Trumpf GE, GR, GS, GY Manual de Servicio

Operating table SATURN GE, GR, GS, GY
Service Manual
This is a medical product of class I according to appendix IX of the Medical Product Directive (MDD)
93/42/EEC of 14 June 1993.
The manufacturer declares that the device is compliant with the fundamental requirements according to
Appendix I of MDD, and that a conformity assessment procedure is performed as required for Class I products
according to Appendix VII of MDD. This is documented by the CE symbol.
TRUMPF Medizin Systeme GmbH

Postfach 1263
D-07303 Saalfeld

Carl-Zeiss-Straße 5
D-07318 Saalfeld
Sales and Phone +49 3671 586-0

distribution Telefax +49 3671 586 166
Service Phone +49 3671 586 172

+49 3671 586 176
Telefax +49 3671 586 175
We are constantly working on further developments.

Therefore, please understand that we must reserve the right to change the scope of the delivery in respect of
the form, equipment and technology at any time.
Reprinting, copying or translating this document in whole or in part is forbidden without the express written
permission of TRUMPF Medizin Systeme GmbH.
All rights under the copyright laws are expressly reserved by TRUMPF Medizin Systeme GmbH.
Within the framework of the legal requirements, the manufacturer is only responsible for the safety
characteristics of this device if the maintenance, repair and modifications performed on this device are carried
out by the manufacturer, or by a person authorised by the manufacturer and in accordance with the
manufacturer’s instructions.
© 10/03 TRUMPF Medizin Systeme GmbH

Contents
Contents
1 Important Information
1.1 Notes for Service Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Explanation of Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Safety Instructions for Working in the Operating Area . . . . . . . . . . . . . . . . . . . . . . . 8
1.5 Instructions for Protecting the Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 Repair Instructions
2.1 Electrical Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1.1 Replacing the Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1.2 Adjusting the column in case of breakdown of the electronic unit . . . . . . . . . . . . . . 10
2.1.3 Replacing the Electronic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1.4 Checking the fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1.5 Replacing cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2 Replacing sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2.1 Position of the sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2.2 Sensor Tilting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2.3 Sensor Trendelenburg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.3 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3.1 Replace cylinder, aggregate and control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3.2 Replacing hydraulic fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3.3 Refill oil in the hydraulic aggregate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.3.4 Replace pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.4 Lifting cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.5 Servicing the table top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.5.1 Replacing the bowden cable - longitudinal shift . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.5.2 Replacing the gas spring in the backplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.5.3 Replacing the drive of the coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.5.4 Adjusting the coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.6 Servicing leg supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.6.1 Replacing the gas springs (leg support in four parts) . . . . . . . . . . . . . . . . . . . . . . . 26
2.6.2 Replacing the bowden cable (leg support in four parts) . . . . . . . . . . . . . . . . . . . . . 27
2.6.3 Replacing the lever for releasing the leg support. . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.7 Replacing the snap-in shaft in head section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3 Test program
3.1 Launching the test program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.2 Launching the various test program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.3 Description of the test programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4 Disposal and recycling of the parts

4.1 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.2 Electric system/Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.3 Mechanic parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Service Manual SATURN GE, GR, GS, GY 4 900 305 - 10/03 1

Contents
5 Maintenance
5.1 Needs of maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.2 Maintenance by TRUMPF Medizin Systeme GmbH based on a contract . . . . . . . . . 32
5.3 Service contract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.4 Self maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.5 Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.5.1 General Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.5.2 Checking the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.5.3 Checking the electronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6 Course offers Equipment

6.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.2 Contents and Purpose of the Course. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.3 Types of Training and Timetable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.4 Services/Costs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.5 Certificate of Course Completion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7 Spare Parts SATURN GE

Lifting column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Running gear, directed wheel with brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Running gear, non-directed wheel with brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Head section, simple, 4 544 443 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Head section, adjustable, 4 544 444 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Back section for table with longitudinal shift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Table top with snap-in longitudinal shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Snap-in for table with longitudinal shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Leg support, one part, 4 544 480 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Leg support, two parts, 4 544 481 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Leg support, four parts, 4 544 482. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Sensors and remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Guiding of hydraulic tubes and cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Hydraulic pump and fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8 Connection diagram
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
9 Hydraulic diagram control unit

Hydraulic diagram control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
10 Second-hand parts SATURN Family . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2 Service Manual SATURN GE, GR, GS, GY 4 900 305 - 10/03

Contents
11 Service Manual Operating Table SATURN GR

11.1 Replacing Cylinder (1 219 289) in Back Section. . . . . . . . . . . . . . . . . . . . . . . . . . 83
11.2 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
12 Service Manual Operating Table SATURN GS

12.1 Replacing the bowden cable - longitudinal shift . . . . . . . . . . . . . . . . . . . . . . . . . . 85
12.2 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
13 Service Manual Operating Table SATURN GY

13.1 Replacing Hydraulic Cylinder 4 144 183 and 4 144 182 . . . . . . . . . . . . . . . . . . . 87
13.2 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Contents

Important Information
1 Important Information
Please follow this manual exactly when performing repairs and keep to all the scheduled
repair steps.
We would be grateful to receive any corrections to this manual and also any tips for
performing repairs more efficiently than described here.
Please contact our Service Department in Saalfeld.
1.1 Notes for Service Personnel
This repair manual is intended for trained service and maintenance personnel.
Refer to the user manual for information about operating the device.
Please contact our Service Department if a problem occurs which cannot be remedied with
the assistance of this repair manual.
Repairs may only be performed by trained personnel.

We offer training for this purpose.
This service manual also serves as training documentation.
Repairs which are not covered by this service manual may only be performed after
consultation with TRUMPF Medizin Systeme GmbH or be performed by
TRUMPF Medizin Systeme GmbH in Saalfeld.
After all repairs or settings, a functional test or test must be performed in accordance with
the instructions in this service manual.
The device may only be handed over to the customer after being tested and in a fully
functional condition.
The handover must be made in writing and must be confirmed by the customer.
The device must be demonstrated to the customer at the handover.

