Exam Light III Book.book
Contents
1. Service Manual 488061 Rev B Welch Allyn Exam Light 1 Blank Page Troublshooting Section 3 Initial Screening 1 Inspect the Exam Light for physical damage cracked cover etc 2 Attempt to confirm reason for return 3 If reason can not be determined contact the sender Light Pipe 1 Flex the light pipe at each bend and replace any that A Have noisy monocoils B Show signs of not holding position C Have excessive springback when positioned in a U position NOTE When the light pipe is placed in the U shape at the center bend the pipe should not spring back by more than 8 to 9 inches When the light pipe is bent in a U shape at the light source bend the spring back should not be more than 4 to 5 inches Focusing Sleeve 1 Check for cracks or damage 2 Check for smooth operation of the lens when the sleeve is turned 3 Replace any lens that have scratches Electrical Troubleshooting WARNING Turn off and unplug unit between each of the next steps CAUTION 1 Lamp does not light and the green rocker switch does not light A Pull fuses out and check fuses with ohm meter B Attach a known good power cord C Replace the green rocker switch D Check the AC connector for damage and cracks Service Manual 488061 Rev B Welch Allyn Exam Light 1 Section 3 Troubleshooting 2 Green rocker switch light is illuminated but the lamp does not light A Check for proper lamp It should2. phillips head screw 2 Welch Allyn Exam Light III Service Manual 488061 Rev B Disassembly and Repair Section 4 7 Light Pipe Connector Assembly Removal Light Pipe With a 5 64 hex wrench slightly back the hex Connector nut off the pipe connector assembly Slide the pipe connector assembly out The pipe con nector assembly can only be removed from the inside of the main housing 8 Transformer Removal Remove the 4 phillips head screws NOTE Note the wire orientation and wire color on the illuminated offon switch The wires must be removed from the illuminated switch before the illuminated switch can be removed The photo shows the wiring as wired for domestic 120V See the wiring diagram in Appendix C for the wiring in your local area Service Manual 488061 Rev B Welch Allyn Exam Light III 3 Section 4 Disassembly and Repair 9 Illuminated Switch Removal Squeeze the outer tabs on the switch and push outward NOTE Notice the orientation of the switch when properly installed 10 Fan Removal Use a 3 16 driver on the hex nut and a flat bed screw driver on the screw and remove all four fasteners Disconnect the fan connector from the PCB 4 Welch Allyn Exam Light III Service Manual 488061 Rev B Disassembly and Repair Section 4 NOTE A Notice how the wires are secured to the chassis B Notice how wires are routed through the channel with rubber grommets C Notice wire t
3. 375 PH PN ST ZN 8 236733 FUSE DRAWER 9 236706 3114 FUSE 500MA USA 10 443071 1 TRANSFORMER 35W 11 443093 SPARE WIRE CAPS 12 236706 3112 FUSE 315 MA EUROPE UK Aus 13 488307 4 FUSE 630 MA JAPAN 14 761076 0 POWER CORD DETACH DOM JAPAN 15 761076 2 POWER CORD DETACH EUROPEAN 16 761076 4 POWER CORD DETCHBL U K 17 761076 6 POWER CORD DETACH AUSTRALIA 18 106130 2 QUICK CONNECT RECEPTACLE 19 488082 MOLEX CONNECTOR 20 48200 FIBER OPTIC LITE PIPE ASSY 21 48605 FOCUSING SLEEVE ASSEMBLY 22 488106 INNER SLEEVE 23 488401 2 BODY MAIN MACHINED 24 488406 CAM SLEEVE 25 488403 REAR LEANS 26 488405 END WINDOW 27 488408 FRONT OUTER BODY 28 488404 FRONT LENS 29 488407 REAR BODY 30 488035 RETAINING COLLAR 31 488034 INSULATOR 32 488311 FILTER HEAT 33 106101 2 RETAINING RING 34 488432 BRAKE 35 488312 GASKET HEAT FILTER 36 106113 22 SET SCREW 6 32 X 125 CUP 37 488001 502 PIPE CONNECTOR ASSEMBLY 38 236707 1 ILLUMINATED SWITCH DOMESTIC 125VAC 39 488118 501 REAR HOUSING ASSY COMPLETE 40 747187 8 32 HEX NUT CAD PLID 4 483412 8 EXTERNAL LOCK WASHER 42 106137 2 NUT 8 32 EXTLOCK Service Manual 488061 Rev B Welch Allyn Exam Light 1 Appendix A Bubble Part Description Repair Parts 43 488110 KEYHOLE STANDOFF 44 488112 CAPTIVE PANEL SCREW 45 106140 3 4 40 X 25 WASHER 46 488070 487 MODEL LABEL JAPAN 47 488069 487 MODEL LABEL DOM 488083 LAMP CH
