Skytron Elite 3500 Surgical Table - Maintenance Manual

ELITE SERIES SURGICAL TABLES
MAINTENANCE MANUAL
MODEL ELITE 3500 AND 3500B

AUGUST 2000
Page 65
TABLE OF CONTENTS
SECTION I HYDRAULIC SYSTEM ......................................................................................................................... 1
1-1. General ........................................................................................................................................................ 1

1-2. Component Operation .................................................................................................................................. 2
a. Motor/Pump Operation ............................................................................................................................ 2
b. Pressure Relief Valve ............................................................................................................................. 2
c. Mini-Valves ............................................................................................................................................. 3
d. Mini-Valve in Neutral Position ................................................................................................................. 3
e. Mini-Valve Right Port Activated .............................................................................................................. 4
f. Mini-Valve Left Port Activated ................................................................................................................ 4
g. Hydraulic Cylinders (Slave Cylinders) ..................................................................................................... 5
h. Elevation Cylinder Return Circuit ............................................................................................................. 7
i. Brake System ......................................................................................................................................... 7
j. Emergency Brake Release ...................................................................................................................... 8
k. Flex/Reflex System ................................................................................................................................. 8
1-3. Hydraulic Adjustments ................................................................................................................................. 9
a. Fluid Level. ............................................................................................................................................. 9
b. Bleeding The Hydraulic System .............................................................................................................. 9
c. Pressure Relief Valve ............................................................................................................................. 9
d. Speed Controls ....................................................................................................................................... 9
SECTION II MECHANICAL TABLE ADJUSTMENTS ........................................................................................... 11
2-1. Back Section Gear Mesh Adjustment ........................................................................................................ 11

2-2. Hydraulic Cylinder Adjustment ................................................................................................................... 11
a. Back Section ........................................................................................................................................ 11
b. Leg Section ........................................................................................................................................... 11
c. Slide and Kidney Lift Cylinders .............................................................................................................. 12
2-3. Slide Roller Adjustment .............................................................................................................................. 12
SECTION III HYDRAULIC TROUBLESHOOTING ................................................................................................. 13
3-1. Precautions ............................................................................................................................................... 13

3-2. Troubleshooting Notes ............................................................................................................................... 13
3-3. ELEVATION DIAGNOSIS CHART ............................................................................................................. 14
3-4. TRENDELENBURG DIAGNOSIS CHART .................................................................................................. 15
3-5. LATERAL - TILT DIAGNOSIS CHART ...................................................................................................... 16
3-6. BACK SECTION DIAGNOSIS CHART ....................................................................................................... 17
3-7. FLEX SYSTEM DIAGNOSIS CHART ......................................................................................................... 18
3-8. LEG SECTION DIAGNOSIS CHART .......................................................................................................... 19
3-9. KIDNEY LIFT DIAGNOSIS CHART ........................................................................................................... 20
3-10. SLIDE DIAGNOSIS CHART ....................................................................................................................... 21
3-11. BRAKE CIRCUIT DIAGNOSIS CHART ...................................................................................................... 22
3-12. Flexible Hose Identification and Placement ................................................................................................ 23
3-13. Kidney Lift System ..................................................................................................................................... 24
SECTION IV ELECTRICAL SYSTEM ................................................................................................................... 26
4-1. General ...................................................................................................................................................... 26

4-2. Components .............................................................................................................................................. 26
4-3. Battery Model Components ......................................................................................................................... 26
SECTION V ELECTRICAL SYSTEM TROUBLESHOOTING ................................................................................ 28
5-1. Troubleshooting Notes ................................................................................................................................ 28

5-2. Main Switch ................................................................................................................................................ 28
5-3. Pendant Control .......................................................................................................................................... 29
5-4. Relay Box ................................................................................................................................................... 30
5-5. Solenoids .................................................................................................................................................... 32
Although current at time of publication, SKYTRON's policy of continuous development makes this manual subject to change
without notice.
Page 62 03/02
TABLE OF CONTENTS (cont.)
SECTION V ELECTRICAL SYSTEM TROUBLESHOOTING (cont.) ..................................................................... 28
5-6. Motor/Pump Assembly ............................................................................................................................... 33

5-7. Return-to-Level Micro-Switches .................................................................................................................. 35
5-8. Return/Inhibit System Troubleshooting ....................................................................................................... 36
SECTION VI -3500B- BATTERY MODEL, ELECTRICAL TROUBLESHOOTING ................................................. 42
6-1. General ...................................................................................................................................................... 42

6-2. Troubleshooting Notes ................................................................................................................................ 42
6-3. Main Switch ................................................................................................................................................ 42
6-4. Batteries .................................................................................................................................................... 44
6-5. Battery Charging Box/AC120V Transformer ............................................................................................... 44
6-6. Switch-Over Relay ..................................................................................................................................... 46
6-7. Pendant Control .......................................................................................................................................... 47
6-8. Auxiliary Switches ..................................................................................................................................... 48
6-9. Relay Box ................................................................................................................................................... 48
6-10. Main Wire Harness Continuity Test ............................................................................................................ 50
6-11. Solenoids .................................................................................................................................................... 51
6-12. Motor/Pump Assembly ............................................................................................................................... 52
6-13. Return-to-Level Micro-Switches .................................................................................................................. 53
6-14. Return/Inhibit System Troubleshooting ....................................................................................................... 54
SECTION VII -3500B- BATTERY MODEL, ELECTRICAL SYSTEM ADJUSTMENTS ......................................... 60
7-1. Relay Box Adjustments .............................................................................................................................. 60
Page 63
SECTION I HYDRAULIC SYSTEM
1-1. General
Electro-Hydraulic System hand-held push button pendant control. The power

requirements for the table are 120 VAC, 5 amp, 60
The hydraulic system (with the exception of the Hz.
hydraulic cylinders and hoses) is contained within
the base of the table. The hydraulic valves and The table contains the following components. Re-
pump are electrically controlled by the use of a fer to the block diagram (figure 1-1) for relationship.
Figure 1-1. Hydraulic Block Diagram

Page 1
a. Oil Reservoir - Main oil supply. Approximately b. Pressure Relief Valve
two quarts.
This device provides an alternate oil path when the
b. Motor/Pump Assembly - A positive displace- hydraulic cylinders reach the end of their stroke
ment gear type pump provides the necessary oil and the pump continues to run. If this path were not
pressure and volume. provided, the pump motor would stall because the
oil cannot be compressed. The pressure relief
c. Pressure Relief Valve - Provides an alternate oil valve is directly connected to the mini-valve bodies
path when the hydraulic cylinders reach the end of and shares both the common internal main pres-
their stroke. sure oil galley, and the return oil galley, that inter-
nally connect to the reservoir.
d. Electro/Hydraulic Mini-Valve Assemblies -These
direct the fluid to the appropriate hydraulic cylin- The main component of the valve is an adjustable
ders. spring loaded plunger that is pushed off from its
seat by the oil pressure. The oil then flows back into
e. Hydraulic Lines, Fittings, Connections - They the reservoir. Turning the adjustment nut clock-
provide a path for the hydraulic oil. wise increases the amount of oil pressure required
to open the valve, and turning it counterclockwise
f. Hydraulic Cylinders - They convert the hydraulic decreases the amount of oil pressure. (See adjust-
fluid pressure and volume into mechanical motion. ment section for specification.)
1-2. Component Operation
a. Motor/Pump Operation
PRESSURE RELIEF
ADJUSTMENT NUT
The motor/pump assembly is a gear type pump that
provides the oil pressure and volume for the entire
SPRING LOADED
hydraulic system. The pump has an inlet side and PRESSURE PLUNGER
an outlet side. The inlet side is connected to the GAUGE
reservoir which provides the oil supply. The reser-
voir has a very fine mesh screen strainer which
prevents foreign material from entering the oil
system.
The output line of the pump is connected to the main

oil galley which is internal and common to all the
hydraulic mini-valves and pressure relief valve. Figure 1-3. Pressure Relief Valve Not
Also, common to the hydraulic mini-valves and Functioning
pressure relief valve is an oil galley that internally
connects to the oil reservoir to provide a return path
for the hydraulic oil. See figure 1-2.
PUMP PRESSURE RELIEF

MAIN RETURN MAIN PRESSURE ADJUSTMENT NUT
OIL GALLEY OUTLET OIL GALLEY
(INTERNAL) (INTERNAL)
MINI-VALVES SPRING LOADED

PLUNGER
PRESSURE
GAUGE
MOTOR/PUMP PRESSURE
ASSEMBLY RELIEF VALVE
OIL
PUMP INLET RESERVOIR
Figure 1-2. Figure 1-4. Pressure Relief Valve Functioning

Page 2
c. Mini-Valves
The operation of the mini-valves is identical for all Also, by using this control method, it doesn’t matter
table functions except the elevation and Single what size cylinder and piston is used because the
Action Brake circuits. These two hydraulic circuits speed can be controlled by restricting the return oil.
use a 3-way (single check valve) type mini-valve. If the pump puts out more volume to a certain slave
All other functions use a 4-way (dual check valve) cylinder than the speed control is allowing to go
type mini-valve. back to the reservoir, the pressure relief valve
provides an alternate path for the pump oil.
Either type mini-valve is controlled by two pushing
type, electrically operated solenoids. The sole- d. Mini-Valve in Neutral Position
noids push the spool valve (located in the lower (No fluid flow) See figure 1-5.
portion of the valve) one way or the other. This
motion opens the main supply galley (which has 1. Spool Valve Centered - This closes off both
pump pressure) allowing the oil to flow through the oil pressure and oil return galleys.
various parts of the mini-valve to the function. The
spool valve also opens an oil return circuit which 2. Pilot Plungers Both Closed -The pilot plung-
allows the oil to return to the oil reservoir. ers control the opening of the check valves. If they
are closed, the check valves must be closed.
The main components of the mini-valve and their
functions are listed below: 3. Check Valves - Both check valves are
closed trapping the oil in the cylinder and oil lines.
1. Spool Valve - Opens the main oil galley
(pump pressure) to either mini-valve outlet depend- 4. Speed Adjustment - When the mini-valve is
ing on which direction the spool valve is pushed. in the neutral position, the speed adjustment does
Also it provides a return path for the oil returning not affect anything because there is not any oil flow.
back into the reservoir.
2. Pilot Plunger - There are two plungers in a OIL LINE BALL OIL LINE
VALVE
four-way mini-valve (one in a 3-way mini-valve),
one under each check valve. The purpose of the SPEED
CONTROL
pilot plungers is to mechanically open the return
PILOT
check valve allowing the oil to return back into the PLUNGER
reservoir. CHECK
VALVE
3. Check Valve - Two are provided in each

four-way mini-valve to seal the oil in the cylinders
and oil lines and prevent any movement of the table.
One check valve is provided in a 3-way mini-valve.
4. Speed Adjustments - There are two speed

adjustments in each mini-valve. They are needle
valve type controls which restrict the volume of oil
returning back into the reservoir, thereby control- OIL GALLERY OIL RETURN SPOOL SOLENOID
(PRESSURE) (RETURN) VALVE PISTON
ling the speed of the table surface movement. A 3-
way mini-valve has only one speed adjustment. Figure 1-5. Mini-Valve in Neutral Position
The speed controls are always located in the return
oil circuit. This prevents uncontrolled movement of
the piston in the slave cylinder due to one side of the
piston being loaded with hydraulic pressure and
the other side having no load.
Page 3
e. Mini-Valve Right Port Activated f. Mini-Valve Left Port Activated
(See figure 1-6) (See figure 1-7.)
Slave Cylinder Piston Moves to Left Slave Cylinder Piston Moves to Right
Right Mini-Valve Port is Supply Line Left Mini-Valve Port is Supply Line
Left Mini-Valve Port is Return Line Right Mini-Valve Port is Return Line
INLET OUTLET
Figure 1-6. Mini-Valve Right Port Activated Figure 1-7 Mini-Valve Left Port Activated
1. Spool Valve - Pushed to the left by electric 1. Spool Valve -Pushed to the right by electric
solenoid. This opens the internal oil pressure gal- solenoid. This opens the internal oil pressure galley
ley allowing the fluid to go through the check valve allowing the fluid to go through the check valve and
and on to the cylinder. Also, the spool valve opens on to the cylinder. Also, the spool valve opens the
the oil return line providing an oil path through the oil return line providing an oil path through the
internal oil galley back to the reservoir. internal oil galley back to the reservoir.
2. Pilot Plunger Valve - Left pilot plunger valve 2. Pilot Plunger Valve - Right pilot plunger valve
is pushed up by the incoming oil pressure mechani- is pushed up by the incoming oil pressure mechani-
cally opening the check valve located above it in cally opening the check valve located above it in
the return circuit. This action allows the oil from the the return circuit. This action allows the oil from the
left side of the slave cylinder to go back into the right side of the slave cylinder to go back into the
reservoir. The right pilot plunger valve is not reservoir. The left pilot plunger valve is not affected
affected in this operation mode. in this operation mode.
3. Check Valves - Both check valves are 3. Check Valves - Both check valves are
opened in this operation mode. The right check opened in this operation mode. The left valve is
valve is pushed open by the oil pressure created by pushed open by the oil pressure created by the
the pump. The oil then continues to go through the pump. The oil then continues to go through the
lines and pushes the slave cylinder piston to the lines and pushes the slave cylinder piston to the
left. At the same time, the left check valve is held right. At the same time, the right check valve is held
open mechanically by the pilot plunger providing a open mechanically by the pilot plunger providing a
return path for the oil through the mini-valve back to return path for the oil through the mini-valve back to
the reservoir. the reservoir.
4. Speed Adjustment - The right speed control 4. Speed Adjustment - The left speed control
(output side) does not have any effect in this (output side) does not have any effect in this oper-
operation mode because the oil is routed around ation mode because the oil is routed around the
the speed adjustment through a by-pass valve and speed adjustment through a by-pass valve and
then to the output port. The left speed adjustment then to the output port. The right speed adjustment
controls the speed of the table function by restrict- controls the speed of the table function by restrict-
ing the amount of oil going back into the reservoir. ing the amount of oil going back to the reservoir.
Page 4
g. Hydraulic Cylinders (Slave Cylinders)
There are several different types of hydraulic cylin- O-RING O-RING

ders used in the table that activate the control
functions. With the exception of the elevation and
brake cylinders, all operate basically the same
way. The control functions are listed below: (See PISTON
figure 1-8.).
Trendelenburg--1, double action cylinder RAM
HYDRAULIC LINE
Back Section--2, double action cylinders
Leg Section--2, double action cylinders
Slide--1, double action cylinder Figure 1-9. Back Section Cylinder
Kidney Lift--2, double action cylinders
Lateral Tilt--1, double action cylinder
Elevation--1, single action cylinder 2. Slide Cylinder Assembly - This cylinder
Brakes--4, single action cylinders arrangement has two pistons, one on each end of
a ram which has rack gear teeth cut into its top
surface. These teeth mesh with a gear arrange-
BACK SECTION ment that drives a rack gear connected to the
CYLINDER LEG SECTION
CYLINDER bottom of the side frame.
When hydraulic fluid is pumped into one side of the
cylinder, the pistons are pushed in one direction,
the gear arrangement rotates and causes the table
top to slide. Oil pressure can be applied to either
piston, making the table slide end for end. See
figure 1-10.
RACK GEAR
LATERAL TILT
CYLINDER SLIDE
CYLINDER RAM
KIDNEY LIFT
CYLINDER
TRENDELENBURG
CYLINDER
ELEVATION
CYLINDER
O-RINGS
O-RINGS
PISTONS
Figure 1-8. Cylinder Placement
1. Trendelenburg, Back Section and Leg Sec- Figure 1-10. Slide Cylinder Assy.
tion Cylinders - The double action cylinders are
closed at one end and have a movable piston with
hydraulic fluid on both sides. Connected to this 3. Kidney Lift Cylinders - The two kidney lift
piston is a ram or shaft that exits out of the other end cylinders are similar to the slide cylinder in that the
of the cylinder. Through the use of either a ball and ram has rack gear teeth cut into the top surface. O-
socket, a gear, or clevis and pin arrangement, the Rings on each end of the ram allow the ram to also
ram is connected to a movable table surface. serve as the pistons.
The movable surface can be moved one way or The rack teeth cut into the top of the ram meshes
the other by pumping hydraulic fluid into the cylin- with a pinion gear. This gear meshes with other
der on either side of the piston. Obviously, if oil is gears to supply the up or down drive for the kidney
pumped into one side of the cylinder, a return path lift bars, depending on which direction the oil is
must be provided for the oil on the other side. See pumped into the cylinder. See figure 1-11.
figure 1-9.
Page 5
The cylinder is set in the center of the elevation
main column. The two stage cylinder is elevated by
the driven force of the oil pressure. When lowering,
the oil that is accumulated in the cylinder is returned
to the oil reservoir through the mini-valve due to the
table top weight.
A slider support assembly is used to support the
RAM weight of the upper table section. A stainless steel
PINION
GEAR shroud covers the flexible hydraulic hoses and
slider. See figure 1-13.
O-RINGS O-RINGS ELEVATION