Service
Carl-Zeiss-Str. 5
D-07318 Saalfeld, Germany
Telephone +49 3671 586 172

+49 3671 586 176
Telefax +49 3671 586 175

1.2 Explanation of Symbols
Important information in this user manual is marked with symbols and keywords.
Keywords such as WARNING, CAUTION and ATTENTION indicate the level of danger
involved. The symbols emphasise the message visually. Additional symbols can indicate
injury hazards or danger to life and limb.
The measures to prevent dangers arising must be implemented without fail!
WARNING!
Danger to life and limb (for example electric shock)!
Risk of serious injuries and damage to property.
CAUTION!
Risk of injury and damage to property.
ATTENTION!
Risk of damage to property.
NOTE!
Useful additional information and tips.
TEST!
Performance of functional testing, measurements and tests.
ENVIRONMENT!
Notes on disposal in a way which does not harm the environment!

1.3 General Safety Instructions
Observe the following general safety regulations:

• Be especially careful when working at gas springs!
• When working in the operating area observe the safety instructions found under
section 1.4!
• Only perform those repairs and settings for which you have been trained and which are
described in the service manual! The service department of
TRUMPF Medizin Systeme GmbH is responsible for all other work, particularly that on
the hydraulics!
• Use only those spare parts which are provided by TRUMPF Medizin Systeme GmbH in
the spare parts catalogue!
• Keep the area around the appliance clean and tidy both during and after maintenance!
• Do not perform any action which could place persons in danger or render the appliance
a source of danger!
• During service, store removed parts of the operating table in a safe place.
• Put your toolbox in a safe place so nobody can fall over it.
• Make sure your clothing cannot be caught in the operating table or parts of it. Button up
the sleeves of your jacket or shirt or roll them up. Tie long hair together or put it up. Fix
the ends of scarves and ties to your clothes.
• Wear protective goggles when:
- disassembling/replacing gas springs
- driving pins in or out using a hammer
- working with an electric drill
- inserting springs or using spring hooks
- soldering
- using solvents, cleansing liquids or other chemicals
- your eyes are in danger due to working conditions.
• After service, readjust all safety devices such as covers, safety instructions and ground
cables! Check equipotential and grounding connections after assembling!
• Change faulty or unusable parts, also if not included in the service order.

1.4 Safety Instructions for Working in the Operating Area

CAUTION!
Danger of infection in the entire hospital!
Observe all safety precautions!
Service technicians must also observe the hygiene requirements in the
medical facilities!
Safety Instructions:
• Observe the hygiene requirements of the medical facilities in respect of clothing,
cleaning regulations and disinfection procedures!
• Obtain this information from the hospital personnel before starting any work!
• Observe all the rules regarding your conduct, especially in the operating area!
• Do not perform any work in the operating area without first obtaining the appropriate
permission!
• Before performing maintenance or repair work on the operating tables make sure that
they have been disinfected!
• The disinfection of the interior components of the operating table must be arranged in
advance and carried out by the medical facility before repair or maintenance work
commences!
• Should symptoms of illness occur, seek medical attention immediately!
After you have worked in dangerous areas, tell the doctor about the nature of these
activities - even months later!
Instructions for endangered persons:
NOTE!
Ask a doctor about the possible dangers and the relevant protective
measures which you should take in your work as a service technician!
• Endangered persons must be inoculated against hepatitis B!

A booster inoculation is required every three to five years!
• The incubation period for hepatitis B is from 1 to 6 months!
1.5 Instructions for Protecting the Environment

• Follow the recycling regulations for components which have been removed, particularly
in the case of:
- batteries
- circuit boards
- cables.

Repair Instructions
2 Repair Instructions
2.1 Electrical Unit
2.1.1 Replacing the Accumulator
CAUTION!
Disconnect the power supply!
1. Bring lifting in upper position.

2. Push cover upward and fix it.
3. Pull off plugs from the accumulators and the connecting cables.
4. Remove the 4 screws (M3) fixing the accumulator, remove accumulators.
5. Insert new accumulators, tighten the four screws and connect cables.
NOTE!
Check the firm fitting of the plug (thick side of the plug points towards the
accumulator)!
Stud must be stick tightly to the accumulators!
6. Measure charging current; optimal value at 800 mA. The charging current depends on
load condition of the accumulators!
7. Reassemble cover.
TEST!
Carry out Test 3!

Repair Instructions
2.1.2 Adjusting the column in case of breakdown of the electronic unit

If the lifting is in lowest position and the electronic unit is broken, there is an opportunity of
adjusting the table by directly applying a voltage (24 V DC) to the connectors of the
electrovalves and the hydraulic motor.
1. Push cover downwards.

2. Disconnect membrane keyboard!
J5 J4 J7 J6 J1 J2 J3
Electronic unit
Figure 1: Plugs and terms above the electronic unit
3. Remove plugs J2 (motor 1) and J3 (valve) above the electronic unit.

4. Apply 24 V (approx. 6 A) to:
+ white lead of J2 (pin 1), white and green leads of J3 (pin 1 and 3)
- brown lead of J2 (pin 2), blue lead of J3 (pin 12).
5. Bring lifting in uppermost position.
6. Connect plugs J2 and J3.
7. Check electronic unit, replace if necessary.
CAUTION!
Danger of connecting to the wrong poles!
Lock security elements when connecting membrane keyboard!

Repair Instructions
2.1.3 Replacing the Electronic Unit
CAUTION!
1. Remove cover.
2. Remove locking of the bellows.
4. Disconnect accumulators.
CAUTION!
Danger of short circuit at the connectors of the accumulators! Before
proceeding in the repairs, cover connectors of the accumulators!
5. Open electronic unit (remove 4 screws M5 in the lid).

6. Pull ten plugs off the PCB, unscrew the pull reliefs and lay down lid with transformator.
J6 Pull reliefs (Screening plates)

J7
L Excerpt from
J8 F1 connection diagram
J9 Circuit for 230 V
N J ul 1B J ul 1A
F2
J20 F3
J 17
J 11 J 18
J 11
J 12
J 12
EPROM free
J 13 J 19
J 14 F7
J 15
J 16 J 15
J 16 black F4
primary 230 V
J8 blue
J9 brown black
J11 blue blue white
J13 brown brown white

J14 blue blue
J15 brown brown Connection 115 V

blue primary
brown
J20 J17 J19 J18
Figure 2: Connectors on the PCB
7. Pull off plugs J1 through J7.