4. 488061 Rev B Wele Allyn Service Manual Exam Light III Examination Light Welch Allyn Medical Division 4341 State Street Road P O Box 220 Skaneateles Falls NY 13153 0220 Copyright 2002 488061 Page 24 Bubble 81 488119 D 08 12 09 D changed to new 714160 D See SAP DIR for change number approver name and date of approval Drawings and or illustrations and or part numbers contained in this document are for refer ence purposes only For current revisions call the Welch Allyn Customer Service phone number listed in Section 1 page 3 Service Manual 488061 Rev B Welch Allyn Exam Light i Table Of Contents Section 1 General Information AA DOULE Tie LE EE 1 U O Saati 1 APNO TEE __ _ _ ___________ 1 Gauuons and Warm En ay naa CD oto GTA 2 edl e TAN AN 3 Section 2 Incoming Inspection Tone IS G NONG AA afe ab l O Y an AA O 1 EE 1 Section 3 Troubleshooting Male Na AA aa 1 bed a gal D E AA AA FE FR 1 FOCUS tege 1 Electrical NO ON ng RD NANANA FUR 1 Section 4 Disassembly and Repair COV ET Removal as ANA ANA FFY e 1 eniova E 1 Lamip CO ROMO A e HN EN AW FT Y FPA NN HRN RF FN A 1 Lamp Removal RF FOR FN CW _________ ARF 2 Lamp Holder REMOVA EE 2 Lanp bill OTO E 2 Light Pipe Connector Assembly Removal 3 Transtormer REMOVA ee _______ Din 3 Illumina
5. ANGE LABEL 488116 WIRE TIE 443083 WIRE TIE W MOUNTING HOLE 106100 4 PHPS 4 40 X 38 LG 488066 EMI SHIELD 35W 488076 501 TRANSFORMER WIRE HARNESS DOM 488043 503 FAN WITH WIRE HARNESS 488073 501 WIRE HARNESS LAMP REC BOARD 488058 LAMP HARNESS CONNECTOR 495073 LAMP HARNESS CONNECTOR 106137 1 NUT 4 40X 250 HEX KEPS EXTLOCK 106102 40 FHPS 78 32 X 500 488023 BRACKET WALL MOUNT 488206 MOUNTING PLATE 48780 ONLY 488082 Molex Connector 714160 Operation Instruction 488061 Service Manual 2 Welch Allyn Exam Light III Service Manual 488061 Rev B Exploded View Drawings Photos Appendix B o Service Manual 488061 Rev B Welch Allyn Exam Light lll 1 Appendix B Exploded View Drawings Photos Transformer Insulator Ni Ng 2 Welch Allyn Exam Light Service Manual 488061 Rev B Exploded View Drawings Photos Appendix B Service Manual 488061 Rev B Welch Allyn Exam Light lll 3 Appendix B Exploded View Drawings Photos 4 Welch Allyn Exam Light Ill Service Manual 488061 Rev B Exploded View Drawings Photos Appendix B Service Manual 488061 Rev B Welch Allyn Exam Light lll 5 Appendix B Exploded View Drawings Photos 6 Welch Allyn Exam Light lll Service Manual 488061 Rev B Exploded View Drawings Photos Appendix B 9 Aen Servi
6. CORD FROM THE OUTLET AND THE LIGHT SOURCE 2 GRASP LAMP CONNECTOR AND PULL STRAIGHT OUT 3 PULL LAMP FROM CONNECTOR AND REPLACE WITH NEW 4 PUSH LAMP BACK INTO HOLDER BEFORE INITIAL LAMP REPLACEMENT ONLY 1 GRASP WIRE CLIP AT TOP OF LAMP 2 ROTATE CLIP TOWARD THE BASE OF THE LAMP AND REMOVE 3 DISCARD CLIP Welch Allyn Exam Light lll 11 Appendix B Exploded View Drawings Photos 12 Welch Allyn Exam Light lll Service Manual 488061 Rev B Electrical Schematic Appendix C FAN RED BLACK LAMP IEC a CONNECTOR RECTIFIER FUSE swiTCH TRANSFORMER ACLNE BRN GND SA cy BLU RED BRN NEUTRAL fg GRN YEL Jumm 12VAC a ou pala BLU l BRN DPST CHASSIS YEL WHT TRANSFORMER PRIMARY Service Manual 488061 Rev B BLU COMMON WHT 100V TAP BLK 120V TAP BRN 230V TAP GRAY 240V TAP Welch Allyn Exam Light III 1 Blank Page
