Gen Med Wall Unit Service Manual
Contents
1. angled Strain Relief Bush EP79 10243 and Coiled Cable into the Base Moulding EP19 50924 by squeezing the Right angled Strain Relief Bush EP79 10243 at the points shown preferably with the HEYCO No 29 Insertion Tool 8 Prepare the ends of the Coiled Cable as shown below according to which side it is to be fitted L H HANDLE R H HANDLE a N l MARKED MARKED CORE I CORE a dAL CV DETAIL OF RELIEF BUSHES AND CABLES SHOWING CUT LENGTHS AND CONNECTIONS TO PCB Issue A 28 08 2008 Page 8 Gen Med Wall Unit Service Manual Keeler Part No 2415 P 7020 9 Re solder the connections as shown Note that the cores marked with a stripe go to connections A and D and the unmarked cores go to B and C Reassembly 1 Refit the PCB 1964 P 5002 ensuring that the cables are not trapped and the LEDs fit into their cut outs 2 Secure the PCB 1964 P 5002 using 2 off M2 5 x 12 Pan head Screws SP72 55078 3 Carefully fit 2 off Actuators EP39 51320 with their pips in the holes on the Base Moulding EP19 50924 as shown 4 Carefully fit 2 off Levers EP 51339 with their pips in the holes on the Base Moulding EP19 50924 with 2 off Springs EP79 10235 as shown ensuring that the ends of the Springs EP79 10235 are inside the edges of the Base Moulding EP19 50924 Issue A 28 08 2008 Page 9 Keeler Gen Med Wall Unit Service Manual Part No 2415 P 7020 5 Carefully fit the Top Mould2. the Sleeved Grommet EP79 48831 in the Cap Moulding EP29 50827 and Handle PCB EP39 51291 as shown ensuring that the marked core is aligned with holes A amp B and it reaches approximately 5mm beyond point C 6 Separate the cores back to where they go through the Handle PCB EP39 51291 7 Strip approximately 5mm of insulation from the unmarked core 8 Solder the unmarked core to the pad at C 9 Cut the marked core approximately 15mm past point A and strip approximately 15mm of insulation from the marked core 10 Twist the wires of the marked core together and thread through hole a round the edge of the Handle PCB EP39 51291 and then through hole B so that the bare wire will contact the inside of the Handle Assy 1999 P 5679 11 Solder both point A and point B Issue A 28 08 2008 Page 12 Gen Med Wall Unit Service Manual Keeler Part No 2415 P 7020 Coiled Cable 1 Carefully unscrew the Bottom Cap EP29 50879 from the Handle Assy 1999 P 5679 and withdraw the Handle PCB EP39 51291 The threaded section is Loctited during manufacture and some force may be necessary to break the seal Carefully un solder the Coiled Cable EP79 24872 from points A amp B from the Handle PCB EP39 51291 It may be necessary to cut the wires Clean the holes on Handle PCB EP39 51291 so that the wires an the new Coiled Cable EP79 24872 can be threaded through Unthread the old Coiled Cable EP79 24872 from both the Handle P
3. 20 Precautions Care should be taken to carry out any repair work on a clean soft surface to minimise damage to the outside of the unit and lenses Solvents should not be used for cleaning Issue A 28 08 2008 Page 4 Gen Med Wall Unit Service Manual Keeler Part No 2415 P 7020 Disassembly Main Unit 1 Remove 5 off M2 5 x 12 Pan head Screws SP72 55078 holding the Top Moulding EP19 50932 to the Base Moulding EP19 50924 2 Take care not to lose the 2 Actuators EP39 51320 2 Springs EP79 51395 and 2 Levers EP39 51339 which are released as the two mouldings are parted 3 Remove 2 off M2 5 x 12 Pan head Screws SP72 55078 holding the PCB nn Er0ss1007 es 1964 P 5002 to the Base Moulding EP19 50924 Issue A 28 08 2008 Page 5 Keeler Gen Med Wall Unit Service Manual Part No 2415 P 7020 Replacements Main Unit PCB 1 Carefully un solder 4 off connections A B C D 2 Remove the old PCB 1964 P 5002 3 If either of the Corded Handle Assys 1964 P 5003 are to be changed refer to the Corded Handle Assy section below 4 Prepare the 4 wires for re soldering note the length of wire required below If this cannot be achieved it will be necessary to refer to the Corded Handle Assy section below a L H HANDLE RH AANDLE i MARKFT kN re S AN ro ae hr E DETAIL OF RELIEF BUSHES AND CABLES SHOWING CUT LENGTHS AND CONNECTICNS TO PCB 5 Care
4. CB EP39 51291 and the Sleeved Grommet EP79 48831 Thread the long end of the new Coiled Cable EP79 24872 through the narrow end of Sleeved Grommet EP79 48831 in the Cap Moulding EP29 50827 and Handle PCB EP39 51291 as shown ensuring that the marked core is aligned with holes A amp B and it reaches approximately 5mm beyond point C separate the cores back to where they go through the Handle PCB EP39 51291 7 Strip approximately 5mm of insulation from the unmarked core 8 Solder the unmarked core to the pad at C 9 Cut the marked core approximately 15mm past point A and strip approximately 15mm of insulation from the marked core 10 Twist the wires of the marked core together and thread through hole A round the edge of the Handle PCB EP39 51291 and then through hole B so that the bare wire will contact the inside of the Handle Assy 1999 P 5679 11 Solder both point A and point B Issue A 28 08 2008 Page 13 Gen Med Wall Unit Service Manual Keeler Part No 2415 P 7020 Spare Parts Parts not listed are generally not available as spares Current prices for spare parts are available from Technical Service Technical Service Keeler Ltd Clewer Hill Road Windsor Berks SL4 4AA Phone 44 0 1753 827110 Fax 44 0 1753 827114 Issue A 28 08 2008 Page 14 Gen Med Wall Unit Service Manual Keeler Part No 2415 P 7020 Spare Parts List Part No Description 1964 P 5002 Gen Med PCB Assy 1964 P 5003 C