8. Unscrew casing (4 x M4x25).
9. Replace the PCB, insert distance washers and seals correctly!
10. Insert the jumpers corresponding to the type of the operating table!
X = inserted

Repair Instructions
Type of Table JU 1A JU 1B
GE X X
GR X
GY X
SM X
SF
JU 1A
JU 4
JU 1B
Figure 3: Jumper JU 1A and JU 1B
11. Insert the jumper for the charging current correctly!

X = inserted
Type of Accumulator JU 4
12 Ah X
ATTENTION!
The Infrared-Code of the device is permanently stored in the EPROM!
Remove EPROM from the old PCB and insert in the new one. Mind the
marks!
12. Assemble casing, connect plugs as in figure 1.

13. Connect 10 plugs, tighten pull reliefs.
14. Assemble transformator with lid.
15. Connect accumulators.
16. Apply power supply of 230 V. Measure charging current; optimal value at 800 mA.
The charging current depends on the load condition of the accumulators!
TEST!
Carry out Test 3!

Repair Instructions
17. Check Trendelenburg function!
NOTE!
If Trendelenburg does not correspond to the low position of the head
section, exchange the jumpers J6 and J7 (figure 1)!
18. Close lid and lock the screws!
CAUTION!
Check the guiding of the cables!
Avoid chafe marks and sharp edges!
19. Lock the cover.
TEST!
Carry out Test 3!

Repair Instructions
2.1.4 Checking the fuses
CAUTION!
1. Bring lifting in upper position.

2. Open cover an push downward.
3. Disconnect membrane keyboard!
4. Open electronic unit.
F6
F8
F3
F1 F4
F2
F7
Figure 4: Position of the fuses on the PCB
Purpose of fuse Name Value
Power supply F1, F2 at 115 V SPT 4 A

at 230 V SPT 2 A
Charging current F3 FST 1.6 A
Operating voltage F4 FST 6.3 A
Motor F6 FSF 6.3 A
Electronic unit F7 FSF 250 mA
Electrovalves F8 FSF 4 A
5. Check fuses, replace if necessary. If so, find cause for defect fuse and repair it.
CAUTION!
6. Reassemble in reversed order.
TEST!
Carry out Test 3!

Repair Instructions
2.1.5 Replacing cables
1. Remove the cover.

2. Disconnect membrane keyboard.
3. Disconnect accumulator.
4. Open locking of the bellows.
5. Replace defect cable (see connection diagram of electronic unit).
6. Fix cable.
ATTENTION!
Check guidance of the cable!
Avoid chafe marks and sharp edges!
7. Connect accumulator.
CAUTION!
Lock security elements when connecting shielding foil!
TEST!
Carry out Test 3!

Repair Instructions
2.2 Replacing sensors
2.2.1 Position of the sensors
Figure 5: Position of the sensors Tilting and Trendelenburg

Repair Instructions
2.2.2 Sensor Tilting

If the operating table SATURN does not or not properly move into neutral position, the
sensor at the cylinder must either be adjusted or replaced:
1. Push cover upwards and fix it.

2. Pull off connectors from accumulator.
3. Open the locking of the bellows.
4. Screw off sensor with locking plate.
5. Replace sensor.
6. Tighten the screws of the locking plate, connect sensor to J4.
CAUTION!
Snap in security elements when connecting membrane keyboard!
TEST!
Carry out Test 3

Repair Instructions
2.2.3 Sensor Trendelenburg

If the operating table does not or not properly move into neutral position, the sensor at the
cylinder must be replaced.
Trendelenburg
Figure 6: Sensor Trendelenburg
1. Remove cover.
3. Disconnect accumulator.
4. Open the locking of the bellows.
5. Screw off sensor with locking plate.
6. Replace sensor.
7. Tighten the screws of the locking plate, connect sensor to J4.
CAUTION!
TEST!
Carry out Test 3!

Repair Instructions
2.3 Hydraulic system
2.3.1 Replace cylinder, aggregate and control unit
NOTE!
These works are carried out by TRUMPF Medizin Systeme GmbH Service.
2.3.2 Replacing hydraulic fittings

In case of leakages or faulty parts:
1. Open cover and push it downwards.
CAUTION!
Make sure to carry out 3. and 4. carefully!
This avoids lowering of the cylinders and strong leaking of oil when opening
the fittings.

3. Bring table in uppermost position and support lifting cylinder using a piece of wood.
4. Drive in Trendelenburg- and Tilting cylinders.
5. Remove faulty part and replace it.
6. Guide hydrauling tubes in the same way as before disassembling.
7. Use cable straps to fix the tubes in their positions.
ATTENTION!
When replacing elements of the hydraulic system for tilting and
Trendelenburg, move table to final positions to make sure the tubes are
guides properly!
8. Deaerate the tubes by using the function „System“ several times.

9. Check oil level and correct if necessary!
CAUTION!
TEST!
Carry out Test 3!

Repair Instructions
2.3.3 Refill oil in the hydraulic aggregate

2. Remove oil refilling screw at the hydraulic aggregate.
3. Drive lifting upwards:
Distance between oil refilling screw and ground plate of the lifting cylinder
approx. 350 mm.
The operating table should now be in neutral position.
4. Check oil level in the tank using a measuring stick. Fill up if necessary.
TEST!
Carry out Test 3!
2.3.4 Replace pressure switch

3. Disconnect accumulators.
4. Replace switch.
In order to be sealed, the switch has taper fitting thread G1/8".
The connectors of the switch should stand upright.
The switch is preadjusted to switch off at 135 bar.
NOTE!
Do not use any function of the operating table while the switch is
removed
TEST!
Carry out Test 3!

Repair Instructions
2.4 Lifting cylinder

The torsion play of the operating table can be adjusted with block element [1] at the lifting
cylinder. The play is to be adjusted in a way that the table can not be rotated and can still
lift the maximum weight of 135 kg.
1
2
1 3
4
5
3
4
6
4
7
Figure 7: Block element
CAUTION!
Danger of short circuit at the connectors of the accumulators
2. Loosen screws [5] and [6].

