, segment by segment (each one: 4 countersunk
screws; lowermost metal cover: 6 countersunk screws) and store safely.
8. CAUTION
Turn the operating table with at least 2 people!
Turn the operating table on the side without a membrane keyboard and lay down
safely on an even surface.

Spindle
10
11
9
Figure 21 Spindle
8 Lifting pin 10 Lifting motor holder
9 Lifting motor 11 Toothed belt
9. Remove the retaining ring and the 2 washers from one side of the lifting pin [8], above
on the spindle suspension.
10. Remove the lifting pin [8] and the washers.
Remove all cable binders from the lifting motor [9], remove the plugs and the cable
(1 fillister-head screw, 1 washer, and 1 serrated lock washer).
12. Take note of the mounting position of the lifting motor!
Unscrew 4 machine screws from the lifting motor holder [10] (lifting unit drive).
13. Slightly push the holder [10] into the direction of the column and carefully lift it out from
the screws.
14. Carefully pull out the lifting motor from the toothed belt [11].
15. Put the lifting motor in a safe place.

Spindle
17
15
14
16 13
12
Figure 22 Spindle
12 M4x10 countersunk screw 15 M6x10 machine screw
13 Sheet plate 16 Toothed belt
14 Bearing support assembly 17 Spindle
16. Open the column from below (remove 4 countersunk screws [12]).
17. Carefully pry off the plate [13] (glued with silicone) and store safely.
18. Remove 6 machine screws [15] from the bearing support assembly [14].
19. Make note of the bearing support assembly [14] installation position! Do not damage
the toothed belt [16]!
Pull out the bearing support assembly (with spindle) from the column, below.
20. Make note of the spindle’s [17] screw-in depth and use it for the new spindle.
21. Make sure that the bearing support assembly is its original installation position! Pay
attention to the toothed belt!
Insert the new bearing support assembly [14] (with spindle) into the column from
below.
22. Push 2 washers onto the lifting unit pin [8].
23. Insert the lifting unit pin [8] above on the spindle’s suspension and assemble
(2 washers and 1 retaining ring).
24. Extend the column (pull on the tabletop or push on the running gear - with 2 people)
until the bearing support assembly fits correctly below (into the column base).
25. Assemble the bearing support assembly [14] on the column base (6 machine
screws [15]).
26. Carefully set the lifting motor [9] (lifting unit drive) in the new toothed belt.
27. Make sure that the lifting motor is in its original installation position!
Place the lifting motor holder [10] on the screws in the base of the column.

Spindle
18
19
Figure 23 Spindle
18 Cap 19 M5 machine screw
28. From outside, remove the cap [18] that is on the side of the running gear and screw
1 machine screw [19] into the lifting motor holder. Set the toothed belt tension by
means of adequately turning the screw in or out.
29. Screw the lifting motor’s holder [10] tightly (4 machine screws).
30. Unscrew the machine screw [19] on the side of the running gear again and insert the
cap [18].
32. Remove any silicone residues from the column base and the plate [13] and degrease.
33. Apply silicone to the plate [13] and assemble (4 countersunk screws).
34. CAUTION
Mount the operating table with at least 2 people!
35. Do not jam or damage the expansion bellows [3].
screws).
38. Install the metal covers, segment by segment, starting from the inside towards the
outside.
TEST

Toothed belt (main drive)
4.15 Toothed belt (main drive)

The toothed belt (main drive) is part of the bearing support assembly. If a part of the bearing
support is defective, the entire bearing support assembly (with spindle) is always replaced.
See section 4.14 “Spindle” page 44.

Lifting unit limit switches, MARS 2.03 to 2.06
4.16 Lifting unit limit switches, MARS 2.03 to 2.06

NOTE
The lifting device limit switches (Hall sensors) are magnetic. In case of malfunction, look for
possible magnetically attracted washers/disks!
9
1
5 7
6
Figure 24 Limit switches of column lift

1 Metal cover without membrane keyboard 6 Hall sensor board
2 Metal cover with membrane keyboard 7 Tapped plate
3 Expansion bellows 8 Plug and cable
4 other cladding components 9 Underlay
5 Sensor plate
6. Remove plug and cable [3] (1 machine screw and 1 serrated lock washer) from the
Hall sensor printed circuit board.
7. Unscrew the sensor plate [5] from the guide (3 machine screws, 1 cable clip) and
remove carefully.
8. Remove the Hall sensor printed circuit board [6] from the sensor plate [5] (3 machine
screws and 1 threaded anchor plate [7]).

Lifting unit limit switches, MARS 2.03 to 2.06
9. Place the new Hall sensor printed circuit board [6] between the sensor plate [5] and
the threaded anchor plate [7] and assemble (3 machine screws; leave the top right
thread free).
10. Assemble the sensor plate [5] with the Hall sensor printed circuit board [6] onto the
guide (2 machine screws on the right side).
11. Connect plug and cable [8] (1 machine screw and 1 serrated lock washer) to the Hall
sensor printed circuit board [6].
12. Put the cable back into their original position and fix with cable binder (1 machine
screw).
13. TEST
Perform a functional test!

TEST

Trendelenburg limit switch
4.17 Trendelenburg limit switch

3. MARS 2.02 to 2.06
Figure 25 Head cover

1 Pad 4 Expansion bellows
2 Plastic plate 5 M8 ball-head
3 Head cover 6 M4x6 fillister-head screw
7. Press the bellows [4] carefully down.

Trendelenburg limit switch
7
A
7
Figure 26 Trendelenburg limit switch

7 Limit switch

Disconnect all plugs from the defective limit switch [7].
9. Remove the defective limit switch [7] (2 machine screws).
10. Install the new limit switch [7] (2 machine screws).
11. Connect all plugs (see section 9 “Circuit Diagram” page 177).
screws).
15. Press the pad [1] onto the 4 ball-heads [5].
TEST

Cables
4.18 Cables
3. MARS 2.02 to 2.06
5. For cables in the column base:
- Unscrew 2 countersunk screws from the very bottom of the metal cover.
- Slide the metal cover upwards and fix it securely to the column guide with the M6
retaining screw.
For cables on the column:
- Open the column (see section 4.3 “Metal covers (without membrane keyboard)”

Cables
For cables going to the tabletop:
- Open the table top (see section 4.5 “Head cover” page 21, work steps 5. to 7.).
- Unscrew the bellows from the tabletop (8 fillister-head screws).
- Press the bellows carefully down.
Remove the defective cable’s plug, disconnect the leads, remove cable binders and
clips, and remove the cable.
7. WARNING
Risk of injuries!
Pay attention to the polarity!!!
Insert a new cable that is identical in construction.
Only use limed resin as the flux for soldered joints!
Put the cables back into their original positions, and connect the plugs (see section 9
“Circuit Diagram” page 177). Fix the cables with cable binders and/or cable clips.
11. CAUTION
Do not crush or squeeze the cables! Observe all motion sequences on the operating
table. When needed, interrupt the sequence and fix the cable’s position!
TEST


Cables

CAUTION
14. Remove both battery fuses and store safely.
15. Disconnect the positive connectors from the both batteries.
16. For cables in the column base:
- Remove retaining screw from the column guide and slide the metal cover
downwards.
- Close the metal cover (2 countersunk screws).
For cables on the column:
- Guide the remaining cladding components upwards and hook them into place.
- Mount the metal cover without membrane keyboard (3 countersunk screws at the
For cables going to the tabletop:
- Screw the expansion bellows tightly onto the tabletop (8 fillister-head screws).
- Do not jam or damage the expansion bellows. Place the head cover carefully on the
tabletop, and screw tight (4 fillister-head screws).
- Remount the plastic plate on the seat section (4 ball-heads).
- Press the pad onto the 4 ball-heads.
TEST

Energy chain
4.19 Energy chain

3. MARS 2.02 to 2.06
1
2
3
Figure 27 Energy chain

1 Metal cover 3 End piece
2 Energy chain
5. Unscrew 2 countersunk screws from the very bottom of the metal cover [1].
retaining screw.
7. Unhook the energy chain [2] from the upper and/or lower end piece respectively.
8. Open the energy chain. In order to do this, carefully pry up the transverse bars of the
individual chain links on the right side with a screwdriver (flat).
Remove the cables.
10. Renew defective parts of the energy chain. Lock the chain links completely together.
11. If needed, unscrew the upper and/or lower end piece [3] of the energy chain
(2 countersunk screws or 2 machine screws) and replace.
12. Put the cables back into their original positions.
Lay the cables into the energy chain (do not cross them over) and close the flexible
cover securely.
13. Hook the energy chain [2] into the upper and/or lower end piece [3]. Lock the chain
links completely together.
15. Close the metal cover [1] (2 countersunk screws).
TEST

Plastic plate
5 Repair Guide for the Tabletop
5.1 Plastic plate

1
2
Figure 28 Pad plate

1 Pad 3 M8 ball-head
2 Plastic plate
5. Pull pad [1] off the relevant section, and put it down in a safe place.
6. Unscrew the associated plastic plate [2] (4 ball-heads [3]).
7. Mount a new plastic plate (4 ball-heads [3]).
8. Press the previously removed pad [1] onto the 4 ball-heads [3].

Leg section gearbox (LS)
5.2 Leg section gearbox (LS)

1
2
Figure 29 Pad plate

2 Plastic plate
5. Unscrew the plastic plate [2] (4 ball-heads [3]), and put them down in a safe place.

13
15
9 19
14 18
10
7
11 16
8
12
A
69 5
17
Figure 30 Leg sections gearbox

4 Cover (sheet metal guard) 12 M5x50 machine screw
5 Cover foil 13 M8x16 machine screw
6 LS joint 14 Leg section motor
7 Cylindrical pin Ø 10 mm x 24 mm 15 LS gear
8 M4x12 machine screw 16 M3x16 machine screw
9 Slip ring 17 Standard rail joint
10 Groove ring 18 M4x12 machine screw
11 LS drive unit (consists of items 14 19 Leg section toothed belt
and 15)
6. Unscrew the standard rail joint [17] (2 countersunk screws), and put them down in a
safe place.
7. Pull the self-adhesive covering foil off the seat section strut.
8. Remove the cover (sheet metal guard) [4] (2 machine screws), and put them down in
a safe place.
9. Unclip the red and black cables (leg section motor) from the plug.
10. Unscrew the LS drive unit [11] (2 machine screws [12] from the front of the seat section
strut, and 2 machine screws [13] from the strut).
11. Take care not to damage the cables of the leg section motor. Carefully pull out the LS
drive unit [11].
12. Take note of the mounting position of the toothed belt.
Carefully pull the leg section motor [14] out of the leg section toothed belt [19].
13. Carefully pull out the LS drive unit [11], and put it down safely.
14. Remove the self-adhesive covering foils [5] from the left and right of the LS joint [6].
15. Remove 6 cylindrical pins [7] with a pin remover, and put them down in a safe place.
16. Remove 6 machine screws [8], and put them down in a safe place.

17. Pull off the LS joint [6], remove 2 slip rings [9] and groove rings [10] in each case, and
put them down in a safe place.
18. Unscrew the leg section motor [14] from the LS joint [15] (4 machine screws), and
remove it.
19. Screw the leg section motor [14] to the new LS gear (4 machine screws).
20. CAUTION
Risk of damaging the insulation on the sensor cable.
Take care that cables are not crushed during assembly.
Slide the LS drive unit [11] together with the connecting cables carefully into the seat
section strut, and thread in the cables of the leg section motor.
21. Ensure that the toothed belt is fitted correctly (over the tension roller).
Carefully insert the leg section motor [14] into the leg section toothed belt [19].
22. Mount the LS drive unit [11] (2 machine screws [12] on the front of the seat section
strut and 2 machine screws [13] on the strut).
23. If necessary insert new groove rings [10] left and right into the grooves in the LS gear
housing.
24. CAUTION
Danger: Incorrect positioning causes wear on the slip rings.
Ensure that the slip rings are lying in the correct positions.
Press slip rings [9] onto the groove rings, and slide the LS joint [6] onto the LS gear [15].
25. Align the LS joint [6] horizontally (zero position), and screw it to the LS drive unit [11]
26. Knock in 6 cylindrical pins [7].
27. Mount the joint [17] (2 countersunk screws).
28. If necessary, attach new self-adhesive covering foils [5] to the left and right of the LS
joint [6].
29. Connect the red and black cables of the leg section motor to the plug (see section 9
“Circuit Diagram” page 177).
30. Adjust the leg section toothed belt [19]:
- Loosen the central machine screw [18] in the leg section motor (clamping plate of
the drive unit).
- Determine the frequency of vibration of the toothed belt with the SM4 strand tension
gauge, and set the tension of the toothed belt with the aid of the two vertical machine
screws [16] on the leg section motor (check initial tension 95 Hz ± 5 three times
consecutively).
- Tighten the central machine screw [18].

34. TEST
Check the functional efficiency of the sensor(s) on the corresponding seat section strut.
Readjust the sensor(s) if necessary (see section 6 “Adjustment” page 114).
CAUTION
37. Carefully insert the plug into the seat section strut.
38. Mount the cover (sheet metal guard) [4] and connect the cable shielding (2 machine
screws).
39. If necessary, attach new self-adhesive covering foils over the apertures in the seat
section strut.
TEST
Check the operating table functions.

Leg section motor
5.3 Leg section motor

1
2
Figure 31 Pad plate

2 Plastic plate
5. Unscrew the plastic plate [2] from the seat section (4 ball-heads [3]), and put them
down in a safe place.
7
9
12
11
8
5
9
6 A
Figure 32 Leg section motor

4 Cover (sheet metal guard) 8 Leg section motor
5 LS drive unit (consists of items 8 9 LS gear
and 9) 10 M3x16 machine screw
7 M8x16 machine screw 12 Leg section toothed belt
a safe place.

Leg section motor
drive unit [5].
13. Unscrew the leg section motor [8] from the LS joint [9] (4 machine screws), and
remove it.
14. Screw the new leg section motor to the LS gear [9] (4 machine screws).
15. CAUTION
17. Mount the LS drive unit [5] (2 machine screws [6] on the front of the seat section strut
and 2 machine screws [7] on the strut).
the drive unit).
consecutively).
23. TEST

Leg section motor

CAUTION
screws).
section strut.
TEST

Leg section toothed belt
5.4 Leg section toothed belt

1
2
Figure 33 Pad plate

2 Plastic plate

13
10
12 4
11
7
5 12
8 15
14
A
6
Figure 34 Leg section toothed belt

4 Cover (sheet metal guard) 10 Toothed-belt guide
5 LS drive unit 11 Bridge
7 M8x16 machine screw 13 Seat section strut
8 Leg section motor 14 M3x16 machine screw
9 Toothed-belt cover 15 M4x12 machine screw
a safe place.
drive unit [5].
13. Repeat work steps 6. to 12. on the other seat section strut.
14. MARS 2.02 to 2.06
Remove the toothed-belt cover [9] (4 countersunk screws), and put them down in a safe
place.
Pull the leg section toothed belt [12] through the seat section struts [13], and remove it.

