MFI Headlight Service Manual
Contents
1. __ Unscrew the top nut Use collet or equivalent __ Pull the top cap off of lens housing __ Remove O rings 1 2 Remove Bottom Housing __ Unscrew bottom housing from lens housing These parts are held together using a thread locking adhesive Use of a collet will be needed to break the bind of the threadlocker Note The back plate and the mirror cannot be replaced as they are pinned and glued into the bottom housing If the mirror is broken or loose replace the complete bottom housing assembly 1 3 Remove Iris Assembly __Unscrew the small pin in the side of the control sleeve Use 1 16 flat blade screwdriver Note If the iris pin is sheared it might be removed by grabbing it with a small diagonal cutters and unscrewing it If not replace lens housing Asy __ Pull control sleeve from the lens housing __ Remove O rings __ Unscrew the iris retaining nut using the Welch Allyn tool T 14452 or equivalent Service Manual Welch Allyn Fiber Optic Headlight System Page 6 Section 2 Disassembly and Reassembly __ Heat the 2 56 set screw holding the iris in place before attempting to loosen it The setscrew can be heated by inserting the hex key into the setscrew and applying heat from a soldering iron to the hex key wrench __ Unscrew the 2 56 set screw holding the iris in place Use a 035 hex key __ Remove the iris 1 4 Remove Condensing Lenses and Spacers __ Heat the three 2 56 set screws before loosening due to2. 425 Threadlocker to the lens housing threads __ Install the top cap nut onto the lens housing and tighten with the appropriate collet or eguivalent __ Rotate the top cap a few turns to make sure it rotates smoothly Service Manual Welch Allyn Fiber Optic Headlight System Page 10 Section 2 Disassembly and Reassembly Abstract of disassembly and reassembly of 49540 luminaire suspension The following is the process for adjusting or repairing the luminaire suspension In most cases the end user will probably indicate that the luminaire no longer stays where it is put This condition is caused by wear to the friction washers in the suspension mechanism or loosening of the assembly screws The assembly screw s can be tightened to compensate for the wear of the washers or in severe cases the washers will need to be replaced Special notes for Repairing the Luminaire Suspension Refer to assembly drawing 495570 in this manual for proper reassembly and torque specifications Reapply threadlocking adhesive Loctite 425 to any screws that are tightened or loosened __ Remove the set screws located inside the three pivot nuts using a 1 16 hex key __Loosen the three pivot nuts to break any of the threadlocker free so that the nut turns freely and blow out any loose debris left from the old threadlocker __ Tighten the three pivot nuts to the specified torque as described on drawing 495570 __ Apply a drop of Loctite 425 threa
3. the threadlocker that is used The set screw can be heated by inserting the hex key into the setscrew and applying heat from a soldering iron to the hex key wrench If the set screws become stripped then the entire lens and iris assembly will need to be replaced __Unscrew the three 2 56 set screws from the lens housing Use a 035 hex key __Remove the spacer condensing lens spacer and small condensing lens Service Manual Welch Allyn Fiber Optic Headlight System Page 7 Section 2 Disassembly and Reassembly Re assembly of model 49540 Luminaire 1 4 1 5 Special Notes for Reassembly of Luminaire Refer to assembly drawing 495550 in this manual Use new set screws and O rings when reassembling luminaire Remove any threadlocking adhesive from parts by chasing threads with taps or dies Do not touch lenses or mirror with fingers Clean them with cotton swabs and lens Install Condensing Lenses and Spacers __Insert clean condensing lens into the lens housing so that the convex portion is up __Insert a condensing lens spacer into the lens housing so the large diameter is facing up Push it down onto the condensing lens __ Insert the next lens this lens is the same on both sides into the lens housing on top of the condensing lens spacer Install Iris assembly __Insert the iris spacer into the lens housing chamfered end first Push it down so it seats on the lens fully __Compress the spacers and lenses