CYLINDER
Figure 1-11. Kidney Lift Cylinder Assembly
SHROUD PRIMARY
4. Lateral Tilt Assembly - The lateral tilt assem-
PISTON
bly consists of two cylinders, pistons and connect-
ing rods. The connecting rods attach to the lateral ELEVATION
tilt lever which connects to the table center column COLUMN
assembly. The cylinder housing attaches to the SECONDARY
table top and is attached to the center column PISTON
assembly by pivots. See figure 1-12.
The pistons and connecting rods are attached to a
non-movable surface. Therefore, when hydraulic
fluid is pumped into one side, the cylinder housing Figure 1-13. Elevation Cylinder Assembly
itself moves around the lateral tilt lever causing the
table top to tilt to one side. 6. Brake Cylinders - The brake cylinders are
To tilt the table top in the opposite direction, fluid is single action type similar to the elevation cylinder.
pumped into the opposite cylinder. The movable piston's ram is connected to a brake
pad. See figure 1-14. Oil pumped into the top of the
O-RINGS CONNECTING RODS cylinder pushes the piston down raising the table
base off its casters. An internal return spring on the
bottom of the piston, pushes the piston up to return
the oil through the mini-valve to the reservoir.
PISTON
OIL LINE
PISTON RETURN
SPRING
O-RINGS
LATERAL
TILT LEVER PISTON
BRAKE RAM
Figure 1-12. Lateral Tilt Cylinder Assembly PAD
5. Elevation Cylinder - This single action cylin-

der does not have hydraulic fluid on both sides of
the piston. It depends on the weight of the table top
assembly to lower it. Figure 1-14. Brake Cylinder
Page 6
h. Elevation Cylinder Return Circuit 1. Single action slave cylinders (4 each).
A three-way (single check valve type) mini-valve 2. 3-way (single check valve type) mini-valve.
controls both the elevation and return circuits. The
elevation circuit operation within the mini-valve is 3. Manually controlled emergency brake re-
identical to the operation of the four-way valves lease.
previously described (inlet pressure opens the
check valve allowing the oil to enter the cylinder). In 4. Plumbing terminal, flexible hoses, copper
the return position, inlet pressure pushes the pilot lines and "O" rings.
plunger up and opens the return check valve. See
figure 1-15. The open check valve allows a path for 5. Portions of the electrical system.
the oil in the elevation cylinder to return to the
reservoir. When the pilot plunger valve is opened,
BRAKE
the continuing pump pressure opens the pressure CYLINDERS MINI-VALVE
BRAKE
relief valve which provides a return oil path to the
reservoir.
The mini-valve used in the elevation circuit con- EMERGENCY

tains only one check valve (all four-way mini- BRAKE
RELEASE
valves use two check valves). The check valve is
used to trap the oil in the elevation cylinder thereby
supporting the table top. When the top is being
lowered the check valve is mechanically held open
by the pilot plunger through pump pressure. PRESSURE
RELIEF
VALVE
BACK LEG KIDNEY SLIDE

ELEVATION
CYLINDER
CHECK
SPEED VALVE
CONTROL Figure 1-16. Brake System Block Diagram
PILOT
PLUNGER Each corner of the cast-iron table base has a
SPOOL hydraulic brake cylinder. These single action cyl-
VALVE
inders are hydraulically connected in parallel to the
PRESSURE mini-valve and all four are activated together. It is
RELIEF VALVE
normal for one corner of the table to raise before the
others due to the weight distribution of the table.
An electronic timer in the relay box is activated

RESERVOIR when any function on the pendant control is
pushed momentarily. The pump/motor and brake
system mini-valve is activated and the brake cylin-
Figure 1-15. Elevation Return Circuit ders are completely set. The electronic timer runs
for approx. 8-10 seconds.
i. Brake System The brakes are released by pushing the BRAKE

UNLOCK button momentarily. An electronic timer
The brake system consists of the following compo- in the relay box activates the brake function hy-
nents: (figure 1-16) draulic mini-valve and pump/motor.
Page 7
When activated, the return hydraulic circuit oper- 1. The brakes will release slowly- depending
ates similar to the elevation cylinder return circuit. on how loose the valve is, this could take anywhere
Return springs inside the single action brake cylin- from a few minutes to several hours.
ders retract the brake pads and provide the pres-
sure to return the hydraulic oil back to the reservoir. 2. None of the table functions will operate
The electronic timer operates the return circuit for properly if the valve is wide open. All of the
approximately 8-10 seconds. hydraulic fluid from the pump is simply pumped
through the brake bypass circuit because that is
j. Emergency Brake Release the easiest path for the oil to follow.
The emergency brake release is simply a manually k. Flex/Reflex System

operated bypass valve connected in parallel to the
brake cylinders and the oil reservoir. See figure 1- The Flex/Reflex system has a mini-valve which
17. When the valve is opened (turned counter- connects the trendelenburg and back section hy-
clockwise) a return circuit for the brake hydraulic draulic systems in a series. When FLEX is acti-
fluid is opened. The return springs force the pistons vated by the pendant control, the Flex/Reflex mini-
up pushing the hydraulic oil back into the reservoir valve opens the oil pressure path to the Reverse
and retracting the brake pads. Trendelenburg piston. The return oil path from the
trendelenburg piston is routed through the back
section cylinder to the mini-valve return port. See
figure 1-18.
TREND
EMERGENCY BRAKE BACK UP
RELEASE LEVER
REV. TREND
Figure 1-17. BACK

DOWN
IMPORTANT
•The emergency brake release valve PLUMBING

TERMINAL
must be tightened securely when not in
use.
•If the emergency brake release valve FLEX/REFLEX

MINI-VALVE
has been operated, the UNLOCK but-
ton on the pendant control may have to
be pressed before brakes will lock
again.
If the emergency brake release valve is open or Figure 1-18. Flex/Reflex System
loose, two conditions could occur:
Page 8
1-3. Hydraulic Adjustments c. Pressure Relief Valve
a. Fluid Level. The pressure relief valve is adjusted by turning the

adjustment nut until the desired pressure is reached.
The fluid level should be approximately 1/2" below
the filler hole or gasket surface. If additional fluid is To adjust:
needed, remove the filler vent cap with a phillips
screwdriver and add fluid through this opening 1. Remove the plumbing bolt securing the
using a funnel. See figure 1-19. brake system line to the pressure relief valve and
attach a hydraulic pressure gauge as shown in
NOTE figure 1-20 using a long 6mm plumbing bolt.
The elevation cylinder should be com-

pletely down and all the other control PRESSURE
RELIEF VALVE
functions in their neutral position when
checking oil level. PRESSURE
GAUGE
FILLER VENT
FILLER
CAP
RESERVOIR
OPENING
LONG 6 mm
PLUMBING
BOLT
Figure 1-19. Figure 1-20.
The type of oil that should be used is Mobil DTE #25

or equivalent. This is a very high quality hydraulic 2. Raise the table top until the piston reaches
oil. The table requires approximately two quarts of the end of its stroke and stalls. Observe reading
oil to operate properly. on pressure gauge and turn the adjustment nut
(clockwise to increase oil pressure, counter-
b. Bleeding The Hydraulic System clockwise to decrease) until desired reading is
obtained. Pressure should be 80KG/CM2 -1138
To purge the air from the hydraulic system, operate PSI.
each function back and forth at least two or three
times. d. Speed Controls
NOTE The speed controls restrict the volume of oil return-

ing back to the reservoir thereby controlling the
Whenever a hydraulic line or com- speed of each control function.
ponent is replaced, bleed the air out of
the lines using the pump pressure be- All four-way mini-valves, have two speed controls
fore making the final connection. Then located in the ends of each valve body. All three-
operate the function until it stalls in both way mini-valves have only one speed control.
directions.
Page 9
One speed control adjusts one direction of a A pressure gauge should be used to set the speed
particular function and the opposite speed control of the back section, trendelenburg and flex control
adjusts the other direction. They are adjustable by functions.
using a small straight blade screwdriver and
turning the adjustment screw clockwise to de- To adjust:
crease the speed and counterclockwise to
increase the speed. Refer to figure 1-21. 1. Attach the pressure gauge onto the main oil
galley as shown in figure 1-20.
TABLE DOWN TILT RIGHT
TREND
REFLEX
BRAKE 2. The gauge should read the following values
BACK UP when operating the various control functions in
LEG DOWN either direction. Turn the speed controls until
KIDNEY UP desired values are obtained.
SLIDE
HEAD
Back Section Up 65KG/CM2 -925PSI
Dn 65KG/CM2-925PSI
REV.
TREND
Trendelenburg Up 65KG/CM2 -925PSI
TILT LEFT SLIDE Dn 65KG/CM2 -925PSI
FOOT
FLEX
BACK DOWN KIDNEY Flex 70KG/CM2 -995PSI
DOWN
LEG UP
Reflex 70KG/CM2 -995PSI
Figure 1-21.
NOTE
Any control function should move in either direc-
tion at the same rate. If the rate of a certain function When adjusting Flex/Reflex speed con-
is too slow, open the speed control slightly and trols, set Reflex last.
recheck. Use the second hand on a watch and time
a particular function. Match that time in the opposite Elevation - There is not a speed adjustment for
direction by opening or closing the speed control. raising the table. The speed control will only affect
Approximate operating times are as follows: the rate of descent and it should equal the rate of
elevation.
Elevation Down 30 seconds
Lateral Tilt 7 seconds
Leg-Up 25 seconds
Leg-Down 15 seconds
Kidney Lift 7 seconds
Slide 20 seconds
Page 10
SECTION II MECHANICAL TABLE ADJUSTMENTS
2-1. Back Section Gear Mesh Adjustment Any twisting or flexing of the back section as it
approaches the stalled position indicates that one
The gear mesh is adjusted by the use of an eccen- of the cylinders is not reaching its fully extended
tric cam. This cam moves the gear teeth closer position at the same time as the other. This
together to eliminate gear lash. This adjustment condition would require an adjustment.
arrangement compensates for any wear between
the gears that might occur. To adjust:
Remove the top from the seat section for access to
To adjust: the locking set screws.
Loosen the cam locking allen set screw. Use an
allen wrench to rotate the eccentric cam. See Loosen the set screw located above the eccentric
figure 2-1. Tighten the set screw when adjustment cam in each side frame. Use an allen wrench to
is complete. turn the cylinder eccentric cams as required to shift
either cylinder fore or aft as needed so no twisting
or flexing of the back section is observed when it is
stalled in the full up position. Tighten the set screws
and replace the seat section top when proper
ECCENTRIC adjustment has been achieved. See figure 2-2.
CAM
SET SCREW
BACK SECTION
SEAT SECTION TOP
ALLEN
WRENCH
Figure 2-1. Eccentric Cam Adjustment BACK SECTION CYLINDER

SET
SCREW ECCENTRIC CAM
2-2. Hydraulic Cylinder Adjustment
Back & Leg Sections
The hydraulic cylinder rams that control both the

back and leg sections must move together so that
these sections are not twisted when operated. This
is accomplished by the use of eccentric cams that
move the cylinder bodies fore and aft to adjust their
effective stroke. Figure 2-2. Back Section Adjustment
NOTE b. Leg Section
Adjust gear mesh before adjusting ec- Position the leg section all the way up until it is
centric cams for the back section. horizontal. Both sides of the leg section should
stop moving at the same time and should not show
a. Back Section any signs of twisting.
Position the back section all the way up until it Any twisting or flexing of the leg section as it
stalls. Both sides of the back section should stop approaches the stalled position indicates that one
moving at the same time and should not show any of the cylinders is not reaching its fully extended
signs of twisting. position at the same time as the other and an
adjustment is required.
Page 11
To adjust: 2-3. Slide Roller Adjustment
Loosen the cam locking set screws located on the The pivot pins on the slide rollers are eccentric
bottom of the cylinder mounting plates inside the cams. The rollers can be adjusted if required to
table side frames. Use an allen wrench to turn the maintain proper top slide operation.
cylinder eccentric cams as required to shift either
cylinder fore or aft as needed so no twisting or To adjust:
flexing of the leg section is observed when it is Remove the Seat section top, the hose cover and
stalled in the horizontal position. Tighten set screws the right and left lateral tilt frame covers for access
when proper adjustment is achieved. See figure 2- to the top rollers.
3.
LEG SECTION 1. Align the table top so the rollers to be
adjusted are contacting the slide bars.
2. Loosen the adjustment cam set screw and

adjust the roller using an 8mm Allen wrench. See
figure 2-5. To avoid any possible binding in the slide
LEG SECTION CYLINDER mechanism, adjust the roller on the opposite side of
ECCENTRIC CAM
the table in the same manner (cam turned toward
same end of table on each side).
SET SCREW
Figure 2-3. Leg Section Adjustment 3. Adjust rollers so top slides smoothly with no
up or down movement of the table top.
c. Slide and Kidney Lift Cylinders
If the Slide or Kidney Lift cylinder has been re- 4. When adjustment is complete, tighten set
moved, the distance from the end of the piston to screws, replace covers and top section.
the end of the cylinder housing must be checked to
make sure the functions will operate correctly.
SET SCREW
With table top centered, the distance from the end
of the Slide piston to end of cylinder is:
Head End - 82 mm Foot End - 120 mm SLIDE
ROLLER
The table top should slide 7-1/2" toward the head
and 13-1/4" toward the foot when positioned prop-
erly. Refer to figure 2-4.
With Kidney Lift all the way down, the distance

from the end of the Kidney Lift piston to end of
cylinder is:
Head End - 82 mm Tail End - 11 mm
8mm
ALLEN
WRENCH
13-1/4"
7-1/2" SLIDE
SLIDE TOWARD
TOWARD FOOT
HEAD
120mm
82mm
Figure 2-4. Figure 2-5.

