service manual cama

8/13/2019 Service Manual Cama

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PRELIMINARIES

Preface

Read and understand this manual before attempting to service or repair theequipment.

Warnings, Cautions and Notes

WARNINGSgiven in this manual identify possible hazards in procedures orconditions which, if not correctly followed, could result in death, injury or otherserious adverse reactions.

Cautionsgiven in this manual identify procedures or conditions which, if notcorrectly followed, could result in equipment failure or damage.

Notesgiven in this manual are used to explain or amplify a procedure orcondition.

General Warnings

April 2003 (i) 746-310-1

This manual is intended to be used by Huntleigh Healthcare Ltd approvedservice technicians. The manual may be provided to a customer in response tocustomer requirements, but in no event will Huntleigh Healthcare Ltd beresponsible for any service or repair performed by customers or third parties.

WARNING

Before starting any service or maintenance procedures, ensurethat the equipment has been adequately decontaminated.

Electrical equipment can be hazardous if misused. Obey safetyinstructions.

Do not use electrically powered beds in the presence of flammablegases such as anaesthetic agents.

The bed and its sub-assemblies are very heavy and appropriateprecautions must be taken to avoid injury when lifting or movingthem.

Sections of the bed may move under battery power even if the bedis disconnected from the mains power supply.


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746-310-1 (ii) April 2003


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April 2003 (iii) 746-310-1

Continued

Contents

I N T R O D U C T I O N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1

About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

O p e r a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3

OPERATIONAL MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Release Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Castors, Brakes and Steering . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Preliminary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Power Operated Functions . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Battery Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Manual Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

T R O U B L E S H O O T I N G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1

SERVICING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

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

Product Assembly Structure . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Special Tools and Equipment. . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Base Cover - Access to components. . . . . . . . . . . . . . . . . . . . . 6-4

Base Cover - Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Castors - Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Mains cable assembly - Replacement . . . . . . . . . . . . . . . . . . . . 6-8

Batteries - Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Control Box - Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Handsets and T piece Cable - Replacement. . . . . . . . . . . . . . . . 6-10


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746-310-1 (iv) April 2003

Contents (continued)

Attendant Control Panel - Replacement. . . . . . . . . . . . . . . . . . . 6-12

Flexible Conduit - Replacement. . . . . . . . . . . . . . . . . . . . . . . 6-13Height Actuators - Replacement . . . . . . . . . . . . . . . . . . . . . . 6-14

Leg Section Actuator - Replacement . . . . . . . . . . . . . . . . . . . . 6-15

Backrest Actuator - Replacement . . . . . . . . . . . . . . . . . . . . . . 6-17

CPR Release Cable - Replacement. . . . . . . . . . . . . . . . . . . . . 6-18

Gas Spring and Release Moulding - Replacement . . . . . . . . . . . . . 6-19

Roller Buffer - Replacement (typical) . . . . . . . . . . . . . . . . . . . . 6-21

X-ray Cassette Module - Replacement . . . . . . . . . . . . . . . . . . . 6-21

Dismantling the Bed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

Assembling the Bed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

Restoration of Paintwork . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Calibration of Height/Tilt Actuators . . . . . . . . . . . . . . . . . . . . . . 7-1

TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1


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1 INTRODUCTION

1.1 About This Manual

This manual contains information on servicing and maintenance of theHuntleigh Healthcare Ltd Contoura 460series beds.The manual comprises the following sections:

Section 1 - Introduction : (this section) Includes a general description of theequipment with an explanation of the function and operation of the controls.

Section 2 - Operational Maintenance : Describes routine procedures and checksto ensure correct operation during the service life of the equipment.

Section 3 - Preventive Maintenance : Gives details of regular, periodic

maintenance actions to ensure correct operation of the equipment.

Section 4 - Testing : Defines a serviceability test to verify correct operation ofthe equipment if function is suspect or following any maintenance or servicingprocedure.

Section 5 - Troubleshooting : Contains details of fault symptoms, their possiblecause and suggested actions to rectify the problem.

Section 6 - Servicing Instructions : Contains illustrated procedures for removal

and installation of replaceable parts and sub-assemblies.

Section 7 - Calibration : Gives calibration procedures for the electrical controlsand actuators.

Section 8 - Technical Data : Contains a list of technical data for the equipmentand components.

Appendix A - Assembly Spares Manual : Contains the Modification Record,

together with drawings and detailed parts lists for the identification ofreplaceable parts.

Appendix B - Disposal of Gas Springs : Contains instructions for the safedisposal of unserviceable gas springs.

April 2003 1-1 746-310-1


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1.2 Product Description

TheContoura 460is an acute care bed with multiple patient positioningfunctions and other features to aid patient therapy. The maximum safe workingload is 180 kg.

The bed has a four section profiling mattress platform with power drivenadjustment of bed height, two-way tilt angle, backrest angle and leg elevation.Kneebreak angle is manually adjustable with power assistance by gas spring.

The mattress platform incorporates a built-in bed extension and removable (lift

off) headboard and foot board. Revolving buffers are provided on all fourcorners.

The bed may have built in, single section ( length) safety sides. Alternatively,

removeable safety sides are available as an accessory.

The bed is mounted on four castors with braking and steering facility. Thecomplete base of the bed is enclosed by a moulded and sculptured cover.

On all models the power driven functions ofheight, backrest angle and legelevationare operated by push button controls. TheAuto-contourbuttonsimultaneously operates both backrest and leg elevation. The pendant type pushbutton handset(s) is accessible to either patient or attendant.

An additional handset, for use by the attendant only, is stored at the foot of the

bed. Tilt anglecan be controlled only from the attendant handset. The Attendant

Control Panel (ACP), mounted at the foot of the bed, enables the power driven

746-310-1 1-2 April. 2003

Fig. 1-1 Model 460 bed


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functions to be individually disabled. Operation of the bed by the patient is thusat the discretion of the attendant.

The electrical actuators consist of a screw and nut assembly driven by a 24Vd.c. motor and gearbox. Power for the actuators is derived from a mains

operated d.c. power supply with emergency battery back up.

The bed may be supplied with an x-ray translucent backrest incorporating a

cassette carrier to providethe facility for chest x-ray photography.

1.3 Operation

1.3.1 Brakes and SteeringAt the foot of the bed is a pair of linked brake pedals which operate on three of

the castors.

When the pedals are in the middle position, the brakes are free and all fourcastors are able to rotate and swivel.

When the pedal is pushed down, the brakes are applied on both foot end castorsand one head end castor.

When the pedal is lifted up, one head end castor is engaged so that it cannot

swivel. Always engage the castor in line and trailing. The bed can then besteered by pushing from the foot end.

April. 2003 1-3 746-310-1

Fig.1-2 Castors - Brakes and steering


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1.3.2 Safety Sides

To lower the safety side:Hold the top rail near the foot end (3). Pull the release

knob (1) and lower the side toward the foot of the bed (2). As the side is being

lowered, let go of the release knob (1).

To raise the safety side:Lift the top rail up and toward the head until the latchengages at maximum height.

The safety side release mechanism has a yellow indicator band (1). When thisindicator band is visible, it means that the safety side is not securely locked inthe raised position.

746-310-1 1-4 April. 2003

WARNING

Safety side contact points are identified by this symbol.

Keep hands and fingers away from these areas to avoid trapping.

2

1

3

Fig. 1-3 Safety side - operation


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1.3.3 Bed Extension (if fitted)

Before extending or shortening the bed, ensure that the leg sections are lowered

to the horizontal position.

To extend the bed:Apply the brakes. Squeeze the latch lever (1) and handle(2) together and pull out the foot end of the mattress platform (3). Allow thelatch to re-engage when the platform is fully extended.

Lift the calf section extension sheet (5), pull the mattress retention rail (4) outtoward the foot of the bed and engage the extension sheet (5) in the outerlocation holes in the calf section deck sheeet.

To retract the bed:Reverse the above procedure.

April. 2003 1-5 746-310-1

1 2

3

Fig. 1-4 Extending or retracting the bed

Fig. 1-5 Extending or retracting the mattress deck


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1.3.4 Kneebreak Angle

When the legs are raised, the kneebreak angle can be manually adjusted by

lowering or raising the foot end of the calf section.

Hold the mattress retention rail (4) on the foot end of the calf section (6), Liftthe release lever (7) and push the foot end down against the action of the gasspring. Let go of the lever to lock the calf section at any angle.

To raise the foot end, lift the release lever and the gas spring will assist the footto rise. There is a release lever on both sides of the calf section.

1.3.5 Power Operation

The bed has power driven adjustment to tilt angle, height, backrest angle and

leg elevation.

1.3.5.1 Control Handsets

The patient handset, accessible to either patient or attendant, is connected to the

bed by an extendable, flexible cable. An additional handset, for use only by theattendant, is located at the foot of the bed.

When a handset push button is pressed the appropriate bed function will operateuntil the button is released or the limit of travel is reached. The auto contour

button simultaneously operates both backrest and leg elevation.Tilt anglecan becontrolled only from the attendant handset. When reverting from a tiltcondition, the bed will automatically pause in the horizontal position for two

seconds before continuing its movement.