4. together using T14601 or equivalent At the same time dip a set screw into the Loctite 425 threadlocker and Install it into one of the three holes in the lens housing using a 035 Hex wrench __Install the iris into the lens housing with the retaining clip of the iris assembly facing upwards There is a slot in the side of the iris which has a tapped hole located in it Align this tapped hole with the slot in the lens housing __ Screw T14600 through the slot in the lens housing and into the iris finger tighten Note This is temporary and will be removed after the iris is locked into place with the iris retainer __ Insert T14448 into the lens housing so that the pin in the center of the tool is in the iris opening and the rubber part of the tool rests on the iris Apply light downward pressure to T14448 and at the same time rotate the tool clockwise Rotating the tool will cause the iris pin tool 14600 to rotate until it contacts the end of the slot in the lens housing Continue rotating the tool until the iris opening closes down onto the pin of T14448 __ Rotate the iris counter clockwise using T14600 until the tool contacts the opposite side of the slot Hold T14448 steady while performing this operation __ Install a set screw with threadlocker Loctite 425 into the top threaded hole on the lens housing using a 035 hex wrench while at the same time apply firm pressure downward with T14448 Note Over tightening of this s
5. 10114 2 56 X 1 16 LG SET SCREW 495550 0013 495515 IRIS DIAPHRAGM 495550 0014 495517 1 PIN IRIS 495550 Service Manual Welch Allyn Fiber Optic Headlight System Page 15 Appendix A Spare Parts List Se Quantity Drawing 495516 1 RETAINER IRIS 0023 M30397 LOCTTE330 0 495550 0024 M30398 LOCTITE738ACTIVATOR Jf O 495550 0026 M30328 LOCTITE 26231 495550 0027 M30373 LOCTITE 425 ASSURETHDLCKER 0 495550 0028 M40156 DOWGCORNING 3452 LUBE 1 495550 Service Manual Welch Allyn Fiber Optic Headlight System Page 16 Appendix A Spare Parts List PAD LOCATION PAD LOCATION STAMP DATED CODE ON REAR RACK ANO PINION HOUSING BEFORE ASSEMBLY OF PAO TORQUE TO BE 5 0 4 1 0 IN LB 4 LIGHT TRANSMISSION 48X MINIMUM WITH IRIS FULLY OPENED AND USING FIBER BUNDLE 49543 ANO 49501 LIGHT SOURCE OR EQUIVALENT 5 SPOT SIZE AT 16 DISTANCE a DS t G65 1818 FULLY CLOSED 4 125 IRIS FULLY OPENED NOTES am ON ADJUSTMENT KNOB TO BE 32 48 IN 0Z WHEN KNOB IS TURNED REFERENCE DWG 495549 VIEW A A A dix A Spare Parts List endix SCALE 1 000 o ONLY THE TOP CAP OF THE LUMINAIRE ASSY HAS BEEN SHOWN FOR SIMPLICITY SECTION 0 0 REFERENCE DWG 495579 NOTES VAN TORQUE TO 28 IN OZ TORQUE TO 20 I IN OZ A TOROUE TO 96 4 INOZ Spare Parts List Appendix A Uff Gg UY YY ez M K 000 SCALE 2 ROE
6. Welch Allyn Multi Fiber Illumination Headlight System Service Manual Models 49540 49520 49522 49524 49526 Copyright 2009 Welch Allyn Inc 4619 Jordan Road Skaneateles Falls NY 13153 0187 Part Number 495623 Rev B WelchAllyn Revision History Page Description of Change ECN Date mniial 5 34457 1 14 97 JSJ MD B Revision to Text and Graphics BEEN 9 1 09 DD Service Manual Welch Allyn Fiber Optic Headlight System Page 2 Introduction To Service Personnel The information in this manual is subject to change without notice and should not be construed as a commitment by Welch Allyn Inc Welch Allyn assumes no responsibility for any errors that may appear in this manual If the product and or its operation varies significantly from any description herein please contact the Welch Allyn Product Service Department at 4619 Jordan Road Skaneateles Falls New York 13153 0187 1 866 801 8428 315 685 2993 This product has been designed to provide a high degree of safety and reliability However we cannot guarantee against the deterioration of components due to aging and normal wear All service and repairs must be performed by authorized Welch Allyn personnel or agents using Welch Allyn replacement parts Failure to do so will invalidate the product warranty Authorized service centers should refer to repair specifications for proper test and device history record requirements Please refer to the pro
7. dlocker onto the threads of a set screw and install it into one of the pivot nuts Tighten with a 1 16 hex wrench Repeat for the remaining two screws Service Manual Welch Allyn Fiber Optic Headlight System Page 11 Section 3 Headband Adjustments and Repair Abstract of adjustment repair of the Headband The following is the process for adjusting or repairing the headband There are only two replaceable components of the headband assembly the three vinyl pads 1set and the fiber optic clips The fit adjustment controls can be adjusted if the knobs are too hard to turn or if the headband will not maintain its fit Loosens Special Notes for Repairing the Headband e Refer to assembly drawing 495540 in this manual for further details e If the vinyl pads need to be removed and reused be sure to release snaps by pushing a fingernail or equivalent between the two halves of the snap The vinyl is extremely thin and will tear if pulled on directly 2 1 Comfort Fit Adjustment Knob __ Tighten the screw in the center of the adjustment knob if the headband continues to loosen __Loosen the screw in the center of the adjustment knob if the knob is too hard to turn 2 2 Fiber Optic Clips __Remove the vinyl pad on the top support of the headband assembly See note above __Unscrew the two screws that hold the respective clip in place and Remove the clip __ Reassemble in reverse order Special Notes for the Fiber Optic Bundle T