5. Keeler Gen Med Wall Unit Service Manual ALWAYS READ THE INSTRUCTIONS A HALMA GROUP COMPANY Keeler Limited Clewer Hill Road Windsor Berks United Kingdom SL4 4AA Tel No 44 0 1 753 857177Fax No 44 0 1 753 830247 Issue A 28 08 2008 Part No 2415 P 7020 Keeler CONTENTS Introduction Service Principles Tools Required Precautions Disassembly Main Unit Replacements Main Unit PCB Corded Handle Assy Reassembly Corded Handle Assy Replacements Handle PCB Coiled Cable Spare Parts Spare Parts List Issue A 28 08 2008 Gen Med Wall Unit Service Manual Part No 2415 P 7020 N ODO DO 1 7 fF W NDN 11 11 11 13 14 15 Gen Med Wall Unit Service Manual Keeler Part No 2415 P 7020 Introduction This manual covers the Gen Med Wall Unit only it does not cover the heads fitted to the Wall Unit Service Principles some parts are only available as assemblies where special tools and adhesives are used in the manufacturing process The remainder of parts are available as kits of relevant parts Issue A 28 08 2008 Page 2 Gen Med Wall Unit Service Manual Keeler Part No 2415 P 7020 Tools Required Most of the tools required will be in a standard electro mechanical toolkit It would be helpful to have an insertion tool for the right angled Strain Relief Bush EP79 10243 HEYCO No 29 Issue A 28 08 2008 Page 3 Gen Med Wall Unit Service Manual Keeler Part No 2415 P 70
6. fully re solder the 4 wires noting that the cores marked with a stripe go to connections A and D and the unmarked cores go to B and C Issue A 28 08 2008 Page 6 Gen Med Wall Unit Service Manual Keeler Part No 2415 P 7020 Corded Handle Assy 1 Follow the instructions above to un solder the connections of the Corded Handle Assy to be changed 2 Remove the Right angled Strain Relief Bush EP79 10243 with the Coiled Cable by squeezing the bush together so that it will pass through the hole preferably with the HEYCO No 29 Insertion Tool This will allow the Bush EP79 10243 to pass into the inside of the Main Unit 3 Remove the Bush EP79 10243 from the Coiled Cable by pulling the clamp out from the Bush 4 Remove the old Corded Handle Assy 5 Thread the Coiled Cable from the replacement Corded Handle Assy 1964 P 5003 from the outside to the inside of the Base Moulding EP19 50924 Issue A 28 08 2008 Page 7 Keeler Gen Med Wall Unit Service Manual Part No 2415 P 7020 6 Fit the Right angled Strain Relief Bush EP79 10243 to the Coiled Cable as shown Ensuring that marked core is on the correct side according to the drawing below and that there is sufficient free cable to allow it to be soldered to the PCB 1964 P 5002 The Right angled Strain Relief Bush EP79 10243 should be compressed by squeezing the points shown to push the Coiled Cable into the Right angled Strain Relief Bush EP79 10243 7 Fit the Right
7. ing EP19 50932 over the Base Moulding EP19 50924 taking care not to disturb the Levers EP 51339 and Actuators EP39 51320 allowing their pips to locate in their holes in the Top Moulding EP19 50932 6 Holding the Top Moulding EP19 50932 and Base Moulding EP19 50924 together turn them over and secure the Base Moulding EP19 50924 to the Top Moulding EP19 50932 using 5 off M2 5 x 12 Pan head Screws SP72 55078 Issue A 28 08 2008 Page 10 Gen Med Wall Unit Service Manual Keeler Part No 2415 P 7020 Corded Handle Assy We do not recommend dismantling the rheostat area of the Handle Assy 1999 P 5679 there are no replaceable parts and jigs are required to fit the parts inside Replacements Handle PCB 1 Carefully unscrew the Bottom Cap EP29 50879 from the Handle Assy 1999 P 5679 and withdraw the Handle PCB EP39 51291 The threaded section is Loctited during manufacture and some force may be necessary to break the seal ANN 2 Cut the 2 wires as close as possible to the solder pads on the PCB 3 Unthread the Coiled Cable EP79 24872 from both the Handle PCB EP39 51291 and the Sleeved Grommet EP79 48831 4 Place the Contact Spring EP79 10235 over the tab on the Handle PCB EP39 51291 and solder it to the pad Issue 28 08 2008 Page 11 70 4277D 7 24407 2 Gen Med Wall Unit Service Manual Keeler Part No 2415 P 7020 5 Thread the Coiled Cable EP79 24872 through
8. ord Slimline Handle 1999 P 5679 Slimline Handle Drill amp Tap EP19 50924 Base Moulding Gen Med Unit EP19 50932 Top Moulding Gen Med Unit EP29 50879 Bottom Cap EP39 51291 Gen Med Handle Flexi PCB EP79 24872 Coiled Cable 1964 P 7000 Fixings Gen Med Unit The following list of parts is for identification only The parts are only available as part of the complete Fixings kit Part No Description EP29 50887 Cap Moulding EP39 51320 Actuator EP39 51339 Lever EP79 10235 Contact Spring EP79 10243 Right Angle Strain Relief EP79 48831 sleeved Grommet EP79 51395 Spring SP13 00077 M3 x 4 Grub Screw SP72 55078 M2 5 x 12 Pan head Screw Issue A 28 08 2008 Page 15
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