746-310-1 1-6 April. 2003

Fig. 1-6 Adjusting the kneebreak angle


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April. 2003 1-7 746-310-1

Fig. 1-8 Attendant handset and ACP

LegElevation Backrest

BatteryChargeIndicator

TiltandHeight

Backrest

LegElevation

Height

Tilt

CPR Button

++ _

Fig. 1-7 Patient handset

Backrest

Height

LegElevation

Auto-Contour


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1.3.5.2 CPR Control Button

There is a CPR button on the attendant handset. Press and hold this button toautomatically return the bed to a flat, horizontal, low height condition. Before

using the CPR button, ensure that all lock out switches on the ACP are in the

vertical, unlocked position.

1.3.5.3 Attendant Control Panel (ACP)

The ACP, is located on a bracket at the foot of the bed.

To prevent operation by the patient, the individual bed functions can be disabledby turning the appropriate lock-out switch so that the pointer is horizontal. Inthis condition the selected function is disabled on both the patient handset and

the attendant handset.

1.3.5.4 Calibration Error

When operating the function buttons, if a bleeping sound is heard and thefunction is inoperative this indicates an actuator calibration error. Refer to

Section 7, Calibration.

1.3.5.5 Batteries

The emergency back-up battery is automatically switched on if the bed is

disconnected from the mains power supply. The batteries will enable emergencypower operation for short periods e.g. when the bed is being moved.

To ensure that the batteries are kept fully charged, the bed must be connected tothe mains power supply at all times during normal use.

If, when the bed is operated using the batteries, a bleeping sound is heard, thisindicates a low charge condition. The bed should be re-connected to the mainspower supply, for a minimum of 24 hours, in order to recharge the batteries.

The battery charge indicator on the ACP illuminates when the batteries arebeing charged.

746-310-1 1-8 April. 2003


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1.3.6 Manually Operated CPR

A CPR emergency release handle is provided on both sides of the bed on the

mattress deck.

To lower the backrest in emergency, lift the CPR release handle at the side ofthe bed. At maximum elevation or with no patient weight, it may be necessaryto push the backrest down.

In addition to the CPR handle there is also a CPR button on the attendant hand

set Refer to para. 1.3.5. Power Operation.

1.3.7 X-ray Facilities (if fitted)

The backrest x-ray cassettecarrier provides the facility for chest x-rayphotography.

For information regarding use refer to the User Manual, publication number746-260.

.

April. 2003 1-9 746-310-1

Fig. 1-9 CPR Emergency release handle

WARNING

The backrest can fall quickly. Keep hands clear to avoid trapping.


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1.3.8 Mains Power Cable

For UK use, the mains supply cable is provided with a BS1363A 13 A, 3-pin

plug.

For European use the mains supply cable terminates in an IEC83-C4 (2 polewith dual earth contacts) non-rewireable plug.

When the bed is to be moved, disconnect the mains cable from the socket outletand store the cable on the cable tidy at the head of the bed. Always remove thecable fully from the cable tidy when it is connected to the power supply.

746-310-1 1-10 April. 2003

WARNING

Do not attempt to insert a two-pin mains connector directly into a13 amp mains outlet.

Make sure that the handset and mains cables cannot becomeentangled with moving parts of the bed.


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2 OPERATIONAL MAINTENANCE

2.1 General

The equipment has been designed to be virtually maintenance free betweenservice intervals. The periodic cleaning and maintenance necessary will bedetermined by use and condition.

Examine the bed for obvious signs of damage. If found take appropriateremedial action.

2.2 Cleaning

Wipe all surfaces with a soft cloth moistened with hot water and a milddetergent (or the hospitals recommended cleaning solution). Take extra care

with areas that may harbour dirt or dust and undersides that may have beensplashed.

Rinse with clean water and dry with paper towels.

The mattress platform panels may be lifted off and washed separately.

To remove potentially infectious material such as body fluids, or when used bya client with a known infection, clean afterwards with NaDCC (i.e. Presept,Actichlor) at 10,000 ppm of available chlorine. Rinse and dry.

Allow the cleaned parts to dry before replacing the mattress.

April. 2003 2-1 746-310-1

WARNING

Before commencing any cleaning procedure, disconnect the bedfrom the electrical power supply.


Gloves and protective clothing should always be worn whencarrying out cleaning procedures.

Caution

Do not use abrasive compounds or pads

Do not use Hypocarbonate or Phenol based cleaning solutions.


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746-310-1 2-2 April. 2003


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3 PREVENTIVE MAINTENANCE

The following preventive maintenance checks and procedures should be carriedout every 6 months.

If the result of any check is unsatisfactory, take the appropriate remedial action.

3.1 GeneralExamine the bed for obvious signs of damage. Make sure that all nuts, bolts andother fastenings are secure and not missing.

Examine the flexible cable for cuts, abrasions, kinking or other deterioration.

Check the power connector plug for damage. Check that the (UK) plug fuse isof the correct type and rating (UK - BS 1362 - 5 amp).

If the power connector plug or cable are damaged, they must be replaced as acomplete assembly.

3.2 Release Cables

After long use, the CPR release cable may stretch. This could prevent proper

operation of the CPR release.

To remedy this, adjust the two lock nuts on the outer cable at the release leverend.

3.3 Castors, Brakes and Steering

Check the brakes for efficient operation. Apply the brakes and push the bed. Ifany of the three braking castors rotate, the brake is not fully effective. Set thebrake pedal in the steering position and verify that one head end castor isengaged so that it cannot swivel.

Brakes that fail to lock effectively indicate that the castor requires to be adjusted

or replaced. Refer to Section 6. Sub-section 6.6 and 6.7.

April. 2003 3-1 746-310-1

WARNING

Before commencing any maintenance activity, disconnect the bedfrom the electrical power supply.

Avoid skin contact with lubricants. Gloves and protective clothingshould be worn when carrying out maintenance work.


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3.4 Batteries

If, when the bed is operated using the batteries a bleeping sound is heard, thisindicates a low charge condition. The bed should be re-connected to the mains

power supply, for a minimum of 24 hours, in order to recharge the batteries.

Check the condition of the batteries using the following procedure:

1. Ensure that the bed has been connected to the mains power supply for24 hours.

2. Disconnect the bed from the mains power supply.

3. Apply a load of 80 kg (12 st person) to the mattress platform.

4. Raise and lower the mattress platform, from minimum to maximumheight, three times.

5. If the bed does not operate satisfactorily in step 4, perform steps 1 to 4again.

If the bed again fails to operate satisfactorily, the batteries are not holding

sufficient charge and they should be replaced. Refer to Section 6. Sub-section6.9.

746-310-1 3-2 April. 2003


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4 TESTING

The following serviceablity tests should be performed before returning the bedto use after service, or if any function is suspect.

These instructions should be read in conjunction with Section 1, Sub-section1.3.

If the result of any test is unsatisfactory, investigate and take the appropriate

remedial action. Refer to Section 5, Troubleshooting and Section 6, ServicingInstructions.

Note: All references to left or right of the bed are when viewed from the headend.

4.1 Preliminary

a) Verify that no furniture or other obstruction can impede themovements of the bed.

b) Connect the bed to the mains power supply.

c) Verify that the battery charge indicator (on the attendant controlpanel) is illuminated.

d) Verify that the rotary switches on the ACP are in the vertical(unlocked) position.

e) Using the attendant handset, level the mattress platform (zero tilt).

4.2 Power Operated Functions

a) Using the patient handset, check the function of bed height,backrest angle and leg elevation. Verify satisfactory operation overthe full range of movement as specified in Section 8, TechnicalData. Verify that the actuators are de-energised when the pushbutton is released or the limit of travel is reached.

b) Repeat step a) using the attendant handset. Verify that the lock out

switches on the ACP disable the push buttons on both the patientand attendant handsets.

April. 2003 4-1 746-310-1

WARNINGIf any electrical assembly or wiring has been replaced or repaired,the appropriate electrical safety checks must be made.


Keep clear of the bed when it is being operated. Severe injury canresult from crushing by moving parts.


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c) Check the function of the tilt control using the attendant handset.Verify satisfactory operation over the full range of movement asspecified in Section 8, Technical Data. Check that, on reaching thehorizontal condition, the mechanism will pause for two secondsthen continue if the push button is still being pressed.

d) Position the bed at near maximum height with both backrest andlegs raised and apply foot down tilt. Press and hold the CPRbutton on the attendant handset Verify that the bed reverts to flat,horizontal, low height condition.

4.3 Battery Operation

a) Disconnect the bed from the mains power supply.

b) Check the functions of bed height, backrest angle, leg elevation

and two-way tilt using the attendant handset. Verify that thepatient handset is inoperative.

c) Re-connect the bed to the mains power supply. Verify that thebattery charge indicator on the ACP is illuminated.

d) Test the batteries as described in sub-section 3.4.

4.4 Manual Functions

4.4.1 Brakes and Steering

a) Refer to para. 1.3.1. Check the brakes for efficient operation.Apply the brakes and push the bed. None of the three brakingcastors should rotate.

b) Set the brake pedal in the steering position and verify that onehead end castor is engaged so that it cannot swivel.