3. Loosen nuts [3].
4. Adjust torsion play using pins [4].
5. Fix nuts [3] using the pins [4].
NOTE!
All loosened and removed screws must be secured using OMNIFIT 100 M!
6. Tighten screws [5] and [6].
ATTENTION
Check torsion play!
Less lifting power when tilted too much!
Column should have no recognizable play!
TEST!
Check lifting function with a weight of 135 kg!

Repair Instructions
2.5 Servicing the table top
2.5.1 Replacing the bowden cable - longitudinal shift
1. Remove H-lever in the seat:

- loosen 4 spherical heads and 4 cylinder screws
- tilt coupling downwards
- pull out H-lever towards the foot end
- unhinge bowden cable
2. Loosen locknut and adjusting screw.
3. Screw off spar plate at the side of the backplate.
4. Unhinge bowden cable and pull it out completely.
NOTE!
Mind guiding in the spar!
Insert new bowden cable using the old one to pull!
Reassemble in reversed order!
TEST!
Check longitudinal shift!

Repair Instructions
2.5.2 Replacing the gas spring in the backplate

2. Loosen locknut at piston rod of the gas spring.
3. Bring backplate in 2/3 uppermost position.
4. Remove circlip at the bottom of the gas spring and pull out bolt.
CAUTION!
Make sure not to endanger people and goods when replacing gas springs!
Gas springs are still under pressure when removed from the operating
table! In faulty gas springs, the releasing pin of the piston rod can fly off like
in an explosion!
ATTENTION!
Do not operate the backplate!
5. Loosen gas spring and its fork.

6. Screw in new gas spring without fork. Press thread against the bushing at the seat
plate and press together while the control lever is released
7. Screw fork of the gas spring to the bottom of the gas spring and align the drill holes.
8. Carefully release the lever of each side thus adjusting the length of the new gas
spring. Fix using a bolt.
9. Secure gas spring using a locknut.
NOTE!
Check releasing of the backplate!
Both gas springs must release simultaneously!

Repair Instructions
2.5.3 Replacing the drive of the coupling
1. Loosen screws at the inside of the coupling.
NOTE!
Note and remember the positions of the disk springs
2. Pull out drive to the front completely.

3. Loosen screws and disk springs of the new drive.
4. Push on new drive from the front.
5. Tighten disk springs from the inside and then adjust.
ATTENTION!
Adjust coupling!

Repair Instructions
2.5.4 Adjusting the coupling
10x
10x
1 3 2 4 5
Figure 8: Parts of the coupling
1. Bring lever [1] in horizontal position.

2. Tighten nut [2], so that cover [3] can still be moved manually.
NOTE!
There must be no braking when the leg support is fixed!
Check:
• Lever [1] (coupling) locked (vertical position):
At the end of the padding of the leg support 40 kg must be carried safely!
• Lever [1] (coupling) loosened (horizontal position):
There must be no braking effect when moving the leg support!
1. Insert screw locking [4] (correct nut [2], if necessary).

2. Lock screw locking [4] using countersunk screw 5 and OMNIFIT 100 M.

Repair Instructions
2.6 Servicing leg supports
2.6.1 Replacing the gas springs (leg support in four parts)
1. Loosen lock nut using special wrench (abraded open-jawed wrench 17 mm).
2. Remove bolt from the bottom of the gas spring (loosen threaded pin).
3. Screw out gas spring holding it at the bottom.
CAUTION!
Make sure not to endanger people and goods when replacing gas springs!
Gas springs are still under pressure when removed from the operating
table! In faulty gas springs, the releasing pin of the piston rod can fly off like
in an explosion!
4. Mount gas spring in fully extended condition, grease thread, screw locknut in to the
end of the thread.
5. Compare screw-in-distance of gas spring with other leg support.
NOTE!
The angles of the leg supports must be equal in fully extended condition!
6. Tighten locknut.
7. Align drill hole of the gas spring with the one of the transition piece, fix using a bolt,
secure with a threaded pin.
TEST!
Check functionality of the release!

Repair Instructions
2.6.2 Replacing the bowden cable (leg support in four parts)
1. Loosen the handles in the lever (2 recessed head screws).

2. Screw out gas spring 5 turns:
- Remove bolt of the gas spring (loosen threaded pin).
- Loosen locknut using a special wrench (abraded open-jawed wrench 17 mm).
(Thus the bowden cable is loosened making it easier to replace.)
3. Loosen setting screw completely.
4. Unhinge bowden cable at both sides.
5. Insert new bowden cable.
NOTE!
Guide bowden cable in the lever under the deflector to make sure the
handle is freely accessible.
6. Guide spar-end of the bowden cable through the setting screw and hinge in.
7. Screw in setting screw completely.
8. Hinge bowden cable into lever, lock handles with the screws.
9. Screw in gas springs 5 turns, tighten locknut, insert bolt, secure using the threaded pin.
10. Adjust bowden cable using the setting screw until gas spring works properly.
2.6.3 Replacing the lever for releasing the leg support
1. Loosen threaded pins on upper side of the leg supports.

2. Pull out lever axis.
3. Replace lever (mind right and left type).
TEST
Check functionality!

Repair Instructions
2.7 Replacing the snap-in shaft in head section
2 3 4 1 4
Figure 9: Replacing snap-in shaft in head section
1. Unscrew cap [1] using a flexible head spanner.

2. Unlock and release handle [2] (in this position the snap-in shaft can be rotated making
it easier to be removed).
3. Replace snap-in shaft [4] (mind left and right types).
4. Stop releasing (bolt [3] snaps in snap-in shaft 4).
5. Lock cap [1] and secure using OMNIFIT 100 M.
TEST!
Check function of the head section adjustment!

