ELITE SERIES SURGICAL TABLES

MAINTENANCE MANUAL

MODEL ELITE 6600

INCLUDING BATTERY MODELS
 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
2-3. Head Section Adjustment ............................................................................................................ 12
2-4. Torque Specifications .................................................................................................................. 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. FLEX SYSTEM DIAGNOSIS CHART ........................................................................................ 17
3-7. BACK SECTION DIAGNOSIS CHART ...................................................................................... 18
3-8. LEG SECTION DIAGNOSIS CHART ......................................................................................... 19
3-9. KIDNEY LIFT DIAGNOSIS CHART ........................................................................................... 20
3-10. BRAKE CIRCUIT DIAGNOSIS CHART ..................................................................................... 21
3-11. Flexible Hose Identification and Placement ................................................................................. 22

9/03

Although current at time of publication, SKYTRON's policy of continuous development makes this manual
subject to change without notice.
 Table of Contents (continued)
SECTION IV ELECTRICAL SYSTEM ................................................................................................... 24

4-1. General ........................................................................................................................................ 24

4-2. Components ................................................................................................................................ 24
4-3. Battery Model Components ......................................................................................................... 24

SECTION V 6600 ELECTRICAL SYSTEM TROUBLESHOOTING .................................................... 26

5-1. Troubleshooting Notes ................................................................................................................. 26
5-2. Main Switch ................................................................................................................................. 26
5-3. Pendant Control ........................................................................................................................... 27
5-4. Auxilliary Switches ....................................................................................................................... 28
5-5. Relay Box .................................................................................................................................... 28
5-6. Solenoids ..................................................................................................................................... 30
5-7. Motor/Pump Assembly ................................................................................................................ 32
5-8. Return-to-Level Micro-Switches. ................................................................................................. 34
5-9. Troubleshooting ........................................................................................................................... 34

SECTION VI -6600B- BATTERY MODEL, ELECTRICAL TROUBLESHOOTING .............................. 40

6-1. General ........................................................................................................................................ 40

6-2. Troubleshooting Notes ................................................................................................................. 40
6-3. Main Switch ................................................................................................................................. 40
6-4. Batteries ....................................................................................................................................... 41
6-5. Battery Charging Box/AC 120V Transformer .............................................................................. 41
6-6. Switch-Over Relay ...................................................................................................................... 43
6-7. Pendant Control ........................................................................................................................... 43
6-8. Auxiliary Switches ....................................................................................................................... 45
6-9. Relay Box .................................................................................................................................... 45
6-10. Main Wire Harness Continuity Tests ........................................................................................... 47
6-11. Solenoids ..................................................................................................................................... 48
6-12. Motor/Pump Assembly ................................................................................................................ 49

SECTION VII ELECTRICAL SYSTEM ADJUSTMENTS ..................................................................... 51

8-1. Relay Box Adjustments ............................................................................................................... 51

WARNING NOTE

Indicates a possibility of personal injury. Indicates important facts or helpful hints.

CAUTION

Indicates a possibility of damage to

equipment.
BASIC RECOMMENDED TOOLS:

1/8". 1/4" STRAIGHT BLADE SCREWDRIVERS

#2 PHILLIPS SCREWDRIVER
HYDRAULIC PRESSURE GAUGE SKYTRON P.N. 6-050-02
METRIC ALLEN® WRENCHES 1.5mm-8mm
ADJUSTABLE CRESCENT WRENCH
DIGITAL VOLTMETER, TRUE RMS
METRIC OPEN END WRENCHES 7mm-18mm
LEVEL (CARPENTERS)

BASIC RECOMMENDED MAINTENANCE PROCEDURES

The basic items notes below should be inspected at a minimal interval period of 6 months (dependant on
usage). For optimal usage, safety and longevity of the product, have it serviced only by an authorized
Skytron representative with authentic Skytron replacement parts.

• Check Power Cord (if applicable)

• Check Pendant Control (if applicable)
• Check Oil Level in Reservoir
• Check For Hydraulic Leaks
• Check Pressure Relief Valve Setting
• Check All Table Functions
• Check Side Rails
• Check Velcro
• Check Lateral Tilt Housing Bolts
• Lubricate Elevation Slider Assembly with SKYTRON Slider Grease P/N D6-010-89
• Tighten X-Ray Top Stand-Offs, Use Loc-tite
• Lubricate Castors
•Check brake pads for wear and inspect brake cylinders for proper operation.

Only facility-authorized SKYTRON trained, maintenance personnel should troubleshoot the

SKYTRON 6600 Surgical Table. Trouble shooting by unauthorized personnel could result in
personal injury or equipment damage.

How to contact us:

Skytron
5000 36th St. SE, Grand Rapids, MI 49512
PH: 1-800-759-8766 (SKY-TRON)
FAX: 616-957-5053
 EQUIPMENT LABELS AND SPECIFICATIONS

INDICATES DANGEROUS VOLTAGE, 120 V, 60 Hz

CLASS I DEFIBRILLATION PROOF, TYPE B EQUIPMENT- IPX4 RATED.

TYPE B INTERNALLY POWERED EQUIPMENT
EQUIPMENT

PROTECTIVE GROUNDING.
IN ORDER TO ENSURE PROPER GROUNDING RELIABILITY,
THIS TABLE MUST BE CONNECTED TO A PROPERLY GROUNDED
HOSPITAL GRADE OUTLET.

N CONNECTION FOR NEUTRAL CONDUCTOR SUPPLIED

UNIT TO BE USED ONLY IN SPECIFIED ENVIRONMENTAL CONDITIONS

TEMPERATURE: 15˚ - 30˚ C (60˚ -85˚ F)
HUMIDITY: 30% - 60% RELATIVE HUMIDITY, NON CONDENSING

AC VOLTAGE

IPX4 ENCLOSURE CLASS

V VOLTAGE RATING OF THE UNIT

A AMPERAGE RATING OF THE UNIT

HZ FREQUENCY OF THE UNIT

ATTENTION, CONSULT MANUAL FOR FURTHER INSTRUCTIONS.

INDICATES SPECIAL USER ATTENTION.

POWERED BY AC VOLTAGE

BATTERY MODELS

POWERED BY BATTERY

BATTERY TYPE: SEALED

LEAD ACID 12V, VALVE REGULATED
16AH, 10HR (530W/10MIN)

FUSE: 15A 15 AMP FAST ACTING INTERNAL FUSE

 6600 Series General Purpose Surgical Table Specifications

15"

10" 19-1/2" 21-1/2" 24"

14-1/2" 19-3/4"

TOP VIEW
76"
60˚ 6"

3" 21-3/4"

90˚

45" MAX
26" MIN

5-3/4"

9"

36-1/2" 19"

SIDE VIEW END VIEW

Electrical Specifications
Power requirements 120 VAC, 60Hz, 450 Watts
Current Leakage Less than 100 micro amps
Power Cord 15 feet w/hospital grade connector(removeable)

ENTELA CERTIFIED
TO UL2601-1
CAN/CSA601.1, IEC 60601-2-46
 SECTION I HYDRAULIC SYSTEM

1-1. General a. Oil Reservoir - Main oil supply. Approximately

two quarts.
Electro-Hydraulic System
b. Motor/Pump Assembly - A positive displace-
The hydraulic system (with the exception of the ment gear type pump provides the necessary oil
hydraulic cylinders and hoses) is contained within pressure and volume.
the base of the table. The hydraulic valves and
pump are electrically controlled by the use of a hand- c. Pressure Relief Valve - Provides an alternate oil
held push button pendant control. The power re- path when the hydraulic cylinders reach the end of
quirements for the table are 120 VAC, 5 amp, 60 Hz. their stroke.

The table contains the following components. Refer d. Electro/Hydraulic Mini-Valve Assemblies -These
to the block diagram (figure 1-1) for relationship. direct the fluid to the appropriate hydraulic cylin-
ders.

Figure 1-1. Hydraulic Block Diagram

Page 1
e. Hydraulic Lines, Fittings, Connections - They The main component of the valve is an adjustable
provide a path for the hydraulic oil. spring loaded plunger that is pushed off from its
seat by the oil pressure. The oil then flows back into
f. Hydraulic Cylinders - They convert the hydraulic the reservoir. See figure 1-4. Turning the adjust-
fluid pressure and volume into mechanical motion. ment nut clockwise increases the amount of oil
pressure required to open the valve, and turning it
counterclockwise decreases the amount of oil pres-
1-2. Component Operation sure. (See adjustment section for specification.)

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
PRESSURE
hydraulic system. The pump has an inlet side and GAUGE
an outlet side. The inlet side is connected to the
reservoir which provides the oil supply. The reser-
voir has a very fine mesh screen strainer which SPRING LOADED
prevents foreign material from entering the oil sys- PLUNGER
tem.

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.
Also, common to the hydraulic mini-valves and
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.

Figure 1-3. Pressure Relief Valve Not

Functioning

PRESSURE RELIEF
ADJUSTMENT NUT

PRESSURE
GAUGE

SPRING LOADED
PLUNGER
Figure 1-2.
b. Pressure Relief Valve

This device provides an alternate oil path when the

hydraulic cylinders reach the end of their stroke
and the pump continues to run. If this path were not
provided, the pump motor would stall because the
oil cannot be compressed. The pressure relief
valve is directly connected to the mini-valve bodies
and shares both the common internal main pres-
sure oil galley, and the return oil galley, that inter-
nally connect to the reservoir. See figure 1-3. Figure 1-4. Pressure Relief Valve Functioning

Page 2
c. Mini-Valves
Also, by using this control method, it doesn’t matter
The operation of the mini-valves is identical for all what size cylinder and piston is used because the
table functions except the elevation and brake speed can be controlled by restricting the return oil.
circuits. These two hydraulic circuits use a 3-way If the pump puts out more volume to a certain slave
(single check valve) type mini-valve. All other func- cylinder than the speed control is allowing to go
tions use a 4-way (dual check valve) type mini- back to the reservoir, the pressure relief valve
valve. provides an alternate path for the pump oil.

Either type mini-valve is controlled by two pushing d. Mini-Valve in Neutral Position

type, electrically operated solenoids. The sole- (No fluid flow) See figure 1-5.
noids push the spool valve (located in the lower
portion of the valve) one way or the other. This 1. Spool Valve Centered - This closes off both
motion opens the main supply galley (which has oil pressure and oil return galleys.
pump pressure) allowing the oil to flow through the
various parts of the mini-valve to the function. The 2. Pilot Plungers Both Closed -The pilot plung-
spool valve also opens an oil return circuit which ers control the opening of the check valves. If they
allows the oil to return to the oil reservoir. are closed, the check valves must be closed.

The main components of the mini-valve and their 3. Check Valves - Both check valves are
functions are listed below: closed trapping the oil in the cylinder and oil lines.