4.4.2 Safety Sides

a) Refer to para. 1.3.2. Check operation of the safety sides (if fitted).Verify that the release button is effective and the sides are firmlylocked when raised.

4.4.3 Backrest CPR Release

a) Using any push button handset, raise the backrest to approximately60.

b) Refer to para. 1.3.6. Lift the release handle and push the backrestdown. Verify that the release mechanism is effective and the

backrest reclines in a smooth, controlled manner with minimumforce applied.

746-310-1 4-2 April. 2003


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4.4.4 Kneebreak

a) Using either push button handset, raise the legs to maximumheight.

b) Refer to para. 1.3.4. Verify that the foot end of the calf section

can be raised and lowered over the full range of movement asspecified in Section 8.

c) Lift the foot end to an intermediate position and check that the gasspring is firmly locked. Lower the foot end again.

d) Using either push button handset, lower the legs. Check that thekneebreak angle returns to zero as the legs are lowered tohorizontal.

4.4.5 Bed Extension

a) Refer to para. 1.3.3. Check the operation of the bed extension.Verify that the latching mechanism is effective.

April. 2003 4-3 746-310-1


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746-310-1 4-4 April. 2003


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5 TROUBLESHOOTING

The following table identifies some fault symptoms, their possible cause andsuggested remedial action.

Teststep

Symptom Possible cause Action

4.2 None of the actuatorswill work

Power disconnected orbatteries discharged

Fuse blown

Make sure power supplylead is connected

Check fuse in (UK) plug

4.2 One actuator doesnot work

Actuator plugdisconnected

Check that actuator plugis fully inserted in thecontrol box

4.3 Battery chargeindicator not

illuminated

Power disconnected orfuse blown

ACP disconnected

Battery charger fault

Check and rectify

Check that plugs arefully inserted in thecontrol box (see note 2)

Check by substitutionof control box

4.5.1 Brakes or steeringlock not effective

Wear or damage Adjust or replacecastor

4.5.3 Backrest CPRrelease not effective

Release mechanismnot correctly adjusted

Check and re-adjust

April. 2003 5-1 746-310-1


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.

.

746-310-1 5-2 April. 2003


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6 SERVICING INSTRUCTIONS

6.1 General

The servicing procedures given in this section include instructions forreplacement of specific components and sub-assemblies, dismantling and

assembly of the main structure and restoration of paint finish

Procedures which are considered to be self evident have not been included.

Do not disassemble more than is necessary to replace a defective item.

Before removing any electrical wire or connector, make a note of its positionand identity as an aid during assembly.

Remove old Loctite screw adhesiveand other contamination from componentsbefore reassembly. Apply Loctite screw adhesive to screw threads on assembly

of items as specified in Appendix A or in the text. Before applying Loctite,clean and degrease both internal and external screw threads using a suitablevolatile solvent e.g. methylated spirits.

Apply Rocol Sapphire grease to bushes and joints on assembly of items asspecified in Appendix A or in the text.

Throughout this section, numbers given in parenthesis thus (2-14) refer to the

Assembly Spares Manual drawing sheet and item number for the part.

All references to left or right of the bed are when viewed from the head end.

These instructions have been written with reference to a Model 460 bed with

footend extension. The same procedures generally apply even when differentmodular assemblies are used in the construction.Always refer to theappropriate drawing in the Assembly Spares Manual, Appendix A to

identify component Part Numbers.

April. 2003 6-1 746-310-1

WARNING

Before starting any service or maintenance procedures, ensure

that the equipment has been adequately decontaminated.

Avoid skin contact with lubricants. Rubber gloves and protectiveclothing should be worn when carrying out maintenance work.

Heavy equipment hazard. The bed and its sub-assemblies are veryheavy and could cause serious injury or death by crushing. Whenworking beneath the platform, the equipment must be properlysupported with suitable lifting devices, blocks or stands.

Sections of the bed may move under battery power even if the bed

is disconnected from the mains power supply.


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Before the bed is returned to use following service or repair:

Carry out a visual inspection for signs of damage

Perform a seviceability test as given in Section 4

Clean the equipment using the method described in Section 2

6.2 Product Assembly Structure

Each bed comprises a number of modules or sub-assemblies as detailed in the

Assembly Spares Manual - Appendix A.

The Model number (Ref No) and Serial number of the bed are marked on alabel which is visible just below the moulded base cover at the head end.

The Model number e.g. 460 AA4 A31B 1AB indicates the chosen options used

in the construction.

The Serial Number relates to the date of manufacture and is individual to eachbed.

TheModularBed Matrixin Appendix A in conjunction with the ModelNumber defines the basic configuration of the bed as shown below.

TheModular Assemblies Modification Sheetin Appendix A in conjunction with

the Serial number will identify the build standard of the modules used in theconstruction.

746-310-1 6-2 April. 2003

Model

Bed Colour

Power Plug

Castor Type

Base Cover

Backrest Type

Bed Extension

Deck Sheets

Safety Sides

Head / Foot Panels

Infil Colour

460 - XXX - XXXX - XXX


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April. 2003 6-3 746-310-1

1

2

3 4

5 6

7

8 89

10

1112

2

DECK

BASE

1. Control Box 2. Base Actuator 3. Backrest Actuator 4. Leg Actuator 5. Patient Control Handset 6. Attendant Control Handset7. Mini ACP 8. Plug/ Socket9. Tee Piece Cable 10. Deck Earthing point11. Base Earthing Point 12. Mains Cable

Fig. 6-1 Block diagram of electrical system


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6.3 Special Tools and Equipment

In addition to normal workshop tools, the special tools and equipment listedbelow will be required for servicing.

Item Description Part No. Use

1 Hoist SWL 225 kg 745.07 General

2 Sling strap (2) 745.08 General

3 Brake cam rotating tool 745.04 Fitting castors

6.3.1 Using the Hoist

When using the hoist to lift any part of the bed, always ensure that the sling

straps are applied to main frame sections and do not bear upon components or

minor fabrications.

When lifting the entire bed or the deck assembly, first remove all decksheetsand lift off the head end and the foot end. Pass both sling straps around the

main longitudinal members of the deck frame.

6.4 Base Cover - Access to components

The moulded cover can be raised to provide limited access to components in the

base assembly.

6.4.1 Removal

a) Raise the mattress deck to maximum height. Lift the head end ofthe base cover (27-1) pivoting on the brake bar, and secure it tothe deck with cord or wire hooks.

If it is necessary to raise the foot end of the base cover, proceed as follows.

b) Remove screws (24-12) and washers (24-11) and pull off the brake

pedals (24-13). Slide the brake bar (24-10) through the frame justfar enough to free the base cover on one side, then slide it back tofree the other side.

c) Lift the base cover (27-1) at both ends and secure it to the deckwith cords or wire hooks.

If you have to remove the base cover from the bed, it is necessary to separatethe mattress deck from the base as described in 6.5.

6.4.2 Installation

a) Remove cords or wire hooks. Fit the cover over the brake bar(24-10) by sliding the bar (24-10) first to one side then the other.

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Install the brake pedals (24-13) and secure with screws (24-12) andwashers (24-11).

6.5 Base Cover - Replacement

6.5.1 Removal

a) Release the base cover from the brake bar as described in 6.4 butdo not secure it to the deck.

b) Use the hoist (Tool No.1) to support the deck assembly.

c) Use a suitable flat bladed tool to remove eight pivot covermouldings (13-27). Remove four nuts (13-9), screws (13-34), andwashers (13-4). Collect four pivot bushes (13-26).

d) Use the hoist (tool no.1)to raise the deck assembly, together withthe upper radius arm fabrications, far enough to remove themoulded base cover from the bed.

6.5.2 Installation

a) Install the moulded cover over the radius arms (13-24). Fit thecover over the brake bar (24-10) by sliding the bar (24-10) first toone side then the other. Install the brake pedals (24-13) and securewith screws (24-12) and washers (24-11).

b) Apply Rocol grease to the bush holes in the upper radius arms andinstall four pivot bushes (13-26) with the heads on the inside.

c) Use the hoist to lower the deck assembly and align the holes inthe upper and lower radius arms. Install four screws (13-34) andwashers (13-4) with the screw heads on the outside and secure

with nuts (13-9).d) Fit eight pivot cover mouldings (13-27). Secure pivot cover

moulding with adhesive when fitted to nut (13-9).

April. 2003 6-5 746-310-1

CautionTake care not to strain the flexible conduit.


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6.6 Brake Adjustment

a) Remove the base cover and tie it to the deck as described in 6.4.

b) Bend back the shakeproof pressing (24-17) and remove twohexagon head screws (24-16) and the pressing.

c) On the brake/free castors (24-2) turn the bearing housing Aclockwise in 180 steps until the brake is more effective.Alternatively, on the tracking castor (24-1), turn the bearinghousing anti-clockwise until the steering lock is more effective.

d) Do not over-adjust by turning the housing too many times.

e) Fit a new or serviceable shakeproof pressing (24-17) and refit twohexagon head screws (24-16). Bend up the pressing to lock the

screws.f) Refit the base cover as described in 6.4.

g) If satisfactory adjustment cannot be achieved, replace the castor.