Page 12
SECTION III HYDRAULIC TROUBLESHOOTING
3-1. Precautions Once the problem has been determined, concen-

Before attempting to troubleshoot any hydraulic trate on that particular hydraulic circuit or control
problem on the table, please read through the pre- function.
cautions and notes below.
Listed below are the hydraulic components that
CAUTION are common with all hydraulic circuits. If there is a
problem with any of them, it could affect all control
When disconnecting any of the hydrau- functions.
lic lines, fittings, joints, hoses, etc., for
the following control functions, be sure 1. Motor/Pump Assembly
these table surfaces are in their down 2. Reservoir
position or completely supported. 3. Pressure Relief Valve
4. Certain Oil Lines and Galleys
Elevation
Back Section If there was a problem in the following components,
Leg Section only one control function would normally be af-
Kidney Lift fected.
When working on the trendelenburg or 1. Mini-Valve

lateral tilt hydraulic circuits, be sure to 2. Slave Cylinder
support the table top. When working on 3. Oil Lines
the brake system make sure the brakes
are completely retracted. NOTE
CAUTION Whenever a hydraulic line or compo-

nent is replaced, bleed the air out of the
Failure to follow these precautions may lines using the pump pressure before
result in an uncontrolled oil spray and making the final connection. After all
damage to the table or personal injury. connections are tight, cycle the control
function back and forth two or three
times to purge the remaining air from the
3-2. Troubleshooting Notes system.
When troubleshooting a table malfunction, first

determine the following: IMPORTANT
1. Does the problem affect all control func- When installing new "O" rings use hy-
tions? draulic oil to thoroughly lubricate the "O"
rings and cylinder. Keep everything
2. Does the problem affect only one control clean.
function?
Each complete oil circuit is shown on the following
3. If the problem affects one control function is pages. When troubleshooting a particular function,
it in both directions? refer to the appropriate oil circuit diagram and the
list of possible problems.
4. Is the problem intermittent?
5. Is the problem no movement of a table

surface or does the table surface lose posi-
tion?
Page 13
3-3. ELEVATION DIAGNOSIS CHART
Problem Reason
Table will not elevate properly Pressure Relief Valve Not Set Properly
Low on Oil
Spool Valve Not Centered or Adjusted Properly
Defective Pump
Defective Mini-Valve
Defective Solenoid or Wiring
Defective Relay Box or Pendant Control
Table will not descend properly Incorrect Speed Adjustment

Bad Check Valve
Spool Valve Not Centered
Defective Solenoid or Pendant Control
Table loses elevation Bad Check Valve

Leaking Mini-Valve
Loose Fittings, Joints, Hoses
Leaking "O" Ring Inside Cylinder
PRIMARY
PISTON
O-RING
SECONDARY
PISTON
COPPER PLUMBING O-RING
LINE TERMINAL
CHECK
VALVE
SPEED
CONTROL INTERNAL OIL FLEXIBLE
FROM PUMP HOSE
INTERNAL OIL RETURN

MINI-VALVE TO RESERVOIR
Figure 3-1. Elevation Circuit
Page 14
3-4. TRENDELENBURG DIAGNOSIS CHART
Problem Reason
Trendelenburg function moves improperly Incorrect Speed Adjustment
Bad Check Valves
Low on Oil
Pinched Hose
Pressure Relief Valve Not Set Properly
Trendelenburg function chatters or loses position Defective or Dirty Check Valve

Oil Leakage in Circuit
Air Inside Cylinder
Pinched Hose
Low on Oil
TRENDELENBURG
CYLINDER ASSEMBLY
PISTON
COPPER PLUMBING
LINES TERMINAL
O-RING
CHECK
VALVE
SPEED
CONTROL
MINI-VALVE
INTERNAL OIL RETURN
TO RESERVOIR
INTERNAL OIL
FROM PUMP
Figure 3-2. Trendelenburg Circuit
Page 15
3-5. LATERAL TILT DIAGNOSIS CHART
Problem Reason
Lateral tilt function moves improperly Incorrect Speed Adjustment
Bad Check Valves
Low on Oil
Pinched Hose
Defective Solenoid
Lateral tilt function chatters or loses position Defective or Dirty Check Valves
Air Inside Cylinder
Pinched Hose
Low on Oil
LEFT TILT
CYLINDER
HOUSING
CYLINDER CAP
FITTING
PISTON O-RING
COPPER PLUMBING
LINES TERMINAL RIGHT TILT
CHECK
VALVE
SPEED
CONTROL
MINI-VALVE
INTERNAL OIL RETURN
TO RESERVOIR
INTERNAL OIL
FROM PUMP
Figure 3-3. Lateral Tilt Circuit
Page 16
3-6. BACK SECTION DIAGNOSIS CHART
Problem Reason
Back Section function moves improperly Incorrect Speed Adjustment
Bad Check Valves
Low on Oil
Pinched Hose
Back Section function chatters or loses position Defective or Dirty Check Valves
Air Inside Cylinder
Pinched Hose
Low on Oil
BACK SECTION
CYLINDER ASSEMBLY
NOTE: ONE SIDE

SHOWN FOR CLARITY UP CIRCUIT
DOWN CIRCUIT
COPPER PLUMBING
LINES TERMINAL
CHECK
VALVE
SPEED
CONTROL
MINI-VALVE
INTERNAL OIL RETURN
TO RESERVOIR
INTERNAL OIL
FROM PUMP
Figure 3-4. Back Section Circuit
Page 17
3-7. FLEX SYSTEM DIAGNOSIS CHART
Problem Reason
Back Section or Trendelenburg function moves Incorrect Speed Adjustment (Trendelenburg, Back
improperly Section or Flex - check with gauge)
Bad Check Valves
IMPORTANT Low on Oil
Pinched Hose
If Flex System does not function prop- Defective Mini-Valve
erly, check the back section and tren- Pressure Relief Valve Not Set Properly
delenburg functions before adjusting Defective Solenoid or Wiring
the flex system. Defective Relay Box or Pendant Control
Back Section or Trendelenburg function chatters Defective or Dirty Check Valves

or loses position Oil Leakage in Circuit
Air Inside Cylinder
Pinched Hose
Low on Oil
BACK SECTION
CYLINDER ASSEMBLY
TRENDELENBURG
CYLINDER ASSEMBLY
UP CIRCUIT
DOWN CIRCUIT
TO TRENDELENBURG
MINI-VALVE
PISTON
O-RING
PLUMBING
TERMINAL
TO BACK SECTION
CHECK MINI-VALVE
VALVE
SPEED
CONTROL
MINI-VALVE
INTERNAL OIL RETURN
TO RESERVOIR
INTERNAL OIL
FROM PUMP
Figure 3-5. Flex System Circuit
Page 18
3-8. LEG SECTION DIAGNOSIS CHART
Problem Reason
Leg function moves improperly Incorrect Speed Adjustment
Bad Check Valves
Low on Oil
Pinched Hose
Leg function chatters or loses position Defective or Dirty Check Valves

Air Inside Cylinder
Pinched Hose
Low on Oil
LEG SECTION
CYLINDER ASSEMBLY
NOTE: ONE SIDE

DOWN CIRCUIT
SHOWN FOR CLARITY
UP CIRCUIT
COPPER PLUMBING
LINES TERMINAL
CHECK
VALVE
SPEED
CONTROL
MINI-VALVE
INTERNAL OIL RETURN
TO RESERVOIR
INTERNAL OIL
FROM PUMP
Figure 3-6. Leg Section Circuit
Page 19
3-9. KIDNEY LIFT DIAGNOSIS CHART
Problem Reason
Kidney Lift moves improperly Incorrect Speed Adjustment
Bad Check Valve
Low on Oil
Pinched Hose
Kidney Lift chatters or loses position Defective or Dirty Check Valve

Air Inside Cylinder
Pinched Hose
Low on Oil
Lift Rods Binding
KIDNEY LIFT
CYLINER ASSEMBLY
UP CIRCUIT
DOWN
CIRCUIT
COPPER PLUMBING
LINES TERMINAL
CHECK
VALVE
SPEED
CONTROL
MINI-VALVE
INTERNAL OIL RETURN
TO RESERVOIR
INTERNAL OIL
FROM PUMP
Figure 3-7. Kidney Lift Circuit
Page 20
3-10. SLIDE DIAGNOSIS CHART
Problem Reason
Slide function moves improperly Incorrect Speed Adjustment
Bad Check Valves
Low on Oil
Pinched Hose
Slide function chatters or loses position Defective or Dirty Check Valve

Air Inside Cylinder
Pinched Hose
Low on Oil
SLIDE
CYLINDER ASSEMBLY
PISTON
PISTON
PLUMBING
TERMINAL
COPPER
LINES
CHECK
VALVE
SPEED
CONTROL
MINI-VALVE
INTERNAL OIL RETURN
TO RESERVOIR
INTERNAL OIL
FROM PUMP
Figure 3-8. Slide Circuit
Page 21
3-11. BRAKE CIRCUIT DIAGNOSIS CHART
Problem Reason
Brakes will not set properly Emergency Brake Release Valve Open or Defec-
tive
NOTE Bad Check Valve
If brakes have been released with the Low on Oil
Emergency Brake Release Valve, Pressure Relief Valve Not Set Properly
brakes will not reset until BRAKE UN- Pinched Hose
LOCK Circuit has been activated. Defective Mini-Valve
Brakes will not stay locked Emergency Brake Release Valve Open or Defec-
tive
Defective or Dirty Check Valve
Leaking "O" Ring Inside Cylinder
Brakes will not retract properly Incorrect Speed Adjustment

Bad Check Valve
Spool Valve Not Centered
Pinched Hose
BRAKE
CYLINDER
BRAKE
CYLINDER
PLUMBING
TERMINAL CHECK
VALVE
MINI-VALVE
BRAKE
CYLINDER
SPEED
CONTROL
RETURN TO
RESERVOIR
EMERGENCY
COPPER BRAKE RELEASE
LINE
BRAKE
CYLINDER RELEASE LEVER
Figure 3-9. Brake System Circuit
Page 22
3-12. Flexible Hose Identification and Place-
ment
The flexible hydraulic hoses used in the table are

number coded to aid in the correct placement of the
hoses from the plumbing terminal to their respec-
tive hydraulic cylinders. Figure 3-10 shows the
correct placement of the flexible hydraulic hoses
and their respective number codes.
Figure 3-10. Flexible Hoses
Page 23
3-13. Kidney Lift System LEFT
B CYLINDER A
The Kidney Lift cylinders are connected in series

so that both cylinders operate simultaneously.
Hydraulic pressure on one side of the lead piston BYPASS VALVE
causes the piston to move. The piston movement

D OPEN C
forces the hydraulic fluid on the other side of the
piston through the system to the other cylinder.
This simultaneously activates the other piston. A
RIGHT
bypass system is connected to the right cylinder CYLINDER
assembly for initial set-up and adjustment of the UP
kidney lift system. Use the following procedures to Figure 3-12.
bleed or adjust the system if needed. LEFT
B CYLINDER A
a. Bleeding the System - If the hydraulic lines or
cylinders have been disconnected from the kidney
lift system for any reason, use the following proce-
dure to bleed the air from the system. BYPASS VALVE
1. Remove the kidney lift top section and begin D OPEN C

the procedure with both pistons in the down posi-
tion (chambers A & C) as shown in figure 3-11.
RIGHT
CYLINDER
2. Make sure the bypass valve is closed (valve
UP
screw tight) and activate "KIDNEY DOWN". The
hydraulic fluid will fill cavity "D" as shown in figure Figure 3-13.
3-11.
LEFT 5. Repeat steps 3 and 4 as needed to remove
B CYLINDER A
any remaining air in the system.
6. With both pistons in the full down position,

activate "KIDNEY DOWN" to apply full system
BYPASS VALVE pressure and close the bypass valve (tighten the
screw).
D CLOSED C
b. Cylinder Adjustment - If either of the kidney lift

cylinders reaches the end of the down stroke
RIGHT
CYLINDER before the other one, an adjustment is needed. Use
DOWN
the following procedure to adjust the system.
Figure 3-11. 1. If the right side bottoms out before the left
side, open the bypass valve and activate "KIDNEY
3. Open the bypass valve by loosening the DOWN" to align the cylinders.
screw in the bottom of the valve and activate
"KIDNEY UP". Hydraulic fluid fills cavity "A" and 2. If the left side bottoms out before the right
pushes the piston into cavity "B". The open valve side, activate "KIDNEY UP" to raise the cylinders.
allows a path for air to escape from cavity "B" When the cylinders are at the full up position, open
without affecting the piston in "C". See figure 3-12. the valve and activate "KIDNEY UP" to align the
cylinders. Close the valve before lowering the
4. Leave the bypass valve open and activate cylinders.
"KIDNEY DOWN". Hydraulic pressure keeps the
piston in chamber "C", the hydraulic fluid passes 3. When the adjustment is complete, make
through the bypass valve and fills cavity "B" push- sure the cylinders are completely down, activate
ing the piston into cavity "A". See figure 3-13. "KIDNEY DOWN" and tighten the valve.
Page 24
Page 25
SECTION IV ELECTRICAL SYSTEM
4-1. General 4-2. Components
The complete electrical system (with the excep- Refer to figure 4-1 for the relationship of the elec-
tion of the hand-held pendant control and the return trical components.
circuit micro-switches) is contained within the base
of the table. The pump motor and the hydraulic a. Wires, Connectors, Switches, Fuse - These
valves are controlled electrically with the pendant provide the path for the various electrical circuits.
control.
b. Relay Box - Contains the step down trans-
The electrically operated functions are as follows: former, full wave rectifier, and relay switches. The
relay switches are activated by the pendant control
- TRENDELENBURG - Head up and down and in turn energize the solenoid.
- LATERAL TILT - Right and left c. Hand-Held Pendant Control - Closes micro-
switches to activate relay box. Operates on 5
- BACK SECTION - Up and Down VDC.
- ELEVATION - Up and Down d. Solenoids - These electrically open and

close the hydraulic ports of the mini-valve to direct
-TOP SLIDE the fluid to the correct cylinders. They operate on
120 VAC.
- LEG SECTION - Up and Down
e. Motor/Pump Assembly - 120 VAC, 60 HZ,
- FLEX / REFLEX 200 Watt capacitor induction motor.
- KIDNEY LIFT - Up and down 4-3. Battery Model Components
- RETURN TO LEVEL The functions of the battery model tables are the
same as the standard 120 VAC models. The
- BRAKE UNLOCK - Brake release electrical components and operation however, vary
greatly between the two models. To simplify the
The power requirements are 120 VAC, 60 Hz, fuse troubleshooting procedures, the battery model
protected. The main power on-off switch is an tables are covered separately in Section VI.
enclosed DPST type and the power cord is a three-
wire, fifteen foot long, UL listed cord with a three-
prong hospital grade plug.
Page 26
3500
Figure 4-1. 3500 Electrical Circuit Block Diagram
Page 27
3500
SECTION V ELECTRICAL SYSTEM TROUBLESHOOTING
5-1. Troubleshooting Notes
The basic operation of each component will be 2. Disconnect connector CN4 from the relay
defined along with a drawing and explanation on box. See figure 5-1. Leave all other connectors
how to check it out. connected.
Certain defective components could cause the

entire table to stop functioning or only one control
function to stop. It would depend on what part of the
component failed. Other defective components
would only cause one control function to stop.
The following defective components could cause