16. MARS 2.01

Put the toothed belt back into its original position.
Insert the ends of the new leg section toothed belt carefully into the two seat section
struts, and place between the pins.
17. MARS 2.02 to 2.06
Carefully thread the ends of the leg section toothed belt into the two seat section
struts [13], and insert it into the bridge [11] (between the toothed-belt guides [10]).
18. CAUTION
Tension equally at both ends.
the drive unit).
consecutively).
24. MARS 2.02 to 2.06
Mount the toothed-belt cover [9] (4 countersunk screws).
28. TEST


CAUTION
screws).
section strut.
TEST

Leg section joint (LS)
5.5 Leg section joint (LS)

CAUTION
1
2
Figure 35 Pad plate

2 Plastic plate
10
7 5
8
9
11
4
Figure 36 Leg section joint

4 Cover foil 8 Slip ring
5 LS joint 9 Groove ring
6 Cylindrical pin Ø 10 mm x 24 mm 10 LS gear
7 M4x12 machine screw 11 Standard rail joint
7. Unscrew the standard rail joint [11] (2 countersunk screws), and put them down in a
safe place.
8. Remove the self-adhesive covering foils [4] from the left and right of the LS joint [5].

Leg section joint (LS)
11. Pull off the LS joint [5], remove 2 slip rings [8] and groove rings [9] in each case.
12. If necessary insert new groove rings [9] left and right into the grooves in the LS gear
housing.
13. CAUTION
Press slip rings [8] onto the groove rings, and slide the new LS joint [5] onto the LS
gear [10].
14. Align the LS joint [5] horizontally (zero position), and screw it to the LS drive unit
16. Mount the joint [11] (2 countersunk screws).
17. If necessary, attach new self-adhesive covering foils [4] to the left and right of the LS
joint [5].
TEST

Back section gearbox (BS)
5.6 Back section gearbox (BS)

1
2
Figure 37 Pad plate

2 Plastic plate
4. Pull pads [1] off the seat and back sections, and put them down in a safe place.
5. Unscrew the plastic plates [2] from the seat and back sections (4 ball-heads [3] from
each), and put them down in a safe place.
16 8
4 7
17
9
14
10 12
5
A
13
6
A
18
11
15
Figure 38 Back section gearbox

4 M4x12 machine screw 12 BS drive unit (consists of items 15
5 Cover foil and 18)
6 Cylindrical pin Ø 10 mm x 24 mm 13 M5x50 machine screw
8 Strut of the BS joint 15 Back section motor
9 Slip ring 16 M3x16 machine screw
10 Groove ring 17 Back section toothed belt
11 Cover (sheet metal guard) 18 BS gear
6. Remove the self-adhesive covering foils [5] from the left and right of the strut of the BS
joint [8].

9. Pull off the strut of the BS joint [8], remove 2 slip rings [9] and groove rings [10] in each
case, and put them down in a safe place.
a safe place.
12. Unclip the red and black cables (back section motor) from the plug.
13. Unscrew the BS drive unit [12] (2 machine screws [13] from the front of the seat section
strut and 2 machine screws [14] from the strut).
14. Take care not to damage the cables of the back section motor. Carefully pull out the
BS drive unit [12].
Carefully pull the back section motor [15] out of the back section toothed belt [17].
16. Pull out the BS drive unit [12], and put it down in a safe place.
17. Unscrew the back section motor [15] from the BS gear [18] (4 machine screws), and
remove it.
18. Screw the back section motor [15] to the new BS gear (4 machine screws).
19. CAUTION
Slide the BS drive unit [12] together with the connecting cables carefully into the seat
section strut, and thread in the cables of the back section motor.
Carefully insert the back section motor [15] into the back section toothed belt [17].
21. Mount the BS drive unit [12] (2 machine screws [13] on the front of the seat section
strut and 2 machine screws [14] on the strut).
22. If necessary insert new groove rings [10] left and right into the grooves in the BS gear
housing.
23. CAUTION
Press slip rings [9] onto the groove rings, and slide the strut of the BS joint [8] onto the
BS gear.
24. Align the strut of the BS joint [8] horizontally (zero position), and screw it to the BS drive
unit [12] (6 machine screws [7]).
26. If necessary, attach new self-adhesive covering foils to the left and right of the strut of
the BS joint [8].
27. Connect the red and black cables of the back section motor to the plug (see section 9

28. Adjust the back section toothed belt [17]:

- Loosen the central machine screw [4] in the back section motor (clamping plate of
the drive unit).
screws [16] on the back section motor (check initial tension 95 Hz ± 5 three times
consecutively).
32. TEST
CAUTION
screws).
section strut.
38. Mount the plastic plates [2] on the seat and back sections (each held by 4 ball-
heads [3]).
39. Press the previously removed pads [1] onto the 4 ball-heads [3].
TEST

Back section motor
5.7 Back section motor

1
2
Figure 39 Pad plate

2 Plastic plate
A 8
7
9 6
10 11
4
12
A
Figure 40 Back section motor
4 Cover (sheet metal guard) 8 Back section motor
5 BS drive unit (consists of items 8 9 BS gear
and 9) 10 M3x16 machine screw
7 M8x16 machine screw 12 Back section toothed belt
a safe place.

Back section motor
9. Hold the back section strut securely.
Unscrew the BS drive unit [5] (2 machine screws [6] from the front of the seat section
BS drive unit [5].
13. Unscrew the back section motor [8] from the BS gear [9] (4 machine screws), and
remove it.
14. Screw the new back section motor to the BS gear [9] (4 machine screws).
15. CAUTION
17. Mount the BS drive unit [5] (2 machine screws [6] on the front of the seat section strut
the drive unit).
consecutively).
23. TEST

Back section motor

CAUTION
screws).
section strut.
heads [3]).
TEST

Back section toothed belt
5.8 Back section toothed belt

1
2
Figure 41 Pad plate

2 Plastic plate
6
10
A 9
8
13 17
7
11 15 16
13
4
14
13
12
A
Figure 42 Back section toothed belt
4 Cover (sheet metal guard) 11 Toothed-belt guide
5 Back section strut 12 Bridge
6 BS drive unit (consists of items 9 13 Back section toothed belt
and 17) 14 Seat section strut
9 Back section motor 17 BS gear
10 Toothed-belt cover

a safe place.
9. Hold the back section strut [5] securely.
BS drive unit [6].
14. MARS 2.02 to 2.06
Remove the toothed-belt cover [10] (4 countersunk screws), and put them down in a
safe place.
Pull the back section toothed belt [13] through the seat section struts [14], and remove
it.
16. MARS 2.01
Insert the ends of the new back section toothed belt carefully into the two seat section
struts, and place between the pins.
17. MARS 2.02 to 2.06
Carefully thread the ends of the back section toothed belt into the two seat section
struts [14], and insert it into the bridge [12] (between the toothed-belt guides [11]).
18. CAUTION


Tension equally at both ends.
the drive unit).
consecutively).
24. MARS 2.02 to 2.06
Mount the toothed-belt cover [10] (4 countersunk screws).
28. TEST
CAUTION
screws).
section strut.
heads [3]).
TEST

Back section (BS) joint and its components
5.9 Back section (BS) joint and its components

CAUTION
2
10
9
8
4 5
6
11 7
Figure 43 Back section joint

1 Tension bolt 7 Cam lever
2 BS joint 8 Thrust washer
3 Disc springs 9 Thrust sleeve
4 Cylindrical pin 10 Shim ring
5 Locking lever 11 Cylindrical pin
6 Pressure spring
5. Open the cam lever [7] on the corresponding BS joint.

6. Knock the cylindrical pin [4] out, and put it down in a safe place.
NOTE
Prevent the compression spring [6] from springing out.

7. Carefully remove and safely put down the cam lever [7].
8. Remove the thrust washer [8], shim rings [10] and thrust sleeve [9], and put them down
in a safe place.
9. Carefully knock the tension bolt [1] out with a plastic hammer, and put it down in a
safe place.
10. Remove the disc springs [3] and put them down in a safe place.
11. Remove the BS joint [2].

Back section (BS) joint and its components
12. CAUTION
Ensure that the teeth mesh. The teeth must mesh - not lie tooth on tooth.
Attach the new BS joint.
NOTE
Also renew other damaged or defective parts.
13. Insert disk springs [3] (make sure they are fitted correctly).
14. Carefully knock the tension bolt [1] in with a plastic hammer.
15. Slide on the thrust sleeve [9], shim rings [10] and thrust washer [8].
16. Mount the cam lever [7] (knock in 1 cylindrical pin [4]).
17. Close cam lever [7].
NOTE
The cam lever [7] must move easily. Toothing has no play in tensioned state.
If necessary, readjust with shim rings [10].
TEST

Back section strut
5.10 Back section strut

CAUTION
1
2
Figure 44 Pad plate

2 Plastic plate

Back section strut
5
13
12
11
8
7
9
14 10
Figure 45 Back section joint

4 Tension bolt 10 Cam lever
5 BS joint 11 Thrust washer
6 Disc springs 12 Thrust sleeve
7 Cylindrical pin 13 Shim ring
8 Locking lever 14 Cylindrical pin
9 Pressure spring
7. Open the cam lever [10] on the corresponding BS joint [5].

8. Knock the cylindrical pin [7] out, and put it down in a safe place.
NOTE
Prevent the compression spring [9] from springing out.

9. Carefully remove and safely put down the cam lever [10].
10. Remove the thrust washer [11], shim rings [13] and thrust sleeve [12], and put them
11. Carefully knock the tension bolt [4] out with a plastic hammer, and put it down in a
safe place.
12. Remove the disc springs [6] and put them down in a safe place.
13. Remove the BS joint [5], and put it down in a safe place.

Back section strut
17
18
20
15
19
16
21
Figure 46 Back section strut (strut of the BS joint)

15 Groove ring 19 M4x12 machine screw
16 Cover foil 20 Slip ring
17 Strut of the BS joint 21 BS drive unit
18 Cylindrical pin Ø 10 mm x 24 mm
14. Remove the self-adhesive covering foils [16] from the left and right of the strut of the
BS joint [17].
17. Pull off the strut of the BS joint [17], remove 2 slip rings [20] and groove rings [15] in
each case.
18. If necessary insert new groove rings [15] left and right into the grooves in the BS gear
housing [21].
19. CAUTION
Press slip rings [22] onto the groove rings [15], and slide a new strut of the BS joint [17]
onto the BS drive unit [21].
20. Align the strut of the BS joint [17] horizontally (zero position), and screw it to the BS
drive unit [21] (6 machine screws [19]).
22. If necessary attach new self-adhesive covering foils [16] to the left and right of the strut
of the BS joint [17].
23. CAUTION
Ensure that the teeth mesh. The teeth must mesh - not lie tooth on tooth.
Attach the BS joint [5].

Back section strut
NOTE
Also renew other damaged or defective parts.
24. Insert disk springs [6] (make sure they are fitted correctly).
25. Carefully knock the tension bolt [4] in with a plastic hammer.
26. Slide on the thrust sleeve [12], shim rings [13] and thrust washer [11].
27. Mount the cam lever [10] (knock in 1 cylindrical pin [7]).
28. Close cam lever [10].
NOTE
The cam lever must move easily. Toothing has no play in tensioned state.
If necessary, readjust with shim rings [13].
heads [3]).
TEST

Energy chain (not MARS 2.01)
5.11 Energy chain (not MARS 2.01)

1
4
4 2
A 3
Figure 47 Energy chain

1 Plate (panel) 3 Energy chain
2 Plate (Energy chain cover) 4 End piece
4. Remove the plate (panel) [1] from the side of the seat section strut (2 countersunk
screws), and put them down in a safe place.
5. Remove the plate (energy chain cover) [2] from the column head (2 machine screws),
and put them down in a safe place.
6. Remove the cable binders, and unhook the energy chain [3] from one/both end
piece(s) [4].
Carefully pull the cables out of the energy chain.
8. If necessary, unscrew the end pieces [4] of the energy chain (2 countersunk screws),
and replace with new ones.
9. CAUTION
Risk of damaging the insulation on the cable.
Put the cables back into their original positions.
Lay the cables into the energy chain (do not cross them over).
10. Hook the energy chain [3] onto the end pieces [4]. Lock the chain links completely
together.
11. Fix the cables with cable binders.

Energy chain (not MARS 2.01)
12. CAUTION
Mount the plate (energy chain cover) [2] on the column head (2 machine screws).
13. Mount the plate (panel) [1] on the side of the seat section strut (2 countersunk screws).
TEST

Locking unit (not MARS 2.01)
5.12 Locking unit (not MARS 2.01)

1
2
Figure 48 Pad plate

2 Plastic plate
5
7
Figure 49 Locking unit

4 Head cover 7 upper bolt
5 M5x12 machine screw 8 lower bolt
6 Locking unit

Locking unit (not MARS 2.01)
7. NOTE

Remove the head cover [4] (4 fillister-head screws), and put them down in a safe place.
Pull the plug out of the defective locking unit at the side of the membrane keyboard on
the column head [6], and remove the cable binders.
9. Remove 4 machine screws [5] from the locking unit [6], and put them down in a safe
place.
10. Remove one retaining washer from each of the upper [7] and lower bolts [8] (not from
the bolt with the hinge springs), and put them down in a safe place.
11. Hold the locking unit [6] securely.
Remove the upper [7] and lower bolts [8], and put them down in a safe place.
12. Take note of where the locking unit [6] had been fitted.
Carefully pull the defective locking unit out of the column head, and remove it.
13. Put the locking unit back into its original position.
Carefully insert the new locking unit into the column head.
14. Insert the lower bolt [7], and mount the retaining washer.
15. Insert the upper bolt [8], and mount the retaining washer.
16. Mount the locking unit [6] on the column head (4 machine screws [5]).
17. Put the cables back into their original positions, and connect the plugs to the new
locking unit [6]. Fix the cables with cable binders.
screws).
20. Press the seat section pad [1] onto the 4 ball-heads [3].
TEST

Distributor board
5.13 Distributor board

3. MARS 2.02 to 2.06
1
2
Figure 50 Pad plate

2 Plastic plate

Distributor board
4
5
6
5 7
6
Figure 51 Distribution board with holder

4 Head cover 6 Holder
5 Distributor board 7 Snap-in lug
7. NOTE

Pull all plugs out of the defective distributor board [5], and remove the cable binders.
9. Unscrew the holder [6] with the distributor board [5] from the tabletop (4 countersunk
screws), free it up, and carefully remove it in an upward direction.
10. Press 4 snap-in lugs [7] (spacers) together, starting on one side of the distributor
board [5], and carefully pull the printed circuit board up and off the holder [6].
11. Place the new distributor board on the snap-in lugs [7] of the holder [6], and click it
securely into place.
12. Insert the holder [6] carefully into the tabletop, and mount (4 countersunk screws).