6.7 Castors - Replacement

6.7.1 Foot end Castors - Removal

a) Use the hoist to raise the bed by approximately 20 cm. Supportthe base frame on suitable wooden blocks.

746-310-1 6-6 April. 2003

(24-10)

(24-1) (24-2)

(24-17)

Fig. 6-2 Adjusting the brake


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b) Ensure that the brake pedals are in the free position. Removescrews (24-12) and washers (24-11) and pull off the brake pedals(24-13). Raise the base cover as described in 6.4).

c) Slide the brake bar (24-10) through the frame just far enough to

clear the castor tube. Bend back the shakeproof pressing (24-17),remove two hexagon headed screws (24-16) and withdraw thecastor (24-2) from the base fabrication.

6.7.2 Foot end Castor - Installation

a) When inserting braking castors, ensure that the flat on the castorcam is vertical (Tool No 3) and facing the head of the bed. Insertthe stem of the castor into the base fabrication and align the holes.

b) Install a new or serviceable shakeproof pressing (24-17) and two

hexagon headed screws (24-16) but do not tighten yet.c) Use a small screwdriver or other suitable device inserted in the

threaded hole in the end of the brake bar (24-10) to align the barwith the castor cam. Drive the brake bar through. Tighten the twohexagon headed screws (24-16) and bend up the shakeproofpressing (24-17) to lock the screws.

d) Install the moulded base cover as described in 6.4. Install thebrake pedals (24-13) and attach with screws (24-12) and washers(24-11).

6.7.3 Steering Castor - Removal

a) Use the hoist to raise the bed by approximately 20 cm. Supportthe base frame on suitable wooden blocks. Raise the head end ofthe moulded base cover as described in 6.4. Ensure that the brakepedals are in the free position.

b) Drive out and discard the roll pin (24-7) and withdraw the D bar(24-8). Bend back the shakeproof pressing ((24-17), remove twohexagon headed screws (24-16) and withdraw the castor (24-1)

from the base fabrication.

6.7.4 Steering Castor - Installation

a) When inserting the braking and steering castor (24-1), ensure thatthe flat on the castor cam is vertical (Tool No 3) and facing thehead of the bed. Insert the stem of the castor into the basefabrication and align the holes.

b) Install a new or serviceable shakeproof pressing (24-17) and twohexagon headed screws (24-16) but do not tighten yet.

c) Insert the D bar (24-8) through the castor stem into the castorlever (24-5) and align the holes. Drive in a new roll pin (24-7).

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Tighten the two hexagon headed screws (24-16) and bend up theshakeproof pressing (24-17) to lock the screws.

d) Refit the moulded base cover.

6.7.5 Free Castor - Removala) Use the hoist to raise the bed by approximately 20 cm. Support

the base frame on suitable wooden blocks. Raise the head end ofthe moulded base cover as described in 6.4.

b) Bend back the shakeproof pressing (24-17), remove two hexagonheaded screws (24-16) and withdraw the castor (24-3) from thebase fabrication.

6.7.6 Free Castor - Installation

a) Insert the stem of the castor into the base fabrication and align theholes. Install a new or serviceable shakeproof pressing (24-17) andtwo hexagon headed screws (24-16). Tighten the screws and bendup the shakeproof pressing to lock them.

b) Refit the moulded base cover.

6.8 Mains cable assembly - Replacement

6.8.1 Removal

a) Disconnect the mains cable from the electrical power supply. Raisethe base cover at the head end as described in 6.4.

b) Release the cable and strain relief bush from the control boxbracket (13-11). Remove screw (13-16), nut (13-13) and the cableanchor clip (13-12) to release the mains cable. Disconnect themains cable assembly from the control box and remove the cableassembly from the bed.

6.8.2 Installation

a) Connect the mains cable assembly to the control box. Position thecable first around the end of the control box and then beneath thecontrol box bracket (13-11) to the anchor clip (13-12).

b) Secure the cable with the anchor clip (13-12), screw (13-16) andnut (13-13). Ensure that the cable is not strained and bend radiusis not too small. Install the cable and strain relief bush on thecontrol box bracket (13-11) and tighten the cable clamping nut.

c) Refit the base cover.

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6.9 Batteries - Replacement

6.9.1 Removal

a) Raise the bed to maximum height and raise the base cover as

described in 6.4. Disconnect bed from mains power supply.b) Remove four screws and remove the lid of the battery

compartment on the control box (12-8).

c) Disconnect the batteries from the control box by removing theconnector plug inside the battery compartment. Remove bothbatteries, together with the battery fuse and wiring. Disconnect thebattery wires by pulling the connectors off the battery terminals.

6.9.2 Installation

a) Position the new batteries side by side with the terminal facesuppermost and reconnect the battery wires and fuse in accordancewith the instruction label in the lid. Turn the batteries so theterminal faces are abutting and place the batteries, wiring and fusein the control box, ensuring correct orientation. Refit the batteryconnector plug.

b) Refit the lid and attach with four screws.

6.10 Control Box - Replacement

6.10.1 Removal

a) Disconnect the mains cable from the electrical power supply. Raisethe base cover at the head end as described in 6.4.

b) Remove the strip over the connection ports and disconnect allseven cables from the control box. Disconnect the earth bondingstraps (13-31)(13-32) from the control box.

c) Alternative 1. Remove four M5 screws (13-30) and nuts (13-13)and remove the control box from the bracket (13-11).

April. 2003 6-9 746-310-1

WARNING

To avoid short circuiting the battery, remove rings, watches orother metal objects. Use tools with insulated handles.

Lead-acid batteries are a potential environmental and health

hazard. Store batteries in accordance with manufacturersinstructions. Dispose of unserviceable batteries safely inaccordance with local authority regulations.


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d) Alternative 2. Remove two M5 screws (13-17) and nuts (13-13)and release the conduit clamp (13-14) and flexible conduit (13-15)from the control box bracket (13-11). Loosen three socket buttonhead screws (13-10) and remove the fourth screw which attachesthe anti-static chain. Slide the control box bracket toward the foot

end on the keyhole slots and remove the bracket together with thecontrol box. Remove three socket button head screws (13-10).

6.10.2 Installation

a) Install the control box on the control box bracket (13-11) andattach with four M5 screws (13-30) and nuts (13-13).

b) Apply Loctite to three button head screws (13-10) and insert thempart way in the threaded holes in the base fabrication. Position thecontrol box bracket (13-11) on the screws and slide the bracket on

the keyhole slots toward the head end and before tightening thescrews. Attach the anti-static chain assembly (13-29) with thefourth screw (13-10) and allow the chain to drop through thescrew access hole. Attach the flexible conduit (13-15) to thecontrol box bracket (13-11) with conduit clamp (13-14), screws(13-17 and nuts (13-13).

c) Lightly lubricate the O rings on the actuator cable connectorswith petroleum jelly (Vaseline). Reconnect all seven cables to thecontrol box and fit the retaining strip which prevents accidental

disconnection of the plugs.d) Refit the base cover.

6.11 Handsets and T piece Cable - Replacement

6.11.1 Removal

a) Disconnect the bed from the mains power supply. Raise the headend of the base cover moulding as described in 6.4.

b) Disconnect the attendant handset (6-19) from the socket on thecable channel fabrication (6-10) at the foot end of the bed.Disconnect the patient handset (6-20) from the socket beneath theseat area on the deck assembly.

c) Refer to the Electrical Assembly Schematic, sheet 62 anddisconnect the T piece cable (62-9) from the control box (62-6).

d) Remove two screws (14-29), nuts (14-28), toothed washer (14-32)and conduit clamp (14-30) to release the flexible conduit from the

deck fabrication (14-3). This also releases the deck earthing strap(13-32).

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e) Remove two screws (13-17), nuts (13-13) and conduit clamp(13-14) to release the flexible conduit from the control box bracket(13-11). Spring open the split flexible conduit (13-15) and pull thecable out of the conduit and into the deck area.

f) Make a note of the position of the sockets, the cable and the Tjoint in the cable channel. Remove screws (6-15) and nuts (6-14)to release the cable sockets from the cable channel fabrication(6-10) and the deck assembly. Release the cable anchor clips(6-12) by using a small screwdriver to depress the locking tab (A).Free the T piece cable and remove it from the bed.

6.11.2 Installation

a) Refer to the Electrical Assembly Schematic, sheet 62 and identifywhich limb of the T piece cable is to be connected to the controlbox. Spring open the split flexible conduit (13-15) and install theT piece cable (62-9) between the deck and the base. Close thejoint in the flexible conduit.

b) Attach the conduit clamp (14-30) to the upper end of the flexible

conduit and secure it to the deck fabrication (14-3) with screws(14-29), toothed washer (14-32) and nuts (14-28). Do not fullytighten the nuts yet.

c) Attach the conduit clamp (13-14) to the lower end of the flexibleconduit and secure it to the control box bracket (13-11) withscrews (13-17) and nuts (13-13).

d) Connect the earthing strap (13-32) to the deck fabrication (14-3)using one of the conduit clamp screws (14-29). Ensure that thetoothed washer (14-32) is under the earth strap. Fully tighten the

conduit clamp screws (14-29) and nuts (14-28).