CN4
all control functions to be affected:
RELAY BOX
a. Motor/Pump Assembly (starting capacitor)
b. Main Switch Circuit and Wiring
The following defective components could cause

Figure 5-1. Main Power Test
all control functions to be affected or only one
control function:
CAUTION
a. Relay Box
Line voltage (120 VAC) will be mea-
b. Pendant Control
sured in this test. Do not touch uninsu-
The component listed below would only affect one lated connector pins or meter test leads.
control function:
3. Use an AC voltmeter capable of measuring
Solenoid 120 VAC and measure the voltage between pins
1 and 2 (black and white wires) located in connec-
When troubleshooting an electrical circuit, start at tor CN4. See figure 5-2. You should receive line
the problem and work back to the power source. voltage 120 VAC.
5-2. Main Switch
The main power supply, 120 VAC, 60 HZ, comes in ACV

through the power cord and through the main
switch. The main switch opens both lines when in
the "OFF" position. Two 10 amp fuses are used to
protect the complete electrical system and are
5
located next to the main switch.
3
4 2
a. Main Switch Test 1
The following test will determine if line voltage is PIN NO. COLOR
applied to connector CN4, which in turn would 1 White

2 Black
power the table. 3 Red
4 Blue
5 Yellow
1. Plug the power cord into the 120VAC power
supply (wall receptacle) and turn ON the main
switch. Figure 5-2. Connector CN4
Page 28
3500
b. Test Results a. Pendant Control Test
If you do not receive the correct voltage measure- The following test will determine if the micro-switches
ment, the problem would have to be in the wires, inside the Pendant Control are function-ing cor-
main switch, fuses, or power cord. If the correct rectly.
voltage is obtained, everything is good up to this
point and the problem would have to be in another 1. Unplug the pendant control from the base of
area. the table. You will be checking the cord side
connector.
5-3. Pendant Control
2. Use an ohmmeter R x 1 scale and check the
The Pendant Control consists of 18 micro-switches continuity between pin 1 and pins 4 through 24.
(buttons). When any of the circuits are completed See figure 5-3.
(by depressing a control button) the appropriate
3. Ohmmeter must show continuity between
relay contacts (located in the relay box) close
the pins that are indicated when the appropriate
applying 120V potential to the appropriate solenoid
buttons are pressed.
to operate the mini-valve and the pump/motor. The
Pendant Control has only 5-6 volts applied to it.
Figure 5-3. Pendant Control Test
Page 29
3500
NOTE d. Test Results:
Pins 2 and 3 are connected to the green
LED (power ON light on the pendant If you do not receive the correct voltage reading,
control) and pin 20 is connected to the the wiring or connector pins may be faulty. Discon-
amber LED (slide center light on the nect connector CN8 from the relay box and using
pendant control) these pins cannot be an ohmmeter, test the continuity between the cor-
checked with an ohmmeter. responding pins in connectors CN8 and the table
base connector. See figure 5-5. If the correct
b. Test Results: readings are obtained, this part of the circuit is
okay.
If you do not receive continuity between any of the
pins, either the micro-switch in the Pendant Control BASE BASE
is defective or a wire is broken. Either of these CONNECTOR CONN. COLOR CN8
problems can be repaired easily. OHM
1 Red/White A1
2 White B1
3 Black A2
If you receive correct readings with the meter, the 4 Red B2
Pendant Control is okay. 5 White/Red A3
6 Yellow B3
CN8 7 Brown A4
8 White/Brown B4
c. Wiring Harness Test 9 Blue/Whte A5
10 Orange B5
A1 11 White/Orange A6
The following test checks the wires leading from 12 Gray B6
13 White/Gray A7
the relay box connector CN8 to the 24 pin connec- A13 14 White/Yellow B7
tor table socket. These wires apply low voltage to B1 15 Purple/White A8
16 Black/White B8
the pendant control buttons. 17 Purple A9
18 White/Purple B9
19 Blue/Yellow A10
1. The power cord should be plugged into the 20
21
Blue/Red B10
A11
B13 CN8
wall socket and the main switch turned ON. 22 B11
23 Blue A12
24 White/Blue B12
2. Disconnect the pendant control from the A13
B13
base connector. All other connectors should be
connected.
3. Use a DC voltmeter 10V scale and measure

Figure 5-5. Base Connector Continuity Test
the following pins located in the 24 pin table base
connector. See figure 5-4.
5-4. Relay Box
NOTE
The 120 volt power supply is directly connected to
Pin 19 in table base connector will have
the relay contacts. When these contacts are
no voltage potential unless 1 of the
closed, 120 volts is supplied to the solenoids which
return-to-level micro-switches are acti-
are mounted on the hydraulic mini-valves. One
vated, i.e. trendelenburg, tilt, etc.
relay is used to supply 120V to the pump/motor and
is always activated no matter what control function
is selected. The brake locking circuit relay is also
activated when any control function other than
BRAKE UNLOCK is initially selected.
Also, inside the relay box is a step-down trans-
former and full-wave rectifier which decreases the
line voltage to 5.5 volts. This low voltage potential
controls the relays by the use of the hand-held
+ TEST - TEST DC
LEAD LEAD VOLTS
pendant control buttons. Basically the relays en-
able a 5.5 volt potential to control the 120 volt circuit.
1 2, 3, 21, 22 0
1 4 - 20, 23, 24 5-6 The following tests will determine if the relay box is
functioning correctly.
Figure 5-4. Table Base Connector
Page 30
3500
a. Relay Box Input Connector CN4 d. Test Results:
1. Plug the power cord into the 120 VAC power If you do not receive the correct meter readings, the
supply (wall receptacle) and turn the main switch relay box or wiring is defective. If the correct
ON. Leave all connectors connected. readings are obtained, this part of the relay box is
okay. Proceed to the next step.
CAUTION
Line voltage (120 VAC) will be mea- e. Relay Box Output Connectors CN6, CN7A
sured in this test. Do not touch uninsu- & CN7B
lated connector pins or meter test leads.
This test checks the high voltage (120V) that is
2. Use an AC voltmeter capable of measuring used to energize the solenoids.
120 volts and measure the voltage between pins 1
(white) and 2 (black) of connector CN4 for input CAUTION
voltage. See figure 5-6. Meter should read line 120 VAC will be measured in this test.
voltage 120 VAC. Do not touch uninsulated connector
pins or meter test leads.
3. Activate any table function with the Pendant
Control and using an AC voltmeter, test the voltage 1. The power cord should be plugged into the
at pins 3 and 4 of CN4 for output to the pump. Meter wall receptacle and main switch turned ON.
should read 120 VAC.
2. Disconnect the motor connector CN15. All
other connectors should be connected. Test con-
4
1 ACV nectors CN6, CN7A and CN7B from the back while
2 attached to the relay box.
PIN NO. COLOR
3
1
2
White
Black 5 3. Activate each of the Pendant Control buttons
3 Red and using an AC voltmeter capable of measuring
4 Blue
5 Yellow 120VAC, measure the voltage between the appro-
priate connector pins located in connector CN6,
CN7A or CN7B. See figure 5-7. Polarity of meter
Figure 5-6. Connector CN4
test leads is not important. Meter should read
120VAC.
b. Test Results:
If you do not receive the correct meter readings, the ACV

relay box or wiring is defective. If the correct
readings are obtained, this part of the relay box is 1
okay. Proceed to the next step.
CN6, CN7A OR CN7B
c. Relay Box Output Connector CN8 16
CN6 CN7A
This test checks the low voltage applied to the pen-
FUNCTION PINS FUNCTION PINS
dant control buttons.
Table Up 1-2 Leg Up 1-2
Table Down 3-4 Leg Down 3-4
1. The power cord should be plugged into the Rev Trend 5-6 Kidney Up 5-6
Trend 7-8 Kidney Down 7-8
wall receptacle and main switch turned ON. Back Up 9 - 10 Brake Set 9 - 10
Back Down 11 - 12 Brake Unlock 11 - 12
Tilt Right 13 - 14 Flex 13 - 14
2. Disconnect Pendant Control connector. All Tilt Left 15 - 16 Reflex 15 - 16
other connectors should be connected. CN7B
Slide Head 1-2

3. Using a DC voltmeter, measure the voltage Slide Foot 3-4
between pin 1(+) and pins 4 through 24 (-) of the
table base connector. See figure 5-4. Meter should Figure 5-7. Relay Box Output Connectors
read 5-6 volts. CN6 and CN7
Page 31
3500
f. Test Results: b. Step #1
If you do not receive the correct meter readings, the 1. Plug the table cord into the wall receptacle
relay box or wiring is defective and should be and turn main switch ON.
replaced.
NOTE 2. Disconnect the 2 pin connector from the
solenoid in question. See figure 5-8.
Before deciding the relay box is de-
fective, check the wires and pins in the 3. Use a voltmeter capable of measuring 120
connector blocks to make sure they are VAC and measure the voltage across the 2 pin
not loose or making a bad connection connector. Polarity of meter leads is not important.
with their mate.
NOTE
5-5. Solenoids
The appropriate pendant control but-
The solenoids are energized by 120 volt potential ton must be pushed during this test.
that is controlled by the relays located inside the The motor will run when this test is
relay box. performed, and the brake locking sole-
noid will be activated by any function
The solenoid windings are protected from exces- other than UNLOCK if brakes are not
sive heat with an internal thermal fuse that will open set.
after approximately seven (7) minutes of continu-
ous operation. The solenoid must be replaced if the c. Test Results:
internal thermal fuse has been blown. The sole-
noids are mounted directly on either side of the If you do not receive the correct voltage, the prob-
hydraulic mini-valves and push the spool valve in lem could be in the wires leading to connectors
one direction or the other depending upon which CN6, CN7A and CN7B. The problem could also be
solenoid is activated. in the relay box or the Pendant Control (refer to
appropriate section for troubleshooting).
a. Solenoid Test
If the correct voltage is obtained, everything is good
The following tests check the voltage applied to the up to that point and the problem is more than likely
solenoids and the resistance of the solenoid coil. the solenoid.
NOTE d. Step #2
If a solenoid does not function when the The solenoid can be checked out using an ohm-
pendant control button is pushed, the meter R x 1 scale.
problem could be the pendant control,
the relay box, or the solenoid. 1. Measure the resistance between the two
pins of the connector in question. See figure 5-8.
NOTE Connector being tested must be disconnected.
Polarity of meter leads is not important.
Each solenoid is controlled with 120V
source coming from the relay box. This 2. The meter should read approximately 80-90
source can easily be checked by mea- ohms at room temperature (58 ohms for tables S.N.
suring the voltage at the 2 pin connector 1997-4&L).
in question.
3. Measure the resistance between either pin
CAUTION and solenoid housing.
Line voltage will be measured in this 4. Meter should read infinity.

test. Do not touch uninsulated connec-
tor pins or meter test leads.
Page 32
3500
e. Test Results: 5-6. Motor/Pump Assembly
If the solenoid does not check out with the meter, The electric motor is a capacitor start type with a
it is more than likely defective and must be re- rating of 120 VAC, 200 watts. The field windings
placed. are protected with a thermal protector that will open
the winding circuit if the motor is run continuously
NOTE for approximately 10 minutes. This protector will
take about 10 minutes to automatically reset. The
Whenever there are several compo- oil pump unit is attached to the bottom of the motor
nents of the same type, a defective unit and is a gear type displacement pump with a
can also be detected by substituting a pumping capacity of .4 liter per min. The Motor/
known good unit or wire connector. In Pump Assembly is mounted on an insulated motor
some cases this may be faster than plate in the base of the table. The starting capacitor
using a multi-meter. is mounted along side the motor/pump assembly.
Figure 5-8. Solenoid Test

Page 33
3500
a. Motor/Pump Test c. Test Results:
The following tests will check the voltage applied to If you do not receive the correct meter readings, the
the motor and the resistance of the motor field problem could be in the wires, connectors, relay
windings. box, or main switch (refer to appropriate section for
troubleshooting).
CAUTION
If the correct voltage is obtained, everything is good
Line voltage will be measured in this up to that point and the problem could be either the
test. Do not touch uninsulated connec- motor or the starting capacitor.
tor pins or meter test leads.
d. Step #2
b. Step #1
If the starting capacitor is shorted or grounded, the
1. Plug the power cord into 120 VAC power motor will not run. Capacitors very seldom fail, and
supply (wall receptacle). Turn main switch ON. it requires a dielectric tester to accurately test one.
However, an ohmmeter can be used to determine
2. Disconnect the 3 pin connector CN15 at the if the capacitor will store a low voltage charge and
motor. Leave all other connectors connected. See most of the time this is adequate.
figure 5-9.
1. Turn the main switch OFF.
PUMP/MOTOR 2. Connector CN15 should be disconnected.

ASSEMBLY
3. Use the R x 100 scale of the ohmmeter and

CN15 touch pins 2 and 3 of connector CN15. See figure
5-10.
CAPACITOR
e. Test Results:
Figure 5-9. The meter needle should move up scale and then
back down to infinity. This would indicate that the
3. Use a voltmeter capable of measuring 120 capacitor is storing an electrical charge.
VAC and measure the following connector pins in
connector CN15. See figure 5-10.
NOTE
The capacitor may have to be dis-

ACV charged first (by shorting pins 2 and 3
together) before you will be able to see
3 the ohmmeter needle swing up the scale.
f. Step #3
2
1
The motor windings can be statically checked for
PIN NO AC VOLTS resistance using an ohmmeter.
1-2 120
1-3 120
2-3 0 1. Turn main power switch OFF.
2. Connector CN15 should be disconnected.