Distributor board
B
Figure 52 Distributor board
A Seat section strut side B Column head side
X2 IR/RS485 interface (only MARS 2.01) X7 REF/BP -35° sensors

X3 RS485/232 interface (1x MARS 2.01, 2x Mars 2.02-2.06) X9 End sensors
X4 HE (head end) IR/interface X13 Spare
X5 LE (foot end) IR/interface X14 OR adapter sensor
X6 LD microbutton
13. Put the cables back into their original positions, and insert all plugs into the new
distributor board [5] (see section 9 “Circuit Diagram” page 177). Fix the cables with
cable binders.
screws).
TEST

Longitudinal displacement (LD) microbutton (not MARS 2.01)
5.14 Longitudinal displacement (LD) microbutton (not MARS 2.01)

1
2
Figure 53 Pad plate

2 Plastic plate
Figure 54 LD microbutton
4 Head cover 5 Distributor board
7. NOTE


6
9 8
Figure 55 LD microbutton
6 Plate (panel) 8 Plate (Energy chain cover)
7 Energy chain 9 LD microbutton
8. Remove the plate (panel) [6] from the side of the seat section strut (2 countersunk
screws), and put them down in a safe place.
9. Remove the plate (energy chain cover) [8] from the column head (2 machine screws),
12. Switch on the operating table, and carefully displace the tabletop toward the foot end
until it meets the stop.
CAUTION
14. Remove and safely put down the both battery fuses.
16. Take note of the mounting position of the LD microbutton.
Unscrew the LD microbutton [9] together with holding plate (on the right-hand side at
the bottom of the column head above the energy chain [7]; 2 countersunk screws).
Pull the LD microbutton plugs out of the distributor board [5], and remove the cable
binders.
18. Remove the holding plate together with LD microbutton and its cable from the column
head.
19. Unscrew the defective LD microbutton [9] from the holding plate (2 machine screws).
20. Mount the new LD microbutton [9] on the holding plate (2 machine screws).

21. Put the LD microbutton back into its original position.

Insert and mount the LD microbutton [9], together with the holding plate, in the column
head (2 countersunk screws).
22. Put the cables back into their original positions, and insert the plug of the LD
microbutton [9] into the appropriate socket on the distributor board [5]. Fix the cables
with cable binders.
25. Switch on the operating table, and carefully displace the tabletop toward the head end
until it meets the stop.
CAUTION
27. CAUTION
Mount the plate (energy chain cover) [8] on the column head (2 machine screws).
28. Mount the plate (panel) [6] on the side of the seat section strut (2 countersunk screws).
screws).
TEST

OR adapter sensor MARS 2.01
5.15 OR adapter sensor MARS 2.01

5. Pull the central self-adhesive covering foil off the right-hand seat section strut.
Pull the plug of the OR adapter sensor out of the distributor board, and remove the
cable binders.
7. Unscrew the standard rail from the right-hand seat section strut (3 countersunk screws),
8. Remove OR adapter sensor.
9. Put the cable back into its original position.
Thread the cable of the new OR adapter sensor through the strut into the column head,
and insert the sensor plug into the appropriate socket on the distributor board. Fix the
cable with cable binders.
10. Position the OR adapter sensor, and mount the standard rail on the seat section strut
(3 countersunk screws).
11. If necessary, attach new self-adhesive covering foil over the aperture in the seat section
strut.
Place the head cover carefully on the tabletop, and screw tight (4 fillister-head screws).
13. Remount the plastic plate on the seat section (each held by 4 ball-heads).
14. Press the previously removed pads onto the 4 ball-heads.
TEST

OR adapter sensor (not MARS 2.01)
5.16 OR adapter sensor (not MARS 2.01)

2
2
Figure 56 OR adapter sensor

1 Head cover 3 Distributor board
2 OR adapter sensor 4 M3x6 machine screw

Pull the plug of the OR adapter sensor [2] out of the distributor board [3], and remove
the cable binders.
6. Unscrew the OR adapter sensor [2] from the foot end of the column head (2 machine
screws [4]).
7. Remove the defective OR adapter sensor [2] and its cable from the column head.
8. Thread the cable of the new OR adapter sensor into the column head, and mount the
sensor (2 machine screws [4]).
9. Put the cables back into their original positions, and insert the plug of the OR adapter
sensor [2] into the appropriate socket on the distributor board [3]. Fix the cables with
cable binders.
screws).
12. Press the seat section pad onto the 4 ball-heads.
TEST

Leg section (LS) end sensor
5.17 Leg section (LS) end sensor

1
2
Figure 57 Pad plate

2 Plastic plate
6. Pull the self-adhesive covering foils off the right-hand seat section strut.
13
12
4
11
A
7
A
8
10 14
5
9
6
Figure 58 LS end sensor (right-hand seat section strut)

4 Cover (sheet metal guard) 10 LS end sensor
5 LS drive unit 11 M3x16 machine screw
8 Leg section motor 14 Terminal block
9 M4x12 countersunk screw

a safe place.
8. Unclip the blue and brown (LS end sensor) and red and black (leg section motor)
cables from the plug.
drive unit [5].
13. Loosen the countersunk screw [9] on the inner side of the seat section strut.
NOTE
Do not completely unscrew the countersunk screw [9] as the terminal block [14] would
then fall.
14. Pull the defective LS end sensor [10] out of the seat section strut.
15. Push the new LS end sensor [10] through the terminal block [14] in the seat section
strut.
16. CAUTION
19. Clip the blue and brown (LS end sensor) and red and black (leg section motor) cables
onto the plug (see section 9 “Circuit Diagram” page 177).
the drive unit).
consecutively).
21. Position the LS end sensor [10] in the seat section strut, and fixate with an countersunk
screw [9].

25. TEST
Check that the sensor is in good working order.

If necessary, readjust the LS end sensor [10] (see section 6 “Adjustment” page 114).
CAUTION
screws).
section strut.
TEST

Back section (BS) end sensor
5.18 Back section (BS) end sensor

1
2
Figure 59 Pad plate

2 Plastic plate
6. Pull the self-adhesive covering foils off the right-hand seat section strut.

6 8 5
15
7
4
A
12 11
14
10 13
Figure 60 BS end sensor (right-hand seat section strut)

4 Cover (sheet metal guard) 10 BS end sensor
5 Back section strut 11 M3x16 machine screw
8 Back section motor 14 Terminal block
9 M4x12 countersunk screw 15 BS drive unit
a safe place.
8. Unclip the blue and brown (BS end sensor) and red and black (back section motor)
9. Hold the back section strut [5] securely.
Unscrew the BS drive unit (2 machine screws) [6] from the front of the seat section strut,
and 2 machine screws [7] from the strut).
BS drive unit.
NOTE
then fall.
14. Pull the defective BS end sensor [10] out of the seat section strut.
15. Push the new BS end sensor [10] through the terminal block [14] in the seat section
strut.

16. CAUTION
19. Clip the blue and brown (LS end sensor) and red and black (back section motor) cables
onto the plug (see section 9 “Circuit Diagram” page 177).
the drive unit).
consecutively).
21. Position the BS end sensor [10] in the seat section strut, and fixate with an countersunk
screw [9].
25. TEST

Readjust the BS end sensor [10] if necessary (see section 6 “Adjustment” page 114).
CAUTION
screws).
section strut.
heads [3]).


TEST

Leg section reference sensor (LS)
5.19 Leg section reference sensor (LS)

1
2
Figure 61 Pad plate

2 Plastic plate
6. Pull the self-adhesive covering foils off the left-hand seat section strut.
A 15
17
B
4
10
4
47
49
14
13
A 57
85 12
5 11
46
B
Figure 62 LS reference sensor (left-hand seat section strut)
4 Cover (sheet metal guard) 10 LS reference sensor
5 LS drive unit 11 M3x16 machine screw
6 M5x50 machine screw 12 LS -35° sensor
8 Leg section motor 14 Leg section toothed belt
9 M4x12 countersunk screw 15 Terminal block
a safe place.

8. Unclip the blue and brown (LS reference sensor) and red and black (leg section motor)
drive unit [5].
NOTE
then fall.
14. Pull the defective LS reference sensor [10] out of the seat section strut.
15. Push the new LS reference sensor [10] through the terminal block [15] in the seat
section strut.
16. CAUTION
19. Clip the blue and brown (LS reference sensor) and red and black (leg section motor)
cables onto the plug (see section 9 “Circuit Diagram” page 177).
the drive unit).
consecutively).
21. Position the LS reference sensor [10] in the seat section strut, and fixate with an
countersunk screw [9].

25. TEST
Check that the sensors are in good working order.

If necessary, readjust the LS reference sensor [10] and the LS -35° sensor [12] (not
MARS 2.01) ( see section 6 “Adjustment” page 114).
CAUTION
screws).
section strut.
TEST

Back section reference sensor (BS)
5.20 Back section reference sensor (BS)

1
2
Figure 63 Pad plate

2 Plastic plate
11 12
13 7
8
5
B
B 4 A 6
10
14
9
Figure 64 BS reference sensor (left-hand seat section strut)

4 Cover (sheet metal guard) 10 BS reference sensor
5 BS drive unit 11 M3x16 machine screw
8 Back section motor 14 Terminal block
9 M4x12 countersunk screw

a safe place.
8. Unclip the blue and brown (BS reference sensor) and red and black (back section
motor) cables from the plug.
9. Hold the back section strut securely.
BS drive unit [5].
NOTE
then fall.
14. Pull the defective BS reference sensor [10] out of the seat section strut.
15. Push the new BS reference sensor [10] through the terminal block [14] in the seat
section strut.
16. CAUTION
19. Clip the blue and brown (LS reference sensor) and red and black (back section motor)
the drive unit).
consecutively).
21. Position the BS reference sensor [10] in the seat section strut, and fixate with an
countersunk screw [9].


25. TEST

If necessary, readjust the BS reference sensor [10] ( see section 6 “Adjustment”
page 114).
CAUTION
screws).
section strut.
heads [3]).
TEST

Leg section (LS) -35° sensor (not MARS 2.01)
5.21 Leg section (LS) -35° sensor (not MARS 2.01)

1
2
Figure 65 Pad plate

2 Plastic plate
A
4
11 14
13
15
10
5 12
8
9 A
Figure 66 LS -35° sensor (left-hand seat section strut)

4 Cover (sheet metal guard) 10 M3x16 machine screw
5 LS drive unit 11 LS reference sensor
6 M5x50 machine screw 12 M4x12 countersunk screw
8 Leg section motor 14 Leg section toothed belt
9 LS -35° sensor 15 Terminal block
a safe place.

8. Unclip the blue and brown (LS -35° sensor) and red and black (leg section motor)
drive unit [5].
13. Loosen the countersunk screw [12] on the outer side of the seat section strut.
NOTE
Do not completely unscrew the countersunk screw [12] as the terminal block [15]
would then fall.
14. Pull the defective LS -35° sensor [9] out of the seat section strut.
15. Push the new LS -35° sensor [9] through the terminal block [15] in the seat section strut.
16. CAUTION
19. Clip the blue and brown (LS reference sensor) and red and black (leg section motor)
20. Adjust the led section toothed belt [14]:
the drive unit).
consecutively).
21. Position the LS -35° sensor [9] in the seat section strut, and fixate with an countersunk
screw [12].
23. Insert both battery fuses in the battery compartment.

25. TEST
Check that the sensors are in good working order.

If necessary, readjust the LS reference sensor [11] and the LS -35° sensor [9] (see
section 6 “Adjustment” page 114).
CAUTION
screws).
section strut.
TEST

Inclination sensor
6 Adjustment
6.1 Inclination sensor

NOTE
The inclination sensor is a part of the distribution board. They cannot be replaced
separately.
The following equipment is needed for adjusting the inclination sensor:

• PC/notebook with PC software service tool
• Connecting cable for RS232 port on the operating table
• Spirit level with digital display
The inclination sensor is adjusted in several stages:

1. Prepare the operating table (zero position) (see section 2.3 “Operating table”
page 11).
3. MARS 2.02 to 2.06
Actuate the longitudinal displacement to bring the tabletop into its central position.
4. Start PC/notebook.
5. Connect the PC/notebook to the RS232 port on the operating table by the adapter
cable.
6. Start the PC software service tool:
- Connect to the operating table: Menu “Operating table Æ create connection”
- Call the menu for calibrating the inclination sensor: “Operating table Æ set motor
and sensor parameters Æ calibrate inclination”
7. Zero the Trendelenburg and tilt of the tabletop with the aid of a spirit level (set
horizontally):
- Place the spirit level on the inner joint sections in order to zero the Trendelenburg
- Place the spirit level on the seat section (without pad) in order to zero the tilt
- If necessary, readjust the tabletop by means of the Trendelenburg/tilt functions on
the remote control/column keypad
8. Transfer the zero position to the PC software service tool: “Neutral position Æ set”
The zero position of the tabletop has now been saved.
9. Set the tabletop to approx. a 24° Trendelenburg or 32° anti-Trendelenburg position
with the remote control/column keypad. Read the exact angle of inclination on the
spirit level, input it into the PC software service tool under “Actual Trendelenburg
value”, and save with the “Calibrate” button (Note: don’t forget the sign of the value
input). Return the Trendelenburg to the zero position (Zero position button on remote
control/column keypad).