April. 2003 6-11 746-310-1

A

Fig. 6-3 Releasing the cable anchor clips


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e) Install the cable and T joint in the cable channel as noted ondisassembly and attach the cable sockets with screws (6-15) andnuts (6-14). Secure the cable with the anchor clips (6-12). Fold thesurplus length of the tie and tuck it into the loop.

f) Refer to the Electrical Assembly Schematic, sheet 62 and connectthe T piece cable (62-9) to the control box (62-6). Arrange thecable tidily in the control box bracket and refit the moulded basecover. Connect the attendant handset (6-19) to the socket at thefoot of the bed. Connect the patient handset (6-20) to the socketbeneath the deck assembly.

6.12 Attendant Control Panel - Replacement

6.12.1 Removal

a) Disconnect the bed from the mains power supply. Raise the headend of the base cover moulding as described in 6.4.

b) Refer to the Electrical Assembly Schematic, sheet 62 anddisconnect the mini ACP cable (62-5) from the control box (62-6).

c) Remove two screws (14-29), nuts (14-28), toothed washer (14-32)and conduit clamp (14-30) to release the flexible conduit from thedeck fabrication (14-3). This also releases the deck earthing strap

(13-32).

d) Remove two screws (13-17), nuts (13-13) and conduit clamp(13-14) to release the flexible conduit from the control box bracket(13-11). Spring open the split flexible conduit (13-15) and pull thecable out of the conduit and into the deck area.

e) Remove two screws (6-17) and nuts (6-18) to release the miniACP (6-16) from the cable channel fabrication (6-10). Release thecable anchor clips (6-12) (Ref Fig. 6-3) to free the mini ACP cableand remove it from the bed.

6.12.2 Installation

a) Install the mini ACP (6-16) on the cable channel fabrication (6-10)and attach with two screws (6-17) and nuts (6-18).

b) Arrange the cable in position on the mattress platform. Springopen the split flexible conduit (13-15) and install the cablebetween the deck and the base. Close the joint in the flexibleconduit.

c) Attach the conduit clamp (14-30) to the upper end of the flexibleconduit and secure it to the deck fabrication (14-3) with screws

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(14-29), toothed washer (14-32) and nuts (14-28). Do not fullytighten the nuts yet.

d) Attach the conduit clamp (13-14) to the lower end of the flexibleconduit and secure it to the control box bracket (13-11) with

screws (13-17) and nuts (13-13).e) Connect the earthing strap (13-32) to the deck fabrication (14-3)

using one of the conduit clamp screws (14-29). Ensure that thetoothed washer (14-32) is under the earth strap. Fully tighten theconduit clamp screws (14-29) and nuts (14-28).

f) Install the cable in the cable channel and secure the cable anchorclips (6-12). Fold the surplus length of the tie and tuck it into theloop.

g) Refer to the Electrical Assembly Schematic, sheet 62 and connectthe mini ACP cable (62-5) to the control box (62-6). Arrange thecable tidily in the control box bracket and refit the moulded basecover.

6.13 Flexible Conduit - Replacement

6.13.1 Removal

a) Raise the backrest and leg sections. Disconnect the bed from themains power supply. Raise the moulded base cover at the head endas described in 6.4.

b) Remove two screws (14-29), nuts (14-28), toothed washer (14-32)and conduit clamp (4-30) to release the flexible conduit from thedeck fabrication (14-3). This also releases the deck earthing strap(13-32).

c) Remove two screws (13-17), nuts (13-13) and conduit clamp(13-14) to release the flexible conduit from the control box bracket

(13-11).d) Spring open the joint in the flexible conduit and remove it from

the bed.

6.13.2 Installation

a) Spring open the joint in the new flexible conduit (13-15) and wrapit around the cables between the deck and the base.

b) Attach the conduit clamp (14-30) to the upper end of the flexibleconduit and secure it to the deck fabrication (14-3) with screws

(14-29), toothed washer (14-32) and nuts (14-28). Do not fullytighten the nuts yet.

April. 2003 6-13 746-310-1


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c) Attach the conduit clamp (13-14) to the lower end of the flexibleconduit and secure it to the control box bracket (13-11) withscrews (13-17) and nuts (13-13).

d) Connect the earthing strap (13-32) to the deck fabrication (14-3)

using one of the conduit clamp screws (14-29). Ensure that thetoothed washer (14-32) is under the earth strap. Fully tighten theconduit clamp screws (14-29) and nuts (14-28).

e) Arrange the cables tidily in the control box bracket and refit themoulded base cover.

6.14 Height Actuators - Replacement

6.14.1 Removal

a) If the actuators are functional: Lift off the head panel and footpanel. Remove the deck sheets. Raise the deck to maximum heightand use the hoist to support it. Disconnect the bed from the mainspower supply.

b) If the actuators are not functional and the bed is at low height:Lift off the head panel and foot panel. Remove the deck sheets.Disconnect the bed from the mains power supply. Use the hoist tosupport the deck and tilt the bed on one side far enough to gain

access to the actuators. Remove the E ring (13-8), washer (13-7)and clevis pin (13-6) to release the actuator ram from the radiusarm (13-24). Set the bed back on its castors and use the hoist toraise the deck to maximum height.

c) Raise the base cover at both ends as described in 6.4.

d) Refer to the Electrical Assembly Schematic, sheet 62 anddisconnect the height actuator cables (62-4) from the control box(62-6). Cut and remove cable ties to release the cables from thebase assembly.

e) If not already done in b) above, remove the E ring (13-8),washer (13-7) and clevis pin (13-6) to release the actuator ramfrom the radius arm (13-24). Remove the E ring (13-5), washer(13-4) and clevis pin (13-3) and remove the actuator from the bed.

6.14.2 Installation

a) Apply Rocol grease to all pivot points prior to assembly.

b) Position the actuator, ensuring correct orientation and attach the

body to the base fabrication (13-1) with clevis pin (13-3), washer

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(13-4) and E ring (13-5). The clevis pin should be installed withthe head toward the inside of the bed.

c) Refer to the Electrical Assembly Schematic, sheet 62 andtemporarily connect the actuator cable to the control box (62-6).Use the control handset to extend the actuator and align the holein the ram with the hole in the radius arm (13-24). Attach theactuator ram to the radius arm with clevis pin (13-6), washer(13-7) and E ring (13-8). The clevis pin should be installed withthe head toward the outside of the bed.

d) Arrange the cable tidily and secure with cable ties as necessary.Lightly lubricate the O rings on the actuator cable connectorswith petroleum jelly (Vaseline). Reconnect cables to the controlbox and fit the retaining strip which prevents accidentaldisconnection of the plugs.

e) Refit the base cover as described in 6.4. Calibrate the actuators asdescribed in Section 7.

6.15 Leg Section Actuator - Replacement

6.15.1 Removal

a) Lift off the head panel and foot panel. Remove the deck sheets.Disconnect the bed from the mains power supply. Raise the headend of the base cover moulding as described in 6.4.

b) Refer to the Electrical Assembly Schematic, sheet 62 anddisconnect the actuator cable (62-1) from the control box (62-6).

c) Remove two screws (14-29), nuts (14-28), toothed washers (14-32)and conduit clamp (14-30) to release the flexible conduit from thedeck fabrication (14-3). This also releases the deck earthing strap(13-32).

d) Remove two screws (13-17), nuts (13-13) and conduit clamp(13-14) to release the flexible conduit from the control box bracket(13-11). Spring open the joint in the split flexible conduit (13-15)and pull the cable out of the conduit into the deck area.

e) Use the hoist to support the leg sections. Using a suitable flatbladed tool, remove and discard the two star washers (14-17).

April. 2003 6-15 746-310-1

WARNING

Take care to avoid trapping fingers during the following procedure.


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Remove the clevis pins (14-16) and remove the actuator from thebed.

6.15.2 Installation

a) Apply grease to both pivot points prior to assembly.b) Position the actuator, ensuring correct orientation and attach the

body of the actuator to the deck fabrication (14-3) with clevis pin(14-16) and a new star washer (14-17).

c) Use the hoist to adjust the height of the leg sections and align thehole in the actuator ram with the hole in the thigh sectionfabrication (16-16). Attach the actuator ram with clevis pin (14-16)and a new star washer (14-17).

d) Spring open the joint in the flexible conduit (1-15) and install thecable between the deck and base.

e) Attach the conduit clamp (14-30) to the upper end of the flexibleconduit and secure it to the deck fabrication (14-3) with screws(14-29), toothed washer (14-32) and nuts (14-28). Do not fullytighten the nuts yet.

f) Attach the conduit clamp (13-14) to the lower end of the flexibleconduit and secure it to the control box bracket (13-11) withscrews (13-17) and nuts (13-13).

g) Connect the earthing strap (13-32) to the deck fabrication (14-3)using one of the conduit clamp screws (14-29). Ensure that thetoothed washer (14-32) is under the earth strap. Fully tighten theconduit clamp screws (14-29) and nuts (14-28).

h) Lightly lubricate the O ring on the actuator cable connector withpetroleum jelly (Vaseline). Reconnect cable to the control box andfit the retaining strip which prevents accidental disconnection ofthe plugs. Arrange the cable tidily and secure with cable ties asnecessary.