Page 34
3500
3. Use the R x 1 scale of the ohmmeter and The kidney lift has a back section-up inhibit switch
measure the resistance between the pins located to prevent the table back section from damaging
in the pump connector CN15. See figure 5-11. the kidney lift when the lift is raised. The back
section still has the capability to be lowered and
raised, but will not raise more than 45° above
horizontal until the kidney lift is completely down. If
OHM the back section is raised more than 45° above
horizontal, the system will not allow the kidney lift to
be raised.
The slide function has inhibit switches to prevent

PIN NO METER damage to the back and leg sections. If the back
1-2 Approx. 5 ohms section is below horizontal the top will not slide
1-3 Approx. 4 ohms
2-3 Approx. 8 ohms toward the foot end. If the leg section is lowered
more than 45° below horizontal the top will not slide
Figure 5-11. Pump Connector CN15 toward the head end. Likewise, if the top is slid
toward the foot end, the back section will not go
g. Test Results: below horizontal. If the top is slid toward the head
end, the leg section will not go more than 45° below
If you do not receive the correct meter readings, the horizontal.
motor or wiring is defective.
The return-to-level/inhibit system consists of 12
micro-switches, an electrical connector, 2 terminal
5-7. Return-to-Level Micro-Switches. strips and the related wiring. The micro-switches
are mounted on or adjacent to the function they
The return-to-level feature is activated by a single control and are wired for normally open or normally
button on the pendant control and automatically closed operation. The micro-switches are cam or
levels the major table functions, lateral tilt, tren- lever actuated and can be adjusted at the individual
delenburg, flex, back section, and leg section. switch mounting brackets. See figure 5-12.
CS-3 NS-7 CS-2 CS-1
NS-6
CS-5
NS-1
NS-4
NS-3
NS-2
NS-5
CS-4 NS-1 TREND
NS-2 REV. TREND
NS-3 TILT LEFT
NS-4 TILT RIGHT
RELAY BOX NS-5 BACK - DOWN TO LEVEL / SLIDE INHIBIT
NS-6 BACK - UP TO LEVEL
NS-7 LEG - DOWN TO LEVEL
CN2
CS-1 SLIDE/LEG DOWN INHIBIT
CS-2 SLIDE/BACK DOWN INHIBIT
CS-3 KIDNEY/BACK 45˚ UP INHIBIT
CS-4 LEG DOWN 45˚/SLIDE INHIBIT
CS-5 BACK UP 45˚/KIDNEY UP INHIBIT
Figure 5-12. Page 35

3500
The micro-switches operate on low voltage, and cover on the top of the elevation column. Connector
control the function circuits (pump/motor and ap- CN2 plugs into the relay box and is the most
propriate solenoid valves) when activated by the convenient location to make circuit continuity
pendant control RETURN button. checks. See fig. 5-13 for connector pin locations.
The micro-switches are wired to the relay box a. Switch Test

through 2 terminal strips, a riser cord and the 15 pin
connector CN2. See figure 5-12 for switch location Turn Main Power ON, lock the table brakes, and
and identification. place the table top sections in a level position with
the Kidney Lift down. Disconnect connector CN2
5-8. Return/Inhibit System Troubleshooting from the relay box and using an ohmmeter, test the
wiring and switch operation at the appropriate pin
If a problem is suspected in the return circuits, numbers for the micro-switch in question as shown
disconnect the connector CN2 from the Relay Box in figures 5-14 through 5-21.
to eliminate the circuits. Ensure that all table
functions operate properly using the Pendant Con- NOTE
trol. If the functions do not work properly using the
Pendant Control, refer to the appropriate test sec- Be sure to isolate the circuit when mak-
tion and make all needed repairs before working on ing continuity checks.
the return circuits.
NOTE
NOTE
It is normal for the back section to move If you do not receive the proper continu-
up if the RETURN button is pushed ity results at connector CN2 it does not
when connector CN2 is disconnected necessarily mean the micro-switch is
from the relay box. defective. There could be a problem
with the riser cord between connector
All of the micro-switches are connected to the relay CN2 and terminal strips 1 and 2, or in
box via a wiring harness and the micro-switch riser the wiring from the switch to the terminal
cord from terminal strips 1 and 2 to connector CN2. strips. Further tests will have to be
The terminal strips are located under the hose made to determine the exact problem.
Figure 5-13. Return / Inhibit Micro-Switch Test

Page 36
3500
1 WHITE NC
NS-1
5 LIGHT BLUE NO
COM
1
14
2
COM
CN-2 NO
2 BLUE NS-2
NC
TS-1
NS-1. Trendelenburg NS-2. Reverse Trendelenburg

Test at pins 1 & 14 Test at pins 2 & 14
Table Switch Meter Table Switch Meter

Position Position Reading Position Position Reading
Level Open Infinity Level Open Infinity

Head Up Open Infinity Head Up Closed 0
Head Dn Closed 0 Head Dn Open Infinity
When table is in Trendelenburg Position, When table is in Reverse Trendelenburg

NS-1 brings the top back to level. Position, NS-2 brings the top back to
level.
Figure 5-14. Trendelenburg Return Switches
NS-3. Lateral Tilt-Left NS-4. Lateral Tilt-Right



Tilt Right Open Infinity Tilt Right Closed 0
Tilt Left Closed 0 Tilt Left Open Infinity
When table is inTilt-Left Position, NS-3 When table is in Tilt-Right Position, NS-4
brings the top back to level. brings the top back to level.
Figure 5-15. Lateral Tilt Return Switches

Page 37
3500
NS-6
6 7 RED/WHITE NO COM
PINK
13 8
TS-1
13 8
PINK
RED
5
6
NO COM
CN-2 TS-1
NS-5
NOTE
When CN-2 is disconnected, BACK-
DOWN function will not operate.
NS-5. Back Section Down NS-6. Back Section Up


Level Closed 0 Level Open Infinity

Back Dn Open Infinity Back Dn Open Infinity
Back Up Closed 0 Back Up Closed 0
When the Back Section is Down, NS-5 When the Back Section is Up, NS-6
brings the Back Section Up to level and brings the Back Section Down to level.
will not allow Top Slide toward foot.
Figure 5-16. Back Section Return Switches
NS-7
1 BROWN
7
NC
COM
8 NO
13 PINK
CN-2
TS-2
NS-7. Leg Section Down

Test at pins 7 & 13
Table Switch Meter

Position Position Reading
Level Open Infinity

Leg Dn Closed 0
When the Leg Section is Down, NS-7

brings the Leg Section Up to level.
Figure 5-17. Leg Section Return Switch

Page 38
3500
NOTES
SLIDE function will not operate when
CN-2 is disconnected.
3 BLACK
9
4 BLACK/WHITE
10
13 7 PINK
CN-2 TS-2 NC NC
COM COM
CS-2 CS-1
CS-1. Leg Down 45˚ Inhibit CS-2. Back Down Inhibit


Center Closed 0 Center Open Infinity

Slide Hd Closed 0 Slide Hd Closed 0
Slide Ft Open Infinity Slide Ft Open Infinity
When Top is slid toward head, CS-1 will When Top is slid toward foot, CS-2 will
not allow Leg Section to go more than not allow Back Section to go below
45˚ below horizontal. horizontal.
Figure 5-18. Leg Down / Back Down Inhibit Switches
CS-3. Back Up Inhibit Switch

Test at pins 11 & 13
Table Switch Meter

K-Lift Dn Open Infinity

K-Lift Up Closed 0
When K-Lift is Up, CS-3 will not allow

Back Section to go more than 45° above
horizontal.
Figure 5-19. Back Up Inhibit Switch

Page 39
3500
CS-4. Slide Inhibit

Test at pins 8 & 13
Table Switch Meter

Level Open Infinity

Leg Dn Closed 0
more than 45°
When Leg Section is more than 45°

below horizontal, CS-4 will not allow Top
to Slide toward head.
Figure 5-20. Slide to Head Inhibit Switch
CS-5. Slide Inhibit

Table Switch Meter

Back Up Less Than 45° Open Infinity

Back Up More Than 45° Closed 0
When Back Section is more than 45° above hori-

zontal, CS-5 will not allow Kidney Lift to operate.
Figure 5-21. Kidney Lift Inhibit Switch

Page 40
3500
b. Switch Adjustment. 3. To adjust the Leg Section switches remove
seat section top, loosen the two Phillips head
If proper readings are not obtained during test or if screws securing the bracket, adjust the switch,
table does not properly return to level, use the tighten screws and replace seat section top. See
following procedure to adjust the switches. figure 5-23.
1. Apply table brakes and (using a level) level

the table top using the TRENDELENBURG and PHILLIPS HEAD
SCREWS
LATERAL-TILT function buttons on the pendant
control.
LEG SECTION BRACKETS
2. For all switches except the Leg Section MICRO-SWITCH
switches, carefully loosen the switch retaining

screws, and adjust the switches as needed. See
figure 5-22.
RETAINING Figure 5-23. Leg Section Micro-Switch

SCREWS
Adjustment.
MICRO-SWITCH
Figure 5-22. Micro-Switch Adjustment
Page 41
3500B
SECTION VI -3500B- BATTERY MODEL, ELECTRICAL TROUBLESHOOTING
6-1. General 6-3. Main Switch
The battery table components operate on 24VDC. The main power supply, 120 VAC, 60 HZ, comes
The internal charging system also incorporates the in through the power cord and through the main
components to transform the 120VAC input to switch. The main switch opens both lines when
24VDC output to the components. in the "OFF" position. Two 10 amp fuses are used
to protect the complete electrical system and are
6-2. Troubleshooting Notes located next to the main switch.
The basic operation of each component will be a. Main Switch Test

defined along with a drawing and explanation on
how to check it out. The following test will determine if line voltage is
applied to connector CN12, which in turn would
Certain defective components could cause the supply 120VAC power to the table.
entire table to stop functioning or only one control
function to stop. It would depend on what part of the 1. Plug the power cord into the 120VAC supply
component failed. Other defective components (wall receptacle) and turn the main switch ON.
would only cause one control function to stop.
2. Disconnect connector CN12. See figure
The following defective components could cause 6-2. Leave all other connectors connected.
all control functions to be affected:
a. Motor/Pump Assembly CAUTION
b. Main Switch Circuit and Wiring
Line voltage (120 VAC) will be mea-
The following defective components could cause sured in this test. Do not touch uninsu-
all control functions to be affected or only one lated connector pins or meter test leads.
control function:
a. Relay Box 3. Use an AC voltmeter capable of measuring
b. Pendant Control 120 VAC and measure the voltage between pins 1
and 2 (black and white wires) located in connector
The component listed below would only affect one CN12. See figure 6-1. You should receive line
control function: voltage 120 VAC.
Solenoid
When troubleshooting an electrical circuit, start at BLACK

(2)
the problem and work back to the power source.
NOTE
On the battery model tables, troubleshoot- ACV WHITE
(1)
ing should begin by switching the operating
mode. For example; if a function fails when
attemptingtooperatethetableintheAC120V
mode, switch to the BATTERY mode. If the Figure 6-1. Connector CN12 Test
function now operates, the problem is prob-
ably located between the power cord and
the relay box. If the function also fails when b. Test Results
in battery operation, use the auxiliary
switches to operate the function. If the If the correct voltage is obtained, everything is
function now operates, the problem is prob- good up to this point and the problem would have
ably in the pendant control, connectors or to be in another area.
wiring from the pendant control to the relay If you do not receive the correct measurements,
box. All connector pins are numbered the problem would have to be in the wires, main
usually with very small numbers. switch, fuses, or power cord.
Page 42
3500B
SOLENOID
COIL 24VDC
PENDANT
CONTROL
MINI-VALVES
AUXILIARY
CONNECTOR
CN14
CN13
CN3
CN7
CN1 TS1
CN8 TO
RELAY BOX RETURN
CIRCUIT
AUXILIARY TS2
SWITCHES CN2A
CN10
CN2B
BATTERIES
CHARGER BOX
CN4
CAPACITOR
PUMP
SWITCH-OVER
RELAY
CN16 CN15
22 VAC FROM
TRANSFORMER
120 VAC TO
TRANSFORMER
CN51
FUSE
CHARGER 15AMP
BOX CN12
CN14 CN13
POWER
CORD MAIN
POWER
SWITCH
ICN1
FUSE
10AMP
BATTERY CHARGE
INDICATOR
Figure 6-2. Electrical Circuit Block Diagram, Model 3500B

Page 43
3500B
Check the continuity from the power cord connec- 4. Continue to press the TABLE UP button on
tor ICN1, through the fuses, switch and wiring to the pendant control so that the pump motor contin-
connector CN12. Remove the power cord, discon- ues to run and using a DC voltmeter, check the
nect CN12 (black and white wires), and test as voltage drop of each battery individually. See figure
shown in figure 6-3. 6-4.
5. Meter should read 12VDC ± 1VDC.

BLACK
TO GROUND
ICN1 CN12
WHITE
2
1 BATT 1 BATT 1
N
L OHM
DCV
Figure 6-3. CN12 to ICN1 Continuity Test
Figure 6-4.
6-4. Batteries b. Test Results
The BATTERY operating mode is powered by two A reading of 11 volts or below indicates the battery
12 volt batteries connected in series to provide the needs charging.
24 volt operating power.
After batteries have been fully charged, repeat the
The battery system voltage should be 24VDC at a full load test. If either battery's voltage drops below
range of 22VDC to 26VDC. If the battery charge 11VDC it should be replaced.
level falls below 23.5 volts the BATTERY operation
indicator on the pendant control will blink indicating 6-5. Battery Charging Box/AC120V
that the batteries require recharging. The built-in Transformer
charging system automatically keeps the batteries
at the proper charge level when the AC120V oper- The Battery Charging Box contains the battery
ating mode is ON. The charging system will charging system as well as the components for
operate while the table is being operated in the AC120V operation (except the transformer).
AC120V mode.
a. Battery System Test a. Transformer Test
1. Disconnect the main power cord and using 1. Confirm 120VAC input at CN12 using Main
a DC voltmeter, test each individual battery at its Switch test in 6-3a.
terminals. Meter should read 12VDC ± 1V.
2. Connect CN12, disconnect CN13 (brown
2. To accurately test the batteries, they must and red wires) and using an AC voltmeter, test the
be tested under a full load. Disconnect the main transformer output at CN13. See figure 6-5.
power cord and make sure all other connectors are
connected. 3. Meter should read 22VAC.
3. Turn BATTERY power ON and elevate the

table to its full up position.
Page 44
3500B
BROWN
(2) d. Test Results
If you do not receive the correct readings, the

ACV RED charger system, connectors, wires, or the trans-
(1) former may be defective.
Figure 6-5. Connector CN13 Test e. Charging System Output Adjustment
If output reading at pins 3 and 4 is not 26.5 ± 1VDC,

b. Test Results the output can be adjusted at the variable resistor
VR-51 on the circuit board inside the Charging Box.
If the correct voltage is obtained, everything is See figure 6-7. Turn the adjuster clockwise to
good up to this point and the problem would have decrease the voltage. Counterclockwise to in-
to be in another area. crease the voltage.
If you do not receive the correct measurements,
the problem may be in the wires, connectors, or
transformer. The transformer is located in the rear NOTE
of the base under the stainless steel base cover. The battery connectors must be dis-
The stainless steel cover will have to be discon- connected to adjust the battery charger
nected and lifted from the base for access to the output.
transformer for further testing.
c. Battery Charging Box Test
1. Make sure all connectors are connected and

turn AC120V operation ON. Using a DC voltmeter,
test pin 3(+) and pin 4(-) of CN51. DO NOT
disconnect connector CN51. See figure 6-6.
VR51
CN51
RED
(3)
5 3
(5) RED / WHITE 1 Figure 6-7
(6) BLUE / WHITE
BLACK
(4) DCV
(2) BROWN (1) BROWN
2. Meter should read 26.5 ±1VDC.
3. Test pin 5(+) and pin 6(-) of CN51 with DC

voltmeter to test operation of CHARGING indicator
light (next to power cord connector).
4. Meter should read 26.5 ±1VDC if charger is

operating. If batteries are fully charged there will be
under 5 volts at pins 5 and 6.
Page 45
3500B
6-6. Switch-Over Relay NOTE
The battery charging circuit is only
a. Switch-Over Relay in OFF Position operational when the table is in the
AC120V operating mode.
The Switch-Over Relay supplies the 24 volt
input power from either the BATTERY or c. Switch-Over Relay Test
AC120V operating modes to the relay box for
table operation. In the normal OFF position, Using a DC voltmeter, test the operation of the
BATTERY power is supplied to the relay box. relay in both the OFF (AC120V - OFF) and
See figure 6-8. Activated (AC120V - ON) positions. See figure
6-10.
RELAY BOX (-) NOTE
CN4 The Switch-Over Relay mounting
S-O RELAY block may have to be removed from
FUSE the base for test access.
15A 2 7
OFF: (AC120V - OFF)
1 8 term. 7(-) and term. 1(+) = 24 to 28VDC
3 6 term. 7(-) and term. 6(+) = 0VDC
4 5
Activated: (AC120V - ON)
term. 7(-) and term. 6(+) = 26.5±1VDC
BATTERY (+)
Figure 6-8. Relay in OFF Position
b. Switch-Over Relay in Activated Position
2 7 DCV
When the AC120V mode is activated by the main
switch, a signal from the relay box activates the 1 8
Switch-Over Relay. The relay then supplies the
AC operating mode output power to the relay box
and also activates the battery charging circuit. See
figure 6-9.
3 6
RELAY BOX RELAY BOX (-)
SIGNAL OUT 4 5
CN4
S-O RELAY Figure 6-10. Switch-Over Relay
FUSE
15A 2 7
1 8
3 6
4 5
CAPACITOR
BATTERY (+)
CN14 CN51
CHARGING
BOX
Figure 6-9. Relay in Activated Position