8. duct warranty for specific coverage Welch Allyn Welch Allyn Inc 4619 Jordan Road Skaneateles Falls New York 13153 0187 USA 1 866 801 8428 315 685 2993 Service Manual Welch Allyn Fiber Optic Headlight System Page 3 Introduction Service Manual Welch Allyn Fiber Optic Headlight System Table of Contents Part Number Model name Section Page 49540 Luminaire Disassembly Repair 1 6 11 49540 Suspension Repair Adjustment 1 11 495591 502 Headband Assembly 2 12 49543 Fiber optic cable 2 12 all Required tools 3 13 all Problem Solving 4 14 all Recommended spare parts Appendix A 15 16 all Drawings and Figures Appendix A e lf you have technical questions or need other assistance call Welch Allyn customer service personnel at 1 866 801 8428 Cleaning Warnings DO NOT IMMERSE the luminaire in any type of liquid Do not spray it heavily with any type of liquid The liquid might enter the luminaire and create a service problem DO NOT AUTOCLAVE the whole luminaire Only the joystick is autoclavable separately Follow Cleaning and Maintenance instructions in Owner s Manual PN495608 Caution Turn off light source before disconnecting fiber optic bundle from headlight or light source Clean exterior surfaces of luminaire headband and fiber optic bundle by wiping clean with any of these solutions Banicide Cidex Cidex Plus Cidex 7 Metracide 10 Wescodyne 10 chlorine bleach 70 Isopropyl alcohol Wavecide01 mild soap a
9. et screw will cause the iris to bind Service Manual Welch Allyn Fiber Optic Headlight System Page 8 Section 2 Disassembly and Reassembly _ Remove tool T14448 Apply 2 to 3 drops of Loctite 425 threadlocker to the iris retainer threads then Install the iris retainer using T14452 Note When the iris is at full closed position a 090 diameter pin should not go through the hole in the center of the iris Open and close the iris the operation should be smooth 1 6 Assemble Bottom Housing to Lens Housing __ Open the iris to full open position and blow out any dust in the lens housing assembly using an Aero duster or equivalent __ Close iris Blow any dust out of the bottom housing assembly with an aero duster __ Apply 3 to 4 drops of Loctite 425 threadlocker to the large external threads of the lens housing and screw it into the bottom housing Tighten the assemblies together with the appropriate collet __ Place the fiber optic cable leading from the Solarc Light Source into the top of the luminaire assembly __ Inspect the spot for any dirt or dark spots by shinning onto a white piece of paper Also Rotate the iris and check for proper operation Any small dust spots not noticed within 2 seconds are generally acceptable Large dark or hair like spots are not acceptable 1 7 Control Sleeve and Top Cap __Install 2 large O rings into the lower grooves on the lens housing __ Install 1 large O ring onto the top of the fir
10. he Fiber optic bundle 49543 is a multi fiber cable which transmits the light generated at the light source into the luminaire assembly There is no repair for this item It must be replaced if the fibers become damaged Note Refer to owner s manual 495608 for cleaning and disinfection Broken Fibers __Hold one end of the fiber bundle up to a light and look at the other end Dark areas are broken fibers The fiber optic cable will need to be replaced if the dark area covers 20 or more of the entire bundle surface Service Manual Welch Allyn Fiber Optic Headlight System Page 12 Section 4 Tools and Equipment List Tools and Equipment List General purpose tools supplies 1 16 hex key 035 hex key Peer 7 tweezers 4 Flat Blade screwdriver 2 Phillips screwdriver 1 Phillips screwdriver Collet Block 5C Collet for Top Nut Cap 382 5C Collet for Lens Housing 438 5C Collet for Bezel 1 06 Jeweler s s flat blade screwdriver 1 5mm x 40mm for Iris Pin Aero Duster canned air or equivalent Compressed air is not recommended due to oils and moisture that are often found in compressed air Welch Allyn tools and fixtures T14600 Extended iris pin T14448 Iris aperture adjustment tool T14452 Spanner wrench for iris retainer nut 49501 Solarc Light Source 49543 MFI Fiber Optic Cable Service Manual Welch Allyn Fiber Optic Headlight System Page 13 Section 5 Problem Solving Troubleshooting Symptom Pos