Test program
3 Test program
3.1 Launching the test program

Press the buttons on the operating panel in the following order to launch the program:
1. Tilting right
2. Lifting up
3. Trendelenburg
4. Lifting down
5. Tilting left
The test program appears with the message:

Confirmation test mode: 1 beep for one second
red LED flashing with 0.5 Hz
Test mode can be cancelled:

Test mode cancelled: Activation button, Zero-button
Confirmation: 1 beep for two seconds

Test program
3.2 Launching the various test program
Launching the test Cancelling the test
Launching Confirmation
Test Button Confirmation
with button beep
Test 1
function of the 1 x 0.2 s
column activation button
zero button
Test 2
2 x 0.2 s
Sensors
1 x 1 s beep
Test 3
3 x 0.2 s red LED
5 courses
0.5 Hz
any button
Test 4
4 x 0.2 s
long time test
Test 5
5 x 0.2 s activation button
switching off
3.3 Description of the test programs

Test 1 - Function of the column:
The functions Lifting, Tilting and Trendelenburg are checked without referring to the sensors.
The charging of the accumulators is switched off.
Test 2 - Sensors:
This test is only possible at the operating tables SATURN SM/SF.
Test 3 - Testrun, 5 courses:
Operating table is driven into neutral position for functions Trendelenburg and Tilting.
After that, the following movements are repeated five times:
• Lifting up • Antitrendelenburg
• Trendelenburg • Tilting left
• Tilting right • Lifting down
• 2 x 1s beep • 2 x 1s beep
• Pause • Pause
Test 4 - Long time test

Test 5 - Switching off:
After pressing and releasing the zero button the operating table is switched off.

Disposal and recycling of the parts
4 Disposal and recycling of the parts

Removed parts have to be disposed according to environmental laws.
The following sections do not list all disposable parts, but a selection of typical parts shows
the possible ways of disposal.
4.1 Hydraulic system
Part/Material Disposal
hydraulic oil waste oil collection, recycling

hydraulic pump scrap metal after disposing waste oil
hydraulic tube litter after disposing waste oil
4.2 Electric system/Electronics
accumulator collection for lead accumulators

PCB electronic scrap
cables copper scrap metal
4.3 Mechanic parts
Metal parts scrap metal

norm parts scrap metal, waste
plastic parts plastic recycling

Maintenance
5 Maintenance
5.1 Needs of maintenance

All products of TRUMPF Medizin Systeme GmbH are low in maintenance.
We recommend maintenance once a year.
All necessary information for maintenance are to be found in the service manual and the
spare parts catalogue.
Maintenance can be carried out by TRUMPF Medizin Systeme GmbH service, by the
customer, by distributors or by resellers.
Information concerning maintenance contracts and fees can be obtained from our
company.
5.2 Maintenance by TRUMPF Medizin Systeme GmbH based on a contract

Charges are calculated by effort according to valid rates.
5.3 Service contract

Advantages for the customer:
• Regular maintenance
• Foreseeable costs
• 15 % discount on spare parts used for maintenance
5.4 Self maintenance

Maintenance by hospital engineers or engineers of resellers and sales representatives is
possible.
For this job it is compulsory to attend a training session at TRUMPF Medizin Systeme GmbH
Saalfeld.
We inform you about the details

Maintenance
5.5 Service instruction
5.5.1 General Check
Meas.
Method of Set value,
No. Items value,
examination Display
remarks
1 Check safety of power supply test program LED, green

Switch off with Test 3
Connect device to line voltage
green LED on
red LED off after 2s
device switched on
2 Basic functions without load visual function
Lifting, Trendelenburg, Tilt fully
3 Basic functions under load 135 kg on table
Lifting, Trendelenburg, Tilt fully top
Lifting height Measuring 330 ± 2 mm
Time for max. lifting, up stick, 19 ± 1 s
Time for max. lifting, down stop watch 34 ± 3 s
Trendelenburg Protractor approx. 30°
Angle and time until maximum position stop watch 11 ± 1 s
Antitrendelenburg Protractor approx. 30°
Angle and time until maximum position stop watch 11 ± 1 s
Tilting Protractor 20 ± 2°
time until tilted fully to the right stop watch 8±1s
time until tilted fully to the left 8±1s
Check the lifting power with extended visual function
longitudinal shift
head side
foot side
4 Running gear visual function
Locking firm stand
Free running wheels moveable
Directional stability front right wheel
must snap in
Checks:
ground clearance when running free
and in direction
defectiveness of rubber standfirm seat
and defectiveness of cables and rolls
type plate

Maintenance
Meas.
No. Items value,
examination Display
remarks
5 Longitudinal shift visual function

check every snap in on both sides on
even and full release
check release function
check adjustment and guiding of the
bowden cables
function of the release locking for
longitudinal shift
Trendelenburg protractor 8 ± 3°
Antitrendelenburg 8 ± 3°
6 Adjustment of the back section visual
upwards protractor approx. 65°
downwards approx. 45°
simultaneous releasing of both gas
springs
loading of back section with gas springs visual function, at
locked 60 kg max.
7 Connecting and Disconnecting visual function
head- and foot-sections
8 Check locking of the leg supports; visual function
clean if necessary
9 Check coupling according to visual function
section 2.5.4 At the end of the
padding of the
leg support a
weight of 40 kg
must be carried
safely!
10 Check function of head- and visual function
legsections
Release gas spring of leg support visual function at 30 kg
(four parts) max.
11 Reserve at releasing the handles visual 20 % of total
distance
12 Check paddings
After replacing them, the resistance
between the middle of the padding and DVM (Digital < 10 kΩ
the equipotential plug must be Voltmeter)
measured!
13 Type plate, marking, serial number visual available,
readable

Maintenance
5.5.2 Checking the hydraulic system
Meas.
No. Items value,
examination Display
remarks
1 Open cover, Checks! visual tightness

Tightness of
- fittings to the control unit
- the fittings at the cylinders
- the hydraulic choking rings
Level of oil in the tank
Check hydraulic tubes for leakages
Change oil after five years!
5.5.3 Checking the electronic unit
Meas.
No. Items value,
examination Display
remark
1 Open cover, Checks: visual no damages,

Check defectiveness of moving firm seat of all
cables units
Firm seat of the plugs
Check surfaces of the sensors for dust
and damages
Firm seat of cables locks
Firm seat of electrical units
2 Measure current in cables of the
accumulator
Charging current DVM 800 ± 100 mA
according to
charging
condition
Zero signal current DVM 2.3 mA
Stand-by-condition DVM 120 mA
Operating current when lifting in DVM approx. 7 A
highest position, without load