Inclination sensor
10. Set a tilt to the left or right of approx. 22° with the remote control/column keypad. Read
the exact angle of inclination on the spirit level, input it into the PC software service
tool under “Actual tilting value”, and save with the “Calibrate” button (Note: don’t
forget the sign of the value input). Return the tilt to the zero position (Zero position
button on remote control/column keypad).
11. Check the Trendelenburg/anti-Trendelenburg and tilt left/right functions with the
remote control/column keypad. The difference between the inclination value on the
spirit level and that in the service tool (“Column” tab) must not exceed 0.2°. Repeat the
calibration if necessary (if the difference between the displayed values is greater than
0.2°).
12. After the calibration, break the connection to the operating table:
- “Operating table Æ break connection”
- Remove the connecting cable
- Switch the operating table Off
- Power down the PC/notebook

6.2 Leg section (LS) end sensor
3
1
2
Z
Figure 67 Adjustment of LS end sensor (right-hand seat section strut)

1 M4x12 countersunk screw 3 LS end sensor
2 LS joint Z Gap = 0.2 mm ± 0.1 mm
1. Move the corresponding leg section motor to its upper (or lower) switching point.
2. Loosen the countersunk screw [1] at the foot end on the inner side of the right-hand
seat section strut.
NOTE
Do not completely unscrew the countersunk screw as the terminal block would then
fall (see Figure 58, items 9 and 14).
3. Set the sensor gap to the LS joint [2] to 0.2 mm ± 0.1 mm [Z] by shifting the LS end
sensor [3] (use a gauge).
4. Fixate the LS end sensor [3] with an countersunk screw [1].
TEST
Perform a functional test and check the sensor gap again (gap 0.2 mm ± 0.1 mm).
Check the LS end sensors:
• Couple one leg section to each of the two leg section joints.
• Move both the leg sections down (or up) a little.
• Move both leg sections into the upper (or lower) end position.
• The ends of the leg sections must not have drifted more than 1 cm apart when they reach
the final position.
• If necessary, readjust the switching distance of the sensor (it must not exceed 0.3 mm).

6.3 Back section (BS) end sensor
1
Z
Figure 68 Adjustment of BS end sensor (right-hand seat section strut)

1 M4x12 countersunk screw 3 BS end sensor
2 BS joint Z Gap = 0.2 mm ± 0.1 mm
1. Move the corresponding back section motor to its upper (or lower) switching point.
2. Loosen the countersunk screw [1] at the head end on the inner side of the right-hand
seat section strut.
NOTE
3. Set the sensor gap to the strut of the BS joint [2] to 0.2 mm ± 0.1 mm [Z] by shifting
the BS end sensor [3] (use a gauge).
4. Fixate the BS end sensor [3] with an countersunk screw [1].
TEST
Check the BS end sensors:
• Move both of the back section struts down (or up) a little.
• Move the back section struts into the upper (or lower) end position.
• The ends of the back section struts must not have drifted more than 1 cm apart when
they reach the end position.

6.4 Leg section reference sensor (LS)
1
2
Z
Figure 69 Adjustment of the LS reference sensor (left-hand seat section strut)

1 M4x12 countersunk screw 3 LS reference sensor
1. Move the corresponding leg section motor to the central switching point.
2. Loosen the countersunk screw [1] at the foot end on the inner side of the left-hand seat
section strut.
NOTE
3. Set the sensor gap to the LS joint [2] to 0.2 mm ± 0.1 mm [Z] by shifting the LS
reference sensor [3] (use a gauge).
4. Fixate the LS reference sensor [3] with an countersunk screw [1].
TEST
Check the LS reference sensors:
• Move both leg sections up (or down) a little.
• Approach the zero position from the same direction.
the zero position.

6.5 Back section reference sensor (BS)
A
Z
1
3
Figure 70 Adjustment of the BS reference sensor (left-hand seat section strut)

1 M4x12 countersunk screw 3 BS reference sensors
1. Move the corresponding back section motor to the central switching point.
2. Loosen the countersunk screw [1] at the head end on the inner side of the left-hand
seat section strut.
NOTE
3. Set the sensor gap to the strut of the BS joint [2] to 0.2 mm ± 0.1 mm [Z] by shifting
the BS reference sensor [3] (use a gauge).
4. Fixate the BS reference sensor [3] with an countersunk screw [1].
TEST
Check the BS reference sensors:
• Move the back section struts up or down a little.
• Travel to zero position.
• The ends of the back section struts must not have drifted more than 1 cm apart when
they reach the zero position.

6.6 Leg section (LS) -35° sensor (not MARS 2.01)
2
Z
Figure 71 Adjustment of the LS -35° sensor (left-hand seat section strut)

1 M4x12 countersunk screw 3 LS -35° sensor

2. Move the corresponding leg section motor to the lower switching point.
3. Loosen the countersunk screw [1] at the foot end on the outer side of the left-hand seat
section strut.
NOTE
4. Set the sensor gap to the LS joint [2] to 0.2 mm ± 0.1 mm [Z] by shifting the LS -35°
sensor [3] (use a gauge).
5. Fixate the LS -35° sensor [3] with an countersunk screw [1].
TEST
Check the LS -35° sensors:
• Move both leg sections up a little.
• Move both leg sections to the lower end position.
the final position.

Batteries
7 Repair Guide for the Running Gear
7.1 Batteries
CAUTION
Always replace the complete set of batteries!
1. Prepare the operating table (section 2.3 “Operating table” page 11).
CAUTION
5
1
3 4

1 Cover battery compartment 4 Fuse
2 Cover plate 5 Battery-fastening bracket
3 Battery
5. Remove the cover plate [2] (4 countersunk screws), and put them down in a safe place.
6. Remove and store both battery fuses safely [4].
7. Remove two cables from each of the 2 batteries (on the battery set) [3].
8. Remove the battery-fastening bracket [5] (2 machine screws) and store safely.
9. Remove the entire battery set.
10. Install a new battery set.
11. Assemble the battery-fastening bracket [5] (2 machine screws).

Batteries
12. CAUTION
Danger of a short circuit!
Connecting the battery terminals incorrectly causes damage.
Connect the batteries [3] correctly (positive and negative terminals)! The voltage
between brown (bn) and white (ws) is 24 V DC.
13. Insert both battery fuses [4].
14. Mount the cover plate [2] (4 countersunk screws).
15. Put the cover battery compartment [1] on the running gear.
16. Check the charge in the batteries (charge with mains power supply if necessary!).
TEST

Mains socket
7.2 Mains socket

CAUTION
4
Foot end
1 5
3 6
Figure 73 Mains socket in the running gear
1 Running gear 4 Mains socket (plug filter)
2 Potential connection 5 M3x8 fillister-head screw
3 Cover 6 Fuse socket
4. Lift the mains socket [4] cover [3] and remove 2 fillister-head screws [5].
5. Carefully pull the mains socket [4] forward, out from the running gear [1].
6. Make note of the installation position and the pin assignment!
Disconnect all cables and remove the mains socket [4].
7. Pry out the fuse socket [6] from the defective and the new mains socket with a
screwdriver.
8. CAUTION
Bear in mind the wiring diagram (page 177) and the fuse overview!
Remove the defective mains socket’s fuses individually; test; replace if necessary and
stick them into the new mains socket’s fuse socket.
9. Insert the new fuse socket into the new mains socket.
10. Pay attention to the cables’ pin assignment!
Connect all cables to the new mains socket [4] (see also section 9 “Circuit Diagram”
page 177).
11. Make sure that the mains socket is in its original installation position (fuse socket on
top)!
Carefully insert the mains socket [4] into the running gear [1] and assemble (2 fillister-
head screws [5]).
TEST

Power supply fuses
7.3 Power supply fuses

CAUTION
4 6
Foot end
1
2
5
3 5
Figure 74 Mains socket with fuse block

1 Running gear 4 Mains socket (plug filter)
2 Potential connection 5 Fuse socket
3 Cover 6 Fuse
4. Raise the mains socket [4] cover [3] and prise the fuse socket [5] out with a screwdriver.
5. CAUTION
Remove the fuses [6] individually; test; and replace if needed.
6. Install fuse socket [5].
TEST

Battery fuses
7.4 Battery fuses

CAUTION
5
1
2
4 5
3
Figure 75 Fuses in battery compartment

1 Cover battery compartment 4 M3x6 countersunk screw
3 Battery
5. Remove the cover plate [2] (4 countersunk screws [4]), and put them down in a safe
place.
6. Disconnect the positive connectors from the both batteries [3].
7. CAUTION
Remove the fuses [5] individually; test; and replace if needed.
8. Reattach the positive connectors to the both batteries [3].
9. Mount the cover plate [2] (4 countersunk screws [4]).
10. Put the cover battery compartment [1] on the running gear.
TEST

Castor with locking device MARS 2.01/2.02
7.5 Castor with locking device MARS 2.01/2.02

CAUTION
4. CAUTION
Risk of injuries!
Turn the operating table on the side with a membrane keyboard and lay down safely
on an even surface.
5. Set the foot lever TRAVEL MODE in the directional travel position (see FOOT LEVER
OPERATION pictogram!).
3
4
1
2
7
2
3
5
Figure 76 Front castor, foot end, with brake and directional travel MARS 2.01/2.02
1 Front cap 5 Shaft
2 Castor with locking device 6 Pull frame
3 Brake Bowden cable 7 Lever
4 Directional travel Bowden cable
6. Remove front cap [1] from the defective castor [2] and store safely.
7. Take note of where the Bowden cables have been laid!
Unscrew the defective castor [2] (4 machine screws).
8. Unhook the directional travel Bowden cable [4] from the castor’s lever [7].
9. Note the screw depth of the brake Bowden cable [3].
10. Unscrew the brake Bowden cable [3] from the axle [5] in the pull frame [6] with the
help of pliers.
11. Restore the original screw-in depth of the brake Bowden cable!
Screw in the brake Bowden cable [3] into the axle [5] in the pull frame of the new castor
with locking device.

12. Hook the directional travel Bowden cable [4] into the new castor’s lever [7].
13. Mount the new castor (4 machine screws).
14. Put the Bowden cables [3]/[4] back into its original position.
15. Set the brake and directional travel so that they function safely and smoothly. If
necessary, readjust the Bowden cables [3]/[4] with the nuts (on the drive axle).
16. Clip the front cap on [1].
17. Set the foot lever TRAVEL MODE in the brake position (see FOOT LEVER OPERATION
pictogram!).
18. CAUTION
Risk of injuries!
TEST
Check traveling functions!

7.6 Castor with locking device MARS 2.03/2.05

2. Carry out work steps 1., 3. and 4. from section 4.1 “Remove the power from the
operating table” page 15.
3. CAUTION
Risk of injuries!
on an even surface.
4. Switch off and jack down the operating table (remote control).
CAUTION
5. Remove and safely put down both battery fuses in the battery compartment.
8
3
7
4
1
2
2
3
5
Figure 77 Front castor, foot end, with brake and directional travel MARS 2.03/2.05
1 Front cap 5 Shaft
2 Castor with locking device 6 Pull frame
3 Brake Bowden cable 7 Lever
4 Directional travel Bowden cable 8 Directional travel switch
Unscrew the defective castor [2] (4 machine screws).
9. Pull out the connector from the directional travel switch [8].
10. Unhook the directional travel Bowden cable [4] from the castor’s lever [7].
help of pliers.

Screw in the brake Bowden cable [3] into the axle [5] in the pull frame of the new castor
with locking device.
14. Hook the directional travel Bowden cable [4] into the new castor’s lever [7].
15. Mount the new castor (4 machine screws).
17. Plug in the directional travel switch cable plug into the new directional travel switch [8]
on the new castor.
WARNING
Danger to life and limb by an electric shock!
Be especially careful and cautious while working! Secure the work area so that no other
people can access it! The operating table must be switched on for the following work steps.
20. Switch the operating table on.
23. Jack up the operating table.
24. CAUTION
Risk of injuries!
27. Connect the power supply.
TEST

Front castor
7.7 Front castor

3. only MARS 2.01/2.02
Switch off the operating table (remote control).
CAUTION
4. CAUTION
Risk of injuries!
on an even surface.
5. MARS 2.01/2.02
Set the foot lever TRAVEL MODE in the directional travel position (see FOOT LEVER
MARS 2.03 to 2.06
Switch off and jack down the operating table (remote control).
CAUTION
4 3
5
3
1
2
Figure 78 Front castor, foot end, with brake

1 Front cap 4 Front castor
2 M8x20 machine screw 5 Shaft
3 Brake Bowden cable 6 Pull frame
7. Take note of the mounting position of the Bowden cable!
Unscrew the defective castor [4] (4 machine screws [2]).
help of pliers.

Front castor
Screw in the brake Bowden cable [3] into the axle [5] in the pull frame [6] of the new
front castor.
11. Mount the new castor (4 machine screws [2]).
12. Put the Bowden cable [3] back into its original position.
13. only MARS 2.03 to 2.06
Switch the operating table on.
14. Set the brake so that it is functioning safely and smoothly. If necessary, readjust the
Bowden cable [3] with the nuts (on the drive axle).
16. MARS 2.01/2.02
Set the foot lever TRAVEL MODE in the brake position (see FOOT LEVER OPERATION
pictogram!).
MARS 2.03 to 2.06
Jack up the operating table.
17. CAUTION
Risk of injuries!
19. only MARS 2.01/2.02
TEST

Rear castor MARS 2.01/2.02
7.8 Rear castor MARS 2.01/2.02

CAUTION
4. CAUTION
Risk of injuries!
on an even surface.
6. Remove the cap from the running gear (behind, on the head end) and store safely.
4
2
3
Figure 79 Rear castor at the head end with brake MARS 2.01/2.02
1 M8x20 machine screw 5 Locking ring 5
2 Rear castor 6 Spindle
3 Axle holder (shaft holder) 7 Drive axle (shaft)
4 M8x20 machine screw

Unscrew both rear castors [2] (4 machine screws [1] in each case).
8. Unscrew both axle holders [3] (2 machine screws [4] in each case) and store safely.
9. Remove the lock washer [5] at the end of the drive axle [7] (inside) and on the side of
the defective castor.
10. Pull out the shaft [6] (brake Bowden cable attached to it) and remove the rear defective
castor [2]. Watch out for the bushes.
11. Insert the new rear castor and assemble with the shaft [6] (brake Bowden cable
attached to it) to the drive axle [7] (lock washer [5]). Watch out for the bushes.