Page 46
3500B
6-7. Pendant Control b. Test Results
The Pendant Control is part of the solid state, multi-
plex, logic control system. The pendant control If you do not receive the correct readings, the
contains illuminated, circuit board mounted switches wiring or connector pins may be faulty.
and a micro processor. The encoded output from the
pendant control is serial bit stream logic. c. Base Connector Test
The output signal is transmitted to the micro proces- If correct readings are received, test the wiring from
sors in the relay box where the logic is decoded and
the appropriate relays for the selected function are the base connector to connector CN7 at the Relay
activated. Box. Disconnect connector CN7 from the Relay
Box and using an ohmmeter, test the continuity
Pendant Control troubleshooting should begin by between the corresponding pins in connectors
switching the operating mode of the table. For CN7 and the base connector. See figure 6-12.
example; if a function fails when attempting to operate
the table in the AC120V mode, switch to the BAT-
TERY mode. If the function now operates, the
problem is not the pendant control and probably is a
problem located between the power cord and the
relay box. If the function also fails when in battery OHM
operation, use the auxiliary switches to operate the
function. If the function now operates, the problem is 1
probably in the pendant control, connectors or wiring 1 2 2
3
from the pendant control to the relay box. 3 4 5 4
5
6 7 6
a. Pendant Control Test 7
BASE CN7
There are no servicable components within the Pen- CONNECTOR
dant Control. The cord is detachable and can be
tested for continuity between the pins on the connec-
tors. Use the following procedure to test the pendant
control cord. Figure 6-12. Base Connector Continuity Test
Disconnect the cord from the base connector and If the correct readings are obtained, this part of
from the pendant control connector and using an the circuit is okay and the problem may be
ohmmeter, test the continuity between the corre- Pendant Control or the Relay Box. Contact
sponding pins in the connectors. See figure 6-11. SKYTRON if all tests performed indicate that the
problem is located in the Pendant Control.
OHM
RED 1 2 BROWN H
A G
4 ORANGE
B F
BLUE 3 5 BLACK
C
WHITE 6 E
7 GREEN D
Test Leads
Base Conn. Pend. Conn. Base Conn. Pend. Conn.
Pin Pin Pin Pin
1 A 5 E
2 B 6 F
3 C 7 G
4 D
Figure 6-11. Pendant Control Cord Test Page 47

3500B
6-8. Auxiliary Switches
The following tests will determine if the auxiliary

OHM
switches are functioning properly.
a. Switch Test Figure 6-14. Auxiliary Switch Test

Disconnect connector CN3 at the Relay Box and 6-9. Relay Box
using an ohmmeter check for continuity at the
connector pins (pin 1A common) while activating The power supply is directly connected to the relay
the appropriate switch. See figure 6-13. Meter contacts. When these contacts are closed, 24
should read 0 ohms. volts is supplied to the solenoids which are mounted
on the hydraulic mini-valves. One relay is used to
b. Test Results supply power to the pump/motor and is always
activated no matter what control function is se-
If proper meter readings are not received, test the lected. The brake locking circuit relay is also
individual switches as necessary. Using an ohm- activated when any control function other than
meter, test the operation of an individual switch with BRAKE UNLOCK is initially selected.
the (+) test lead at the center terminal of the switch
and the (-) test lead at the terminal opposite the Also, inside the 3500B relay box is a step-down
direction of the switch actuation. See figure 6-14. transformer and full-wave rectifier which decreases
Meter should read 0 ohms. If the switches check the voltage to 5-6 volts. This low voltage potential
out, the problem would have to be in the wires or controls the relays by the use of the hand-held
connector CN3. pendant control buttons. Basically the relays en-
able a 5-6 volt potential to control the 24 volt circuit.
The following tests will determine if the relay box is

functioning correctly.
B8/B2 B8/A3 B8/A4 B8/A1 B8/A7 B8/B6
CN3
SW1
TABLE UP
1
TABLE DOWN B8/A2 B8/B3 B8/B4 B8/B1 B8/B7 B8/A6
2
HEAD DOWN SW2
3
HEAD UP OHM
4
15 (A8)
RIGHT DOWN
5
LEFT DOWN SW3
6
16 (B8)
BACK UP 1 (A1)
7
BACK DOWN
8
9 SW4
2 (B1) CN8
10
KIDNEY DOWN PIN NO COLOR PIN NO COLOR
11
KIDNEY UP SW5 1 (A1) Red 9 (A5) --
12
2 (B1) White/Red 10 (B5) --
LEG UP
13 3 (A2) Brown 11 (A6) White/Purple
LEG DOWN 4 (B2) Yellow 12 (B6) Purple
14
PUMP MOTOR 5 (A3) Orange 13 (A7) Grey
15 SW6
6 (B3) White/Orange 14 (B7) White/Grey
+24V 7 (A4) White/Brown 15 (A8) Red/White
16
8 (B4) Blue/White 16 (B8) Pink
Figure 6-13. Auxiliary Switch Connector CN3

Page 48
3500B
a. Checking Relay Box Input Power d. Checking Output to Solenoids
1. Connect power cord to table. Plug the power This test checks the voltage that is used to
cord into the 120VAC supply (wall receptacle). energize the solenoids.
Disconnect connector CN4, leave all other con-
nectors connected. 1. Activate either BATTERY or AC120V oper-
2. Using a DC voltmeter, test input power for ating mode.
both the BATTERY and AC120V operating modes.
See figure 6-15. Meter should read approximately NOTE
24 -28 volts. •The Brake Lock function is activated
by pressing any function button (except
BATTERY mode AC120V mode BRAKE UNLOCK). A timer in the Re-
(Main Power OFF) (Main Power ON) lay Box allows continuous output for
pin1=(+) pin 5=(+) about 7 seconds. If the brakes are
pin2=(-) pin 6=(-) already locked, no output is provided.
Connector CN4 Color Code •The BRAKE UNLOCK button activates

Pin 1 Red Pin 5 White another timer in the relay box which
Pin 2 Blue Pin 6 Black allows continuous output for the brake
Pin 3 Yellow Pin 7 Yellow release function for approximately 7
Pin 4 Blue seconds. If the brakes are already
released (using the BRAKE UNLOCK
button) no output is provided.
2. Test connectors CN1, CN2A and CN2B

from the back while attached to the relay box. All
7 connectors should be connected.
4
6 3
5 2 3. Activate each of the pendant control buttons
DCV 1 and measure the output voltage for the correspond-
ing connector pins with a DC voltmeter. See figure
6-16. Meter should read 24 volts.
Figure 6-15. Relay Box Input
b. Test Results: ACV
1
If you do not receive the correct meter readings,
the problem is in the input wiring, connectors or
components. If the correct readings are obtained, CN1, CN2A OR CN2B
proceed to the next step. 16
CN1 CN2A
c. Checking Output to Pump FUNCTION PINS FUNCTION PINS
Table Up 1-2 Back Up 1-2

1. Disconnect pump connector CN15, connect Table Down 3-4 Back Down 3-4
Trend 5-6 Slide Foot 5-6
all other connectors and activate the AC120V Rev Trend 7-8 Slide Head 7-8
operating mode. Tilt Right 9 - 10 Kidney Up 9 - 10
Tilt Left 11 - 12 Kidney Down 11 - 12
Reflex 13 - 14 Leg Up 13 - 14
Flex 15 - 16 Leg Down 15 - 16
2. Test CN15 at pin 1(+) and pin 2(-) with a DC
voltmeter. Meter should read approximately 24-28 CN2B
volts when any function button is activated. If no Brake Set 1-2
Brake Unlock 3-4
voltage is present, use an ohmmeter to test the
continuity from CN15 to CN4 (yellow and blue
wires). Refer to figure 6-15 for CN4 pin locations. Figure 6-16. Solenoid Output Connectors
Page 49
3500B
e. Test Results: NOTE
The 15 amp battery protection fuse is in
If you do not receive the correct meter readings, the the line between CN4 pin 1 and the
relay box is defective and should be replaced. battery connector. Test the continuity
of the fuse if correct meter reading is not
NOTE received.
•Before deciding the relay box is de-
fective, check the wires and pins in the b. CN4 to Pump Test
connector blocks to make sure they
are not loose or making a bad connec- 1. Disconnect connectors CN4, CN15 and
tion with their mate. CN16. Leave all other connectors connected.
•If the battery power is ON and no table
functions have been activated for 3 2. Using an ohmmeter, test for continuity
hours, the power off circuit will interrupt between the pins of CN4 and pins on CN15 and
the battery power. CN16. See figure 6-18.
f. Checking Output to Pendant Control
The output to the Pendant Control can not be tested

7
without specialized equipment. If all tests have 4 2
been conducted and it appears that the Relay Box 6 3 1 CN15 OR CN16
is faulty, contact SKYTRON. 5 2 CN4
1
NOTE
The Relay Box connectors CN7 (Pen- OHM
dant Control), and CN8 (Auxiliary Base
Connector), are interchangeable. CN-4 CN-15 CN-16 OHMS
3 1 0
6-10. Main Wire Harness Continuity Tests 4 2 0
7 1 0
4 2 0
If correct meter readings are not received in tests
between components, before replacing the compo- Figure 6-18.
nents, test the Main Wire Harness to be sure all
connectors and wires are making a good connec-
c. CN4 to Charging Box Test
tion.
1. Disconnect connectors CN4, CN14 and
a. CN4 to Batteries Test
CN51. Leave all other connectors connected.
1. Disconnect connectors CN4 and the (+) and
2. Using an ohmmeter, test for continuity
(-) connectors from the batteries. Leave all other
between pins 4, 5 and 6 of CN4, pins 1 and 2 of
connectors connected.
CN14, and pin 4 of CN51. See figure 6-19.
2. Using an ohmmeter, test for continuity CN51
between pin 1 of CN4 and battery (+) connector.
53
Also test between pin 2 of CN4 and battery (-) CN4 1
connector. See figure 6-17.
6 CN14
4
7 2
4 OHM
6 3
7 5 2
4 1
6 3 (+)
2 (-)
5
1 CN4 CN-14 CN-4 CN-51 OHMS
1 5 0
OHM 6 4 0
2 4 0
Figure 6-17. Figure 6-19. CN4, CN14, and CN51

Page 50
3500B
6-11. Solenoids 3. Use a DC voltmeter and measure the
voltage across the 2 pin connector. Pin 1(+), and
The solenoids are energized by 24 volt potential pin 2(-). Meter should read approximately 24-28
that is controlled by the relay box. volts.
The solenoid windings are protected from exces- NOTE
sive heat by an internal thermal fuse that will open •The appropriate pendant control but-
after approx. 7 minutes of continuous operation. ton must be pushed during this test.
The solenoid must be replaced if the internal ther- The motor will run when this test is
mal fuse has been blown. performed, and the brake locking sole-
The solenoids are mounted directly on either side noid will be activated by any function
of the hydraulic mini-valves and push the spool other than MOVE.
valve in one direction or the other depending upon
which solenoid is activated. •If a solenoid does not function when
the pendant control button is pushed,
a. Solenoid Test the problem could be the pendant con-
trol, the relay box, or the solenoid.
The following tests will check the voltage applied
to the solenoids and the resistance of the solenoid c. Test Results:
coil.
If you do not receive the correct voltage, the prob-
b. Test #1 lem could be in the wires leading down to the
1. Activate either BATTERY or AC120V oper- connector. The problem could also be in the relay
ating mode. box or the Pendant Control (refer to appropriate
2. Disconnect the 2 pin connector from the section for troubleshooting).
solenoid in question, all other connectors should be
connected. See figure 6-20. If the correct voltage is obtained, everything is good
up to that point and the problem is more than likely
the solenoid.
OHM ACV
BLUE BLUE
WHITE/BLUE RED
BLUE BLUE
WHITE/BLUE BROWN
BLUE BLUE
CN1
WHITE/BLUE ORANGE 16
BLUE BLUE 15
14
13
WHITE/BLUE BROWN/WHITE 12
11
BLUE BLUE 10
9
WHITE/BLUE WHITE/BROWN 8
7
BLUE BLUE 6
5
4
WHITE/BLUE WHITE/GREY 3
2
BLUE BLUE 1
WHITE/BLUE PURPLE
BLUE BLUE
WHITE/ WHITE
BLUE BLUE BLUE
WHITE/ BLACK/
UP HD RT. REFX UP DN. UP FT. UN BLUE WHITE
DN. LOCK
CN2B
4
LAT. BACK LEG TABLE 3
ELEV. TREND TILT FLEX SECT. SECT. KIDNEY SLIDING BRAKE 2
1
HD
DN. UP. LT. FLEX DN. UP DN. HD. LOCK
BLUE BLUE
CN2A
WHITE/BLUE WHITE/BLACK 16
BLUE BLUE 15
14
13
WHITE/BLUE BLACK 12
BLUE BLUE 11
10
9
WHITE/BLUE WHITE/PURPLE 8
BLUE BLUE 7
6
5
WHITE/BLUE GREY 4
3
BLUE BLUE 2
1
WHITE/BLUE BLUE/WHITE
BLUE BLUE
WHITE/BLUE RED/WHITE
BLUE BLUE
WHITE/BLUE WHITE/ORANGE
BLUE BLUE
WHITE/BLUE YELLOW
BLUE BLUE
WHITE/BLUE WHITE/RED
Figure 6-20. Solenoid Test