Maintenance
Meas.
No. Items value,
examination Display
remark
3 Security checks according to „Rigel“- Tester

VDE 0750
Test 2 230 ± 5 V
Test 5, Resistance of protective < 0.2 Ω
conductor
Test 11, Measured against the cover max. 10 µA
First error
Protective conductor open
First error
Line open

Course offers Equipment
6 Course offers Equipment
6.1 General Information

Courses for engineers of our customers and sales representatives and courses for sales
staff (modified).
Instructions can be requested at the service department of TRUMPF Medizin Systeme GmbH
in Saalfeld.
We will then inform you about the next possible dates.
6.2 Contents and Purpose of the Course

This course will consist of the following topics:
• Knowledge about usage and function
- Overview over control elements, mechanics and electronics, structure and
function of the constructional units
- Function of the electronics and sensors
- Function of the mechanics
- Function of the safety elements
• Information about use and operation of the devices
- Information on possible results of wrong usage
- Consolidation of knowledge by training units
• Systematic proceeding in case of a fault
- Exchanging information when searching for faults and repairing
• Guided training of repairs
Aim of the course: Course certificate

Course offers Equipment
6.3 Types of Training and Timetable

For first users of TRUMPF Medizin Systeme GmbH products:
The appliance programme can be tailored to the customer’s specific needs.
Duration: at least 2 days
Timetable:
Arrival on previous day

Day 1 Day 2
Begin 8.00 o’clock 8.00 o’clock
Lunch break 12.00-13.00 o’clock 12.00-13.00 o’clock
End 17.00 o’clock 17.00 o’clock
For customers with knowledge and experience of TRUMPF Medizin Systeme GmbH
operating tables:
The appliance programme can be tailored to the customer’s specific needs.
Duration: 1 day
Timetable:
Arrival on previous day

Day 1
Begin 8.00 o’clock
Lunch break 12.00-13.00 o’clock
End 17.00 o’clock
6.4 Services/Costs
TRUMPF Medizin Systeme GmbH pays the costs of:
• Training
• Overnight accommodation
• Full board
• Training materials
Travel costs and continued payment of wages are born by the participant.
6.5 Certificate of Course Completion

The participant receive a certificate for completing the training and successful participation.
It is the pre-requisite for obtaining authorisation to perform independent maintenance and
repair work!

Spare Parts SATURN GE
7 Spare Parts SATURN GE

Lifting column
Lifting column
3 9 16
10
4
11, 12
13
18
17
6, 7 14
19 15
20
27
23
28
21
24
25
29
26
30

Pos. Mat. no. Description SP

1 4 144 075 Bellows, Fa. Hübner X
2 4 144 104 Plug PL-TK 15 399, sw
3 4 214 106 Seat GE
4 4 144 463 Bushing DU MB 1815 DX
5 4 144 507 Electronic unit IR SATURN SX, GE, GR 1.0 X*
6 4 144 332 O-ring 2,9x1,78, 2-006, N 674-70
7 4 144 500 Control unit 17-05820-00 X
8 4 144 342 Lead accumulator X
9 4 144 464 Bushing DU MB 1820 DX
10 4 144 162 Cylinder pin
11 4 214 159 Panel
12 4 144 095 Tape, double-sided, TESA 4970 50, 50 mm
13 0 143 419 Threaded pin with spigot M4x10 1.4301 DIN 915
14 4 144 320 Cylinder 2 (Trendelenburg) X
15 4 211 632 Slot sensor
16 4 211 766 Hook
17 1 215 371 Hexagon socket head cap screw M6x12
18 4 211 028 Holder
19 4 144 321 Cylinder 3 (Tilting) X
20 1 215 366 Hexagon socket head cap screw M6x50
21 4 145 017 Power train
22 4 214 268 Cover lifting unit, complete X
(incl. pos. 23 (4 214 122), 24, 25, 26)
23 4 214 129 Cover upper part, complete (IR) X
4 214 122 Cover upper part, complete X
24 4 211 137 Cover middle part 2, complete X
25 4 211 136 Cover middle part 1, complete X
26 4 211 135 Cover lower part, complete X
27 4 214 182 Additional control X
28 4 214 251 Cable for additional control X
29 4 102 048 Pressure switch X
30 4 214 119 Hydraulic aggregate (incl. pos. 29) X
* See „Second-hand parts SATURN Family” on page 81.

Running
Running
20
2
11
7 8
6
10
9 17
12
11
13
5 14
15 16
18
4
19


1 4 144 348 Bumber X
2 1 215 355 Hexagon socket head cap screw M8x20 1.4301 DIN 912
3 4 211 321 Front wheel X
4 4 211 306 Directed wheel X
5 4 211 353 Back wheel X
6 1 215 460 Hexagonal nut M6 1.4301 DIN 934
7 1 215 500 Washer A6,4 1.4301 DIN 125
8 1 215 459 Hexagonal nut M5 1.4301 DIN 934
9 4 121 115 Draw spring
10 4 221 025 Locking cam
11 4 101 016 Bowden cable X
12 4 101 017 Bowden cable X
13 4 211 346 Roller
14 4 211 354 Cable holder
15 1 215 503 Washer A10,5 1.4301 DIN 125
16 4 083 174 Circlip 8 DIN 6799-St
17 4 102 032 Cable inlet with strain-relief clamp
19 4 211 361 Cable seat
20 4 144 165 Rubber ball X

1 219 254 Running gear with emergency adjustment crank, complete X
10 4 211 337 Snap in plate (to 1 219 254)
19 4 211 375 Cable suspender (to 1 219 254)

Running gear, directed wheel with brakes
9 brakes
Running gear, directed wheel with
11
10
11
12 15
6 11
6 13
15
16
13 17
11
14
18
3 19
4
20
2 4
6 5
7
8