Rear castor MARS 2.01/2.02
12. Install the axle holders [3] (2x 2 machine screws [4]).
13. Assemble both rear castors [2] (4 machine screws [1] in each case).
14. Put the Bowden cables back into its original position.
necessary, readjust the Bowden cables with the nuts (on the drive axle).
16. Clip the rear cap on.
pictogram!).
18. CAUTION
Risk of injuries!
TEST

Rear castor MARS 2.03 to 2.06
7.9 Rear castor MARS 2.03 to 2.06

3. CAUTION
Risk of injuries!
on an even surface.
CAUTION
5. Remove the cap from the running gear (behind, on the head end) and store safely.
6
8
11
1 7 12
4 10
5
2
3 13
9 8
14
14
Figure 80 Rear castor at the head end with brake MARS 2.03 to 2.06
1 M8x20 machine screw 8 Directional travel Bowden cable
2 Rear castor 9 Bowden cable holder
3 Axle holder (shaft holder) 10 Front articulated axle
4 M8x16 machine screw 11 Retaining ring
5 Locking ring 5 12 Castor
6 Spindle 13 Start-up disk
7 Drive axle (shaft) 14 Jacking unit
6. Take note of the mounting position of the directional travel Bowden cable!
Unscrew the Bowden cable holder [9] from the trip fork (1 machine screw and
1 washer) and store safely.
7. Remove retaining ring [11] and roller [12] from front articulated axle and store safely.
8. NOTE
Pay attention to start-up disks [13] (8 pieces) and roller! Do not allow them to fall into
the running gear!
Knock out the front articulated axle [10] downwards and store safely.

Rear castor MARS 2.03 to 2.06
9. Swivel the jacking unit [14] carefully out of the way.

Unscrew both rear castors [2] (4 machine screws [1] in each case).
11. Unscrew all 3 axle holders [3] (2 machine screws [4] in each case) and store safely.
12. Remove the lock washer [5] at the end of the drive axle [7] (inside) and on the side of
the defective castor.
13. Pull out the shaft [6] (brake Bowden cable attached to it) and remove the rear defective
castor [2]. Watch out for the bushes.
14. Insert up the new rear castor and assemble with the shaft [6] (brake Bowden cable
attached to it) to the drive axle [7] (lock washer [5]). Watch out for the bushes.
16. Assemble both rear castors [2] (4 machine screws [1] in each case).
17. Put the Bowden cables back into its original position.
18. Carefully swivel the jacking unit [14] back into position and position it in the drive
axle’s [7] retainer with four stop discs [13] on the right and four on the left.
19. Insert a roller [12] on the front articulated axle [10] and guide through the jacking
unit [14] from below.
20. Insert a second roller [12] on the front articulated axle [10] and assemble with retainer
ring [11].
21. Put the directional travel Bowden cable back into its original position!
Assemble the Bowden cable holder [9] to the trip fork (1 washer and 1 machine screw).
Bowden cables with the nuts (on the drive axle).
24. Clip the rear cap on.
26. CAUTION
Risk of injuries!
TEST

Brake Bowden cable
7.10 Brake Bowden cable

3. only MARS 2.01/2.02
Switch off the operating table (remote control).
CAUTION
4. CAUTION
Risk of injuries!
on an even surface.
5. MARS 2.01/2.02
Set the foot lever TRAVEL MODE in the directional travel position (see FOOT LEVER
MARS 2.03 to 2.06
Switch off and jack down the operating table (remote control).
CAUTION
7
1 4 3
2 6
5
3
8
Figure 81 Brake Bowden cable

1 Locknut 5 Shaft
2 Setting nut 6 Pull frame
3 Brake Bowden cable 7 Head end wheel
4 Disc 8 Foot end wheel
6. Take note of the mounting position of the brake Bowden cable!

Unscrew the counternut [1] and adjusting nut [2] on the head end (drive axle); remove
washer [4] and store safely.
7. Pull out the brake Bowden cable [3] from the shaft.
8. Make a note of the screw-in depth of the brake Bowden cable [3] at the foot end of
the running gear.

Brake Bowden cable
help of pliers.
Insert the new brake Bowden cable and screw it into the axle [5] in the pull frame [6]
of the foot end wheel [8].
11. At the head end of the running gear, assemble the brake Bowden cable [3] with the
washer [4], adjusting nut [2] -and counternut [1] onto the drive axle.
12. Put the Bowden cable back into its original position.
13. only MARS 2.03 to 2.06
Bowden cable [3] with the nuts (on the drive axle).
15. MARS 2.01/2.02
Set the foot lever TRAVEL MODE in the brake position (see FOOT LEVER OPERATION
pictogram!).
MARS 2.03 to 2.06
Jack up the operating table.
16. CAUTION
Risk of injuries!
18. only MARS 2.01/2.02
TEST

Directional travel Bowden cable MARS 2.01/2.02
7.11 Directional travel Bowden cable MARS 2.01/2.02

CAUTION
4. CAUTION
Risk of injuries!
on an even surface.
7 10
8
9
8
4
4 5
4
3
2 6
1
Figure 82 Directional travel Bowden cable MARS 2.01/2.02

1 Locknut 6 Wheel with locking device
2 Setting nut 7 Locking ring 8
3 Locking piece 8 Castor
4 Directional travel Bowden cable 9 Cable holder
5 Lever 10 Shaft
Unscrew the counternut [1] and adjusting nut [2] on the head end (drive axle) and store
safely.
7. Pull out the directional travel Bowden cable [4] from the locking piece [3] on the foot
lever.
8. At the foot end of the running gear, unhook the directional travel Bowden cable [4]
from the lever [5] of the wheel with locking device [6].
9. Remove lock washer [7] from the roller [8] and store safely.
10. Remove washer, cable holder [9], and roller [8] from the axle [10] and store safely.

11. Remove the defective directional travel Bowden cable [4].

12. Insert new directional travel Bowden cable.
13. Push the roller [8], cable holder [9], and washer onto the axle [10] and assemble with
lock washer [7].
14. At the foot end of the running gear, hook the directional travel Bowden cable [4] into
the lever [5] of the wheel with locking device [6].
15. At the head end of the running gear, insert the directional travel Bowden cable [4] into
the locking piece [3] on the foot lever, and assemble the adjusting nut [2] and
counternut [1] onto the drive axle.
16. Put the Bowden cable [4] back into its original position.
17. Set the directional travel so that it is functioning safely and smoothly. If necessary,
readjust the Bowden cable [4] with the nuts (on the drive axle).
pictogram!).
19. CAUTION
Risk of injuries!
TEST


3. CAUTION
Risk of injuries!
on an even surface.
CAUTION
8
4
8
1
5
2
1 3
7 8 4
4
10 6
9
1 Bowden cable holder 6 Wheel with locking device
2 Trip fork 7 Locking ring
3 Locknut 8 Castor
4 Directional travel Bowden cable 9 Cable holder
5 Lever 10 Shaft
Unscrew the Bowden cable holder [1] from the trip fork [2] (1 machine screw and
1 washer).
8. Note the screw depth of the directional travel Bowden cable [4].
9. Unscrew the directional travel Bowden cable [4] out of the cable holder [1] with the
help of pliers.
10. At the foot end of the running gear, unhook the directional travel Bowden cable [4]
from the lever [5] of the wheel with locking device [6].

13. Repeat work steps 11. and 12. with the second roller.
16. Push a roller [8], cable holder [9], and washer onto each of both axles [10] and
assemble with lock washer [7].
17. At the foot end of the running gear, hook the directional travel Bowden cable [4] into
the lever [5] of the wheel with locking device [6].
18. Restore the original screw-in depth of the directional travel Bowden cable!
Screw in the new directional travel Bowden cable into the Bowden cable holder [1] and
secure with the counternut [3].
At the running gear head end , assemble the Bowden cable holder [1] to the trip
fork [2] (1 washer and 1 machine screw).
WARNING
23. Set the directional travel so that it is functioning safely and smoothly. If necessary,
readjust the Bowden cable [4] with the counternuts [3] (on the cable holder [1]).
25. CAUTION
Risk of injuries!
TEST


3. CAUTION
Risk of injuries!
on an even surface.
CAUTION
5
8
4
8
1
13
2
1 3
7 8
4 5
6
10
9 11 12
1 Bowden cable holder 8 Castor
2 Trip fork 9 Cable holder
3 Locknut 10 Shaft
4 Directional travel Bowden cable 11 Screwed pin M3
5 Nut M6 12 Switch lever
6 Bearing bracket 13 Jacking shaft
7 Locking ring
Unscrew the Bowden cable holder [1] from the trip fork [2] (1 machine screw and
1 washer).
8. Note the screw depth of the directional travel Bowden cable [4].

9. Unscrew the directional travel Bowden cable [4] out of the Bowden cable holder [1]
with the help of pliers.
10. At the running gear foot end, release the jacking shaft’s [13] bearing bracket [13]
(remove 2 nuts [5]), carefully push upwards (from the jacking shaft), remove, and store
safely.
Release the directional travel Bowden cable [4] from the jacking shaft [13] (1 threaded
pin [11]) and carefully remove the switching lever [12].
12. Note the screw depth of the directional travel BowdenBowden cable [4].
13. Unscrew the directional travel Bowden cable [4] out from the fork of the spring-loaded
pin on the switching lever [12] with the help of pliers.
16. Repeat these work steps 14. and 15. with the second roller.
19. Push a roller [8], cable holder [9], and washer onto each of both axles [10] and
assemble with lock washer [7].
Screw in the new directional travel Bowden cable in the fork of the spring-loaded pin
on the switching lever [12].
At the running gear foot end, push the switching lever [12] with new directional travel
Bowden cable onto the jacking shaft [13] and install it in the groove (1 threaded
pin [11]).
22. Carefully push the bearing bracket [6] from above onto the jacking shaft [13] and
assemble (2 nuts [5]).
Screw in the new directional travel Bowden cable into the Bowden cable holder [1] and
secure with the counternut [3].
At the running gear head end , assemble the Bowden cable holder [1] to the trip
fork [2] (1 washer and 1 machine screw).

11
13
4
14 15
17
16
Figure 85 Travelling drive adjustment MARS 2.04/2.06

4 Directional travel Bowden cable 15 Drive roller
11 Screwed pin M3 16 Travelling drive
13 Jacking shaft 17 Wooden spacer 3 mm
14 Running gear
25. Clamp the wooden spacer [17] between the running gear [14] and the drive unit [16].
26. The directional travel Bowden cable must be taut!
Adjust the directional travel Bowden cable [4] on the jacking shaft [13] (1 threaded
pin [11]).
27. Remove wooden spacer [17].
NOTE
Set the travelling drive so that it is functioning safely and smoothly.

If the adjustment is appropriate, the drive roller [15] rests against the running
gear [14].
WARNING
30. Switch the operating table on and jack up.
31. CAUTION
Risk of injuries!
TEST

Directional travel switch cable MARS 2.03/2.05
7.14 Directional travel switch cable MARS 2.03/2.05

operating table” page 15 .
retaining screw.
5. CAUTION
Risk of injuries!
Turn the operating table on the side with a membrane keyboardkeyboard and lay
down safely on an even surface.
CAUTION
3
2 4
5
1
4
5
Figure 86 Directional travel switch cable MARS 2.03/2.05
1 Cable bushing plate 4 Directional travel switch cable
2 M4x5 machine screw 5 Wheel with locking device
3 Directional travel switch
9. Remove the plug of the directional travel switch cable [4] from the directional travel
switch [3].
10. Remove the cable bushing [1] that is on a side of the running gear plate (2 machine
screws [2]) and store safely.
Remove the other plugs of the directional travel switch cable from the connector
assembly on the energy chain holder; remove cable binder, and release the cable.
12. Remove cable clip (1 nut) and remove the defective directional travel switch cable [4].
13. Insert the new directional travel switch cable.

Directional travel switch cable MARS 2.03/2.05
14. Put the cables back into their original positions and connect the plug of the new
directional travel switch cable to the energy chain holder connector assembly.
15. CAUTION
Risk of cables being crushed!
Insert the grommets for cable protection (in the running gear) and the plate cable
bushing [1] correctly!
Assemble the plate cable bushing [1] (2 machine screws [2]).
16. Plug in the directional travel switch cable plug [4] into the directional travel switch [3]
on the wheel with locking device [5].
Fix the cables with cable clip (1nut) and cable binders.
21. CAUTION
Risk of injuries!
TEST

Foot lever MARS 2.01/2.02
7.15 Foot lever MARS 2.01/2.02

CAUTION
4. CAUTION
Risk of injuries!
on an even surface.
6. Remove the cap on the head side of the running gear and store safely.
6
3 4
1
10
2 14
4 11
12
13 8
5 9
7 7
Figure 87 Foot lever MARS 2.01/2.02

1 Axle holder (shaft holder) 8 Setting nut
2 M8x20 machine screw 9 Locknut
3 Brake Bowden cable 10 Rear castor
4 Directional travel Bowden cable 11 Locking piece
5 Foot lever 12 Drive axle (shaft)
7 Tension spring 14 Rest cam

Unscrew both wheels [10] (4 machine screws [6] in each case).
safely.
lever [5].

Foot lever MARS 2.01/2.02
11. Hold the pedal securely.

Unscrew the foot lever [5] from the drive axle [12] (1 machine screw [13] and
1 washer).
12. Unhook the tension spring [7].
13. Pay attention to flange bushings! Carefully pull out the foot lever [5] from the drive axle
bearing and the rest cam [14].
14. Pay attention to flange bushings! Insert the new foot lever and assemble (1 washer and
1 machine screw [13]).
15. Hook tension spring [7] into place.
16. Insert the directional travel Bowden cable [4] into the locking piece [11] on the foot
lever [5], and assemble with the adjusting nut [8] and counternut [9] onto the drive
axle [12].
18. Mount both castors [10] (4 machine screws [6] in each case).
21. Clip the cap on.
pictogram!).
23. CAUTION
Risk of injuries!
TEST

Rest cam MARS 2.01/2.02
7.16 Rest cam MARS 2.01/2.02

CAUTION
4. CAUTION
Risk of injuries!
on an even surface.
6. Remove the cap on the head side of the running gear and store safely.
6
3 4
1
10 7
2
4 11
12
8 13
5 9
Figure 88 Rest cam MARS 2.01/2.02

1 Axle holder (shaft holder) 8 Setting nut
2 M8x20 machine screw 9 Locknut
3 Brake Bowden cable 10 Rear castor
4 Directional travel Bowden cable 11 Locking piece
5 Foot lever 12 Drive axle (shaft)
7 Rest cam

Unscrew both wheels [10] (4 machine screws [6] in each case).
safely.
lever [5].