1. Spool Valve - Opens the main oil galley 4. Speed Adjustment - When the mini-valve is
(pump pressure) to either mini-valve outlet de- in the neutral position, the speed adjustment does
pending on which direction the spool valve is not affect anything because there is not any oil
pushed. Also it provides a return path for the oil flow.
returning back into the reservoir.

2. Pilot Plunger - There are two plungers in a

four-way mini-valve (one in a 3-way mini-valve),
one under each check valve. The purpose of the
pilot plungers is to mechanically open the return
check valve allowing the oil to return back into the
reservoir.

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-
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 OUTLET INLET

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) O-RING O-RING

There are several different types of hydraulic cylin-

ders used in the table that activate the control
functions. With the exception of the elevation and PISTON
brake cylinders, all operate basically the same
way. The control functions are listed below. See RAM
figure 1-8. HYDRAULIC LINE
Back Section--2, double action cylinders
Leg Section--2, double action cylinders
Trendelenburg--1, double action cylinder Figure 1-9. Back Section Cylinder
Lateral Tilt--1, double action cylinder
Elevation--1, single action cylinder 2. Trendelenburg Cylinder Assembly - This
Kidney Lift--1, double action cylinder cylinder / piston arrangement has rack teeth cut
Brakes--4, single action cylinders into the top of each piston. These teeth mesh with
a pinon gear that is connected directly to the table
BACK SECTION side frames. The pinion gear shaft and table side
TRENDELENBURG
CYLINDER frames are supported by bearings at either side.
CYLINDER
When hydraulic fluid is pumped into one side of the
cylinder, the pistons are pushed in one direction,
moving the pinion gear and table side frames with
them. Oil pressure can be applied to either side of
the piston, making the table tilt end for end. See
figure 1-10.

TABLE TOP

KIDNEY LIFT LEG SECTION PINION GEAR

CYLINDER CYLINDER
PISTONS

ELEVATION LATERAL TILT

CYLINDER CYLINDER
SIDE VIEW

Figure 1-10. Trendelenburg Cylinder Assy.

Figure 1-8. Cylinder Placement In order to remove any looseness or play in the
table top, the trendelenburg pistons are made in two
1. Back Section and Leg Section Cylinders - pieces as shown in figure 1-11. This arrangement
The double action cylinders are closed at one end eliminates any gear lash between the piston teeth
and have a movable piston with hydraulic fluid on and the table pinion gear due to oil pressure always
both sides. Connected to this piston is a ram or being present on both sides of the pistons.
shaft that exits out of the other end of the cylinder.
Through the use of either a gear, or clevis and pin OIL PRESSURE OIL PRESSURE
arrangement, this ram is connected to a movable
table surface.
The movable surface can be moved one way or
the other by pumping hydraulic fluid into the cylin-
der on either side of the piston. Obviously, if oil is
SPLIT PISTONS TOP VIEW
pumped into one side of the cylinder, a return path REMOVE GEAR LASH
must be provided for the oil on the other side. See
figure 1-9. Figure 1-11. Trendelenburg Cylinder Pistons

Page 5
 3. Lateral Tilt Assembly - The lateral tilt assem- 5. Kidney Lift - The kidney lift cylinder assem-
bly consists of two cylinders, pistons and connect- bly is a unique type of double action cylinder where
ing rods. The connecting rods attach to the lateral the piston remains stationary and the outer housing
tilt lever which connects to the table side frames. or cylinder has the relative motion. The cylinder
When hydraulic fluid is pumped into one cylinder, housing has rack teeth cut into the top which
the piston and connecting rod pushes the lateral tilt meshes with a pinion gear. This gear meshes with
lever which tilts the table top to one side. To tilt the other gears to supply the up or down drive for the
table top in the opposite direction, fluid is pumped kidney lift bars, depending on which direction the oil
into the opposite cylinder. See figure 1-12. is pumped into the cylinder. See figure 1-14. A
cross shaft transmits the rotary motion of the
TABLE TOP
cylinder pinion gear to a gear set on the other side
of the table. This enables the kidney lift bars to
move up and down together without binding.
LATERAL TILT
LEVER PINION
GEARS KIDNEY
LIFT BAR

PISTON CONNECTING PISTON

RODS
Figure 1-12. Lateral Tilt Cylinder Assembly

4. Elevation Cylinder - This single action cylin- OIL FLOW

der does not have hydraulic fluid on both sides of PISTON CYLINDER
the piston. It depends on the weight of the table top HOUSING
assembly to lower it.
The cylinder is set in the center of the elevation Figure 1-14. Kidney Lift Cylinder Assembly
main column. The two stage cylinder is elevated by
the driven force of the oil pressure. When lowering, 6. Brake Cylinders - The brake cylinders are
the oil that is accumulated in the cylinder is returned single action type similar to the elevation cylinder.
to the oil reservoir through the mini-valve due to the The movable piston's ram is connected to a brake
table top weight. pad. See figure 1-15. Oil pumped into the top of the
A slider support assembly is used to support the cylinder pushes the piston down raising the table
weight of the upper table section. A stainless steel base off its casters. An internal return spring on the
shroud covers the flexible hydraulic hoses and bottom of the piston, pushes the piston up to return
slider. See figure 1-13. the oil through the mini-valve to the reservoir.

ELEVATION
CYLINDER

EXTERIOR PISTON
SHROUD OIL LINE

PRIMARY RETURN
SLIDER PISTON SPRING
SUPPORT
ASSEMBLY

SECONDARY
PISTON BRAKE RAM
PAD

Figure 1-13. Elevation Cylinder Assembly Figure 1-15. Single Action Brake Cylinder

Page 6
h. Elevation Cylinder Return Circuit

A three-way (single check valve type) mini-valve 3. Manually controlled emergency brake re-
controls both the elevation and return circuits. The lease.
elevation circuit operation within the mini-valve is
identical to the operation of the four-way valves 4. Plumbing terminal, flexible hoses, copper
previously described (inlet pressure opens the lines and "O" rings.
check valve allowing the oil to enter the cylinder). In
the return position, inlet pressure pushes the pilot 5. Portions of the electrical system.
plunger up and opens the return check valve. See
figure 1-16. The open check valve allows a path for
the oil in the elevation cylinder to return to the
BRAKE SYSTEM
reservoir. When the pilot plunger valve is opened,
the continuing pump pressure opens the pressure
relief valve which provides a return oil path to the
reservoir.

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

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

INLET
RESERVOIR PUMP/MOTOR
ASSEMBLY

Figure 1-17. Brake System Block Diagram

Each corner of the cast-iron table base has a

hydraulic brake cylinder. These single action cyl-
inders are hydraulically connected in parallel to the
mini-valve and all four are activated together. It is
normal for one corner of the table to raise before the
TO RESERVOIR RETURN TO others due to the weight distribution of the table.
THROUGH RESERVOIR
PRESSURE
RELIEF VALVE An electronic timer in the relay box is activated
when any function on the pendant control is
Figure 1-16. Elevation Return Circuit
pushed momentarily. The pump/motor and brake
system mini-valve are activated and the brake
i. Brake System
cylinders are completely set. The electronic timer
runs for approx. 8-10 seconds.
The brake system consists of the following compo-
nents: (figure 1-17)
The brakes are released by pushing the BRAKE
UNLOCK button momentarily. An electronic timer
1. Single action slave cylinders (4 each).
in the relay box activates the brake function hy-
draulic mini-valve and pump/motor.
2. 3-way (single check valve type) mini-valve.

Page 7
When activated, the return hydraulic circuit oper-
ates similar to the elevation cylinder return circuit.
Return springs inside the single action brake cylin-
ders retract the brake pads and provide the pres-
sure to return the hydraulic oil back to the reservoir.
The electronic timer operates the return circuit for k. Flex/Reflex System
approximately 8-10 seconds.
The Flex/Reflex system incorporates an additional
mini-valve which connects the trendelenburg and
j. Emergency Brake Release back section hydraulic systems in a series. When
FLEX is activated by the pendant control, the Flex/
The emergency brake release is simply a manually Reflex mini-valve opens the oil pressure path to the
operated bypass valve connected in parallel to the Reverse Trendelenburg piston. The return oil path
brake cylinders and the oil reservoir. See figure 1- from the Trendelenburg piston is routed through the
18. When the valve is opened (turned counter- back section cylinder to the mini-valve return port.
clockwise) a return circuit for the brake hydraulic See figure 1-19
fluid is opened. The return springs force the pistons
up pushing the hydraulic oil back into the reservoir
and retracting the brake pads.

BACK UP
TREND REV TREND

BACK
DOWN

EMERGENCY BRAKE
RELEASE LEVER PLUMBING
TERMINAL

Figure 1-18.

NOTE
FLEX/REFLEX
•The emergency brake release valve
MINI-VALVE
must be tightened securely when not in
use.

•If the emergency brake release valve Figure 1-19. Flex/Reflex System
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

loose, the brakes will release slowly- depending on
how loose the valve is, this could take anywhere
from a few minutes to several hours.

Page 8
1-3. Hydraulic Adjustments To adjust:

a. Fluid Level. 1. Remove the blind cap and attach a hydraulic

pressure gauge to the main oil galley using a 6mm
The fluid level should be approximately 1/2" below plumbing bolt. See figure 1-21.
the filler hole or gasket surface. If additional fluid is
needed, remove the filler vent cap with a phillips
screwdriver and add fluid through this opening
using a funnel. See figure 1-20. PRESSURE
RELIEF VALVE
PRESSURE
NOTE
GAUGE
The elevation cylinder should be com-
pletely down, the brakes released and
all the other control functions in their
neutral position when checking oil level.

FILLER VENT
FILLER ATTACH
HERE
CAP BACK VIEW OF
RELIEF VALVE

Figure 1-21.

2. Raise the table top until the piston reaches

the end of its stroke and stalls. Observe reading
RESERVOIR on pressure gauge and turn the adjustment nut
OPENING (clockwise to increase oil pressure, counter-
Figure 1-20. clockwise to decrease) until desired reading is
obtained. Pressure should be 8MPA (80KG/CM2 -
The type of oil that should be used is Mobil DTE #25 1138 PSI). An erratic reading and/or inability to
or equivalent. This is a very high quality hydraulic adjust to the recommended setting may indicate
oil. The table requires approximately two quarts of the need for replacement of the pressure relief
oil to operate properly. Excercise caution when valve.
determining equivalance to avoid damage to the
hydraulic system. d. Speed Controls

b. Bleeding The Hydraulic System The speed controls restrict the volume of oil return-
ing back to the reservoir thereby controlling the
To purge the air from the hydraulic system, operate speed of each control function.
each function back and forth at least two or three
times. All four-way mini-valves, have two speed controls
NOTE located in the ends of each valve body. All three-
Whenever a hydraulic line or compo- way mini-valves have only one speed control.
nent is replaced, bleed the air out of the
lines using the pump pressure before One speed control adjusts one direction of a
making the final connection. Then oper- particular function and the opposite speed control
ate the function until it stalls in both adjusts the other direction. They are adjustable by
directions. using a small straight blade screwdriver and
turning the adjustment screw clockwise to de-
c. Pressure Relief Valve crease the speed and counterclockwise to
increase the speed. See figure 1-22.
The pressure relief valve is adjusted by turning the
adjustment nut until the desired pressure is reached.
Page 9
 TREND A pressure gauge should be used to set the speed
TABLE DOWN of the back section, trendelenburg and flex control
TILT RIGHT
REFLEX functions.
BACK UP
FOOT DOWN To adjust:
KIDNEY UP
1. Attach the pressure gauge onto the main oil
REV TREND galley as shown in figure 1-21.
TILT LEFT
FLEX 2. The gauge should read the following values
BACK DOWN BRAKE when operating the various control functions in
FOOT UP either direction. Turn the speed controls until
KIDNEY DOWN desired values are obtained.