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6.16 Backrest Actuator - Replacement

6.16.1 Removal

a) Lift off the head panel and foot panel. Remove the deck sheets.

Disconnect the bed from the mains power supply. Raise the headend of the base cover moulding as described in 6.4.

b) Refer to the Electrical Assembly Schematic, sheet 62 anddisconnect the actuator cable (62-2) from the control box (62-6).

c) Remove two screws (14-29), nuts (14-28), toothed washer (14-32)and conduit clamp (14-30) to release the flexible conduit from thedeck fabrication (14-3). This also releases the deck earthing strap(13-32).

d) Remove two screws (13-17), nuts (13-13) and conduit clamp(13-14) to release the flexible conduit from the control box bracket(13-11). Spring open the joint in the split flexible conduit (13-15)and pull the cable out of the conduit into the deck area.

e) Remove screws (14-26), nuts (14-28) and P clips (14-27) to freethe actuator cable from the deck fabrication (4-3).

f) Using a suitable flat bladed tool, remove and discard the starlockwasher (15-11) to release the CPR cable inner. Remove nut fromthe CPR cable outer and release it from the deck fabrication

(14-3).g) Use the hoist to support the backrest. Using a suitable flat bladed

tool, remove and discard two star washers (15-12). Remove twoclevis pins (15-13) and remove the actuator from the bed.

h) Remove self locking nut (32-8), washer (32-7) and screw (32-6).Remove self tapping countersunk head screw (32-9) and removethe CPR assembly from the actuator.

6.16.2 Installation

a) Apply grease to both pivot points prior to assembly.

b) If removed, attach the release cable (32-2) to the release cablebracket (32-3) with hexagonal nut (32-4). Loosely assemblerelease cable bracket (32-3) and actuator release bracket (32-5)with screw (32-6), washer (32-7) and nut (32-8) and install themon the actuator.

c) Secure the assembly with self tapping screw (32-9) ensuring thatthe screw is inserted parallel to the hole. Tighten the nut (32-8)ensuring that the actuator release bracket (32-5) can rotate freely.

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d) Position the actuator and CPR assembly, ensuring correctorientation and attach the body of the actuator to the deckfabrication (14-3) with clevis pin (15-13) and a new starlockwasher (15-12).

e) Use the hoist to adjust the height of the backrest and align thehole in the actuator ram with the hole in the backrest fabrication(16-7). Attach the actuator ram with clevis pin (15-13) and a newstarlock washer (15-12). Remove the hoist.

f) Spring open the joint in the split flexible conduit (13-15) andinstall the cable between the deck and the base.

g) Secure the cable to the deck fabrication with P clips (14-27),screws (14-26) and nuts (14-28).

h) Attach the conduit clamp (4-30) to the upper end of the flexibleconduit and secure it to the deck fabrication (4-3) with screws(4-29), toothed washer (4-32) and nuts (4-28). Do not fully tightenthe nuts yet.

i) Attach the conduit clamp (13-14) to the lower end of the flexibleconduit and secure it to the control box bracket (13-11) withscrews (13-17) and nuts (13-13).

j) Connect the earthing strap (13-32) to the deck fabrication (14-3)using one of the conduit clamp screws (14-29). Ensure that the

toothed washer (14-32) is under the earth strap. Fully tighten theconduit clamp screws (14-29) and nuts (14-28).

k) Lightly lubricate the O ring on the actuator cable connector withpetroleum jelly (Vaseline). Reconnect the cable to the control boxand fit the retaining strip which prevents accidental disconnectionof the plugs. Arrange the cable tidily and secure with cable ties asnecessary. Refit the moulded base cover.

l) Connect the CPR release cable outer to the deck assembly withtwo nuts. Apply a small amount of Rocol grease to the spigot on

the CPR lever fabrication (13-13) and attach the CPR release cableinner with a new starlock washer (15-11).

m) Adjust the two nuts on the CPR release cable outer to obtainsatisfactory operation of the release mechanism.

6.17 CPR Release Cable - Replacement

6.17.1 Removal

a) Raise the deck to maximum height, raise the backrest and legsections.

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b) Remove and discard the starlock washer (15-11) to release thecable inner from the CPR lever fabrication (14-13). Remove nutfrom the CPR cable outer and release it from the deck fabrication(14-3).

c) Remove hexagonal nut (32-4) and remove the CPR cable from theactuator release assembly.

6.17.2 Installation

a) Attach the release cable inner to the actuator release bracket (32-5)and secure the cable outer to the release cable bracket (32-3) withhexagonal nut (32-4).

b) Connect the CPR release cable outer to the deck assembly withtwo nuts. Apply a small amount of Rocol grease to the spigot on

the CPR lever fabrication (14-13) and attach the CPR release cableinner with a new starlock washer (15-11).

c) Adjust the two nuts on the CPR release cable outer to obtainsatisfactory operation of the release mechanism.

6.18 Gas Spring and Release Moulding - Replacement

6.18.1 Removal

a) Remove the calf section deck sheet. Raise the leg sections and usethe hoist to support the calf section.

b) Using a suitable flat bladed tool, remove and discard the starlockwasher (14-24). Pull the leg section toward the right of the bedand release the gas spring body from the spigot on the foot endcross member fabrication (14-18).

c) Lift the calf section fabrication (16-18) on its hinges and turn itupside down.

d) Unscrew the gas spring ram from the mounting casting (14-20).

e) Rotate the gas spring mounting casting (14-20) until the flats arealigned with the slots in the calf section fabrication (16-18) andwithdraw the mounting casting.

f) If necessary, remove the starlock washer (16-23), nylon washer(16-22) and clevis pin (16-20) and remove the release moulding(16-21).

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6.18.2 Installation

a) If removed, install the release moulding (16-20) on the calf sectionfabrication (16-18) and attach with clevis pin (16-20), nylonwasher (16-22) and a new starlock washer (16-23).

b) Apply Rocol grease to the grooves in the mounting casting (14-20)and install it in the slots in the calf section fabrication (16-18).Ensure that the longer arm is toward the right of the bed.

c) Apply Rocol grease to the end of the gas spring ram and themounting hole in the gas spring body.

d) Screw the gas spring into the mounting casting (14-20) until

approxmately 1mm of thread is protruding.

e) Turn the calf section fabrication right side up. Lower or raise thecalf section to align the hole in the gas spring body with thespigot on the foot end fabrication (14-18). Pull the leg sectionstoward the right of the bed and install the gas spring body on thespigot. Secure the gas spring with a new starlock washer (14-24).

f) Check setting of the calf release runner (14-22). When the legsection is lowered to the horizontal position, the release moulding(16-21) should just drop off the end of the runner. Adjust if

necessary as follows.

g) Remove two screws (14-21) and remove old Loctite screwadhesive from the screws and the threaded holes. Apply Loctitescrew adhesive to the screw threads and attach the runner 1(4-22)again but do not fully tighten the screws. Lower the leg section tothe fully horizontal position and slide the runner (14-22) on theslotted holes to give a clearance of between 1 and 2mm betweenthe runner and the release moulding (16-21). Fully tighten thescrews (14-21).

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Grease

1 mm

Fig. 6-4 Gas spring mounting casting


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6.19 Roller Buffer - Replacement (typical)

6.19.1 Removal

a) Use a large, flat bladed screwdriver to release the flanges on the

roller buffer retainer (14-8) and pull out the retaining pin (14-10).Remove the roller buffer retainer (14-8) and the integral rollerbuffer moulding (14-9) from the deck assembly (or foot endassembly).

b) If necessary, remove the corner tube liner (14-7).

6.19.2 Installation

a) If removed, insert the corner tube liner (14-7) in the deckfabrication (14-3). Make sure that the integral springs on the

corner tube liner are facing toward the foot end of the bed.b) Install the integral roller buffer moulding (14-9) from below.

c) Fit the roller buffer retainer (14-8) and insert the retaining pin(14-10) toward the foot end, ensuring that the groove engagesbetween the flanges on the moulding.

6.20 X-ray Cassette Module - Replacement

6.20.1 Removal and Disassembly

a) The x-ray cassette assembly is mounted on a laminate decksheet(17-1) permanently attached to the backrest fabrication. Thecassette tray assembly can be dismantled without removing thelaminate decksheet.

b) If it is necessary to replace the decksheet, remove the rivet caps(17-4) and use a 5mm diameter drill to drill out the rivets (17-5).Remove the complete x-ray cassette assembly from the backrestfabrication.

c) Remove two nuts (17-34), screws (17-36) and washers (17-38) andremove the cassette tray assembly (17-35). Remove four nuts(17-7), countersunk head screws (17-2) and two pivot brackets(17-37).

d) Remove two nuts (17-7), two screws (17-3) and the catch plate(17-6). The laminate decksheet can now be replaced withoutfurther disassembly.

e) Remove two screws (17-17), washers (17-32) and two spring studs(17-30) to release the fixed end of the springs (17-29). Removetwo screws (17-41), spring studs (17-30), washers (17-32) andlower bracket guides (17-33) to release the other end of the springs(17-29).