7. be 12 volt 35 watt Welch Allyn 04200 NOTE If the lamp is replaced burn the unit in for at least one hour to confirm there are not other issues B Check transformer output It should measure 12vac C Lift lamp out of bracket and check filter and gasket NOTE The gasket should not be blocking the light The filter should not be cracked chipped or dirty 2 Welch Allyn Exam Light III Service Manual 488061 Rev B Disassembly and Repair Observe All ESD Precautions Turn unit off Unplug the power cord from the outlet and from the light box 1 Cover Removal Unscrew the captured screw at the bottom of the main housing Push the cover up and for ward NOTE Take care when removing the cover The tabs on the cover may break if you do not push the cover all the way up before removal 2 EMI Shield Removal Remove the 5 phillips head screws NOTE Notice manufactured date stamp on the EMI shield 3 Lamp Clip Removal For first time lamp removal grasp the wire clip at the top of the lamp Rotate the clip toward the base of the unit it pops out NOTE Discard the clip It is used only for shipping Service Manual 488061 Rev B Section 4 Welch Allyn Exam Light HI 1 Section 4 Disassembly and Repair 4 Lamp Removal Grasp the lamp connector and pull the lamp straight out of its holder 5 Lamp Holder Removal Remove the two nuts 6 Lamp Baffle Removal Remove the one
8. ce Manual 488061 Rev B Welch Allyn Exam Light lll 7 Appendix B Exploded View Drawings Photos Neonate Lite Pipe For the 48780 8 Welch Allyn Exam Light Ill Service Manual 488061 Rev B Exploded View Drawings Photos Appendix B BA Z ALLOW LAMP TO COOL N Bs ee BEFORE REPLACING WT REPLACE LAMP WITH WELCH ALLY PART NUMBER 04200 TT REPLACE LAMP 1 DISCONNECT POWER CORD FROM THE OUTLET AND THE LIGHT SOURCE 2 GRASP LAMP CONNECTOR AND PULL STRAKSHT OUT a PULL LAMP FROM CONNECTOR AND REPLACE WITH NEW 3 PUSH LAMP BACK INTO Le HOH DER Service Manual 488061 Rev B Welch Allyn Exam Light lll 9 Appendix B Exploded View Drawings Photos Set Screw 10 Welch Allyn Exam Light III Service Manual 488061 Rev B Exploded View Drawings Photos REF 48748 WELCH ALLYN INC SKANEATELES FALLS NY 13153 USA N 3 EH ec INPUT 74227 100 VAC CONFORMSTO 50 60 Hz 500mA IEC STD 60601 1 REF 48742 WELCH ALLYN INC SKANEATELES FALLS NY 13153 USA Service Manual 488061 Rev B REF 48740 WELCH ALLYN INC SKANEATELES FALLS NY 13153 USA ste US 74227 CONFORMS TO UL STD 2601 1 INPUT CERTIFIED TO 120 VAC CAN CSA STD C22 2 60 Hz 400mA No 601 1 REF 48744 WELCH ALLYN INC SKANEATELES FALLS NY 13153 USA Appendix B ALLOW LAMP TO COOL BEFORE REPLACING REPLACE LAMP WITH WELCH ALLYN PART NUMBER 04200 TO REPLACE LAMP DISCONNECT POWER
9. ies on brown wires Note Notice the wiring orientation to the IEC connector and wire colors 11 Rectifier board removal Remove all four phillips head screws Service Manual 488061 Rev B Welch Allyn Exam Light HI 5 Section 4 Disassembly and Repair 12 Light Pipe Connector Assembly Disassembly A Remove the retaining ring B Remove the square heat filter C Remove the heat filter gasket 6 Welch Allyn Exam Light III Service Manual 488061 Rev B Disassembly and Repair Section 4 D Remove the two hex set screws that secure the insulator to the retaining collar E Pull the retaining collar from the insulator F Remove the brake from the inside of the insulator Service Manual 488061 Rev B Welch Allyn Exam Light HI 7 Section 4 Disassembly and Repair 13 Focusing Sleeve Assembly A Insert the rear lens inside the main body NOTE The rear lens is the lens with the smaller diameter convex shape in the middle of the lens The convex shape should be fac ing outward B Insert the front lens into the main body NOTE The front lens is the lens with the larger convex shape The convex shape should be facing outward C Insert the end window into the main body NOTE There are three very small tabs on the lip of the end window Line those three tabs with the three long slots of the main body 8 Welch Allyn Exam Light III Service Manual 488061 Rev B Disassembly and Repai