Back Section Up 65KG/CM2 -925PSI

Figure 1-22.
Dn 65KG/CM2 -925PSI
Trendelenburg Up 65KG/CM2 -925PSI
Dn 65KG/CM2 -925PSI
Flex 70KG/CM2 -995PSI
Reflex 70KG/CM2 -995PSI
Any control function should move in either direc-
tion at the same rate. If the rate of a certain function
is too slow, open the speed control slightly and
recheck. Use the second hand on a watch and time
NOTE
a particular function. Match that time in the opposite
When adjusting Flex/Reflex speed con-
direction by opening or closing the speed control.
trols, set Reflex last.
Approximate operating times are as follows:
Elevation - There is not a speed adjustment for
Lateral Tilt 7 seconds
raising the table. The speed control will only affect
Back Up 25 seconds
the rate of descent and it should equal the rate of
Back Down 15 seconds
elevation.
Kidney Lift 7 seconds

Page 10
 SECTION II MECHANICAL TABLE ADJUSTMENTS

2-1. Back Section Gear Mesh Adjustment

To adjust:
The gear mesh is adjusted by the use of an eccen-
tric cam. This cam moves the gear teeth closer Remove the seat section top for access to the cam
together to eliminate gear lash. This adjustment locking set screws and loosen the set screws.
arrangement compensates for any wear between Use an allen wrench to turn the cylinder eccentric
the gears that might occur. cams as required to shift either cylinder fore or aft
as needed so no twisting or flexing of the back
To adjust: section is observed when it is stalled in the full up
Loosen the cam locking allen set screw. Use an position. See figure 2-2. Tighten the set screws
allen wrench to rotate the eccentric cam. See and replace the seat section top when the adjust-
figure 2-1. Tighten the locking set screw when ment is completed.
adjustment is complete.

ECCENTRIC
CAM
BACK SECTION

SEAT SECTION TOP

SET SCREW

ALLEN SET BACK SECTION CYLINDER

WRENCH SCREW ECCENTRIC CAM
Figure 2-1. Eccentric Cam Adjustment

2-2. Hydraulic Cylinder Adjustment

The hydraulic cylinder rams that control both the

back and foot / 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.

NOTE
Figure 2-2. Back Section Adjustment
Adjust gear mesh before adjusting ec-
centric cams for the back section.
b. Leg Section
a. Back Section
Position the leg section all the way up. Both sides
of the leg section should stop moving at the same
Position the back section all the way up until it
time and should not show any signs of twisting.
stalls. Both sides of the back section should stop
moving at the same time and should not show any
Any twisting or flexing of the leg section as it
signs of twisting.
approaches the stalled position indicates that one
of the cylinders is not reaching its fully extended
Any twisting or flexing of the back section as it
position at the same time as the other and an
approaches the stalled position indicates that one
adjustment is required.
of the cylinders is not reaching its fully extended
position at the same time as the other. This
condition would require an adjustment.

Page 11
 To adjust:
NOTE
Place the head section in level position and remove
the top. See figure 2-4. Loosen but do not remove
The leg section cylinder eccentric cam
the allen bolts securing the bearing block to the
is located under the nameplate on the
frame. Loosen the allen bolt in the top of the frame
side casting. To make an adjustment,
and turn the set screw as required to achieve
the nameplate will have to be removed
proper adjustment. One or both of the blocks may
and a new nameplate will have to be
require adjustment to achieve proper alignment.
installed when the adjustment is com-
Tighten all allen bolts when adjustment is complete.
pleted.
Test the head section throughout its range of travel.
Re-adjust as needed. Replace top section when
To adjust:
proper adjustment is achieved.
Loosen the cam locking set screws located inside ADJUSTMENT
the table side frames. See figure 2-3. Use an allen SET SCREW
wrench to turn the cylinder eccentric cams as ALLEN
required to shift either cylinder fore or aft as needed BOLT
so no twisting or flexing of the leg section is ob-
served when it is stalled in the above horizontal
position. Tighten set screws when proper adjust-
ALLEN
ment is achieved. BOLTS

Figure 2-4. Head Section Adjustment

2-4. Torque Specifications

6600 NAMEPLATE

If the bolts for the Trendelenburg end caps or the

lateral tilt housing are removed, refer to figure 2-5
for the proper torque specifications when installing
the bolts.
LEG SECTION ALLEN BOLT
M10 x 30
TORQUE TO 58 FT-LBS
LEG SECTION CYLINDER ALLEN BOLT
M6 x 20
ECCENTRIC ARM TORQUE TO 156 IN-LBS

TRENDELENBURG LATERAL TILT

TAIL CAP HOUSING

Figure 2-3. Leg Section Adjustment

2-3. Head Section Adjustment

The head section can be adjusted to eliminate any Figure 2-5. Torque Specifications
flexing throughout it's range of travel.
NOTE
Trendelenburg Head Cap Bolts Torque
to 120in-lbs

Page 12
 SECTION III HYDRAULIC TROUBLESHOOTING

3-1. Precautions
5. Is the problem no movement of a table
Before attempting to troubleshoot any hydraulic surface or does the table surface lose position?
problem on the table, please read through the pre-
cautions and notes below. Once the problem has been determined, concen-
trate on that particular hydraulic circuit or control
function.
CAUTION
Listed below are the hydraulic components that
When disconnecting any of the hydrau- are common with all hydraulic circuits. If there is a
lic lines, fittings, joints, hoses, etc., for problem with any of them, it could affect all control
the following control functions, be sure functions.
these table surfaces are in their down
position or completely supported. 1. Motor/Pump Assembly
2. Reservoir
Elevation 3. Pressure Relief Valve
Back Section 4. Certain Oil Lines and Galleys
Leg Section
Kidney Lift If there was a problem in the following components,
only one control function would normally be af-
When working on the trendelenburg or fected.
lateral tilt hydraulic circuits, be sure to
support the table top. When working on 1. Mini-Valve
the brake system make sure the brakes 2. Slave Cylinder
are completely retracted. 3. Oil Lines

NOTE
WARNING
Whenever a hydraulic line or compo-
Failure to follow these precautions may nent is replaced, bleed the air out of the
result in an uncontrolled oil spray and lines using the pump pressure before
damage to the table or personal injury. making the final connection. After all
connections are tight, cycle the control
function back and forth two or three
3-2. Troubleshooting Notes times to purge the remaining air from the
system.
When troubleshooting a table malfunction, first
determine the following:
CAUTION
1. Does the problem affect all control func-
tions? When installing new "O" rings use hy-
draulic oil to thoroughly lubricate the "O"
2. Does the problem affect only one control rings and cylinder. Keep everything
function? clean.

3. If the problem affects one control function is

it in both directions? Each complete oil circuit is shown on the following
pages. When troubleshooting a particular function,
4. Is the problem intermittent? refer to the appropriate oil circuit diagram and the
list of possible problems.

Page 13
 3-3. ELEVATION DIAGNOSIS CHART
Reason
Problem Pressure Relief Valve Not Set Properly
Table will not elevate properly Low on Oil
Spool Valve Not Centered
Defective Pump
Defective Mini-Valve
Defective Solenoid or Wiring
Defective Relay Box or Pendant Control
Leaking Cylinder Hose
Uneven Weight Distribution

Table will not descend properly Incorrect Speed Adjustment

Bad Check Valve
Spool Valve Not Centered
Galled Slider Assembly
Defective Solenoid or Wiring
Defective Relay Box or Pendant Control
Uneven Weight Distribution

Table loses elevation Bad Check Valve

Leaking Mini-Valve
Loose Fittings, Joints, Hoses
Leaking "O" Ring Inside Cylinder

PRIMARY
PISTON
O-RING

SECONDARY
COPPER PLUMBING PISTON
LINE TERMINAL O-RING

CHECK
VALVE

SPEED
CONTROL INTERNAL OIL
FROM PUMP FLEXIBLE
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
Spool Valve Not Centered
Bad Check Valves
Low on Oil
Pinched Hose
Defective Mini-Valve
Pressure Relief Valve Not Set Properly
Bad Solenoid or Wiring
Defective Relay Box or Pendant Control

Trendelenburg function chatters or loses position Defective or Dirty Check Valve

Oil Leakage in Circuit
Air Inside Cylinder
Pinched Hose
Low on Oil

PINION
GEAR REAR PIVOT
BLOCK
O-RING
O-RING
FRONT PIVOT
BLOCK TAIL CYLINDER CAP

PISTON
ASSEMBLY

HEAD
CYLINDER
CAP
O-RING
FLEXIBLE
HOSES

HEAD DOWN
CIRCUIT HEAD UP
CIRCUIT
PLUMBING
TERMINAL

COPPER
LINES

CHECK VALVE

SPEED
INTERNAL OIL
CONTROL
FROM PUMP

MINI-VALVE INTERNAL OIL RETURN

TO RESERVOIR

Figure 3-2. Trendelenburg Circuit

Page 15
 3-5. LATERAL TILT DIAGNOSIS CHART

Problem Reason
Lateral tilt function moves improperly Incorrect Speed Adjustment
Spool Valve Not Centered
Bad Check Valves
Low on Oil
Pinched Hose
Defective Mini-Valve
Pressure Relief Valve Not Set Properly
Bad Solenoid
Defective Relay Box or Pendant Control

Lateral tilt function chatters or loses position Defective or Dirty Check Valves
Oil Leakage in Circuit
Air Inside Cylinder
Pinched Hose
Low on Oil

Figure 3-3. Lateral Tilt Circuit

Page 16
 3-6. FLEX SYSTEM DIAGNOSIS CHART

Problem Reason
Back Section or Trendelenburg function moves Incorrect Speed Adjustment (Trendelenburg, Back
improperly section or Flex - check with gauge)
Spool Valve Not Centered
NOTE Bad Check Valves
Low on Oil
If Flex System does not function prop- Pinched Hose
erly, check the back section and Defective Mini-Valve
Trendelenburg functions before ad- Pressure Relief Valve Not Set Properly
justing the flex system. Bad Solenoid
Defective Relay Box or Pendant Control
Kidney Bridge Raised