Rest cam MARS 2.01/2.02
11. Carefully remove drive axle [12] (complete with foot lever [5] and wheels [10]) and
store safely.
12. Remove defective rest cam [7] (1 machine screw [13]).
13. Assemble new rest cam [7] (1 machine screw [13]).
14. Carefully insert the entire drive axle [12] and assemble with the axle holders [1]
(2x 2 machine screws [2]).
15. Mount both wheels [10] (4 machine screws [6] in each case).
16. Insert the directional travel Bowden cable [4] into the locking piece [11] on the foot
lever [5], and assemble with the adjusting nut [8] and counternut [9] onto the drive
axle [12].
19. Clip the cap on.
pictogram!).
21. CAUTION
Risk of injuries!
TEST

Gas-filled spring device MARS 2.01/2.02
7.17 Gas-filled spring device MARS 2.01/2.02

CAUTION
4. CAUTION
Risk of injuries!
on an even surface.
1 1
3 3
2 2
Figure 89 Gas-filled spring device MARS 2.01/2.02

1 Retaining ring 3 Gas-filled spring device
2 Bolt
6. Remove the retaining rings [1] (4x) from the gas-filled spring device [3] and store safely.
7. Knock the pins [2] (2x) through downwards and store safely.
8. Remove defective gas-filled spring device [3].
9. Insert a new gas-filled spring device.
10. Insert both pins [2].
11. Assemble retaining rings [1] (4x).
pictogram!).
13. CAUTION
Risk of injuries!

TEST

Jacking up switch MARS 2.01/2.02
7.18 Jacking up switch MARS 2.01/2.02

3. CAUTION
Risk of injuries!
on an even surface.
5
6 3
1
2
3
Figure 90 Jacking up switch MARS 2.01/2.02

1 Jacking up switch 4 Jacking up switch cable
2 Cable clamp 5 Drive axle (shaft)
3 Nut M4 6 Jumper ring
5. Take note of where the cable has been laid.

Remove the cable clip [2] (1 nut [3]).
6. Take note of where the module has been laid!
Unscrew the entire jack up switch assembly [1] (2 nuts [3]) and remove carefully.
7. Remove the plug of the jack up switch cable [4] from the defective jack up switch [1].
8. Connect the plug of the jack up switch cable [4] to the new jack up switch assembly.
9. Make sure that the assembly is in its original installation position!
Insert the entire new jack up switch assembly (the jack up switch is located under the
jumper ring [6]) and assemble (2 nuts [3]).
10. Put the cables back into its original positions and secure with cable clip [2] (1 nut [3]).
pictogram!).
12. CAUTION
Risk of injuries!

Jacking up switch MARS 2.01/2.02
TEST

Jacking up switch cable MARS 2.01/2.02
7.19 Jacking up switch cable MARS 2.01/2.02

retaining screw.
5. CAUTION
Risk of injuries!
on an even surface.
2
5
1
3 4
6
Figure 91 Jacking up switch cable MARS 2.01/2.02

1 Cable bushing plate 4 Jacking up switch cable
2 M4x5 machine screw 5 Cable clamp
3 Jacking up switch 6 Drive axle (shaft)
6. Remove the plug of the jack up switch cable [4] from the jack up switch [3].
8. Take note of where the cable has been laid.
Remove the other plugs of the jack up switch cable from the connector assembly on
the energy chain holder; remove cable binder, and release the cable.
9. Remove cable clip [5] (1 nut) and remove the defective jack up switch cable [4].
10. Insert new jack up switch cable.
11. Put the cables back into their original positions and connect the plug of the new jack
up switch cable to the energy chain holder connector assembly.

Jacking up switch cable MARS 2.01/2.02
12. CAUTION
13. Plug in the jack up switch cable [4] plug into the jack up switch [3] (under the drive
axle [6]).
14. Put the cable back into their original positions.
Fix the cable with cable clips (1 nut) and cable binders.
pictogram!).
16. CAUTION
Risk of injuries!
TEST

Jacking unit MARS 2.03 to 2.06
7.20 Jacking unit MARS 2.03 to 2.06

retaining screw.
5. CAUTION
Risk of injuries!
on an even surface.
CAUTION

5 4 2
6
12 1
7 10
5
11 8
7
3
9
11
Figure 92 Jacking unit MARS 2.03 to 2.06

1 Cable bushing plate 7 Start-up disk
2 M4x5 machine screw 8 Rear articulated axle
3 Jacking unit 9 Emergency release
4 Front articulated axle 10 Rocker
5 Retaining ring 11 Stirrup
6 Castor 12 Rod
Remove the plugs of the jacking unit [3] from the connector assembly on the energy
chain holder; remove cable binder, and release the cable.
11. Remove retaining ring [11] and roller [12] from front articulated axle and store safely.
12. NOTE
Pay attention to start-up disks [7] (8 pieces) and roller! Do not allow them to fall into
the running gear!
Knock out the front articulated axle [4] downwards and store safely..
13. Remove retaining ring [5] and two start-up disks [7] from rear articulated axle [8] and
store safely.
14. NOTE
Pay attention to start-up disks (2 pieces)! Do not allow them to fall into the running
gear!
Knock out the rear articulated axle [7] downwards and store safely.

15. Remove defective jacking unit [3].

16. For better assembly, open the emergency releasing device [9] slightly and swing out
the rocker [10].
17. Insert a new jacking unit.
18. Place between the rear rod of the jacking unit [3] and the rocker [10], below two start-
up disks [7].
19. Guide in the rear articulated axle [8] from below into the rocker [10], push through the
start-up disks [7] and the jacking unit’s [3] rod.
20. Place two start-up disks [7] above between the rocker [10] and the jacking unit’s [3]
rod.
21. Push the rear articulated axle [8] completely through and assemble with retaining
ring [5].
22. Place between the front rod [12] of the jacking unit and the drive axle’s retainer [11]
under four start-up disks [7].
23. Guide in the front of the articulated axle [4] with roller [6] from below into the
retainer [11], push through the start-up disks [7] and the jacking unit’s rod.
24. Place four start-up disks [7] above between the retainer [11] and the rod [12].
25. Push the front articulated axle [4] completely through.
26. Insert a second roller [6] on the front articulated axle [4] and assemble with retainer
ring [5].
27. Put the cables back into their original positions and connect the plug of the new jacking
unit on the energy chain holder connector assembly.
28. CAUTION
Fix the cables with cable binders.
33. CAUTION
Risk of injuries!

TEST

Hall sensor circuit board MARS 2.03 to 2.06
7.21 Hall sensor circuit board MARS 2.03 to 2.06

retaining screw.
5. CAUTION
Risk of injuries!
on an even surface.
CAUTION
9. Remove the cable bushing that is on a side of the running gear plate (2 machine
screws) and store safely.
Remove the Hall sensor printed circuit board plug from the connector assembly on the
energy chain holder.

5
11
10
7
4
3
2
9
1
8
Figure 93 Hall sensor circuit board MARS 2.03 to 2.06
1 Jumper ring 7 Hall sensor circuit board
2 M5x16 machine screw 8 Shaft holder
3 Circuit board plate 9 M3x4 machine screw
4 M3x6 machine screw 10 Disc
5 Cable clamp 11 Hall sensor board cable
6 Nut M4

Remove the cable clip [5] (1 nut [6]), remove the cable binder, and release the
cable [11].
12. Take note of the mounting position of the jumper ring!
Remove the jumper ring [1] (1 machine screw [2]) and store safely.
13. Make note of the printed circuit board plate’s installation position!
Unscrew the printed circuit board plate [3] with the Hall sensor printed circuit board
(4 machine screws [4]) and remove carefully.
14. Take note of where the circuit board has been laid!
Unscrew the defective Hall sensor printed circuit board [7] from the printed circuit
board plate [3] (4 machine screws [9] and 1 washer [10] from the voltage connection).
15. Remove plug from the defective Hall sensor printed circuit board [7].
16. Connect the plug to the new Hall sensor printed circuit board.
17. Put the circuit board back into its original position! Assemble together with the voltage
connection cable!
Assemble the new Hall sensor printed circuit board on the printed circuit board
plate [3] (1 washer [10] and 4 machine screws [9]).
18. Put the printed circuit board plate back into its original position!
Insert the printed circuit board plate [3] (sensor connections showing towards the head
end!) and assemble (4 machine screws [4]).
19. Put the cables back into their original positions and connect the plug of the Hall sensor
printed circuit board cable to the energy chain holder connector assembly. Fix the
cables with cable clip (1nut [6]) and cable binders.

20. Put the jumper ring back into its original position!
Set the jumper ring [1] on the drive axle and assemble it by hand tightly (1 machine
screw [2]).
21. Align the jumper ring’s [1] opening next to the shaft holder [8] above the end sensor,
and tightly screw down the machine screw [2].
25. CAUTION
Risk of injuries!
TEST

Travelling drive MARS 2.04/2.06
7.22 Travelling drive MARS 2.04/2.06

retaining screw.
5. CAUTION
Risk of injuries!
on an even surface.
CAUTION
6
2
1
4
7
3
8 5
Figure 94 Travelling drive MARS 2.04/2.06

1 Bearing bracket 5 Travelling drive
2 Nut M6 6 Directional travel Bowden cable
3 Cable bushing plate 7 Screwed pin M3
4 M4x5 machine screw 8 Jacking shaft
9. Draw out the drive unit [5].

10. Remove the plate cable bushing [3] that is on a side of the running gear, next to the
bearing bracket [1] (2 machine screws [4]) and store safely.
Remove the drive unit plug from the connector assembly on the energy chain holder;
remove cable binder, and release the cable.

Release the directional travel Bowden cable [6] on the jacking shaft [8] (1 threaded
pin [7]).
13. Loosen the bearing bracket [1] (2 nuts [2]).
14. Remove the cable clip (1 nut).
15. Hold the defective drive unit [5] securely; unscrew (4 nuts [2]); push upwards; remove
carefully; and remove switching lever with directional travel Bowden cable [6].
Insert the new drive unit into the running gear and push the switching lever with
directional travel Bowden cable [6] onto the jacking shaft [8].
17. Position the drive unit [5] in the bearing bracket [1] and assemble onto the running
gear (4 nuts [2]).
18. Fit the bearing bracket [1] (2 nuts [2]).
19. Put the cables back into their original positions and connect the plug of the new drive
unit to the energy chain holder connector assembly. Fix the cables with cable clip (1nut)
and cable binders.
20. CAUTION
21. Push the switching lever with directional travel Bowden cable [6] on the jacking
shaft [8] towards the groove and assemble (1 threaded pin [7]).
7
8
6
9 10
11
Figure 95 Travelling drive adjustment MARS 2.04/2.06

5 Travelling drive 9 Running gear
6 Directional travel Bowden cable 10 Drive roller
7 Screwed pin M3 11 Wooden spacer 3 mm
8 Jacking shaft
22. Clamp the wooden spacer [11] between the running gear [9] and the drive unit [5].
23. The directional travel Bowden cable must be taut!
Adjust the directional travel Bowden cable [6] on the jacking shaft [8] (1 threaded
pin [7]).

24. Remove wooden spacer [11].
NOTE
Set the travelling drive so that it is functioning safely and smoothly.

If the adjustment is appropriate, the drive roller [10] rests against the running gear [9].
WARNING
28. CAUTION
Risk of injuries!
TEST

Toothed belt travelling drive MARS 2.04/2.06
7.23 Toothed belt travelling drive MARS 2.04/2.06

1. Remove the entire drive unit from the running gear and store safely. See section 7.22
“Travelling drive MARS 2.04/2.06” page 164, work steps 1. to 15.
2
7
4
3
5
6
Figure 96 Toothed belt travelling drive MARS 2.04/2.06

1 Travelling drive motor 5 Toothed belt
2 M5x10 machine screw 6 Toothed-belt pulley
3 M4x25 countersunk screw 7 Rocker
4 Disk main drive
2. Unscrew the travelling drive motor [1] (4 machine screws [2]).

3. Remove the countersunk screw [3] and the disk main drive [4] from the small toothed-
belt pulley [6] and store safely.
4. Pull the toothed-belt pulley [6], and put it down in a safe place.
5. Remove the defective toothed belt [5].
6. Push the toothed-belt pulley [6] onto the axle of the drive unit motor [1] and assemble
(1 disk main drive [4] and 1 countersunk screw [3]).
7. Pull the new toothed belt onto the toothed-belt pulley [6].
8. Assemble the drive unit motor [1] on the rocker [7] (4 machine screws [2]).
9. Assemble the entire drive unit in the running gear and test. See section 7.22 “Travelling
drive MARS 2.04/2.06” page 165, work steps 16. to 33.

Drive roller MARS 2.04/2.06
7.24 Drive roller MARS 2.04/2.06

11
7
A
9
5 10 8
6 12
A
3
4
6
Figure 97 Drive roller MARS 2.04/2.06

1 Travelling drive motor 7 Rocker
2 M5x10 machine screw 8 Drive roller
3 M4x10 countersunk screw 9 Drive shaft
4 Disk main drive 10 Sleeve
5 Toothed belt 11 Retaining ring 15x1
6 Toothed-belt pulley 12 Fitting shim
2. Unscrew the travelling drive motor [1] (4 machine screws [2]).

3. Remove the countersunk screw [3] and the disk main drive [4] from the large toothed-
5. Remove and safely put down the toothed belt [5].
6. Remove and safely put down the retaining ring [11].
7. Make note of the installation position of the drive shaft and to the feather key!
Push the drive shaft [9] through.
8. Remove the sleeve [10] and fitting shim [12] and store safely.
9. Remove defective drive roller [8].
10. Insert new drive roller with fitting shim [12] and sleeve [10].
11. Put the drive shaft back into its original position. Pay attention to the feather keys!
Guide the drive shaft [9] into the rocker [7] and push through the new drive roller [8]
with fitting shim [12] and sleeve [10].
12. Assemble the retaining ring [11] on the drive shaft [9].
13. Push the toothed-belt pulley [6] onto the drive shaft [9] and assemble (1 disk main
drive [4] and 1 countersunk screw [3]).
14. Pull the toothed belt [5] onto the toothed-belt pulleys [6].

Drive roller MARS 2.04/2.06
15. Assemble the drive unit motor [1] on the rocker [7] (4 machine screws [2]).

Travelling drive motor MARS 2.04/2.06
7.25 Travelling drive motor MARS 2.04/2.06

3 4
6
5
Figure 98 Travelling drive motor MARS 2.04/2.06

1 Travelling drive motor 5 Toothed belt
2 M5x10 machine screw 6 Toothed-belt pulley
3 M4x25 countersunk screw 7 Rocker
4 Disk main drive
2. Remove the countersunk screw [3] and the disk main drive [4] from the small toothed-
4. Remove and safely put down the toothed belt [5].
5. Unscrew the defective drive unit motor [1] (4 machine screws [2]) and remove carefully.
6. Insert the new drive unit motor into the rocker [7].
7. Push the toothed-belt pulley [6] onto the axle of the new drive unit motor [1] and
assemble (1 disk main drive [4] and 1 countersunk screw [3]).
8. Pull the toothed belt [5] onto the toothed-belt pulleys [6].
9. Assemble the new drive unit motor [1] on the rocker [7] (4 machine screws [2]).