1 4 144 252 Wheel cover (type Black Rubber)
2 4 144 255 Wheel 2 COLSON
3 4 211 322 Snap in disc
4 4 083 031 Threaded pin M4x10 DIN 914-A2
5 4 211 350 Ring
7 4 083 121 Circlip 9 DIN 6799-St
8 4 211 356 Support
9 4 211 358 Screw
10 4 211 311 Bow (welded assembly)
11 4 083 120 Circlip 5 DIN 6799-St
12 4 121 043 Pressure spring VD-251
13 4 211 315 Bolt, long
14 4 211 341 Bushing welded assembly (direction)
15 4 211 320 Hinge plate (welded assembly) pair
16 4 211 344 Axis
17 4 121 042 Pressure spring VD-180V
18 4 211 345 Lever
19 1 215 701 Threaded pin with tip M5x8 1.4301 DIN 914
20 4 211 329 Pulling bow (welded assembly)

Running gear, non-directed wheel with brakes
Running gear, non-directed wheel with brakes
9
8
2
9
10
9
12 13
4
9
1
3 14
12
4
5
14
13 9
9
6
11


1 4 144 252 Wheel cover (type Black Rubber)
2 4 144 254 Wheel 1 COLSON
3 4 211 350 Ring
5 4 083 121 Circlip 9 DIN 6799-St
6 4 211 356 Support
7 4 211 358 Screw
8 4 211 311 Bow (welded assembly)
9 4 083 120 Circlip 5 DIN 6799-St
10 4 121 043 Pressure spring VD-251
11 4 211 317 Bushing (welded assembly)
12 4 211 320 Hinge plate (welded assembly) pair
13 4 211 315 Bolt, long
14 4 211 332 Pushing shaft (welded assembly), pair

Head section, simple, 4 544 443
Head section, simple, 4 544 443
21
22
8
23
20
19
18
19
10
18
9 11
10
12
12
4
5 13
6 17
14
7
15
16
1
8
2
9
3 16
13
12 15
10
11 12
10 14
22
20
23
17


1 4 212 534 Cap, pair
2 4 212 542 Button X
3 4 212 541 Pin X
4 4 212 543 Button
5 4 212 532 Pin
6 4 212 533 Pin
7 4 121 011 Pressure spring VD-080 B-04
8 4 121 023 Pressure spring VD-173 CJ Gutekunst
9 4 212 531 Snap in bolt
10 1 215 428 Hexagon socket countersunk screw M8x40 1.4301
DIN 7991
11 4 210 526 Bar
12 4 210 518 Distance bush
13 4 212 504 Spar, pair (welded assembly)
14 1 215 576 Grooved pin 5x12 1.4301 DIN 1473
15 4 212 520 Snap in shaft, right and left (pair)
16 4 212 529 Screwable cap
17 4 212 514 Camshaft (welded assembly)
20 4 212 506 Connection, simple
21 4 145 355 Pad, head section X
22 1 215 583 Grooved drive stud semicircular 3x12 DIN 1476-A2
23 4 121 079 Spiral spring

Head section, adjustable, 4 544 444
Head section, adjustable, 4 544 444
26
28
25
27
24
25 1
23
8
10
24
9 11
22 28 12
10
23
12
18
19
13
18
20 14
15
19 21 16
20
21
27
28
4 17
5
6 22
7
17
1
8
2
9
3 16
13
12 15
11
10 12
10 14


1 4 212 534 Cap, pair
2 4 212 542 Button X
3 4 212 541 Pin X
4 4 212 543 Button
5 4 212 532 Pin
6 4 212 533 Pin
8 4 121 023 Pressure spring VD-173 CJ Gutekunst
9 4 212 531 Snap in bolt
DIN 7991
11 4 210 526 Bar
13 4 212 504 Spar, pair (welded assembly)
14 1 215 576 Grooved pin 5x12 1.4301 DIN 1473
15 4 212 520 Snap in shaft, right and left (pair)
16 4 212 529 Screwable cap
17 4 212 514 Camshaft (welded assembly)
19 4 212 552 Bushing, long, in parts
20 4 212 551 Bearing, in parts
21 4 081 028 Hexagon socket head cap screw M4x8 1.4301 DIN 912-A2
22 4 212 510 Connection, joint (welded assembly)
23 4 212 553 Bushing, short, in parts
25 4 212 511 Bearing, pair (welded assembly)
26 4 145 355 Pad, head section X
27 1 215 583 Grooved drive stud semicircular 3x12 DIN 1476-A2
28 4 121 079 Spiral spring

Back section for table with longitudinal shift
Back section for table with longitudinal shift
15
29
31 15
15
25
23
33
30 21 24
15
16
20
22
19
17 18
26
7 28
8
27
9
32
6 10
3 14
13
11
4 12
4
5 6
1
1 2
6
4
1


DIN 7991
2 4 210 422 Bar, back section
3 4 145 276 Cover cap GETO-SNAP GFB 435013
5 4 212 080 Back section (welded assembly)
6 4 210 421 Bolt
7 4 210 394 Lever, right
4 210 399 Lever, left*
8 4 210 429 Bolt
9 4 121 008 Pressure spring VD-180 C
11 4 081 040 Countersunk screw AM4x8 DIN 965-A2
12 4 212 387 Lid, pair
15 4 083 103 Parallel pin 3M6x18 DIN 7-A2
16 4 121 022 Pressure spring VD-180 D
17 4 083 020 Centergrooved dowel pin 3x12 DIN 1475 A2
18 4 212 393 Stop
20 4 081 068 Slotted headless screws M4x10 DIN 427 A2
21 4 212 095 Shaft, pair
22 4 212 386 Seat
23 1 215 501 Disc A8,4 1.4301 DIN 125
DIN 7991
25 4 212 394 Bracket, pair
26 4 144 130 Gas spring 10-23-220-1/500N 380-600-GZ-GZ X
27 4 144 155 Bolt 8x12, 5x16 MBO Norm 77 galZn
28 4 144 156 Locking washer 8 MBO 09 galZn
29 4 213 512 Lever, pair (welded assembly)
30 4 213 538 Bowden cable back section SATURN GE-WA
31 4 213 513 Bow, complete
32 4 144 124 Gas spring-fork Code A5
33 4 212 091 Coupling shaft
* not in the figure

Table top with snap-in longitudinal shift
Table top with snap-in longitudinal shift
4
2 5
3
1 6
6
5
5
6
7
6
5
9
10
10