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

Figure 3-4. Flex System Circuit

Page 17
 3-7. BACK SECTION DIAGNOSIS CHART
Problem Reason
Back Section function moves improperly Incorrect Speed Adjustment
Spool Valve Not Centered
Bad Check Valves
Low on Oil
Pinched Hose
Defective Mini-Valve
Pressure Relief Valve Not Set Properly
Bad Solenoid
Defective Relay Box or Pendant Control
Kidney Bridge Raised
Back Section function chatters or loses position Defective or Dirty Check Valves
Oil Leakage in Circuit
Air Inside Cylinder
Pinched Hose
Low on Oil

Figure 3-5. Back Section Circuit

Page 18
 3-8. LEG SECTION DIAGNOSIS CHART
Problem Reason
Leg function moves improperly Incorrect Speed Adjustment
Spool Valve Not Centered
Bad Check Valves
Low on Oil
Pinched Hose
Defective Mini-Valve
Pressure Relief Valve Not Set Properly
Bad Solenoid
Defective Relay Box or Pendant Control

Leg function chatters or loses position Defective or Dirty Check Valves

Oil Leakage in Circuit
Air Inside Cylinder
Pinched Hose
Low on Oil

Figure 3-6. Leg Section Circuit

Page 19
 3-9. KIDNEY LIFT DIAGNOSIS CHART

Problem Reason
Kidney Lift moves improperly Incorrect Speed Adjustment
Spool Valve Not Centered
Bad Check Valve
Low on Oil
Pinched Hose
Defective Mini-Valve
Pressure Relief Valve Not Set Properly
Bad Solenoid
Defective Relay Box or Pendant Control

Kidney Lift chatters or loses position Defective or Dirty Check Valve

OiI Leakage in Circuit
Air Inside Cylinder
Pinched Hose
Low on Oil
Lift Rods Binding

KIDNEY LIFT
CYLINDER ASSEMBLY

DOWN CIRCUIT
UP CIRCUIT
FLEXIBLE
HOSES

PLUMBING
TERMINAL
COPPER
LINES

CHECK
VALVE

SPEED
CONTROL

MINI-VALVE

INTERNAL OIL INTERNAL OIL RETURN

FROM PUMP TO RESERVOIR

Figure 3-7. Kidney Lift Circuit

Page 20
 3-10. BRAKE CIRCUIT DIAGNOSIS CHART

Problem Reason
Brakes will not set properly Emergency Brake Release Valve Open or Defec-
tive
Spool Valve Not Centered
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
Defective Relay Box or Pendant Control

Brakes Will Not Stay Locked Emergency Brake Release Valve Open or Defec-
tive
Defective or Dirty Check Valve
Oil Leakage in Circuit
Leaking "O" Ring Inside Cylinder

Brakes will not retract properly Incorrect Speed Adjustment

Bad Check Valve
Spool Valve Not Centered
Defective Mini-Valve
Pinched Hose
Defective Solenoid or Wiring
Defective Relay Box or Pendant Control
Defective Brake Cylinder

BRAKE
CYLINDER

PLUMBING FLEXIBLE
TERMINAL HOSES

BRAKE FLEXIBLE
CYLINDER HOSES
FLEXIBLE
HOSE

RETURN TO
RESERVOIR

EMERGENCY
CHECK VALVE BRAKE RELEASE
SPEED
CONTROL
COPPER LINE
MINI-VALVE BRAKE
INTERNAL OIL CYLINDER RELEASE LEVER
FROM PUMP
INTERNAL OIL RETURN
TO RESERVOIR

Figure 3-8. Brake System Circuit

Page 21
3-11. Flexible Hose Identification and Placement KIDNEY CYLINDER
LEG CYLINDER, PISTON
INNER END CAP
(LEFT)
The following figures will show the correct place- KIDNEY CYLINDER
OUTER END CAP LEG CYLINDER, PISTON
ment of the flexible hydraulic hoses used in the (RIGHT)
table and their respective number codes.

Figure 3-9 shows the hose connections to the TOP VIEW

plumbing terminal.
FRONT
2 4 6 8 10 PIVOT BLOCK LEG CYLINDER, RAM (RIGHT)
1 3 5 7 9 11 LEG CYLINDER, RAM (LEFT)

Figure 3-11. Leg Section/Kidney lift Hoses

NUMBER FUNCTION
1 ELEVATION Figure 3-12 shows the placement and number
2 REV TREND code for the long flexible hoses which connect from
3 TREND the plumbing terminal to the front and rear pivot
4 TILT LEFT blocks.
5 TILT RIGHT NOTE
6 BACK DOWN
7 BACK UP The number codes will be on a label or
8 LEG UP stamped into the elevation clamp ring
9 LEG DOWN and the plumbing terminal.
10 KIDNEY DOWN
(3) TREND. (4) LAT. TILT LEFT
11 KIDNEY UP

Figure 3-9. Main Plumbing Terminal

Figure 3-10 shows the placement of the short TOP VIEW

flexible hoses which connect to the back section
cylinders. REAR PIVOT
BLOCK
FRONT
PIVOT BLOCK (2) REV. TREND
(5) LAT. TILT RIGHT
BACK CYLINDER, RAM (RIGHT)
Figure 3-12. Pivot Block Hoses
BACK CYLINDER, RAM (LEFT)
Figure 3-13 shows the placement and number
code for the long flexible hoses that connect from
the elevation clamp ring to the plumbing terminal.
TOP VIEW
FRONT (6) BACK SECTION, (10) KIDNEY, UP
PIVOT DOWN
BLOCK (11) KIDNEY, DOWN
BACK CYLINDER, PISTON (RIGHT) (8) LEG, UP
BACK CYLINDER, PISTON (LEFT)
TOP VIEW
Figure 3-10. Back Section Hoses
FRONT (9) LEG, DOWN
Figure 3-11 shows the placement of the short PIVOT BLOCK (7) BACK
flexible hoses which connect to the leg section SECTION, UP
cylinders and the kidney lift cylinder.
Figure 3-13. Elevation Clamp Ring Hoses

Page 22
Page 23
 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, micro-processor and
relay switches. The relay switches are activated
- ELEVATION - Up and Down by the pendant control signal to the micro-proces-
sor and in turn energize the solenoids.
- TRENDELENBURG - Head up and down
c. Hand-Held Pendant Control - Contains
- LATERAL TILT - Right and left circuit board mounted switches and a micro-pro-
cessor which activate the relay box. Operates on
- BACK SECTION - Up and Down 5 VDC.

- LEG SECTION - Up and Down d. Solenoids - These electrically open and

close the hydraulic ports of the mini-valve to direct
- FLEX / REFLEX the fluid to the correct cylinders. They operate on
120 VAC.
- KIDNEY LIFT - Up and down
e. Motor/Pump Assembly - 120 VAC, 60 HZ,
- RETURN TO LEVEL 200 Watt capacitor induction motor.

- BRAKE UNLOCK - Brake release

4-3. Battery Model Components
The power requirements are 120 VAC, 60 Hz. The
main power on-off switch is an enclosed DPST The functions of the battery model tables are the
circuit breaker type and the power cord is a three- same as the standard 120 VAC models. The
wire, fifteen foot long, UL listed cord with a three- electrical components and operation however, vary
prong hospital grade plug. greatly between the two models. To simplify the
troubleshooting procedures, the battery model
tables are covered separately in Section VI for the
model 6600B.

Page 24
 SOLENOID PENDANT
COIL 120 VAC CONTROL

CN21
MINI-VALVES THROUGH
CN37

TO CN37
RETURN
CIRCUIT

CN35
CN36
CN3

CN7
BUZZER

CN1

RELAY BOX CN8

CN2A

CN10 AUXILIARY
SWITCHES
CN2B

CN12 CN4

CAPACITOR

CN15 PUMP

CN38
ICN1

MAIN FOOT
POWER CONTROL
SWITCH CONNECTOR
POWER
CORD

Figure 4-1. 6600 Electrical Circuit Block Diagram

Page 25
 SECTION V 6600 ELECTRICAL SYSTEM TROUBLESHOOTING
-1. Troubleshooting Notes
1. Plug the power cord into the 120VAC power
The basic operation of each component will be supply (wall receptacle) and turn ON the main
defined along with a drawing and explanation on switch.
how to check it out.
2. Disconnect connector CN4 from the relay
NOTE box. See figure 5-1. Leave all other connectors
This section does not cover the bat- connected.
tery table components. They are
covered separately in Section 6. WARNING

Certain defective components could cause the Line voltage (120 VAC) will be mea-
entire table to stop functioning or only one control sured in this test. Do not touch uninsu-
function to stop. It would depend on what part of the lated connector pins or meter test leads.
component failed. Other defective components
would only cause one control function to stop.
CN3
CN1 CN7
The following defective components could cause
all control functions to be affected:

a. Motor/Pump Assembly (starting capacitor) CN8

b. Main Switch Circuit and Wiring RELAY BOX CN2A

The following defective components could cause CN10

all control functions to be affected or only one
control function: CN2B
CN4
a. Relay Box
b. Pendant Control

The component listed below would only affect one Figure 5-1. Main Power Test
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 connector
When troubleshooting an electrical circuit, start at 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 Power
Switch. The Power Switch opens both lines when 5
in the "OFF" position. The Power Switch is also a 3
10 Amp circuit breaker that is used to protect the 2
complete electrical system. 4
1

PIN NO. COLOR

a. Main Switch Test 1 White

2 Black
3 Red
4 Blue
The following test will determine if line voltage is 5 Yellow
applied to connector CN4, which in turn would
power the table. Figure 5-2. Connector CN4

Page 26
b. Test Results

If you do not receive the correct voltage measure- OHM

ment, the problem would have to be in the wires,
main switch or power cord. If the correct voltage is
obtained, everything is good up to this point and the
problem would have to be in another area.
BLACK 1 2 BROWN 7 GREEN
5-3. Pendant Control WHITE 6 1 YELLOW
4 GREEN
RED 3 5 BLUE BLUE 5 2 RED
The Pendant Control is part of the solid state, multi-
plex, logic control system. The pendant control WHITE 6 BROWN 4
7 YELLOW 3 BLACK
contains illuminated, circuit board mounted switches
and a micro processor. The encoded output from the Test Leads
Base Conn. Pend. Conn. Base Conn. Pend. Conn.
pendant control is serial bit stream logic. Pin Pin Pin Pin
1 3 5 5
2 4 6 6
The output signal is transmitted to the micro pro- 3 2 7 1
4 7
cessors in the relay box where the logic is decoded
and the appropriate relays for the selected function
are activated. Figure 5-3. Pendant Control Test