7.26 Gas-filled spring device MARS 2.04/2.06

2
9
3
4
8
7
4
5
6
4
Figure 99 Gas-filled spring device MARS 2.04/2.06
1 Jacking shaft 6 Short spacer
2 Rocker 7 Long spacer
3 Tension spring 8 Gas-filled spring device
4 Locking ring 9 Hinge pin spring
5 Bolt
2. Press together the defective gas-filled spring device [8] with a clamp.
3. Unhook the tension spring [3] and store safely.
4. Remove and safely put down the clamp.
5. Remove the lock washer [4] from the rocker [2].
6. Make note of the installation position of the spacer (short [6] and long [7])!
Pull out the pin [5] and safely store all parts.
7. Remove the lock washer [4] from the jacking shaft [1].
8. Pull out the hinge pin spring [9] and put it down in a safe place.
9. Remove defective gas-filled spring device [8].
10. Insert a new gas-filled spring device.
11. Guide the spring joint pin [9] into the holder for the gas-filled spring device on the
jacking shaft [1], push through the new gas-filled spring device’s [8] receptacle and
secure (1 lock washer [4]).
12. Put the spacers back into their original position!
On the rocker [2], seen from the drive roller, guide the pin [5] into the holder for the
gas-filled spring device; push through the short spacer [6], the gas-filled spring device
receptacle [8], and the long spacer [7].
13. Secure the pin [5] (1 lock washer [4]).
14. Press the pneumatic pressure spring [8] and the screw clamp together.

15. Hook tension spring [3] into place.

16. Remove and safely put down the screw clamp.

Lubrication Plan
8 Lubrication Plan
8.1 Tabletop
Interval
Pos. Lubrication point Lubricant/insertion
additional lubrication
A
1
1* Locking device LD: PROFI TURBOGREASE 2 years

bolt, bearing bush, axles, (mat. no. 4 150 050) ⇒ spray
gear teeth
* does not apply to MARS 2.01

Lubrication Plan
Interval
2* Linear guidance TURMOGREASE LC252 2 years

longitudinal displacement (mat. no. 1 355 874) ⇒ with grease gun
(mat. no. 1 259 074 with pointed nozzle)
approx. 3-4 strokes per lubricating nipple
(4 pieces) until grease comes out from the
guiding carriage; then run a longitudinal
displacement.
* does not apply to MARS 2.01
8.2 Column
Interval
3
3
3
3 Guide column ISOFLEX TOPAS NCA 5051 2 years

(mat. no. 4 150 051) ⇒ 4 strokes per
lubricating nipple with grease gun (mat.
no. 1 259 074, with pointed nozzle)
CAUTION: Do not lubricate in the
lowermost stroke position! Raise the
tabletop at least 10 cm!
Perform the lubrication on all sides!

Lubrication Plan
Interval
4 Push tube guide PROFI TURBOGREASE 2 years

(mat. no. 4 150 050) ⇒ spray
5 Trendelenburg PROFI TURBOGREASE 2 years

trapezoidal spindle (mat. no. 4 150 050) ⇒ spray

Lubrication Plan
8.3 Running gear MARS
Interval
MARS 2.03 / 2.04 / 2.05 / 2.06
6 Jacking drive torque rod TURMOPLEX L220 (mat. no. 4 150 047) 2 years
⇒ apply with brush
MARS 2.01 - 2.02
7 Rest cam TURMOPLEX L220 (mat. no. 4 150 047) 2 years

⇒ apply with brush

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
assignment item 10/item 20

Fuse-links Pin Function/signal
Additional help
M0.1
BP left (2.01-2.06) TP strut left
REED-switch
Tabletop with/without LV TP strut right
2.01-2.06 Foot side
F1/F2
F1/F2
-
-
2,5A delay action,
4,0A delay action,
item
item
no.0455653 (230V)
no.0473421 (115V/127V)
1
2
GND_485
+12V_485
RP right (2.07-2.08) (2.01-2.06 is shown, (2.01-2.06 is shown, Standard MARS 2.07-2.08 F3 - 10A delay action, item no.1428460 3 RS485_Ka Ltg.A
M TT rotated by 180° for 2.07/2.08) LD unlocking, (column head) TT rotated by 180° for 2.07/2.08) (standard) MARS 2.01-2.06 F4 - 10A delay action, item no.1428460 4 RS485_Ka Ltg.A M
Leg side TT with column rotated
REF-sensor BP (2.01-2.06)
REF-sensor RP (2.07-2.08)
END-sensor BP -35° (2.01-2.06)
END-sensor RP -55° (2.07-2.08)
all 2.02-2.08 all 2.02-2.08 5 RS232_RxD
by 180° to running gear
6 RS232_TxD
M0 M0.2 Colour of conductor X2/X3 X1 Function/ 7 Flash (Boot)
M6 IR-receiver 1 complete Foot side Head side according to DIN/IEC at VT at StE signal
END-sensor BP (2.01-2.06)
END-sensor RP (2.07-2.08)
24V= BP right (2.01-2.06) 8 GND
without RS232/485 9 VCC (+5V_IR)
9 Circuit Diagram
24V= RP left (2.07-2.08) ws (WH) BK X2.1 X1.1 IR1 signal
Membrane keypad
10 IR2 signal
item no.1363490 RP bn (BN) BN X2.2 X1.2 IR2 signal
<<-- backward / forward -->>

rt
sw
11 IR1 signal
BP gn (GN) RD X2.3 X1.3 RS485_Ka (A)
M0 Drive
(detachable)
gb (YE) OG X2.4 X1.4 RS485_Ka (B)
12 free
VT.X14.1.rt(bn)
VT.X14.2.rt(sw)
rt
sw
24V= gr (GY) YE X2.5 X1.5 +12V
1 motor E chain Motors:
rs (PK) GN X2.6 X1.6 +12V
(Lift)
MARS 2110Operating Table

OR-sensor OR-sensor bl (BU) BU X2.7 X1.7 GND
Control rt (RD) VT X2.8 X1.8 GND Motor 2.01-2.06/2.07-2.08
120 Leg side: 20 110 120 S1 electronics -35° -55° sw (BK) GY X3.1 X1.9 GND M0.1 - BP left /RP right
L 1 - only 2.01 vio (VT) WH X3.2 X1.10 +12V M0.2 - BP right/RP left L
.J1 12 item no.1363490 .J2 K END BP END RP ws/sw (WH/BK) WH/BK X3.3 X1.11 RS485_Vert.(A) M1.1 - RP left /BP right
1
REF BP REF RP
1
END35.bn VT.X7.6.rs p ol Lift left/right column column ws/bn (WH/BN) WH/BN X3.4 X1.12 RS485_Vert.(B) M1.2 - RP right/BP left
VT.X7.5.gr es - all 2.02-2.08 KL.J3.1.ws M1.2.RP.sw
END35.bl KL.J3.2.bn M1.2.RP.rt ws/rt (WH/RD) WH/RD X3.5 X1.13 RS232 - RxD M2 - Lift
REF.bn VT.X7.4.gb item no.1363489 KL.J3.3.gn M0.2.BP.sw M3 - Tilt
REF.bl VT.X7.3.gn VT.X5 Transformer TR L R R L ws/or (WH/OG) WH/OG X3.6 X1.14 RS232 - TxD
item no.1402362 KL.J3.4.gb M0.2.BP.rt
ws/gb (WH/YE) WH/YE X3.7 X1.15 Flash (Boot) M4 - Running gear
REF.bn VT.X7.2.bn VT.X9.4.ws END.bl module LP distributor LP distributor
REF.bl VT.X7.1.ws VT.X9.3.bn END.bn Button LD M5 - Jacking up
M0.1.BP.rt KL.J3.4.gb M6 - LV
M0.1.BP.sw KL.J3.3.gn item no.1377458 VT.X9.2.gn END.bl (2.02-2.08) -75°
Battery Battery
VT.X9.1.gb END.bn M7 - Trend.
Jack motor
Note 1:
1
M1.1.RP.rt KL.J3.2.bn VT.X13/14.gr *
1 END.-75°.bl OR_2.01.sw REF RP REF BP
Si3 Si4
StE.X104.1.ws
StE.X104.2.bn
M1.1.RP.sw KL.J3.1.ws TP strut right (LD button, 2.02-2.08) VT.X13/14.rs * END.-75°.bn OR_2.01.sw to gr/rs stranded conductors from
RP END RP BP END BP
1
1
* item 70 at TT.VT and TT.J2 Abbreviations used:
2
Shield bracket M4 (only 2.01) TP strut right .J2 734-110 734-310
->Note 1 RS - rear side
(near LD motor) * -MARS 2.01
TP.J2.10.rs
(See legend) TP - tabletop
TP.J2.9.gr
* from VT.X14.1.gr at TP.J2.9
Head side Foot side from VT.X14.2.rs at TP.J2.10 RP - back section
right
Info on stranded conductor
END-sensor RP (2.01-2.06)
END-sensor BP (2.07-2.08)
1 -MARS 2.02-2.06 BP - leg section
K gr/rs from item 70: K
to reed switch
left
RL - directional travel
100 40 60 1 See note 1 (legend) gr/rs wires without function
OR-sensor (only 2.01)

Note: LV - longitudinal displacement
50 70 connected to TT.J2.9/10,
TB - Trendelenburg
(in standard rail)

The REF LS und END LS sensors in the zero series MARS 2.08 are faulty connected but insulated/unused to TT.DT
FW - running gear
(only 2.07/2.08)
1 -MARS 2.07-2.08
END-sensor -75°
due to a mounting error (cam plates reversed). To compensate this were also against
(only 2.07/2.08)
Pin assignment X9 from VT.X13.1.gr at TP.J2.9 VT - distribution board
2.01-2.06 Head side
1
1
1
1 -> TP.J2.8.ws each other exchanged the green and yellow wires of the X7 & X9 distributor connectors from VT.X13.2.rs at TP.J2.10 TR - Transformer module
2 -> TP.J2.7.bn (standard)
Ground point M4 Ground point M4 3 -> TP.J2.6.gn M1 of the distributor board. TS - terminal strip
REF-sensor RP (2.01-2.06)
REF-sensor BP (2.07-2.08)
1
X6 X10 X14
4 -> TP.J2.5.gb Note: KM - tilt motor
(near E chain) (on column head) 1
24V= affected S/N: HV - "High version"
at X9
MARS 2.07/2.08 variants are shown LV - "Low version"
X9 100530423, 100531640, 100531663
only system 2.0

with column with TT rotated in
1
Pin assignment X3 M1.2 LP - circuit board
80
1
X8 1 -> free the running gear by 180 degrees. List will be completed.
RP right (2.01-2.06)
sw
rt
2 -> free Sensors/Button:

X11 3 -> TP.J2.9.gr BP left (2.07-2.08)
1
1
4 -> TP.J2.10.rs
I M1 at X7 at X13
* J4 connector assignment to E chain
Distribution board (VT) Distribution board (connector)
-Tabletop - TP
item no.1404780 2x I
24V= all MARS 2.01-2.08 (in 2.07-2.08 3x)
1
TP.J2.10.rs
TT chain-type cable X1 - Hardware start-up only
1
TT chain-type cable item no.1325498 3x
1
1
1
J2 TP.J2.9.gr MARS 2.02-2.08 2.01 2.04 2.03/2.05 X2 - Interface IR/RS485
M1.1 MARS 2.02-2.08 item no.1402362 REED (OR)
2.02 2.06 2.07/2.08 X3 - Interface RS485/232
1
X12 item no.1377458 LD button
RP left (2.01-2.06)
1
1
X13 X6 X10 X14 X4 - IR-/Interface KS
Sensor cable 10 ws Jumper with 10 ws Jumper with 10 ws DT Button/(2) 1 -Directional travel - DT
BP right (2.07-2.08) X5 - IR-/Interface BS
1
X7
1
(N.C. contact) item no.1392074 - Button
1
(2)+4220766 (2)+4220766
X1
item no.1377xxx
1
9 gr 9 gr 9 gr X6 - LV-Position
Head side item no.1377451
1
X9 -Lift - LP Hallsensoren
1
X2
IR-receiver 1 complete X7 - Sensors REF/BP35°
1
1
8 gb 8 gb Jacking up 8 gb
1
D7 µ Button Jacking up X8 item no.1369747
D8 with RS232/485 7 gn (N.O. contact) 7 gn sensors 7 gn X8 - Wedge sensor
sensors -Trendelenburg - TB
6 bn item no.1377449 6 bn item no.1377450 6 bn X9 - END-Sensors
item no.1377450 X11 item no.1403696 - End switch
item no.1363489
1
(3) (3) X10 - not applicable
1
X4
X5
1
5 ws 5 ws 5 ws (3) -Running gear - FW
30
1
Motor cable (jacking up X11 - 2xREED-switch (only System)
Drive item no.1369747 - Hall sensors
X3
item no.1377xxx 4 gb X 4 gb 4 gb X F5
1
signal) X12 - 2xREED-switch (only System)
1
1
734-110 and 734-310 n t mod motor (2) X13
cou e 3 gn X 3 gn 3 gn X
J3
1
J1 D4 at X4 at X5 X13 - Reserve
1
2 bn X 2 bn Jack 2 bn Jack X14 - OR-sensor
1
H 1 ws X 1 ws motor (1) 1 ws motor (1) J2 H
TP.J1.1.ws.BP
TP.J1.2.bn.BP
TP.J1.3.gn.RP
TP.J1.4.gb.RP
TP.J2.1.ws.BP
TP.J2.2.bn.BP
TP.J2.3.gn.RP
TP.J2.4.gb.RP
Representation 1:
1
X12
1
X plugged with item no.1405718 series 231 dummy F6 Distribution board (LEDs) Assignment .J8/.J11/.J12
1
view:
1
F2 F3 X7
1
1 plug side
X1
1
D4 - bus operation signal
1
Plug end view
X2
12 (3) item no.1399721
X4
X5
1
(1) item no.6003318 (2) item no.1403376 1
p ol Head side: D7 D7 - potential difference indicator