Page 51
3500B
d. Test #2
CN15
The solenoid can be checked out using an ohm- DCV
meter R x 1 scale.
2
1
1. Measure the resistance between the two
pin connector in question as shown in figure 6-20. Figure 6-21. Motor Input Voltage
Connector must be disconnected. Polarity of
meter leads is not important. NOTE
If the pump has been activated continu-
2. The meter should read approximately 16 ously for 1-1/2 to 2 minutes, the thermal
ohms at room temperature. protector will interrupt the power to the
pump.
3. Measure the resistance between either pin
and ground. b. Thermal Protector Test
4. Meter should read infinity. The Thermal Protector is built in to the pump motor
and is used to interrupt the current flow to the pump
e. Test Results: motor to protect it from possible damage due to
overheating.
If the solenoid does not check out with the meter, 1. Turn OFF both BATTERY and AC120V
it is more than likely defective and must be operating modes.
replaced.
NOTE 2. Use an ohmmeter to test for continuity
Whenever there are several compo- between terminals 1 and 2 on the connector CN16.
nents of the same type, a defective See figure 6-22.
unit can also be detected by substi-
tuting a known good unit or wire con-
nector. In some cases this may be
faster than using a multi-meter. CN16
DCV
6-12. Motor/Pump Assembly 2

1
The hydraulic pump motor is a 24 volt DC electric

motor. The oil pump unit is attached to the bottom Figure 6-22. Thermal Protector
of the motor and is a gear type displacement
pump with a pumping capacity of .4 liter per min. 3. The Thermal Relay should reset itself after
The Motor/Pump Assembly is mounted on insula- approximately one minute.
tors in the base of the table.
4. The Thermal Relay should activate after 1-
a. Motor/Pump Test 1/2 to 2 minutes of continuous pump operation.
1. Disconnect motor connector CN15. Leave c. Motor Resistance Test

all other connectors connected and activate either
BATTERY or AC120V operating mode. The motor can be statically checked for resistance
using an ohmmeter. This test is not 100% accurate
2. Activate any function and use a DC voltme- because you are checking the motor with very low
ter to measure across the two pin connector. Pin voltage from the meter and without any load.
1(+) and pin 2(-). See figure 6-21. Meter should 1. Using an ohmmeter R x 1 scale, measure the
read 24-28 volts. resistance between the two pins of CN15. See
figure 6-22.
Page 52
3500B
2. The meter should read 1 to 2 ohms at room The slide function has inhibit switches to prevent
temperature. damage to the back and leg sections. If the back
3. Measure the resistance between either pin section is below horizontal the top will not slide
and ground. toward the foot end. If the leg section is lowered
4. Meter should read infinity. more than 45° below horizontal the top will not slide
toward the head end. Likewise, if the top is slid
d. Test Results: toward the foot end, the back section will not go
If you do not receive the correct meter readings, the below horizontal. If the top is slid toward the head
motor or wiring is defective. end, the leg section will not go more than 45° below
horizontal.
6-13. Return-to-Level Micro-Switches.
The return-to-level/inhibit system consists of 12
The return-to-level system for the Model 3500B is micro-switches, an electrical connector, 2 terminal
the same as non-battery models except for the strips and the related wiring. The micro-switches
wiring and connection to the relay box. are mounted on or adjacent to the function they
control and are wired for normally open or normally
The return-to-level feature is activated by a single closed operation. The micro-switches are cam or
button on the pendant control and automatically lever actuated and can be adjusted at the individual
levels the major table functions, lateral tilt, tren- switch mounting brackets. See figure 6-23.
delenburg, flex, back section, and leg section.
The micro-switches operate on low voltage, and
The kidney lift has a back section-up inhibit switch control the function circuits (pump/motor and ap-
to prevent the table back section from damaging propriate solenoid valves) when activated by the
the kidney lift when the lift is raised. The back pendant control RETURN button.
section still has the capability to be lowered and
raised, but will not raise more than 45° above The micro-switches are wired to the relay box
horizontal until the kidney lift is completely down. If through 2 terminal strips, a riser cord and the 15 pin
the back section is raised more than 45° above connector CN10. See figure 6-23 for switch loca-
horizontal, the system will not allow the kidney lift to tion and identification.
be raised.
CS-3 NS-7 CS-2 CS-1
NS-6
CS-5
NS-1
NS-4
NS-3
TS-1 TS-2 NS-2
NS-5
CS-4 NS-1 TREND
NS-2 REV. TREND
NS-3 TILT LEFT
NS-4 TILT RIGHT
NS-5 BACK - DOWN TO LEVEL /SLIDE INHIBIT
RELAY BOX NS-6 BACK - UP TO LEVEL
NS-7 LEG - DOWN TO LEVEL
CS-1 SLIDE/LEG DOWN INHIBIT

CS-2 SLIDE/BACK DOWN INHIBIT
CS-3 KIDNEY/BACK 45˚ UP INHIBIT
CS-4 LEG DOWN 45˚/SLIDE INHIBIT
CN10 CS-5 BACK UP 45˚/KIDNEY UP INHIBIT
Figure 6-23.
Page 53
3500B
6-14. Return/Inhibit System Troubleshooting a. Switch Test
If a problem is suspected in the return circuits, Turn Main Power ON, lock the table brakes, and
disconnect the connector CN10 from the Relay place the table top sections in a level position with
Box to eliminate the circuits. Ensure that all table the Kidney Lift down. Disconnect connector CN10
functions operate properly using the Pendant Con- from the relay box and using an ohmmeter, test the
trol. If the functions do not work properly using the wiring and switch operation at the appropriate pin
Pendant Control, refer to the appropriate test sec- numbers for the micro-switch in question as shown
tion and make all needed repairs before working on in figures 6-25 through 6-32.
the return circuits.
NOTE
NOTE
It is normal for the back section to move Be sure to isolate the circuit when mak-
up if the RETURN button is pushed ing continuity checks.
when connector CN10 is disconnected
from the relay box. NOTE
All of the micro-switches are connected to the relay If you do not receive the proper continu-
box via a wiring harness and the micro-switch riser ity results at connector CN10 it does
cord from terminal strips 1 and 2 to connector not necessarily mean the micro-switch
CN10. The terminal strips are located under the is defective. There could be a problem
hose cover on the top of the elevation column. with the riser cord between connector
Connector CN10 plugs into the relay box and is the CN10 and terminal strips 1 and 2, or in
most convenient location to make circuit continuity the wiring from the switch to the terminal
checks. See fig. 6-24 for connector pin locations. strips. Further tests will have to be
made to determine the exact problem.
TS2
GREY
8
PURPLE
7 15
ORANGE/WHITE
CS-5 6 14
KIDNEY LIFT - INHIBIT CS-5 ORANGE
CS-3 5 13
BACK UP 45˚ - INHIBIT CS-3
BACK DOWN - INHIBIT CS-2 BLACK/WHITE
CS-2 4 12
LEG DOWN - INHIBIT CS-1
BLACK
SLIDE HEAD - INHIBIT CS-4 CS-1 3
11
LEG DOWN - RETURN TO LEVEL NS-7 BROWN/WHITE
CS-4 2
10
BROWN
NS-7 1
9
8
PINK
8
7
RED/WHITE
NS-6 7
RED 6
BACK UP - RETURN TO LEVEL NS-6 NS-5 6
BACK DOWN - RETURN TO LEVEL NS-5 LIGHT BLUE 5
5
SLIDE FOOT - INHIBIT NS-5
TILT RIGHT - RETURN TO LEVEL NS-4 NS-4 GREEN 4
NS-3 4
TILT LEFT - RETURN TO LEVEL NS-3
REV. TREND. - RETURN TO LEVEL NS-2 YELLOW 3
3
TREND. - RETURN TO LEVEL NS-1 NS-2 BLUE 2
NS-1 2
WHITE
1 1
TS1 CN10
Figure 6-24. Return / Inhibit Micro-Switch Test
Page 54
3500B
1 WHITE NC
NS-1
5 LIGHT BLUE NO
COM
1
15
2
COM
CN-10 NO
2 BLUE NS-2
NC
TS-1
NS-1. Trendelenburg NS-2. Reverse Trendelenburg



Head Up Open Infinity Head Up Closed 0
Head Dn Closed 0 Head Dn Open Infinity
When table is in Trendelenburg Position, When table is in Reverse Trendelenburg

NS-1 brings the top back to level. Position, NS-2 brings the top back to
level.
Figure 6-25. Trendelenburg Return Switches
NS-4 NS-3
4 GREEN
4 NO NO
5 COM COM
LIGHT BLUE
15
3 3 YELLOW
CN-10 TS-1
NS-3. Lateral Tilt-Left NS-4. Lateral Tilt-Right



Tilt Right Open Infinity Tilt Right Closed 0
Tilt Left Closed 0 Tilt Left Open Infinity
When table is inTilt-Left Position, NS-3 When table is in Tilt-Right Position, NS-4
brings the top back to level. brings the top back to level.
Figure 6-26. Lateral Tilt Return Switches

Page 55
3500B
NS-6
6 7 RED/WHITE NO COM
PINK
15 8
TS-1
15 8
PINK
RED
5
6
NO COM
CN-10 TS-1
NS-5
NOTE
When CN-10 is disconnected, BACK-
DOWN function will not operate.
NS-5. Back Section Down NS-6. Back Section Up


Level Closed 0 Level Open Infinity

Back Dn Open Infinity Back Dn Open Infinity
Back Up Closed 0 Back Up Closed 0
When the Back Section is Down, NS-5 When the Back Section is Up, NS-6
brings the Back Section Up to level and brings the Back Section Down to level.
will not allow Top Slide toward foot.
Figure 6-27. Back Section Return Switches
NS-7
1 BROWN
7
NC
COM
8 NO
15 GREY
CN-10
TS-2
NS-7. Leg Section Down

Test at pins 7 & 15
Table Switch Meter

Level Open Infinity

Leg Dn Closed 0
When the Leg Section is Down, NS-7

brings the Leg Section Up to level.
Figure 6-28. Leg Section Return Switches

Page 56
3500B
NOTES
SLIDE function will not operate when
CN-10 is disconnected.
3 BLACK
9
4 BLACK/WHITE
10
15 7 PURPLE
CN-10 TS-2 NC NC
COM COM
CS-2 CS-1
CS-1. Leg Down 45˚ Inhibit CS-2. Back Down Inhibit


Center Closed 0 Center Open Infinity

Slide Hd Closed 0 Slide Hd Closed 0
Slide Ft Open Infinity Slide Ft Open Infinity
When Top is slid toward head, CS-1 will When Top is slid toward foot, CS-2 will
not allow Leg Section to go more than not allow Back Section to go below
45˚ below horizontal. horizontal.
Figure 6-29. Leg Down / Back Down Inhibit Switches
CS-3
COM GREY 8 15
ORANGE 5 11
NC TS-2 CN-10
CS-3. Back Up Inhibit Switch

Table Switch Meter

K-Lift Dn Open Infinity

K-Lift Up Closed 0
When K-Lift is Up, CS-3 will not allow

Back Section to go more than 45˚ above
horizontal.
Figure 6-30. Back Up Inhibit Switches

Page 57
3500B
CS-4
2 BROWN/WHITE
8
NC
COM
8 NO
15 GREY
CN-10
TS-2
CS-4. Slide Inhibit

Test at pins 8 & 15
Table Switch Meter

Level Open Infinity

Leg Dn Closed 0
more than 45˚
When Leg Section is more than 45˚

below horizontal, CS-4 will not allow Top
to Slide toward head.
Figure 6-31. Slide to Head Inhibit Switches
CS-5
6 12
NO ORANGE/WHITE
COM PURPLE 7 15
TS-2
CN-10
CS-5. Slide Inhibit

Table Switch Meter

Back Up Less Than 45˚ Open Infinity

Back Up More Than 45˚ Closed 0
When Back Section is more than 45˚ above hori-

zontal, CS-5 will not allow Kidney Lift to operate.
Figure 6-32. Kidney Lift Inhibit Switches
Page 58
3500B
b. Switch Adjustment.
If proper readings are not obtained during test or if 3. To adjust the Leg Section switches loosen
table does not properly return to level, use the the jam nuts, adjust the switch, and tighten the jam
following procedure to adjust the switches. nuts. See figure 6-34.
1. Apply table brakes and (using a level) level PHILLIPS HEAD

SCREWS
the table top using the TRENDELENBURG and
LATERAL-TILT function buttons on the pendant
control.
2. For all switches except the Leg Section LEG SECTION BRACKETS
MICRO-SWITCH
switches, carefully loosen the switch retaining
screws, and adjust the switches as needed. See
figure 6-33.
RETAINING
SCREWS
Figure 6-34. Leg Section Micro-Switch
Adjustment.
MICRO-SWITCH
Figure 6-33. Micro-Switch Adjustment
Page 59
SECTION VIII ELECTRICAL SYSTEM ADJUSTMENTS
7-1. Relay Box Adjustments a. Brake Release Timer