11. i NW NG Y A A Sd o E a w Di EI REFERENCE DWG 495550 A A SECTION SCALE 1 000 NOTES 1 TORQUE ITEM 15 10 74 5 IN LB Dis REFLECTIVE SIDE OF MIRROR MUST FACE INSIDE OF LUMINAIRE PLACES A TOROUE to 3 0 4 25 IN OL 4
12. nd water solution Service Manual Welch Allyn Fiber Optic Headlight System Page 4 Introduction Table of Reference Drawings Appendix A Drawing Description 495540 Welch Allyn Headlight Main Assembly 495570 Suspension Luminaire Assembly 495550 Luminaire Assembly Note that drawings within this manual are for reference only Consult factory for current revisions Service Manual Welch Allyn Fiber Optic Headlight System Page 5 Introduction Section 2 Disassembly and Reassembly Abstract of disassembly and reassembly of 49540 Luminaire The whole luminaire can be disassembled with the exception of the mirror and back plate which are pinned and glued to the bottom housing If moisture is present in the luminaire replace the iris assembly and clean the lenses by following instructions in this manual With the exception of the mirror all components can be replaced as necessary The following is the process for completely disassembling and reassembling the luminaire for O ring replacement O rings are used not to seal out moisture but to provide a smooth moveable connection between parts Only replace O rings if they are worn cracked stretched out or missing If the iris control sleeve is too loose then the O rings have failed 1 1 Removing O rings __ Unscrew joystick from the lower housing __Unscrew the bezel from the luminaire Use the appropriate collet or equivalent The bezel is glued on
13. sible Cause Low Light Damage has occurred to Replace the fiber optic cable the fiber optic cable The attenuator on the Adjust the attenuator to full bright light source is turned position counter clockwise The light source is Repair the light source per service defective manual 495621 Output Light Spot not The luminaire may be Disassemble the luminaire and repair defined flooded as necessary Spot size control is hard to The o rings are binding Replace and lubricate all o rings turn Luminaire droops Friction washers in Readjust suspension or replace suspension are worn out washers if necessary Headband won t keep The fit adjustment is Tighten the adjustment screw on the desired fit slipping appropriate adjustment knob Service Manual Welch Allyn Fiber Optic Headlight System Page 14 Appendix A Spare Parts List 495562 BUNDLE CLIPS a DD Bubble ae Quantity Drawing SOOT KT Tome fn hos 495594 WASMER COUNTERSUNK 2 45608 MNMAL 1 49571 uovstokasv 7 FHPS 6 32 X 312 WASHER BELVILLE 375 OD 6 0004 106103 32 WASHER FLATFRICTION 6 495570 0006 495577 SPACER HEADBAND MOUNT 1 495570 0008 495574 SCREW PIVOT 3 495570 0005 10610432 ORNG 1 6 495550 0006 495513 SPRING CLIP FERRULE 1 495550 0008 495901 CONDENSER LENS 1 1 495550 0009 495509 SPACER CONDENSER LENS 495550 0010 495902 CONDENSER LENS 2 495550 0011 495510 SPACER IRIS 495550 0012 7
14. st shoulder of the lens housing __Apply a light coat of grease to all 3 O rings __Assemble the control sleeve over the lens housing and down to the O rings Rotate the control sleeve so that the hole in the side of it is positioned above the threaded hole in the iris seen through the slot in the lens housing __ Push control sleeve down over the O rings until seated being careful not to rotate the parts __Apply 1 drop of Loctite Adhesive to the threads of an iris pin and install through the hole in the control sleeve and into the iris Tighten w a screw driver until flush or just below Service Manual Welch Allyn Fiber Optic Headlight System Page 9 Section 2 Disassembly and Reassembly __ Rotate control sleeve back and forth to spread grease and check for freedom of movement __ Install 1 large O ring onto the lens housing and push down until seated on top of the control sleeve __ Install 2 large O rings into the lower exposed grooves on the lens housing __ Install 1 small O ring onto the lens housing so that it sit on the shoulder just above the last large O ring __Apply a generous coat of grease to the 2 lower O rings __ Apply a coat of grease to the inside of the top cap __ Install a top cap onto the lens housing so it rests on the O rings Rotate the top cap while pushing it down over the O rings Continue until seated __ Install 1 small O ring down on top of the top cap __Apply 2 3 drops of Loctite
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