10. ls Model 48760 only ETL listed EC 60601 1 AS 3200 1 ge Us EC 60601 1 2 74227 The CE mark on this product indicates that it has been tested to and conforms with the provisions noted within the 89 336 ECC Electromagnetic Compatibility Directive Australia EMC Framework Compliance N344 Service Manual 488061 Rev B Welch Allyn Exam Light III 1 Section 1 General Information Cautions and Warnings Intense Light Lamp is extremely bright Do not stare at the lamp when in use May be harmful to eyes Caution Remove power cord from electrical outlet and allow lamp to cool 10 minutes before replacing with a Welch Allyn lamp Danger Electrical shock hazard Refer servicing to gualified service per sonnel Caution Risk of explosion if used in the presence of flammable anesthet ICS Hot Surface Lamp is hot May be harmful to skin if touched NOTE This product complies with the current required standards for electromagnetic inter ference and should not interfere with other equipment or be affected by other compliant devices As a precaution avoid using this device in close proximity to other equipment 2 Welch Allyn Exam Light III Service Manual 488061 Rev B General Information Help Information Section 1 To assure correct operation and performance all service and repairs must be performed by fully trained and properly equipped personnel using genuine replacement part
11. r Section 4 D Attach the three cam sleeves to the main body Align the cam slots of the cam sleeve with the front and rear lens tabs NOTE Align one sleeve with the front and the rear lens and the other two sleeves with go on easier NOTE Observe how the front and the rear lens tabs on the front and rear Jens fit in the cam sleeve p N Note Observe that each cam sleeve has a slot at the rear of the cam sleeve The slot must face toward the rear of the assembly Service Manual 488061 Rev B Welch Allyn Exam Light 9 Section 4 Disassembly and Repair E Slide the rear body over the main body assembly NOTE There are three tabs in the rear of the rear body The rear body tabs will need to fit into the slots of the cam sleeves You may have to rotate the rear body to get the rear body tabs to fit in the cam sleeve slots F Slide the front body over the assembly You may have to rotate the front body The front body will snap in place 10 Welch Allyn Exam Light III Service Manual 488061 Rev B Repair Parts Appendix A Bubble 7 Part Description 1 236732 IEC CONNECTOR 2 488042 WIRE HARNESS PWR MOD GROUND 5 3 488074 502 WIRE HARNESS POWER MOD SWITCH 4 488074 501 WIRE HARNESS POWER MOD SWITCH 5 236707 2 ILLUMINATED SWITCH EXPORT 250VAC 6 488053 MOLEX HOUSING 7 106140 19 6 32 X 1