The Brake Release Timer is set for about 7 sec-
The Relay Box contains variable resistors for ad- onds and is controlled by the variable resistor VR1
justing the operating timers for the BRAKE SET on the relay box circuit board. Turn the adjuster
and BRAKE UNLOCK functions. The Relay Box clockwise to increase the operating time. Counter-
for the battery model tables also has variable clockwise to decrease the operating time.
resistors for setting the Power Off timer and the
battery recharge warning circuit. These timers are
set at the factory and usually never need adjust- b. Brake Set Timer
ment. If an adjustment is necessary, remove the The Brake Set Timer is set for about 7 seconds and
relay box cover and use the following procedures. is controlled by the variable resistor VR2 on the
See figures 7-1 through 7-3. relay box circuit board. Turn the adjuster clock-
wise to increase the operating time. Counterclock-
wise to decrease the operating time.
VR-1 VR-2
Figure 7-1. Relay Box Adjustments Model 3500
Page 60
VR-4 VR-3 VR-1 VR-2
CN-4
CN-3
CN-2B CN-2A CN-1
Figure 7-2. Relay Box Adjustments Model 3500B
Page 61
RELAY BOX
HOSPITAL GRADE PLUG
+5V MNPC-32 1
F1, FH1
1
2 CN8
MNPC-33B CN3 CN1 #RL-22 C2 + C1
+5V
PS AC
SW1 10A
R7 GND AC115V
1 1 1 #RL-22 RL-23 D24 RL-24 D25 2
3 R9 D24 PB10SU 60Hz
GND 2 2 2 TR1 TR3
F2, FH2
3 3 3 R1 R3
AC115V 200W
#RL-21
4 4 4 4 R5 CN15 P.M 60Hz
5 5 5 C3 VR1 VR2 3 1 3
5 #RL-41 + TR2 + TR4 S C
6 6 6 G TRA1
#RL-42 R2 C4 R4
6 7 7 7 2
#RL-42 T1 T2 M
7 8 8 8 #RL-23 4
9 9 9
8 #RL-41 D14
10 10 10 C7 R6
RL-21
9 11 11 11
5
12 12 12
10 D21 CN4
13 13 13 180V 75µF
RL-1 #RL-1
11 14 14 14 CN5
15 15 15 1 1 SV-1
12 CN-21
16 16 16 D1
13 #RL-2 2 2
17 17 17 RL-2
#RL-29
18 18 18 3 1 SV-2
14
CN-22
19 19 19 D2 #RL-3 4 2
15 DSW2 1 RL-3
20 ON #RL-40 20 20
2
16 21 21 21 5 1 SV-3
3 CN-23
22 22 22 D3
17 4 #RL-4 6 2
23 5 23 23 RL-4
18 24 6 24 24 7 1 SV-4
7 CN-24
25 25 25 D4
8 #RL-5 8 2
26 26 26 RL-5
9
19 10 27 27 9 1 SV-5
CN-25
28 28 D5
20 #RL-6 10 2
29 29 RL-6
R10
21 30 30 11 1 SV-6
CN9 CN-26
22 D6 12 2
1 RL-7 #RL-7
23 2 13 1 SV-7
3 CN-27
24 D7 #RL-8 14 2
4 RL-8
5 15 1 SV-8
6 CN-28
D8 #RL-9 16 2
7 RL-9
8 #RL-39 SV-9
1 1
NS-1HEAD DO WN- LEVEL 9 #RL-30 CN-29
NS-2HEAD UP - LEVEL D9
#RL-10 2 2
10 RL-10
NS-3RIGHT UP - LEVEL 11
#RL-38 #RL-43
SV-10
3 1
NS-4LEFT UP - LEVEL 12 #RL-27 CN5 CN-30
NS-5B ACK DOWN- LEVEL 13
#RL-29 D10
RL-11 #RL-11 4 2
NS-6B ACK UP- LEVEL 1
14 #RL-35
2 R8 5 1 SV-11
NS-7LEG DO WN- LEVEL 15 CN-31
#RL-34
#RL-41 3 D11 6 2
16 RL-12 #RL-12
#RL-42 4
17 #RL-31 7 1 SV-12
5
CS-1B ACK DOWN- PR OHIBIT 18 CN-32
6 D12
CS-2LEG DO WN- PR OHIBIT 19 #RL-37
#RL-24 RL-13 #RL-13 8 2
#RL-44 7
CS-3PR OHIBIT BACK UP 20 9 1 SV-13
8
CS-4LIMIT OF SLIDING TOWARD HEAD 21 #RL-32 CN-33
#RL-26 9 D13
CS-5LIMIT OF KIDNEY BRIDGE UP 22 RL-14 #RL-14 10 2
#RL-37 10
23 11 1 SV-14
#RL-36 R12 11 CN-34
24 #RL-34 33 32 31 30 29 28 27 D26 12 #RL-15 12 2
25 RL-15
13
26 DSW1 1 ON 14 13 1 SV-15
R11
#RL-45 CN-35
2 15 D15
TM1 TM2 3 RL-16 #RL-16 14 2
16
4 15 1 SV-16
17 CN-36
CN2 18 D16
#RL-17 16 2
D34 RL-17
NS-1 1
WHITE
1 19
#RL-25 RL-43 17 1 SV-17
20 CN-37
BLUE D35 D17
2 2 RL-18
#RL-18 18 2
#RL-36 RL-44
NS-2
D36 19 1 SV-18
NS-3 YELLOW CN-38
3 3 D18
#RL-19 20 2
5
D37 RL-19
GREEN
4 4 21
NS-4 RL-25
#RL-27 D38 D19
NS-5 RED RL-26 #RL-20 22
6 5 RL-27 RL-20
RL-28 #RL-35 D39 23
RED-WHITE RL-29
7 6 RL-30
D20
8 NS-6 24
#RL-39 D40
NS-7 BROWN RL-31 D22 RL-22
1 7 BRAKE
RL-32
C5 (SET COIL)
#RL-30 D41
CS-4 BROWN-WHITE RL-33 + TIMER
2 8
RL-34 D23 RL-22
BLACK #RL-38 BRAKE
NC RL-35
COM 3 9 RL-36 C6 (RESET COIL)
CS-1
NO #RL-25 + TIMER
BLACK-WHITE
RL-37
4 10 RL-45
CS-2 ORANGE
RL-38 #RL-28
5 11
CS-3 ORANGE-WHITE
RL-39 #RL-31
7 6 12 RL-40
8 CS-5
13
#RL-33
14
15
Wiring Diagram, Model 3500
Page 63
CN1
R16 MNPC-68 IC7 CN6 CN5 MNPC-70 #RL-1 1
D11
1
SV-1
1 18 1 1 2 2 CN21
C10
RL-1 #RL-2 3 1 ELEV.
5V
IC2 5V IC4
5V
D12
CN22
SV-2
C11 5V 2 2 4 2
C15
+ C12 12 31
A0 PGM 1 24 RL-2 #RL-3 5 1
C9 11 SV-3
A1 32 9 D13
10 Vpp CN23
16 15 14 13 12 11 10 9 A2 1 10 3 3 6 2
VDD OSC C2 C3 SP1 2 3 4 9 Vcc Q0 8
IC1 A3 C13 2 RL-3 #RL-4 7 1 TREND.
8 13 7
R11 R14 SV-4
R15 TC9149 7
A4 D0
14 Q1 6 9 D14
CN24
R X IN
R12 A5 D1 3 5 5V 4 4 8 2
CN7 TR6 GND HP1 2 3 4 5 6 6 15 4
#RL-25 A6 D2 Q2 C18 RL-4 #RL-5 9
D5 5 21 18 1
1 NF1 R7 TR5 1 2 3 4 5 6 7 8 17 SV-5
A7 D3 17 D15
27 18 Q3 2 CN25
A8 D4 22 20 5 5 10
2 28 19 2354 19
R8 R9 R10 R13 A9 D5 RL-5 #RL-6 TILT
C8 23 14 11 1
A10 20 SV-6
D6 13 D16
3 +5v 25 21 6 6 2 CN26
A11 D7 RN1 1 16 12
4 23 #RL-7
A12 15 RL-6
4 GND 28
A13 NC
30 12 11 IC8 13
D17
1
SV-7
29 22 7 7 14 2 CN27
A14 CE TC4514BP 1 18
5 3 24 #RL-8
A15 OE RL-7 15 FLEX
2 16 1
A16 SV-8
D18
6 8 8 16 2 CN28
HN27C101AG-10 5V
RL-8
7 IC11
1
14
C23 #RL-9
CN2A
1 1
D19 SV-9
9 9 CN29
CN8 2 2
9
1 NF2 5V RL-9 #RL-10 BACK
3 1
C19 SV-10
D20 CN30
2 10 10 4 2
7 8 RL-10 #RL-11
RL-25 5V 5 1
3 +5v D21
SV-11
1 #RL-37 CN31
14 11 11 6 2
4 GND C17 RL-11 #RL-12 SLIDE
D6 7 1
SV-12
D22 CN32
5 5V #RL-37 12 12 8 2
5V IC5 RL-12 #RL-13 1
C16 9
6 D23 SV-13
1 24 CN33
7 13 13 10 2
9
7 10 RL-13 #RL-14 K-BRIDGE
11 1
Q0
2
8
7
IC6 14 14
D24
CN34
SV-14
12 2
CN9
Q1
3
6
5
IC9 RL-14 #RL-15 13 1
4 D25 SV-15
1 Q0 (HP1) Q2 1 18
21 18 15 15 2 CN35
14
2 Q1 (HP2) Q3 17 #RL-16
22 RL-15 15 1 LEG
20
2354 SV-16
3 Q2 (HP3) 19 D26
CN36
14 16 16 16 2
4 Q3 (HP4) 13 RL-16 #RL-20
RN2 1 17 1
16 RL-35 SV-17
5 HP5 23 #RL-26 D27
15 CN37
12 11 17 17 18 2
6 SP5 ZNR35 RL-17 #RL-21 19 1 BRAKE
TC4514BP 9
ZNR36 5V SV-18
7 +5v D28
18 18 20 2 CN38
C20
8 GND ZNR31 ZNR32 ZNR33 ZNR34 RL-18
CN2B
RN3
19 19
1 IC10
IC3 1 18 1
5V SW1
NS-1 1
CN10 12 20 20
1 A0 31 2
11 PGM
ZNR17 32
A1 Vpp 3
2 10
2 A2 1 21 21
NS-2 ZNR18 9 Vcc
A3 C14 4
3 SW2
NS- 3 8 13
3 A4 D0 5
5 ZNR19 7 14 RL-39 RL-22 SET
A5 D1 +5V
4 6 22 22 LOCK #RL-17 + C4
4 15 6
A6 D2 RL-22 RESET
NS-4 ZNR20 5 17 9 C41 R-28
A7 D3 5V RL-20 + C5 RL-23 7
NS- 5 5 27 18 D1 SW3
6 A8 D4
ZNR21 28 19 C21 23 23 RL-26
A9 D5 TR1 8
6 23 R3
7 A10 20 RL-21 #RL-22 TR2
8 D6 9
NS-6 ZNR22 25 21 UNLOCK + C6
A11 D7 VR1
7 24 24
NS- 7 1
ZNR23
4
28
A12
30
VS1 RL-19 #RL-23
#RL-18
R4 LOCK 10 SW4
A13 NC D7
CS-4 8 29 22 1 2 3 4 5 D3 +5V 11
2 A14 CE RL-27
ZNR24 25 25
3 24 12
9 A15 OE RL-24 D2
NC 2 16
COM 3 A16 D4
ZNR25 TR3 13 SW5
RESET
CS-1 NO R5
SET
10 HN27C101AG-10 #RL-38 26 26
4 #RL-35 #RL-24 TR4 14
#RL-36
RL-36
ZNR26 #RL-39 C7 + VR2
CS-2 11 UNLOCK 15
#RL-34
5 R6
27 27
#RL-24
#RL-23
ZNR27 SW6
#RL-19
CS-3 12
7 #RL-36 RL-37 16
6
ZNR28
8 CS-5 13 RL-34
28 28
RL-38 1 2 3 4 5 VS2 CN3 +24V
ZNR29
14 R27
5V 5V
5V
ZNR30 29 29
5V 15 D29
#RL-27
RL-30RESET
C22
RL-30SET
#RL-30
30 30 GND R17 R18
#RL-30
TM1 TM2 #RL-32
RL-31
RL-32
1
+
#RL-29 D9 R21 R22 R24 R25
SR1 D8 R19 D10
TR7 C39
2 3 1 R20
NS-1HEAD #RL-28 VR3
+
R23 VR4 TR11
TR9
DOWN- + 4 2 + #RL-31 + R26
3
LEVEL C36 C37 C38 TR8 D30 TR10 D31
+
C40
R17
NS-2HEAD UP 4
- LEVEL
NS-3RIGHT UP 5
NPH16 - 12
- LEVEL RN4 RN5 F-66AD DC12V
CN11 1 1 +24V
CN4 F3 FH3 BAT1 BAT2
1
GND 15A UL
CS-1B ACK DOWN- LP1 #RL-27 2
PROHIBIT 3 1 PUMP
PM1
CS-2LEG DO WN- 6P
CN51 6 5 RL-28 #RL-33
MOTOR
PROHIBIT MNPC-41A 3
2SD1525
4
4 2
CS-3PR OHIBIT BACK UP 10A UL 5
CN15
C E 5 3
FH032 RL-29
8P TR54 6
470µF B #RL-40
50V 6 THERMAL
2SD468 2.2 KW 8 7 1 PROTECTOR
UL. CSA AC SW7 TR1 TR52 R55 RL-33
10A CN12 CN13 1
CORD 1 SC1 R57
150 W 2P LINE
POWER
5 2
1 1 1 CN14 CN16
FH1, F1 3W R52 24DC 3
100V - 1.5 KW 2SC1815 D51 SC2 1 1
+ 2SD468
TR51 TR53
+ C51 4
22V +
2 2 2 R56 1000 P
BR252 C52 3 KW
FH2, F2 200VA 56 W C50 2 7
SB-25 150 W VR51
5A BR252 RL-40
R54
12V 2
ICN1 D52 D53 R51
3P 3P 3 W 3W 1.2 KW
6
2 7 4
R58
Wiring Diagram, Model 3500B

Page 64

Skytron Elite 3500 Surgical Table - Maintenance Manual

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ELITE SERIES SURGICAL TABLES

MODEL ELITE 3500 AND 3500B

1-1. General ........................................................................................................................................................ 1

SECTION II MECHANICAL TABLE ADJUSTMENTS ........................................................................................... 11

2-1. Back Section Gear Mesh Adjustment ........................................................................................................ 11

SECTION III HYDRAULIC TROUBLESHOOTING ................................................................................................. 13

3-1. Precautions ............................................................................................................................................... 13

SECTION IV ELECTRICAL SYSTEM ................................................................................................................... 26

4-1. General ...................................................................................................................................................... 26

SECTION V ELECTRICAL SYSTEM TROUBLESHOOTING ................................................................................ 28

5-1. Troubleshooting Notes ................................................................................................................................ 28

5-6. Motor/Pump Assembly ............................................................................................................................... 33

SECTION VI -3500B- BATTERY MODEL, ELECTRICAL TROUBLESHOOTING ................................................. 42

6-1. General ...................................................................................................................................................... 42

SECTION VII -3500B- BATTERY MODEL, ELECTRICAL SYSTEM ADJUSTMENTS ......................................... 60

7-1. Relay Box Adjustments .............................................................................................................................. 60

Electro-Hydraulic System hand-held push button pendant control. The power

Figure 1-1. Hydraulic Block Diagram

1-2. Component Operation

The output line of the pump is connected to the main

PUMP PRESSURE RELIEF

MINI-VALVES SPRING LOADED

Figure 1-2. Figure 1-4. Pressure Relief Valve Functioning

3. Check Valve - Two are provided in each

4. Speed Adjustments - There are two speed

There are several different types of hydraulic cylin- O-RING O-RING

O-RINGS O-RINGS ELEVATION

5. Elevation Cylinder - This single action cylin-

The mini-valve used in the elevation circuit con- EMERGENCY

BACK LEG KIDNEY SLIDE

An electronic timer in the relay box is activated

i. Brake System The brakes are released by pushing the BRAKE

The emergency brake release is simply a manually k. Flex/Reflex System

Figure 1-17. BACK

•The emergency brake release valve PLUMBING

•If the emergency brake release valve FLEX/REFLEX

a. Fluid Level. The pressure relief valve is adjusted by turning the

The elevation cylinder should be com-

Figure 1-19. Figure 1-20.

The type of oil that should be used is Mobil DTE #25

NOTE The speed controls restrict the volume of oil return-

Figure 2-1. Eccentric Cam Adjustment BACK SECTION CYLINDER

Back & Leg Sections

The hydraulic cylinder rams that control both the

NOTE b. Leg Section

2. Loosen the adjustment cam set screw and

With Kidney Lift all the way down, the distance

Figure 2-4. Figure 2-5.

3-1. Precautions Once the problem has been determined, concen-

When working on the trendelenburg or 1. Mini-Valve

CAUTION Whenever a hydraulic line or compo-

When troubleshooting a table malfunction, first

5. Is the problem no movement of a table

Table will not descend properly Incorrect Speed Adjustment

Table loses elevation Bad Check Valve

INTERNAL OIL RETURN

Figure 3-1. Elevation Circuit

Trendelenburg function chatters or loses position Defective or Dirty Check Valve

Figure 3-2. Trendelenburg Circuit

Figure 3-3. Lateral Tilt Circuit

NOTE: ONE SIDE

Figure 3-4. Back Section Circuit

Back Section or Trendelenburg function chatters Defective or Dirty Check Valves

Figure 3-5. Flex System Circuit