.J3 10 es
- all 2.01-2.08
231-102/026-000 231-102/102-000 231-104/102-000
F9 D8 F7 D8 - potential difference indicator
1 1-ws +12V
Terminal strip (TS) EE.X1 item no.1363489 F8 2-bn GND
1
1
F1 F10 Distribution board 3-gn Out1
X3
(Jumper) 4-gb Out2
1
J3
D4
J1 J1
1
not
SMD-LED 7 and 8:
J2
placed!
StE.X103.1.ws
StE.X103.2.bn
StE.X103.3.gn
StE.X103.4.gb
Ground point M4 Potential difference indicator J3 Representation 4:

G
(in opposite to TS) Column 2.0S/2.0N Assignment socket
IR-receiver BS/KS IC2 IC1 G
(RS232/485, plug end)
1/+12V Hall sensors board
item no.1369747
at .J3 Terminal strip (TS) 2/GND 8/GND
Trend.motor 1
3/Boot 7/RxD
Representation 2: Assignment S2
90 190 Ground point M4 Control electronics (CE) M7 4/RS485
(A)
6/TxD (Directional travel DT)
(at column)
5/RS485 S2
ws
rt
sw
2
at X104 (B)
Transformer module (TR) Energy chain connector Energy chain connector gb 1
X101 Motors: X104 1
1 1
1
TP.LV.2.ws 4
Tilt motor .J4 2.01/2.02/2.04/2.06 with KM.sw
X101/2 X101/1
Lifting motor retainer connector .J4 - 2 4 1 ws
F Transformer switching relay TSRL for each 1x item no.1403376+4220766 KM.rt Tilt Retrofitting instructions F
rt (only 2.07-2.08) item no.1377455 HV/NV + TP.LV.1.bn
J5.1.bn X109 115V/127V/230V: 2 S3
M3 sw ws ws 10 FW.J13.2.bn
item no.1402920 system + Lift 1 LD motor
1
ws
ws 10 .J4.1 J5.2.ws
30 gn 1
(only 2.03/2.05-2.08)
TSRL-types: - unlocking 2
StE.X6.5.gr gr gr 9 FW.J13.1.ws (1)
item no.1388013 190...260VAC (230V) 9 EK.J4.1.ws - primary TSLR transformer cable:
StE.X6.4.gb gb gb 8 FW.J11.4.gb - Jacking up X113 4 4
item no.1388014 90...135VAC (115V/127V) 8 EK.J4.2.bn X103 at X113
X101/3
item no.1403159 HV StE.X6.3.gn gn gn 7 FW.J11.3.gn bn + Bluetooth * item no.1377436 for 230V
7 EK.J4.3.gn
item no.1403160 NV StE.X6.2.bn bn bn 6 FW.J11.2.bn + Running 1 at X1 * item no.1377437 for 127V
6 EK.J4.4.gb
- 1 TB-Motor * item no.1377438 for 115V Representation 3: Assignment S3/S4
Control
StE.X6.1.ws ws ws FW.J11.1.ws ws
5 5 item no.1406412 HV BP-RP- (Trend.-/Antitrend. button)
to FW.J10.1-2 (only 2.01/2.02)

gb gb - Transformer switching relay TSRL:
mains
mains
input
StE.X101.8.gb FW.FM.rt
Distribution board
4 item no.1406506 NV
1
4 (X) 1
Load
Load
item no.1406412 HV gn section X1

StE.X101.7.gn gn FW.FM.sw * item no.1388013 for 230V
1
item no.1406506 NV
3 (X) 3 (2) X2 S3
StE.X101.6.bn bn bn FW.AB.bn /Power * item no.1388014 for 115V/127V 2 ws
transformer 2 (X) 2 X3 gb 1
Lifting motor StE.X101.5.ws ws ws FW.AB.bl 1 supply at X3 1 - power fuses F1/F2:
Membrane keypad column

1 2 3 4 type S1 S2 1 (X) 1
FW.Si2.ws 1 4
rt
sw
1
FW.A2.bn
+ Battery 2 * item no.0455653 for 230V 2 4 1 ws
P Sensors Lift.
X108.1
E Shield bracket M4 M2 item no.1377440 HV/NV FW.Si1.gn
-
X4
* item no.0473421 for 115V/127V
S4 E
R
(motor circuit board) Assignment .J4 for all variants dummy plug + Board Trend.button - power supply cable if necessary: 2
ws
(3) FW.A1.gb Battery 1 1
- gn 1
rt
sw
-> see overview (right) item no.1405718 TR.J7.1.ws 1 1 at X4 (see representation 3/Legend) * item no.4100024 Europe plug 2
X108.2
TR.J7.2.bn ~ secondary Sensors Trend. Pin assignment X3 * item no.4100088 USA plug 4 4
~ end
FW.SF.L1.sw1
.J5 item no.1451519 item no.1403159 HV 1 -> J8.1.ws

FW.SF.N.sw2
260 with 1451375 item no.1403160 NV (transformer) 2 -> J8.2.bn

TR.J6.1.sw1
TR.J6.5.sw2
X108
M2.sw
1 1 StE.X101.4.bn 3 -> J8.3.gn
2
TSRL pointer setting at M2.rt StE.X101.3.ws (4) 1 4 -> J8.4.gb Representation 5: Assignment Transformer module 115V/127V/230V
2 2 2 4
transformer type R:
item no.14xxxxxx Pin assignment X4 4 1
R - ring core transformer Column pot (system only) X5 /Sensors 1: S3 S4 ring core transformer
P - packet core transformer (7) 1 +12V
250 1 -> S3/S4.2.ws
2 -> free
1 Winding 1 marking RSO-0300-001302
Trend.button Antitrend.button
390 380 360 GND
ANW1
3 -> S4.1.gn
S3: 1-gb, 2-ws S4: 1-gn, 2-ws
WAGO terminals W1 W3
ANW2 4 -> S3.1.gb item no.1395888 item no.1390386
item no.1377455 HV/NV Üb1 bl 0V
item no.1402920 system
6 5 4 3 2 1
Üb2
Winding marking "1" bn 115V
item no.1403159 HV
D .J6 W1 W3 item no.1403160 NV at FW Sensor board RL X6 /Sensors 2: 115V ~ gr 127V
D
1 from Transformer
170
1 1 bl 0V 24V~ .J7 item no.1403159 HV
(5) +12V
GND Assignment .J8 switching relay
24V~
1 bl 0V
5
TSRL.2.sw1 item no.1377460 HV Lock
(see representation 1)
6 5 4 3 2 1
bn 115V 1 1 item no.1403160 NV item no.1252392 NV

Unlock
gr 127V rt
1 1 StE.X108.5.ws (6)
Help sensor RL
SMD1-4 SMD5-8 240 .J8 1 bn 115V
230V~ sw StE.X108.6.bn S7 gr 127V
S5 S1 S11 S3
bl 0V 2 2
TSRL.3.sw2 W2
5 bn 115V Ground point M4 S13 S14
WAGO terminals BACK UP LEGS UP TILT L TREND UP
(to energy chain fixation) WAGO terminals
W1 W3
item no.1403375 item no.1403377 S4 item no.1395888 item no.1390386
gr 127V simultaneously shield bracket S6 S2 S12 S8
160 280 bl 0V
WAGO terminals W2 Sensor board lift
6 5 4 3 2 1
item no.1395888 item no.1390386 (lifting column bottom) bn 115V
->Representation 5 BACK DN LEGS DN TILT R REVERSE DOWN
Ground point M4 Assignment energy chain REVERSE only 2.08: 127V ~ gr 127V
(see legend) (1) Place shield with cable binders NORMAL
C (instead of brake symbol) from Transformer C
(on the column bottom) (2) to the E chain sheet metal 24V~
all MARS 2.01-2.08 SMD15 SMD16 SMD9 SMD10 SMD11 SMD12 SMD13 SMD14 switching relay bl 0V
1 3 4 5 6 (except system!) (3)
6
2 (4) Place shield with cable binders ON bn 115V
View to the E chain top (5) to the E chain sheet metal Emergency
Operation S17 S16LEVEL S15 LOCK S9 UNLOCK S10 LOCK UNLOCK
near control electronics (6) gr 127V
W2
ground point M4
(on the column bottom) WAGO terminals W1 W3
360 item no.1395888 item no.1390386
bl 0V
6 5 4 3 2 1
380 bn 115V
230V ~ gr 127V
Power supply all running gears (FW) Running gear (FW) 2.01/2.02 Running gear (FW) 2.04/2.06 Running gear (FW) 2.03/2.05/2.07/2.08 Setting instruction for jack drive hall sensors board from Transformer
EK.J4.2.bn
EK.J4.9.ws
switching relay 24V~

bl 0V
270
5
B B
- jacked up: signal pin3 (IC2=high), bn 115V
EK.J4.6.bn
plug filter (SF)

EK.J4.8.ws
item no.1377440 mechanically jacked Jacking up=Braking Jacking up=Braking

pin4 (IC1=low)
item no.4102151 up/down 390 with jack motor 390 with jack motor
1 Plug end view
Cable Parts List MARS 2.0x gr 127V
PE.GNYE 2x fuse holder
4 - jacked down: signal pin3 (IC2=low), W2
item no.1428447 Button is a N.O. contact:
TR.TSRL.1.sw1 1 - jacked up: closed=on to EK.J4.5-8 to EK.J4.5-8 .J13 pin4 (IC1=high) Assignment .JXX item no.Description
F4 -> where: 1-ws +12V
StE.X108.1.1.ws - jacked down: open=off
high - no metal detected 2-bn GND
1402795 MARS 2.0 TP two-piece with LV The wiring diagram shows version 2.04 with 230V.
TR.TSRL.4.sw2 Assignment .J11 Assignment .J12
item no.1377442 .J10 Drive motor (FM) (see representation 1) low - metal detected 3-gn Out1 1402809 MARS 2.0 TP two-piece without LV
StE.X108.1.3.gn (see representation 1)
F2 F1 4-gb Out2 1464909 MARS 2.0 TP two-piece with LV2
StE.X108.1.4.gb
2 sw rt Sensor end view

.J11 1
item no.1377441 F3
bn 1 sw M4 .J12
1402810 MARS 2.0S column 230V
3 bl 1 1
PE
StE.X108.1.2.bn sw
1402796 MARS 2.0N column 230V index change no. change date name
bn
integrated
A RCL-filter
ws bn gn
1
IC1 IC2 IC2 IC1 1464787 MARS 2.0N column 115V A
+ battery 2 - + battery 1 - Jack motor (AB) Jack motor Medizin Systeme GmbH 07318 Saalfeld
bn
bl
12V/10Ah 12V/10Ah This drawing must not be

bn rt IC1 - Jacking down sensor Sensor circuit board Lock/Unlock 1464902 MARS 2.0N column 127V duplicated, shown or given to
scale
"Jacking up switch compl."

bl M5 sw M5 IC2 - Jacking up sensor (Jacking up/Jacking down) 1402797 MARS 2.0 FW with AB-motor third parties without our
agreement.
1:1 Circuit diagram MARS 2.0X
Hall sensors board Hall sensors board Directional travel button
item no.Nr. 4144 324 item no.Nr. 4144 324 item no.1391481 item no.1369747 item no.1369747 item no.1392074 The instructions AA.08.1381507A-xx MARS II running gear must be observed. 1402811 MARS 2.0 FW with AB+FM 4219300.ZB - 0
L1
dimension
PE
Contraventions may result in

N
1402812 MARS 2.0 FW standard criminal proceedings under

section 18 d. of the law on
without tolerance
information
DIN ISO 2768
unfair competition.
15 9 5 medium
16 14 13 12 11 10 8 7 6 4 3 000-001/9-13090716452073AF3+



Postfach 24 44
Telephone: +49 3671 586-0 e-mail: info@de.trumpf-med.com
Telefax: +49 3671 586-166 www.trumpf-med.com

MARS 2 Operating Table: Service Manual

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

MARS 2 Operating Table: Service Manual

Uploaded by

Copyright:

Available Formats

MARS 2 Operating Table

TRUMPF Medizin Systeme GmbH

TRUMPF Medizin Systeme GmbH

Distribution Telephone +49 3671 586-0

Technical Telephone +49 3671 586-172

We are constantly working on further developments.

© 09/07 TRUMPF Medizin Systeme GmbH

Designation Item no.

Cable remote control MARS 2 BM* 1 416 569

Service Manual MARS 2 1 435 274 - 09/07

Properties MARS variant

Tabletop height -low-

Tabletop with displacement

Service Manual MARS 2 1 435 274 - 09/07

4 Repair Guide for the Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5 Repair Guide for the Tabletop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Service Manual MARS 2 1 435 274 - 09/07 1

5.9 Back section (BS) joint and its components. . . . . . . . . . . . . . . . . . . . . . . 80

7 Repair Guide for the Running Gear . . . . . . . . . . . . . . . . . . . . . . . . 121

2 Service Manual MARS 2 1 435 274 - 09/07

8 Lubrication Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

9 Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

Service Manual MARS 2 1 435 274 - 09/07 3

4 Service Manual MARS 2 1 435 274 - 09/07

Telephone +49 3671 586-172

Service Manual MARS 2 1 435 274 - 09/07 5

1.2 Explanation of symbols

Useful additional information and tips

Performance of functional tests, measurements and tests.

Notes concerning disposal in ways which do not harm the

6 Service Manual MARS 2 1 435 274 - 09/07

1.4 Safety instructions

1.4.1 General information

Service Manual MARS 2 1 435 274 - 09/07 7

1.4.2 Protection against infection

1.4.3 Environmental protection

8 Service Manual MARS 2 1 435 274 - 09/07

Head end Back section joint end (battery

Foot end Leg section joint end (power socket)

Right side Side of operating table without

Service Manual MARS 2 1 435 274 - 09/07 9

2.2 Tools, measuring instruments, equipment

Tools Basic equipment:

Measuring TRUMPF Medizin Systems measuring instruments (specifically for

Equipment - Adhesive Scotch Weld 110DP

10 Service Manual MARS 2 1 435 274 - 09/07

2.3 Operating table

Service Manual MARS 2 1 435 274 - 09/07 11

12 Service Manual MARS 2 1 435 274 - 09/07

the FAULT indicator will show a steady red light.

IDuring emergency operation, all positioning movements are

The emergency mode may also be activated manually in an

Service Manual MARS 2 1 435 274 - 09/07 13

14 Service Manual MARS 2 1 435 274 - 09/07

4 Repair Guide for the Column

4.1 Remove the power from the operating table

Figure 1 Running gear - battery compartment

Service Manual MARS 2 1 435 274 - 09/07 15

4.2 Internal power supply

Figure 2 Running gear - battery compartment

1. Reattach the positive connectors to the both batteries [3].

16 Service Manual MARS 2 1 435 274 - 09/07

4.3 Metal covers (without membrane keyboard)