Pendant Control troubleshooting should begin by c. Table Connector CN37 Test

switching the operating mode of the table. For
example; if a function fails when operating the table If correct readings are received, test the wiring
in the AC120V mode, use the auxiliary switches to from the table connector to connector CN7 at the
operate the function. If the function now operates, Relay Box. Disconnect connector CN7 from the
the problem is probably in the pendant control, Relay Box and using an ohmmeter, test the conti-
connectors or wiring from the pendant control to nuity between the corresponding pins in connec-
the relay box. tors CN7 and the table connector. See figure 5-4.

a. Pendant Control Test

OHM
There are some serviceable components within
the Pendant Control. The cord is detachable and 1
1
2
2
can be tested for continuity between the pins on the 3 4 5
3
4
connectors. Use the following procedure to test the 6 7
5
6
pendant control cord. CN36 7

TABLE CONNECTOR CN7

Disconnect the cord from the table connector and CN37 CN37 - CN7
from the pendant control connector and using an 1 BLACK 5 BLUE
2 BROWN 6 WHITE
ohmmeter, test the continuity between the corre- 3 RED 7 NOT USED
sponding pins in the connectors. See figure 5-3. 4 GREEN

b. Test Results Figure 5-4. Table Connector Continuity Test

d. Test Results
If you do not receive the correct readings, the
If the correct readings are not obtained, test the
wiring or connector pins may be faulty.
wiring from the table connector CN37 to connector
CN36 (located under the elevation column shroud)
and from connector CN7 to CN36. Disconnect
connector CN36 and using an ohmmeter, test the
continuity between the corresponding pins in con-
nectors CN36 to CN7 and CN36 to CN37. See
figure 5-4.

Page 27
If the correct readings are obtained, this part of the
circuit is okay and the problem may be the Pendant
Control circuit board or the Relay Box. Contact
SKYTRON if all tests performed indicate that the OHM
problem is located in the Pendant Control.
Figure 5-6. Auxiliary Switch Test
5-4. Auxiliary Switches
5-5. Relay Box
The following tests will determine if the auxiliary
switches are functioning properly. The power supply is directly connected to the relay
contacts. When these contacts are closed, 120
a. Switch Test volts is supplied to the solenoids which are mounted
on the hydraulic mini-valves. One relay is used to
Disconnect connector CN3 at the Relay Box and supply power to the pump/motor and is always
using an ohmmeter check for continuity at the activated no matter what control function is se-
connector pins (pin 1A common) while activating lected. The brake locking circuit relay is also
the appropriate switch. See figure 5-5. Meter activated when any control function other than
should read 0 ohms. BRAKE UNLOCK is initially selected.
b. Test Results Also, inside the relay box is a step-down transformer
and full-wave rectifier which decreases the voltage to
If proper meter readings are not received, test the 5-6 volts. This low voltage potential controls the
individual switches as necessary. Using an ohmme- relays by the use of the hand-held pendant control
ter, test the operation of an individual switch with the buttons. Basically the relays enable a 5-6 volt poten-
(+) test lead at the center terminal of the switch and tial to control the 120 volt circuit.
the (-) test lead at the terminal opposite the direction
of the switch actuation. Refer to figure 5-6. Meter The following tests will determine if the relay box is
should read 0 ohms. If the switches check out, the functioning correctly.
problem would have to be in the wires, the switch
circuit board or connector CN3.
B8/B2 B8/A3 B8/A4 B8/A1 B8/A7 B8/B6
CN3 REV TILT BACK TABLE LEG BRAKE
SW1 TREND RIGHT UP UP UP LOCK

TABLE UP
1
TREND TILT BACK TABLE LEG KIDNEY
LEFT DOWN DOWN DOWN DOWN
TABLE DOWN
2
B8/A2 B8/B3 B8/B4 B8/B1 B8/B7 B8/A6
TREND SW2
3
REV TREND 15 (A8)
4
TILT RIGHT OHM
5
TILT LEFT SW3 16 (B8)
6
1 (A1)
BACK UP
7
BACK DOWN CN8
8

9 SW4 2 (B1)
10 PIN NO COLOR PIN NO COLOR
KIDNEY DOWN
11 1 (A1) Red 9 (A5) --
BRAKE LOCK SW5 2 (B1) White/Red 10 (B5) --
12
LEG UP 3 (A2) Brown 11 (A6) White/Purple
13
LEG DOWN
4 (B2) Yellow 12 (B6) Purple
14
5 (A3) Orange 13 (A7) Gray
PUMP MOTOR SW6
15 6 (B3) White/Orange 14 (B7) White/Gray
+24V 7 (A4) White/Brown 15 (A8) Red/White
16
8 (B4) Blue/White 16 (B8) Pink
Purple/White (-A) White/Yellow (-A)

Figure 5-5. Auxiliary Switch Connector CN3

Page 28
a. Checking Relay Box Connector CN4
NOTE
1. Connect the power cord to the table. Plug the •The Brake Lock function is activated
power cord into the 120 VAC power supply (wall by pressing any function button (except
receptacle) and turn the main switch ON. Leave all BRAKE UNLOCK). A timer in the Re-
connectors connected. lay Box allows continuous output for
about 7 seconds. If the brakes are
WARNING already locked, no output is provided.
Line voltage (120 VAC) will be mea-
sured in this test. Do not touch uninsu- •The BRAKE UNLOCK button activates
lated connector pins or meter test leads. another timer in the relay box which
allows continuous output for the brake
release function for approximately 7
2. Use an AC voltmeter capable of measuring seconds. If the brakes are released
120 volts and measure the voltage between pins 1 (using the BRAKE UNLOCK button) no
(white) and 2 (black) of connector CN4 for input output is provided.
voltage. See figure 5-7. Meter should read line
voltage 120 VAC. 1. The power cord should be plugged into the
wall receptacle and Power Switch turned ON.
3. Activate any table function with the Pendant
Control and using an AC voltmeter, test the voltage 2. Disconnect the motor connector. All other
at pins 3 and 4 of CN4 for output to the pump. Meter connectors should be connected. Test connectors
should read 120 VAC. CN1, CN2A and CN2B from the back while at-
tached to the relay box.
4 ACV 3. Activate each of the Pendant Control buttons
measure the voltage for the corresponding con-
nector pins with an AC voltmeter. See figure 5-8.
5 Meter should read 120VAC.
PIN NO. COLOR

1 WHITE
2 BLACK
3 RED ACV
4 BLUE
5 YELLOW
1
Figure 5-7. Connector CN4

b. Test Results: CN1, CN2A OR CN2B

16
CN1 CN2A
If you do not receive the correct meter readings, the
relay box or wiring is defective. If the correct FUNCTION PINS FUNCTION PINS

readings are obtained, this part of the relay box is Table Up 1-2 Back Up 1-2
Table Down 3-4 Back Down 3-4
okay. Proceed to the next step. Trend 5-6 Slide Foot 5-6
Rev Trend 7-8 Slide Head 7-8
Tilt Right 9 - 10 Kidney Up 9 - 10
c. Checking Output to Solenoids Tilt Left 11 - 12 Kidney Down 11 - 12
Reflex 13 - 14 Leg Up 13 - 14
Flex 15 - 16 Leg Down 15 - 16
This test checks the high voltage (120V) that is
CN2B
used to energize the solenoids.
Brake Set 1-2
Brake Unlock 3-4

WARNING
120 VAC will be measured in this test.
Figure 5-8. Solenoid Output Connectors
Do not touch uninsulated connector
pins or meter test leads.
Page 29
d. Test Results:

If you do not receive the correct meter readings, the NOTE

relay box or wiring is defective and should be
replaced. Each solenoid is controlled with 120V
source coming from the relay box. This
source can easily be checked by mea-
NOTE suring the voltage at the 2 pin connector
in question.
Before deciding the relay box is de-
fective, check the wires and pins in the
connector blocks to make sure they are WARNING
not loose or making a bad connection
with their mate. Line voltage will be measured in this
test. Do not touch uninsulated connec-
tor pins or meter test leads.
e. Checking Output to Pendant Control

The output to the Pendant Control can not be tested b. Step #1

without specialized equipment. If all tests have
been conducted and it appears that the Relay Box 1. Plug the table cord into the wall receptacle
is faulty, contact SKYTRON. and turn main switch ON.

5-6. Solenoids 2. Disconnect the 2 pin connector from the

solenoid in question. See figure 5-9.
The solenoids are energized by 120 volt potential
that is controlled by the relays located inside the 3. Use a voltmeter capable of measuring 120
relay box. VAC and measure the voltage across the 2 pin
connector. Polarity of meter leads is not important.
The solenoid windings are protected from exces-
sive heat with an internal thermal fuse that will open
after approximately seven (7) minutes of continu- NOTE
ous operation. The solenoid must be replaced if the
internal thermal fuse has been blown. The sole- The appropriate pendant control but-
noids are mounted directly on either side of the ton must be pushed during this test.
hydraulic mini-valves and push the spool valve in The motor will run when this test is
one direction or the other depending upon which performed, and the brake locking sole-
solenoid is activated. noid will be activated by any function
other than UNLOCK.
a. Solenoid Test

The following tests check the voltage applied to the c. Test Results:
solenoids and the resistance of the solenoid coil.
If you do not receive the correct voltage, the prob-
lem could be in the wires leading to the connectors.
NOTE The problem could also be in the relay box or the
Pendant Control (refer to appropriate section for
If a solenoid does not function when the troubleshooting).
pendant control button is pushed, the If the correct voltage is obtained, everything is good
problem could be the pendant control, up to that point and the problem is more than likely
the relay box, or the solenoid. the solenoid.

Page 30
d. Test #2 e. Test Results:

The solenoid can be checked out using an ohm- If the solenoid does not check out with the meter, it
meter R x 1 scale. is more than likely defective and must be replaced.

1. Measure the resistance between the two

pin connector in question as shown in figure 5-9. NOTE
Connector must be disconnected. Polarity of
meter leads is not important. Whenever there are several compo-
nents of the same type, a defective unit
2. The meter should read approximately 58 can also be detected by substituting a
ohms at room temperature. known good unit or wire connector. In
some cases this may be faster than
3. Measure the resistance between either pin using a multi-meter.
and ground.