12. s and correct procedures Failure to do so will also invalidate the product warranty Welch Allyn Inc State Street Plant Corporate Headquarters 4341 State Street Road Skaneateles Falls NY 13153 0220 USA tel 1 800 535 6663 315 685 4100 fax 315 685 3361 www welchallyn com medical support tech Welch Allyn GMBH Zollerstrasse 2 4 72417 Jungingen Germany tel 011 49 7477 927186 fax 011 49 7477 927193 Welch Allyn UK Ltd St Georges House Vernon Gate Derby England DE1 1UQ tel 011 44 01332 206208 fax 011 44 01332 206209 mob 011 44 0467 301814 Welch Allyn Singapore Ltd 300 Beach Road 25 08 The Concourse Singapore 199589 Singapore tel 011 65 291 0882 fax 011 65 291 5780 Welch Allyn Japan K K Bon Marusan 8F 3 5 1 Kanda Jinbo Cho Chiyoda Ku Tokyo 101 0051 Japan tel 011 813 5212 7391 fax 011 813 3261 7372 Service Manual 488061 Rev B MD International 11300 N W 41st Street Miami FL 33178 USA tel 305 669 9003 fax 305 669 1971 Welch Allyn France SARL 814 rue Charles de Gaulle 77100 Mareuil les Meaux France tel 011 33 1 6009 3366 Fax 011 33 1 6009 6797 Welch Allyn Australia Pty The Metro Centre Unit 5 38 46 South Street Rydalmere NSW 2116 Australia Postal address PO Box 132 Rydalmere NSW 1701 Australia tel 011 612 9638 3000 fax 011 612 9638 3500 China Service Center Room 708 Central Plaza No 277 Huang Pi Bei Rd Huang Pi Distric
13. t Shanghai 200003 China tel 011 86 21 63279631 fax 011 86 21 63279632 Welch Allyn Exam Light III 3 Blank Page Service Section 2 Incoming Inspection NOTE Use the following guidelines when unpacking the Exam Light III from its shipping Carton 1 Before opening the Exam Light shipping carton check for damage 2 If damage is apparent stop unpacking the carton and contact the shipping company for further instructions If the carton is intact unpack the Exam Light 3 With the Exam Light out of its carton check to see that all the items listed on the packing slip are in the shipping carton 4 Ifan item is missing first check the carton then check with your receiving department If necessary contact Welch Allyn at the Address and phone number shown in Section 1 5 Clean and disinfect by following the instructions printed in the Operator Manual NOTE Perform all functional tests before and after servicing 6 Operate the Exam Light to verify the customer complaint before making any changes to the unit Call the customer if the complaint is unclear 7 Ifthe unit has caused or is suspected of having caused an injury of any type DO NOT DISASSEMBLE OR REPAIR THE UNIT IN ANY WAY Contact Welch Allyn Customer Service immediately Reguired Tools Phillips Screw Driver Flat Head Screw Driver Standard Needle Nose Pliers 11 32 Nut Driver 5 64 Nut Driver 3 8 Nut Driver 5 64 Hex wrench Digital MultiMeter
14. ted On Off Switch 4 Fow ROMOV AA 4 RECEP Board ee 5 Light Pipe Connector Assembly Dissassembly 6 Focusing Sleeve E 8 Appendix A Repair Part Numbers Appendix B Expoded View Drawings Photos Appendix G Electrical Schematic ii Welch Allyn Exam Light III Service Manual 488061 Rev B Service Manual 488061 Rev B Welch Allyn Exam Light II iii iv Welch Allyn Exam Light III Service Manual 488061 Rev B General Information Section 1 About the Exam Light Welch Allyn s Exam Light takes flexible illumination to a new level It mounts easily to fit on a wall stand or on an examination table The Exam Light delivers bright white fiber optic illumination for better visibility and more accurate diagnosis Features e Durable fiber optic pipe provides cool illumination and is bendable to almost any posi tion e Easy to position small non obstrusive head does not block view for task areas e Light weight focusing sleeve optics are sealed for less dust e Provides homogenous spot and variable spot size e Easy to maintain dichronic halogen lamp provides brighter whiter light 3 2009F e Multiple mounting options for greater flexibility Special UV filters provide safe trans illumination of neonates to detect pneumothorax conditions and intacranial hemorrhaging perform infant venipuncture and locate blood vesse
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