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f) Remove two nuts (17-31), two screws (17-41) and the remainingtwo lower bracket guides (17-33) to release the lower bracket(17-39).

g) Remove pan head screw (17-8), unscrew the knob (17-9) and

remove the clamping plate (17-10) and spring (17-11).h) Remove screw (17-13) to release the upper guide fabrication

(17-28) and cassette tray upper bracket (17-14).

i) Remove two countersunk head screws (17-3) and the plungerhousing (17-26) assembly. Remove hexagon headed bolt (17-25),plunger (17-23) and spring (17-24). If necessary, remove the fingerknob (17-27).

6.20.2 Assembly and Installation

a) Before reassembling the cassette tray components, renew bearingtapes (17-15), (17-16), (17-40) and the rubber strip (17-12) asnecessary. First thorougly clean the component with a volatilecleaning agent (e.g. methelated spirits). Peel off the backing stripfrom the new tape and carefully position it on the component.Press firmly in place.

b) Apply Loctite screw adhesive to the hexagon head bolt (17-25).Lubricate the plunger (17-23) with Rocol grease and assemble theplunger, spring (17-24) and bolt (17-25) in the plunger housing

(17-26). Attach the plunger housing (17-26) assembly to the traywith two countersunk head scews (17-3)

c) Attach the cassette tray bracket (17-39) by the two lower holeswith two screws (17-41), two bracket guides (17-33) and nuts(17-31). Apply Loctite screw adhesive to two screws (17-41) andattach one end of springs (17-29) with the screws, two bracketguides (17-33), two washers (17-32) and spring studs (17-30).

d) Apply Loctite screw adhesive to two screws (17-17) and attach theother end of the springs (17-29) with the screws (17-17), washers

(17-32) and two spring studs (17-30).

e) Check that the cassette tray bracket slides freely in the slots.

f) Place the upper guide fabrication (17-28) in position below thecassette tray. Place the upper bracket (17-14) in position in thetray. Apply Loctite screw adhesive to the screw (17-13) and attachthe upper bracket (17-14) to the guide fabrication (17-28). Notethat the screw (17-13) must not clamp the bracket, it is for theretention of the guide fabrication only. Check that the upperbracket and guide slide freely in the slot.

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g) Assemble the spring (17-11), clamping plate (17-10) and knob(17-9). Apply Loctite screw adhesive to the pan head screw (17-8)and insert the screw to retain the knob (17-9).

h) If the backrest laminate has been removed from the bed, place the

x-ray cassette assembly in position on the backrest fabrication(46-4) etc and attach with pop rivets (17-5). Fit rivet caps (17-4).

6.21 Dismantling the Bed

This sub-section gives procedures for dismantling the main structure of the bed.It must be read in conjunction with the preceding sub-sections which describethe removal of specific components and sub-assemblies.

Dismantling of the bed is not a routine procedure and should only be carried outto the extent necessary.

The information given is for guidance since procedures will be varied

according to the purpose for which they are undertaken. For example, it isnot necessary to take off the deck sections in order to remove the deck from thebase. Minor procedures which may be deemed self evident have not beenincluded.

6.21.1 Safety Sides - Removal

Note: The bed may have integral, factory fitted safety sides or removeablesides may be supplied as an accessory. The construction of both versionsis the same but on removeable sides,the integral clamp screw (54-26) isreplaced by clamp screw (54-29), nut (54-30) and knob (54-31).

a) Remove two hexagon head screws (54-18) and washers (54-17)and pull the safety side off the clamp fabrications (54-21) and(54-25).

b) Alternatively, loosen the integral clamp screws (54-26) (turnclockwise viewed from above) until the clamp fabrications (54-21)(54-25) can be tilted and lifted off the deck fabrication (4-3) toremove the complete assembly from the bed.

c) Remove the integral clamp screws (54-26) and clean the threadsprior to reassembly.

d) Unscrew the catch knob (54-11) from the plunger (54-12) andremove the plunger (54-12) and spring (54-14).

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6.21.2 Footend Extension - Removal

a) Use a flat bladed tool to remove starlock washer (34-24) andremove clevis pin (34-23). Squeeze together the extension handleand lock handle, pull out the footend extension and let the handle

swing down.b) Depress the locking lugs on the extension bushes (14-25) and pull

the extension bushes out of the deck fabrication (14-3). Removethe footend extension module from the bed.

c) Using a suitable flat bladed tool, remove and discard the cappedstarlock washer (34-6). Rotate the extension lock fabrication (34-2)in the extension fabrication (34-1) until it can be withdrawnthrough the keyhole slot. Collect the spring (34-4).

d) Knock out two stop pins (34-25), remove end caps (34-26) andpull the bed stripper fabrication (34-12) off the extensionfabrication (34-1). On some early models the bedstripper wasretained by two rollpins (34-13). Drive out the rollpins to removethe bedstripper fabrication.

e) Drive out two roll pins (34-20) and remove the calf extension bow(34-19), together with the extension sheet (34-17) from the calfsection fabrication (16-18).

6.21.3 Backrest (Pro-contour) - Removal

a) Remove decksheets, raise the backrest and use the hoist to supportit.

b) Using a suitable flat bladed tool, remove and discard starlockwasher (15-12). Remove clevis pin (15-13) to release the actuatorram from the backrest fabrication.

c) Remove two self locking nuts (15-5) and pivot bolts (15-4) torelease the stabiliser fabrication (15-1) from the backrest. Ifnecessary, remove and discard two capped starlock washers (15-3),

remove two nylon bushes (15-2) and release the stabiliserfabrication (15-1) from the deck fabrication (14-3).

d) Remove two nuts (15-6) and shakeproof washers (15-7). Slide theguide rods (15-9) through the frame to release the backrest fromthe deck. Collect two guide bushes (15-8) and guide rods (15-9).

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6.21.4 Calf Section - Removal

a) Remove the gas spring as described in 6.18.

b) Using a suitable flat bladed tool, remove and discard two cappedstarlock washers (16-15). Slide the calf section fabrication (16-18)

sideways off the pivots on the thigh section fabrication (16-16).Collect two nylon washers (16-17).

6.21.5 Thigh Section - Removal

a) Remove the calf section as described in 6.20.4..

b) Use the hoist to support the thigh section. Using a suitable flatbladed tool, remove and discard starlock washer (14-17). Removeclevis pin (14-16) to release the actuator ram from the thighsection fabrication.

c) Remove two nuts (16-13), shakeproof washers (16-12) and screws(16-14) and remove the thigh section from the deck fabrication(14-3). Collect two hinge pivot castings (16-11).

6.21.6 Deck Assembly - Removal

a) Remove head and foot panels. Remove decksheets. Use the hoistto support the deck.

b) If not already removed, disconnect the flexible conduit (13-15) and

cables as follows. Disconnect the bed from the mains powersupply. Raise the base cover at the head end. Refer to theElectrical Assembly Schematic, sheet 62 and disconnect the miniACP (62-5), backrest actuator (62-2) and leg actuator (62-1) fromthe control box (62-6). Release the deck earthing strap (62-11)from the control box. Remove two M5 screws (13-17), nuts(13-13) and the conduit clamp (13-14) to release the flexibleconduit from the control box bracket (13-11).

c) Remove two self locking nuts (13-9), screws (13-25) and washers(13-4) to release the head end upper radius arm fabrication (13-18)from the deck support bracket (6-1). Collect two pivot bushes(13-26).

d) Remove two self locking nuts (13-9), screws (13-25) and washers(13-4) to release the foot end upper radius arm fabrication (13-19)from the deck cross member (6-4). Collect two pivot bushes(13-26).

e) Remove the deck assembly from the base asembly.

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6.21.7 Radius Arms - Removal

a) Remove four self locking nuts (13-9), washers (13-4) and screws(13-25) and remove the stabilising links (13-20) from the upperradius arms (13-18) (13-19). Do not allow the radius arms to fall

when released. Collect four pivot bushes (13-26).b) Use a suitable flat bladed tool to remove four pivot cover

mouldings (13-27). Remove two nuts (13-09), screws (13-34), andwashers (13-4). Remove the head end upper radius arm (13-18).Collect two pivot bushes (13-26).

c) Repeat step b) to remove foot end upper radius arm (13-19).

d) Remove screws (24-12) and washers (24-11) and pull off the brakepedals (24-13). Slide the brake bar (24-10) through the frame justfar enough to free the base cover on one side, then slide it back tofree the other side. Remove the base cover from the bed.

e) If not already removed, remove two E rings (13-8), washers(13-7)and clevis pins (13-6) to release the actuators (13-2) fromthe radius arm fabrications (13-24).

f) Remove self locking nuts (13-9) and remove the radius armfabrications (13-24) together with U bolts (13-21), top bearings(13-22) and bottom bearings (13-23).