4. Meter should read infinity.

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/ BLACK/
UP HD RT. REFX UP DN. UP UN BLUE WHITE
DN. LOCK

CN2B
4
LAT. BACK LEG 3
ELEV. TREND TILT FLEX SECT. SECT. KIDNEY BRAKE 2
1

HD
DN. UP. LT. FLEX DN. UP DN. LOCK
BLUE BLUE
CN2A
WHITE/BLUE WHITE/BLACK 16
15
14
13
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 5-9. Solenoid Test

Page 31
5-7. Motor/Pump Assembly

The electric motor is a capacitor start type with a 3. Use a voltmeter capable of measuring 120
rating of 120 VAC, 200 watts. The field windings VAC and measure the following connector pins in
are protected with a thermal protector that will open connector CN15. See figure 5-11.
the winding circuit if the motor is run continuously
for approximately 10 minutes. This protector will
take about 10 minutes to automatically reset. The
oil pump unit is attached to the bottom of the motor
and is a gear type displacement pump with a ACV
pumping capacity of .4 liter per min. The Motor/ 3
Pump Assembly is mounted on an insulated motor
plate in the base of the table. The starting capacitor
is mounted along side the motor/pump assembly. 2
1

PIN NO AC VOLTS

1-2 120
a. Motor/Pump Test 1-3 120
2-3 0
The following tests will check the voltage applied to
the motor and the resistance of the motor field
windings. Figure 5-11. Connector CN15

WARNING c. Test Results:

Line voltage will be measured in this If you do not receive the correct meter readings, the
test. Do not touch uninsulated connec- problem could be in the wires, connectors, relay
tor pins or meter test leads. box, or main switch (refer to appropriate section for
troubleshooting).

If the correct voltage is obtained, everything is good

b. Step #1 up to that point and the problem could be either the
motor or the starting capacitor.
1. Plug the power cord into 120 VAC power
supply (wall receptacle). Turn main switch ON. d. Step #2

2. Disconnect the 3 pin connector CN15 at the If the starting capacitor is shorted or grounded, the
motor. Leave all other connectors connected. See motor will not run. Capacitors very seldom fail, and
figure 5-10. it requires a dielectric tester to accurately test one.
However, an ohmmeter can be used to determine
if the capacitor will store a low voltage charge and
CAPACITOR most of the time this is adequate.

1. Turn the main switch OFF.

CN15 PUMP 2. Connector CN15 should be disconnected.

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

touch pins 2 and 3 of connector CN15. See figure
5-11.
Figure 5-10.

Page 32
e. Test Results:

The meter needle should move up scale and then

back down to infinity. This would indicate that the
capacitor is storing an electrical charge.

NOTE
OHM
The capacitor may have to be discharged
first (by shorting pins 2 and 3 together)
before you will be able to see the ohmme-
ter needle swing up the scale.
PIN NO METER

1-2 Approx. 5 ohms

1-3 Approx. 4 ohms
f. Step #3 2-3 Approx. 8 ohms

The motor windings can be statically checked for

resistance using an ohmmeter.
Figure 5-12. Pump Connector CN15
1. Turn main power switch OFF.

2. Connector CN15 should be disconnected.

g. Test Results:
3. Use the R x 1 scale of the ohmmeter and
measure the resistance between the pins located If you do not receive the correct meter readings, the
in the pump connector CN15. See figure 5-12. motor or wiring is defective.

Page 33
5-8. Return-to-Level Micro-Switches.
tion. The micro-switches are either cam or lever
The return-to-level feature is activated by a single actuated and can be adjusted at the individual
button on the pendant control and automatically switch mounting brackets.
levels the major table functions, lateral tilt, Trende-
lenburg, back section, and leg section. The micro-switches operate on low voltage, and
control the function circuits (pump/motor and ap-
The kidney lift has a back section-up inhibit switch propriate solenoid valves) when activated by the
to prevent the table back section from damaging pendant control LEVEL button.
the kidney lift when the lift is raised. The back
section still has the capability to be lowered, but will The micro-switches are wired to the relay box
not raise above horizontal until the kidney lift is through a riser cord and to the 15 pin connector
completely down. If the back section is raised CN10. See figure 5-13 for switch location and
above horizontal, the system will not allow the identification.
kidney lift to be raised. An audible alarm will sound
if the kidney lift inhibit switch is activated and either 5-9. Troubleshooting
function is activated - raising back section when
Kidney lift is up or raising kidney bridge when back If a problem is suspected in the return circuits,
section is above horizontal. disconnect the connector CN10 from the Relay
Box to eliminate the circuits. Ensure that all table
The return-to-level / kidney inhibit system consists functions operate properly using the Pendant Con-
of 9 micro-switches, 2 electrical connectors, and trol. If the functions do not work properly using the
the related wiring. The micro-switches are mounted Pendant Control, refer to the appropriate test sec-
on or adjacent to the function they control and are tion and make all needed repairs before working on
wired for normally open or normally closed opera- the return circuits.

NS-6

NS-7

NS-3

TOP VIEW 6600

NS-2 NS-1
NS-4

LS-1

NS-5
NS-8
RISER CORD

CN35 LS - 1 Back Up Inhibit SW.

NS - 1 Trendelenburg
NS - 2 Rev. Trendelenburg
NS - 3 Lateral Tilt (Left)
NS - 4 Lateral Tilt (Right)
NS - 5 Back Section
(Back Down-Level)
RELAY BOX NS - 6 Back Section
(Back Up-Level)
NS - 7 Leg Section
(Leg Down-Level)
NS - 8 Leg Section
(Leg Up-Level)
CN10

Figure 5-13.

Page 34
 a. Switch Test
NOTE
Turn Main Power ON, lock the table brakes, and
It is normal for the back section to move place the table top sections in a level position with
up if the LEVEL button is pushed when the Kidney Lift down. Disconnect connector CN10
connector CN10 is disconnected from from the relay box and using an ohmmeter, test the
the relay box. wiring and switch operation at the appropriate pin
numbers for the micro-switch in question as shown
All of the micro-switches are connected to the relay in figures 5-15 through 5-19.
box via a wiring harness and the micro-switch riser
cord using connectors CN10 and CN35. Connec- NOTE
tor CN35 is located under the slider shroud in the
same area as the hydraulic hoses. Connector Be sure to isolate the circuit when mak-
CN10 plugs into the relay box and is the most ing continuity checks.
convenient location to make circuit continuity
checks. See figure 5-14 for connector pin loca- NOTE
tions.
If you do not receive the proper continu-
NOTE ity results at connector CN10 it does not
necessarily mean the micro-switch is
Wire colors may vary, however, con- defective. There could be a problem
nection from indicated pins on CN35 to with the riser cord between connectors
pins on CN10 remain the same. CN10 and CN35, or in the wiring from
the switch to connector CN35. Further
tests will have to be made to determine
the exact problem.
CN10

NS-1 RED 1
1
TREND WHITE 2
2
NS-2
NS-3 YELLOW 3
3
LAT. TILT GREEN 4
4
NS-4
NS-5 BLUE 5
5
PURPLE
BACK BOARD 6
BROWN/WHITE 6
7
NS-6
NS-7 GRAY 7
8
LEG BOARD BLACK 8
10
NS-8
ORANGE/WHITE 9
KIDNEY LIFT 9
LS-1
10

11

12

RED/WHITE 13
11
BLACK/WHITE
12
PINK (WH/RED -A) 14
13
BROWN
14
ORANGE 5V 15
15

CN10
CN35

Figure 5-14. Return Micro-Switch Test

Page 35
 15

11
RED/WHITE RISER CORD
11 CN10
ORANGE/WHITE
9
COM
CN35

LS-1

KIDNEY LIFT CYLINDER

LS-1. Back Up Inhibit
Test at pins 11 & 15
(Base)
Table Switch Meter
Position Position Reading

K-Lift Dn Open Infinity

K-Lift Up Closed 0

When K-Lift is UP, Back Section Can

Not go above horizontal

Figure 5-15. Back Up Inhibit Switch

Test at pins 1 & 15

RevTrend
Trend
ORANGE
BLACK
NO COM COM NO
WHITE RED
NC NC
NS-2 NS-1

2 SIDE VIEW 1 15 Test at pins 2 & 15

CN35 CN35

RISER CORD RevTrend

Trend

2 1 15
CN10 CN10

Figure 5-16. Trendelenburg Return Switches

Page 36
 15
14

CN35 CN10

Test at pins 3 & 15 Test at pins 4 & 15

Figure 5-17. Lateral Tilt Return Switches

NS-6
5

6
RISER CORD
COM PURPLE CN10
NO 6
BROWN/WHITE
7
CN35

BLUE
6
PINK
NO 13
COM
CN35
5

15
NS-5 RISER CORD
CN10

Test at pins 5 & 15 Test at pins 6 & 15

Figure 5-18. Back Section Return Switches

Page 37
 Test at pins 7 & 15

Table Switch Meter

Position Position Reading

Level Open Infinity

Leg-Dn Closed 0

NS-7 NS-8

COM NO NC NO COM
WHITE

WHITE/BLACK GRAY BLACK

Test at pins 8 & 15
12 8 8
CN35 CN35 Table Switch Meter
Position Position Reading
RISER CORD Level Open Infinity
Leg-Dn Open Infinity

15 7 13
CN10 CN10

Figure 5-19. Leg Section Return Switches

2. For all switches except the Leg Section

b. Switch Adjustment. switches, carefully loosen the switch retaining
screws, and adjust the switches as needed. See
If proper readings are not obtained during test or if figure 5-20.
table does not properly return to level, use the
following procedure to adjust the switches. 3. To adjust the Leg Section switches remove
seat section top, loosen the 2 phillips head screws
1. Apply table brakes and (using a level) level securing bracket, adjust the switch, tighten the
the table top using the TRENDELENBURG and screws and replace the seat section top. See
LATERAL-TILT function buttons on the pendant figure 5-21.
PHILLIPS HEAD
control. SCREWS

RETAINING LEG SECTION BRACKET

SCREWS MICRO-SWITCH

MICRO-SWITCH

JAM
NUTS
Figure 5-20. Micro-Switch Adjustment
Figure 5-21. Leg Section Micro-Switch
Adjustment.
Page 38
 6600B

SOLENOID
COIL 24VDC PENDANT
CONTROL

CN18
MINI-VALVES THROUGH
CN34

TO CN37
RETURN
CIRCUIT

CN28 CN35
CN36
CN3

CN7

CN1

RELAY BOX CN8

BUZZER

CN2A

CN10 AUXILIARY
SWITCHES
CN2B
BATTERIES
CHARGER BOX
CN4
CAPACITOR + -
PUMP

SWITCH-OVER
RELAY

- + CN17 CN16
22 VAC FROM
TRANSFORMER
120 VAC TO
TRANSFORMER

CN14
FUSE
CHARGER 15AMP
BOX CN12
CN15 CN13

3P INLET CONN.
ICN1
CN38

MAIN FOOT
POWER CONTROL
SWITCH CONNECTOR
POWER BATTERY
CORD CHARGE
INDICATOR

Figure 6-1. Electrical Circuit Block Diagram, Model 6600B

Page 39
 6600B
SECTION VI -6600B- 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
components to transform the 120VAC input to Power Switch. The Power Switch opens both
24VDC output to the components. lines when in the "OFF" position. The Power
Switch is also a 10 Amp circuit breaker that is used
6-2. Troubleshooting Notes to protect the complete electrical system.

The basic operation of each component will be a. Main Switch Test

defined along with a figure and an 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 6-1. Leave all other connectors connected.
all control functions to be affected:
a. Motor/Pump Assembly
b. Main Switch Circuit and Wiring CAUTION
c. Pendant control
The following defective components could cause Line voltage (120 VAC) will be mea-
all control functions to be affected or only one sured in this test. Do not touch uninsu-
control function: lated connector pins or meter test leads.
a. Relay Box
b. Pendant Contro l 3. Use an AC voltmeter capable of measuring
c. Auxilliary Switches 120 VAC and measure the voltage between pins 1
The component listed below would only affect one and 2 (black and white wires) located in connector
control function: CN12. See figure 6-2. You should receive line
Solenoid voltage 120 VAC.

When troubleshooting an electrical circuit, start at BLACK

(2)
the problem and work back to the power source.

NOTE
•Battery table troubleshooting should be- ACV WHITE
gin by switching the operating mode. For (1)
example; if a function fails in the AC120V
mode, switch to the BATTERY mode. If Figure 6-2. Connector CN12 Test
the function now operates, the problem is
probably located between the power cord b. Test Results
and the relay box. If the function also fails
in battery operation, use the auxiliary If the correct voltage is obtained, everything is
switches. If the function now operates, good up to this point and the problem would have
the problem is probably in the pendant to be in another area.
control, connectors or wiring from the If you do not receive the correct measurements,
pendant control to the relay box. the problem would have to be in the wires, Power
•All connector pins are numbered usually Switch, Power Cord, or main electrical Power Cord
with very small numbers. connector (3p inlet connector).

Page 40
 6600B
Check the continuity from the power cord connec-
tor ICN1, through the switch and wiring to connec-
tor CN12. Remove the power cord, disconnect
CN12 (black and white wires), and test as shown
in figure 6-3. BATT 1 BATT 1
BLACK
TO GROUND
DCV
ICN1 CN12
WHITE
2
1
N
L OHM

Figure 6-4.
Figure 6-3. CN12 to ICN1 Continuity Test
b. Test Results
6-4. Batteries
A reading of 11 volts or below indicates the battery
The BATTERY operating mode is powered by two needs charging.
12 volt batteries connected in series to provide the
24 volt operating power. After batteries have been fully charged, repeat the
full load test. If either battery's voltage drops below
The battery system voltage should be 24VDC at a 11VDC it should be replaced.
range of 22VDC to 26VDC. If the battery charge
level falls below 23.5 volts the BATTERY operation 6-5. Battery Charging Box/AC120V Transformer
indicator on the pendant control will blink indicating
that the batteries require recharging. The built-in The Battery Charging Box contains the battery
charging system automatically keeps the batteries charging system as well as the components for
at the proper charge level when the AC120V oper- AC120V operation (except the transformer).
ating mode is ON. The charging system will
operate while the table is being operated in the a. Transformer Test
AC120V mode.
1. Confirm 120VAC input at CN12 using Main
a. Battery System Test Switch test in 6-3a.

1. Disconnect the main power cord and using 2. Connect CN12, disconnect CN13 (brown
a DC voltmeter, test each individual battery at its and red wires) and using an AC voltmeter, test the
terminals. Meter should read 12VDC ± 1V. transformer output at CN13. See figure 6-5.

2. To accurately test the batteries, they must 3. Meter should read 22VAC.
be tested under a full load. Disconnect the main
power cord and make sure all other connectors are
connected.
BROWN
(2)
3. Turn BATTERY power ON and elevate the
table to its full up position.

ACV RED
4. Continue to press the TABLE UP button on the (1)
pendant control so that the pump motor continues to
run and using a DC voltmeter, check the voltage drop
of each battery individually. See figure 6-4.
Figure 6-5. Connector CN13 Test
5. Meter should read 12VDC ± 1VDC.

Page 41
 6600B
b. Test Results e. Charging System Output Adjustment

If the correct voltage is obtained, everything is If output reading at pins 3 and 4 is not 26.5 ± 0.5
good up to this point and the problem would have VDC, the output can be adjusted at the variable
to be in another area. resistor VR51 on the circuit board inside the Charg-
If you do not receive the correct measurements, ing Box. See figure 6-7. Turn the adjuster clockwise
the problem may be in the wires, connectors, or to decrease the voltage. Counterclockwise to
transformer. The transformer is located in the rear increase the voltage.
of the base under the stainless steel base cover.
The stainless steel cover will have to be discon-
nected and lifted from the base for access to the NOTE
transformer for further testing.
The battery connectors must be discon-
c. Battery Charging Box Test nected to adjust the battery charger out-
put.
1. Make sure all connectors are connected and
turn AC120V operation ON. Using a DC voltmeter,
test pin 3(+) and pin 4(-) of CN14. DO NOT
disconnect connector CN14. See figure 6-6.

CN14
RED
(3) VR-51
53
(5) RED / WHITE 1

(6) BLUE / WHITE

Figure 6-7.
BLACK
(4) DCV
(2) BROWN (1) BROWN

NOTE
Figure 6-6. Connector CN14
Normal charging time for a fully dis-
charged battery is approximately 8
2. Meter should read 26.5 ± 0.5 VDC. hours.

3. Test pin 5(+) and pin 6(-) of CN14 with DC

voltmeter to test operation of CHARGING indicator
light (next to power cord connector).

4. Meter should read 26.5 ±0.5 VDC if charger

is operating. If batteries are fully charged there will
be under 5 volts at pins 5 and 6.

d. Test Results

If you do not receive the correct readings, the

charger system, connectors, wires, or the trans-
former may be defective.

Page 42
 6600B
6-6. Switch-Over Relay
NOTE
a. Switch-Over Relay in OFF Position The battery charging circuit is only op-
erational when the table is in the
The Switch-Over Relay supplies the 24 volt input AC120V operating mode.
power from either the BATTERY or AC120V oper-
ating modes to the relay box for table operation. In
the normal OFF position, BATTERY power is sup-
plied to the relay box. See figure 6-8. c. Switch-Over Relay Test

RELAY BOX (-) Using a DC voltmeter, test the operation of the

CN4 relay in both the OFF (AC120V - OFF) and Acti-
S-O RELAY vated (AC120V - ON) positions. See figure 6-10.
FUSE
2 7
15A NOTE
1 The Switch-Over Relay mounting block
8
may have to be removed from the base
3 6
for test access.
4 5
OFF: (AC120V - OFF)
term. 7(-) and term. 1(+) = 24 to 28VDC
term. 7(-) and term. 6(+) = 0VDC
BATTERY (+)
Figure 6-8. Relay in OFF Position Activated: (AC120V - ON)
term. 7(-) and term. 6(+) = 26.5±1VDC
b. Switch-Over Relay in Activated Position

When the AC120V mode is activated by the main

switch, a signal from the relay box activates the
2 7 DCV
Switch-Over Relay. The relay then supplies the AC
operating mode output power to the relay box and
1 8
also activates the battery charging circuit. See
figure 6-9.
AC120V operating mode.

3 6
RELAY BOX RELAY BOX (-)
CN4 SIGNAL OUT 4 5
S-O RELAY
FUSE 2 7 Figure 6-10. Switch-Over Relay
15A
1 8
3 6 6-7. Pendant Control
4 5
CAPACITOR The Pendant Control is part of the solid state, multi-
plex, logic control system. The pendant control
BATTERY(+) contains illuminated, circuit board mounted switches
and a micro processor. The encoded output from the
pendant control is serial bit stream logic.
CN15 CN14
The output signal is transmitted to the micro pro-
CHARGING cessors in the relay box where the logic is decoded
BOX and the appropriate relays for the selected function
Figure 6-9. Relay in Activated Position are activated.

Page 43
 6600B

Pendant Control troubleshooting should begin by c. Table Connector CN37 Test

switching the operating mode of the table. For
example; if a function fails when operating the table If correct readings are received, test the wiring from
in the AC120V mode, switch to the BATTERY the table connector to connector CN7 at the Relay
mode. If the function now operates, the problem is Box. Disconnect connector CN7 from the Relay
not the pendant control and probably is a problem Box and using an ohmmeter, test the continuity
located between the power cord and the relay box. between the corresponding pins in connectors
If the function also fails when in battery operation, CN7 and the table connector. See figure 6-12.
use the auxiliary switches to operate the function.
If the function now operates, the problem is prob-
ably in the pendant control, connectors or wiring
from the pendant control to the relay box.
OHM
a. Pendant Control Test
1
1 2 2
3
There are some serviceable components within 3 4 5 4
5
the Pendant Control. The cord is detachable and 6 7 6
7
can be tested for continuity between the pins on the CN36
connectors. Use the following procedure to test the TABLE CONNECTOR CN7
pendant control cord. CN37 CN37 - CN7
1 BLACK 5 BLUE
2 BROWN 6 WHITE
Disconnect the cord from the table connector and 3 RED 7 NOT USED
from the pendant control connector and using an 4 GREEN
ohmmeter, test the continuity between the corre-
sponding pins in the connectors. See figure 6-11. Figure 6-12. Table Connector Continuity Test

d. Test Results

OHM If the correct readings are not obtained, test the

wiring from the table connector CN37 to connector
CN36 (located under the elevation column shroud)
and from connector CN7 to CN36. Disconnect
BLACK 1 2 BROWN
connector CN36 and using an ohmmeter, test the
7 GREEN
4 GREEN
WHITE 6 1 YELLOW continuity between the corresponding pins in con-
nectors CN36 to CN7 and CN36 to CN37. Refer to
RED 3 5 BLUE BLUE 5 2 RED figure 6-12.
BROWN 4
If the correct readings are obtained, this part of
WHITE 6
7 YELLOW 3 BLACK the circuit is okay and the problem may be the
Test Leads Pendant Control or the Relay Box. Contact
Base Conn.
Pin
Pend. Conn.
Pin
Base Conn.
Pin
Pend. Conn.
Pin
SKYTRON if all tests performed indicate that the
1 3 5 5
problem is located in the Pendant Control.
2 4 6 6
3 2 7 1
4 7

Figure 6-11. Pendant Control Test

b. Test Results

If you do not receive the correct readings, the

wiring or connector pins may be faulty.