6.22 Assembling the Bed

6.22.1 Radius Arms - Installation

a) Place four bottom bearings (13-23) in position on the basefabrication (13-1) with flanges on the outside of the frame.Lubricate the bearing surfaces liberally with Rocol grease.

b) Position the radius arm fabrications (13-24) on the bottombearings, ensuring correct orientation ie. With lifting arms pointing

toward the ends of the bed.

c) Apply Rocol grease liberally to the top bearings (13-22) and placethem in position. Fit U bolts (13-21) and secure with self lockingnuts(13-9).

d) Align the hole in the actuator ram with the holes in the radius armfabrication. Apply Rocol grease to the holes and install clevis pin(13-6) with the head toward the outside of the bed. Secure theclevis pin with washer (13-7) and E ring (13-8).

e) Install the moulded base cover over the radius arms. Fit the coverover the brake bar (24-10) by sliding the bar (24-10) first to one

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side then the other. Install the brake pedals (24-13) and securewith screws (24-12) and washers (24-11).

f) Apply Rocol grease to the bush holes at the bottom of the upperradius arms (13-18) and (13-19) and install four pivot bushes

(13-26) with the heads on the inside.Note: Upper radius arm fabrications are fitted with the cross bars toward the

ends of the bed. The cross bar is higher on the foot end fabrication(13-19).

g) Attach the upper radius arms with four screws (13-34) and washers(13-4) with the screw heads on the outside and washers beneaththe heads. Secure with nuts (13-9).

h) Fit eight pivot cover mouldings (13-27). Secure pivot cover

moulding with adhesive when fitted to nut (13-9).

i) At the head end of the bed, apply Rocol grease to the top bushholes in the upper radius arms. At the foot end of the bed, applygrease to the lower holes. Insert four pivot bushes (13-26) in theholes with the heads on the outside.

j) Attach the stabilising links (13-20), flange uppermost, on theoutside of the radius arms with screws (13-25), washers (13-4) andnuts (13-9). The screw head should be on the outside and thewasher beneath the nut.

6.22.2 Deck assembly - Installation

a) Apply Rocol grease to the bush holes in the upper radius arms.(Upper holes at the foot end, lower holes at the head end.) Insertfour pivot bushes (13-26) in the holes with the heads on theinside.

b) Use the hoist to position the deck assembly over the base.

c) Attach the foot end radius arm (13-19) to the deck cross member

(6-4) with two screws (13-25), washers (13-4) and nuts (13-9). Thescrew head should be on the outside with the washer beneath thehead.

d) Attach the head end radius arm (13-18) to the deck supportbrackets (6-1) with two screw (13-25), washers (13-4) and nuts(13-9). The screw head should be on the outside with the washerbeneath the head.

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6.22.3 Thigh Section - Installation

a) Apply Rocol grease to the bearing surface on the pivot castings(16-11) and install them in the thigh section fabrication (16-16).

b) Attach the pivot castings (16-11) to the deck fabrication (14-3)

with hexagonal headed screws (16-14), shakeproof washers (16-12)and nuts (16-13).

c) Use the hoist to support the thigh section and align the hole in thethigh section fabrication with the hole in the actuator ram. ApplyRocol grease to the holes. Install clevis pin (14-16) and securewith a new starlock washer (14-17).

d) Remove the hoist.

6.22.4 Calf Section - Installation

a) Install two nylon washers (16-17) on the pivots on the thighsection fabrication. Apply Rocol grease to the pivots and install thecalf section fabrication. Install two new capped starlock washers(16-15) on the pivots.

b) Use the hoist to support the calf section and install the gas springas described in 6.18.

c) If the leg sections have been removed for any reason,it isimportant to check the setting of the calf release runner (14-22)

and adjust if necessary as described in 6.18.2.

6.22.5 Backrest (pro-contour) - Installation

a) Apply Rocol grease to the pivots on the guide bushes (15-8) andinstall them in the backrest fabrication (16-7). Support the backrestin position and slide the guide rods (15-9) through the holes in thedeck fabrication and through the guide bushes.

b) Secure the guide rods to the deck fabrication with shakeproofwashers (15-7) and nuts (15-6). Use the hexagon head screw

(15-14) to hold the guide rod while tightening the nut. Lightlylubricate the guide rods with Rocol grease.

c) If removed, install the stabiliser fabrication (15-1) by sliding it firstthrough one hole in the deck fabrication then back through theother. Install two nylon bushes (15-2) with the heads toward theoutside of the bed. Install two new capped starlock washers (15-3).

d) Apply Rocol grease to the bearing surface on pivot bolts (15-4).Use the hoist to support the backrest, align the holes and attach thestabiliser fabrication (15-1) to the backrest fabrication with pivot

bolts (15-4) and self locking nuts (15-5).

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e) Use the hoist to support the backrest and align the hole in thebackrest fabrication with the hole in the actuator ram. Apply Rocolgrease to the holes. Install clevis pin (15-13) and secure with anew starlock washer (15-12).

6.22.6 Footend Extension - Installation

a) Assemble extension sheet (34-17) onto the extension bow (34-19).Install and snap on the calf bow stops (34-21). Install theextension bow in the bushes (34-22) on the calf section fabrication(16-18). Support the bow with a suitable anvil and drive in tworoll pins (34-20). Ensure that the rollpins are flush with theunderside and do not foul the calf section release (16-26).

b) Install the bedstripper fabrication (34-12) on the extensionfabrication (34-1) through the bushes (34-14). Install the end caps

(34-26) and secure by pushing in two stop pins (34-25). Inert thestop pins, tapered end first, from the inside toward the outside ofthe bed. On some early models the bedstripper was retained bytwo roll pins. Support the bedstripper fabrication on a suitableanvil and drive in the roll pins (Part no S1021).

c) Turn the extension assembly upside down and place the spring(34-4) in position in the cross member of the extension fabrication(34-1). (With the hook end uppermost and tail end to the left.)Insert the extension lock fabrication (34-2) through the keyhole

slot and the spring and engage the roll pin (34-3) with the spring(34-4). Use a new capped starlock washer (34-6) to secure the lockfabrication.

d) Assemble the extension bushes (14-25) on the runners on theextension fabrication (34-1). Apply a small quantity of Rocolgrease to the runners.

e) Rotate the extension handle counter clockwise against the action ofthe spring. Squeeze together the extension handle and lock handleand install the extension assembly on the deck fabrication (14-3).

Ensure that the locking lugs on the extension bushes are engagedin the holes in the deck fabrication.

f) Install clevis pin (34-23) in the foot end fabrication (4-18) andsecure with a new starlock washer (34-24).

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6.22.7 Safety sides - Installation

Note: Refer to Section 8 sheet 54 for instructions regarding use of Loctite andactivator during assembly.

a) If removed, fit the spring (54-14) onto the plunger (54-12) andinsert the plunger from the inside into the upright fabrication(54-15). Screw on the catch knob (54-11).

b) Lubricate the pivot holes in the clamp fabrications (54-21) and(54-25) with Rocol grease. Attach the clamp fabrications (54-21)and (54-25) to the assembled rails and uprights with hexagon headscrews (54-18) and washers (54-17).

c) Fit integral clamp screws (54-26) from the inside in the clampfabrications (54-21) and (54-25) and screw them in as far as

possible.d) Position the safety side assembly above the mattress deck, tilt the

top inwards and hook the clamps (54-21) and (54-25) onto thedeck fabrication (14-3). Ensure that the clamps are engaged on thelocating pins (54-19) in the deck fabrication.

e) Tighten the integral clamp screws (54-26) to secure the sides.Ensure that the head of the clamp screw (54-26) engages in therecess in the locating nut (54-20). Do not overtighten the clampscrew as this may distort the clamp.

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6.23 Restoration of Paintwork

Damage to the paint finish on the frame or other components can be repaired bybrush application of cellulose based paint obtainable from specialist paint

suppliers or local distributors.

To ensure colour match, contact Huntleigh Nesbit Evans Ltd quoting theproduct code and serial number, for confirmation of finish colour.

6.23.1 Procedure

a) Clean and degrease the damaged area by wiping with a lint freecloth moistened with a suitable volatile solvent e.g. methylatedspirits.

b) Make sure there are no loose chips of paint and use fine siliconcarbide abrasive paper to abrade the area where paint is to beapplied and blend to a smooth surface. Clean and degrease thearea again.

c) Use a soft bristle brush and apply the primer paint to the damagedarea. Allow to dry and then apply the colour finish paint. Use both

in accordance with the manufacturers instructions.

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WARNING

Always use painting materials as directed by the manufacturer andobey the safety instructions.


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7 CALIBRATION

7.1 Calibration of Height/Tilt Actuators

Long use in service may result in non parellelism of the height actuators, as aresult of which the bed may not return to a true horizontal position. This may beautomatically corrected by driving the bed to its lowest height. If this is not

effective, the condition can be rectified by the re-calibration proceduredescribed below.

7.1.1 Preliminary

Ensure that the bed is connected to the mains power supply. Set the rotarylock-out switches on the attendant control panel to enable all the bedfunctions.

7.1.2 Procedure

a) On any of the patient control handsets, press the Backrest Up,Height Up and Height Down buttons simultaneously and keep thempressed.

b) A continuous beep sound should be heard from the control box. Ifnot, repeat step a).

c) After approximately 5 seconds, the continuous sound should

change to an intermittent beep. (This indicates that the control boxis in calibration mode.) Release the push buttons.

d) Press the Height Down button for a few seconds. (This will driveone of the base actuators inwards.)

e) Press the Height Up button for a few seconds. (This will drive theother base actuator inwards.)

f) Repeat steps d) and e) until the deck is level at bottom height.

g) At this stage the system

service manual cama

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