Page 44
 6600B
6-8. Auxiliary Switches

The following tests will determine if the auxiliary OHM

switches are functioning properly.
Figure 6-14. Auxiliary Switch Test
a. 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
supply power to the pump/motor and is always
b. Test Results activated no matter what control function is se-
lected. The brake locking circuit relay is also
If proper meter readings are not received, test the activated when any control function other than
individual switches as necessary. Using an ohm- BRAKE UNLOCK is initially selected.
meter, test the operation of an individual switch Also, inside the 6600B relay box is a step-down
with the (+) test lead at the center terminal of the transformer and full-wave rectifier which decreases
switch and the (-) test lead at the terminal opposite the voltage to 5-6 volts. This low voltage potential
the direction of the switch actuation. Refer to controls the relays by the use of the hand-held
figure 6-14. Meter should read 0 ohms. If the pendant control buttons. Basically the relays en-
switches check out, the problem would have to be able a 5-6 volt potential to control the 24 volt circuit.
in the wires, the switch circuit board or connector
CN3. 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 REV TILT BACK TABLE LEG BRAKE
SW1 TREND RIGHT UP UP UP LOCK

TABLE UP
1
TREND TILT BACK TABLE LEG KIDNEY
LEFT DOWN DOWN DOWN DOWN
TABLE DOWN
2
B8/A2 B8/B3 B8/B4 B8/B1 B8/B7 B8/A6
TREND SW2
3
REV TREND 15 (A8)
4
TILT RIGHT OHM
5
TILT LEFT SW3 16 (B8)
6
1 (A1)
BACK UP
7
BACK DOWN CN8
8

9 SW4 2 (B1)
10 PIN NO COLOR PIN NO COLOR
KIDNEY DOWN
11 1 (A1) Red 9 (A5) --
BRAKE LOCK SW5 2 (B1) White/Red 10 (B5) --
12
LEG UP 3 (A2) Brown 11 (A6) White/Purple
13
LEG DOWN
4 (B2) Yellow 12 (B6) Purple
14
5 (A3) Orange 13 (A7) Gray
PUMP MOTOR SW6
15 6 (B3) White/Orange 14 (B7) White/Gray
+24V 7 (A4) White/Brown 15 (A8) Red/White
16
8 (B4) Blue/White 16 (B8) Pink

Figure 6-13. Auxiliary Switch Connector CN9

Page 45
 6600B
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 connec-
tors 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 Relay
(Main Power OFF) (Main Power ON) Box allows continuous output for about
pin1=(+) pin 5=(+) 7 seconds. If the brakes are already
pin2=(-) pin 6=(-) 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

7 from the back while attached to the relay box. All
4
6 3 connectors should be connected.
5 2
DCV 1 3. Activate each of the pendant control buttons
and measure the output voltage for the corre-
sponding connector pins with a DC voltmeter. See
Figure 6-15. Relay Box Input figure 6-16. Meter should read 24 volts.

b. Test Results:
ACV

If you do not receive the correct meter readings, 1

the problem is in the input wiring, connectors or
components. If the correct readings are obtained,
proceed to the next step. CN1, CN2A OR CN2B
16
CN1 CN2A
c. Checking Output to Pump
FUNCTION PINS FUNCTION PINS
1. Disconnect pump connector CN16, connect Table Up 1-2 Back Up 1-2
all other connectors and activate the AC120V Table Down 3-4 Back Down 3-4
Trend 5-6 Slide Foot 5-6
operating mode. Rev Trend 7-8 Slide Head 7-8
Tilt Right 9 - 10 Kidney Up 9 - 10
Tilt Left 11 - 12 Kidney Down 11 - 12
2. Test CN16 at pin 1(+) and pin 2(-) with a DC Reflex 13 - 14 Leg Up 13 - 14
Flex 15 - 16 Leg Down 15 - 16
voltmeter. Meter should read approximately 24-28
CN2B
volts when any function button is activated. If no
voltage is present, use an ohmmeter to test the Brake Set 1-2
Brake Unlock 3-4
continuity from CN16 to CN4 (yellow and blue
wires). Refer to figure 6-15 for CN4 pin locations. Figure 6-16. Solenoid Output Connectors

Page 46
 6600B
e. Test Results: NOTE

If you do not receive the correct meter readings, the The 15 amp battery protection fuse is in
relay box is defective and should be replaced. the line between CN4 pin 1 and the
battery connector. Test the continuity
NOTE of the fuse if correct meter reading is
•Before deciding the relay box is de- not received.
fective, check the wires and pins in the
connector blocks to make sure they b. CN4 to Pump Test
are not loose or making a bad connec-
tion with their mate. 1. Disconnect connectors CN4, CN16 and
•If the battery power is ON and no table CN17. Leave all other connectors connected.
functions have been activated for 3
hours, the power off circuit will interrupt 2. Using an ohmmeter, test for continuity
the battery power. between the pins of CN4 and pins on CN16 and
CN17. See figure 6-18.
f. Checking Output to Pendant Control

The output to the Pendant Control can not be

7
tested without specialized equipment. If all tests 4
2
have been conducted and it appears that the Relay 6 3 1
2 CN16
Box is faulty, contact SKYTRON. 5
1 CN4
6-10. Main Wire Harness Continuity Tests
OHM
If correct meter readings are not received in tests
between components, before replacing the com-
ponents, test the Main Wire Harness to be sure all CN-4 CN-16 OHMS

connectors and wires are making a good connec- 3 1 0

4 2 0
tion.
Figure 6-18.
a. CN4 to Batteries Test
c. CN4 to Charging Box Test
1. Disconnect connectors CN4 and the (+) and
(-) connectors from the batteries. Leave all other 1. Disconnect connectors CN4, CN14 and
connectors connected. CN15. Leave all other connectors connected.

2. Using an ohmmeter, test for continuity 2. Using an ohmmeter, test for continuity
between pin 1 of CN4 and battery (+) connector. between pins 4, 5 and 6 of CN4, pins 1 and 2 of
Also test between pin 2 of CN4 and battery (-) CN15, and pin 4 of CN14. See figure 6-19.
connector. See figure 6-17. CN14

53
CN4 1

6 CN15
4
7 2
4 OHM
7 6 3
4 5 2
6 3 (+) 1
5 2 (-)
1 CN4
CN-15 CN-4 CN-14 OHMS
OHM 1 5 0
6 4 0
2 4 0

Figure 6-17. Figure 6-19. CN4, CN14, and CN15

Page 47
 6600B
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
after approx. 7 minutes of continuous operation. •The appropriate pendant control but-
The solenoid must be replaced if the internal ther- ton must be pushed during this test.
mal fuse has been blown. The motor will run when this test is
The solenoids are mounted directly on either side performed, and the brake locking sole-
of the hydraulic mini-valves and push the spool noid will be activated by any function
valve in one direction or the other depending upon other than UNLOCK.
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
connector. The problem could also be in the relay
1. Activate either BATTERY or AC120V oper- box or the Pendant Control (refer to appropriate
ating mode. section for troubleshooting).
2. Disconnect the 2 pin connector from the
solenoid in question, all other connectors should If the correct voltage is obtained, everything is
be connected. See figure 6-20. good up to that point and the problem is more than
OHM DCV
likely the solenoid.
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/ BLACK/
UP HD RT. REFX UP DN. UP UN BLUE WHITE
DN. LOCK

CN2B
4
LAT. BACK LEG 3
ELEV. TREND TILT FLEX SECT. SECT. KIDNEY BRAKE 2
1

HD
DN. UP. LT. FLEX DN. UP DN. LOCK
BLUE BLUE
CN2A
WHITE/BLUE WHITE/BLACK 16
15
14
13
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 48
 6600B
d. Test #2
CN16
The solenoid can be checked out using an ohm-
DCV
meter R x 1 scale.

1. Measure the resistance between the two

pin connector in question as shown in figure 6-20.
Connector must be disconnected. Polarity of Figure 6-21. Motor Input Voltage
meter leads is not important.

2. The meter should read approximately 16 NOTE

ohms at room temperature.
If the pump has been activated continu-
3. Measure the resistance between either ously for 1-1/2 to 2 minutes, the thermal
pin and ground. relay will interrupt the power to the
pump.
4. Meter should read infinity.
b. Thermal Protector Test
e. Test Results:
The Thermal Protector is built in to the pump motor
If the solenoid does not check out with the meter, and is used to interrupt the current flow to the pump
it is more than likely defective and must be motor to protect it from possible damage due to
replaced. overheating.
1. Turn OFF both BATTERY and AC120V
NOTE operating modes.

Whenever there are several compo- 2. Use an ohmmeter to test for continuity
nents of the same type, a defective between terminals 1 and 2 on the connector CN17.
unit can also be detected by substi- See figure 6-22.
tuting a known good unit or wire con-
nector. In some cases this may be
faster than using a multi-meter.
CN17
6-12. Motor/Pump Assembly DCV
2
The hydraulic pump motor is a thermally protected 1
24 volt DC electric motor. The oil pump unit is
attached to the bottom of the motor and is a gear
type displacement pump with a pumping capacity Figure 6-22. Thermal Protector
of .4 liter per min. The Motor/Pump Assembly is
mounted on insulators in the base of the table. 3. The Thermal Relay should reset itself after
approximately one minute.
a. Motor/Pump Test
4. The Thermal Relay should activate after 1-
1. Disconnect motor connector CN16. Leave 1/2 to 2 minutes of continuous pump operation.
all other connectors connected and activate either
BATTERY or AC120V operating mode. c. Motor Resistance Test

2. Activate any function and use a DC voltme- The motor can be statically checked for resistance
ter to measure across the two pin connector. Pin using an ohmmeter. This test is not 100% accurate
1(+) and pin 2(-). See figure 6-21. Meter should because you are checking the motor with very low
read 24-28 volts. voltage from the meter and without any load.

Page 49
 6600B

1. Using an ohmmeter R x 1 scale, measure the

resistance between the two pins of CN16. See
figure 6-23.
2. The meter should read 1 to 2 ohms at room
temperature.
3. Measure the resistance between either
pin and ground.
4. Meter should read infinity.

CN16
OHM

Figure 6-23. Motor Connector CN12

d. Test Results:

If you do not receive the correct meter readings, the

motor or wiring is defective.

Page 50
 SECTION VII ELECTRICAL SYSTEM ADJUSTMENTS

7-1. Relay Box Adjustments (Battery Table Only) a. Brake Release Timer

The Relay Box contains variable resistors for ad- The Brake Release Timer is set for about 7 sec-
justing the operating timers for the BRAKE SET onds and is controlled by the variable resistor VR1
and BRAKE UNLOCK functions. The Relay Box on the relay box circuit board. Turn the adjuster
for the battery model tables also has variable clockwise to increase the operating time. Counter-
resistors for setting the Power Off timer and the clockwise to decrease the operating time.
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
relay box cover and use the following procedures. The Brake Set Timer is set for about 7 seconds and
See figure 7-1. is controlled by the variable resistor VR2 on the
relay box circuit board. Turn the adjuster clockwise
to increase the operating time. Counterclockwise
to decrease the operating time.

VR-4 VR-3 VR-1 VR-2

CN-4

CN-3

CN-2B CN-2A CN-1

Figure 7-1. Relay Box Adjustments

Page 51
 5000 36th Street S.E., Grand Rapids, MI 49512
1-800-SKYTRON or 1-616-957-0500 • FAX 1-616-957-5053