1 4 081 013 Hexagon socket head cap screw M6x20 DIN 7984-A2
2 1 215 510 Disc A6,4 1.4301 DIN 9021
3 4 130 006 Ball bearing 6201 2 RSR stainless
4 4 210 303 Bushing
5 4 210 421 Bolt
6 1 215 376 Tallow-drop screw M5x10 1.4301 DIN 7985
7 4 213 557 Spar, right GE-WA
8 4 213 554 Spar, left GE-WA
9 4 210 305 Bow
10 4 144 150 Shaft W30 H6x461 X46CR13 corporation INA

Snap-in for table with longitudinal shift
Snap-in for table with longitudinal shift

1
9
12
10
13
5
2
6 8
7
3
4
5
2
3


1 1 215 331 Hexagon socket screw M6x20
2 4 210 260 Spiral spring, right
3 4 210 258 Bearing bolt
4 4 213 559 Pendulum (welded assembly)
5 4 083 014 Grooved drive stud, semicircular 4x12 DIN 1476-A2
6 4 213 574 Snap-in plate, right
7 4 083 127 Disc 6,4 DIN 134 Ms
8 4 083 016 Circlip 4 DIN 6799-A2
9 4 213 538 Bowden cable (longitudinal displacement) X
back section SATURN GE-WA
10 4 213 558 Angle (welded assembly), right
11 4 213 555 Angle (welded assembly), left*
12 4 081 035 Fillister head screw M3x6 DIN 84-A2
13 1 216 099 Draw spring RZ-081OI 180 GRD out of line
* not in the figure

Coupling
Coupling
3
2
3
1
17
14
16 15 18
13
9
8 12
7
4
11
10
5 6
24
25/14x
24
22 26/16x
21
20
19 23
19


DIN 7991
2 4 213 594 Standard bar
4 4 213 603 Lever X
5 4 083 072 Cylinder pin 4M6x24 DIN 7-A2
6 4 213 606 Pin
7 4 213 610 Pressure disc
8 4 121 033 Pressure spring VD-062 B
9 4 213 623 Lever, small X
10 4 144 483 Washer WC 16 DU
11 4 213 593 Pressure disc
12 4 213 604 Stamp
13 4 210 463 Bronze bushing
14 4 213 584 Coupling, right
15 4 213 585 Coupling, left*
16 4 144 411 Ball, Ø 10 mm
17 4 121 036 Pressure spring VD-155G
18 4 210 445 Switching piece
19 4 121 095 Disc spring 1.4310
20 4 213 626 Locking washer
21 4 213 644 Nut
22 4 213 642 Locknut (welded assembly)
DIN 7991
24 4 213 613 Disc, outside, to 01/1997
25 4 144 521 Inner lamella disc, to 01/1997 10x
26 4 144 520 Outer lamella disc, to 01/1997 10x
* not in the figure

Leg support, one part, 4 544 480
Leg support, one part, 4 544 480
12
2
3 13
4
14
11 16 15
1
17
6 5
7 19 21
10 18
20
8
9
10
8
10
8
21
20


1 4 210 759 Bolt
3 4 214 540 Seat (welded assembly)
4 4 210 757 Plunger
5 4 121 015 Pressure spring VD-198 G
6 4 214 535 Angle
DIN 7991
9 4 212 715 Norm bar
10 4 210 518 Distance bar
11 4 214 531 Frame (welded assembly)
12 4 145 364 Pad leg support, one part X
13 4 210 758 Screw
14 4 214 538 Hinge slide, pair
15 4 081 008 Screw, FLAKO-M6x3 DIN 923-A2
16 4 144 156 Locking washer 8 MBO 09 galZn
17 4 144 470 Collar bushing
18 4 082 004 Hexagonal nut M6 DIN 439-A2
19 4 214 537 Lever
Fastening of the padding:
21 4 210 801 Ring

Leg support, two parts, 4 544 481
Leg support, two parts, 4 544 481
21
22
19
17 19
17
18 23
19
17 20
1 2 3 6 26
5
25
4 9
7
8
10
11
12
24
13
14
15
16
13


1 4 210 623 Plunger
2 4 210 621 Pin
5 4 214 506 Fitting piece, pair
6 4 214 510 Bearing bolt (welded assembly)
7 4 210 624 Slotted headless screws MS
8 4 081 037 Slotted headless screws M5x12 DIN 427-A2
9 1 215 569 Cylinder pin C6M6x30 DIN 7979
10 4 210 625 Disc
11 4 210 607 Lever, complete (pair) X
12 4 210 622 Bolt
13 4 145 018 Hand wheel 62 RD F.M10 DIN 934 Nr.9136 FROLI X
14 4 082 006 Hexagonal nut M10x1 DIN 934-A2
15 4 083 101 Disc 4,3 DIN 9021-A2
DIN 7991
18 4 210 796 Bar
20 4 214 521 Spar, welded assembly (pair)
21 4 145 362 Pad, leg support, right X
22 4 145 363 Pad, leg support, left X
23 4 144 935 Lamella stopper
24 4 212 616 Disc
Fastening of the padding:
26 4 210 801 Ring

Leg support, four parts, 4 544 482
Leg support, four parts, 4 544

22 482
21
23
20
47
30
29
49 24
50
27 42 39
39
40
28 43
41 46
44
27 45
26
28 51
25
31
32
34 33
35
38
37
36
1 2 3 6
5
4 9
7
8
10
11
12
48
19
18
13 17
14
15
16
13


1 4 210 623 Plunger
2 4 210 621 Pin
5 4 214 506 Fitting piece, pair
6 4 214 510 Bearing bolt (welded assembly)
7 4 210 624 Slotted headless screws MS
8 4 081 037 Slotted headless screws M5x12 DIN 427-A2
9 1 215 569 Cylinder pin C6M6x30 DIN 7979
10 4 210 625 Disc
11 4 210 607 Lever, complete (pair) X
12 4 210 622 Bolt
13 4 145 018 Hand wheel 62 RD F.M10 DIN 934 Nr.9136 FROLI X
14 4 082 006 Hexagonal nut M10x1 DIN 934-A2
15 4 083 101 Disc 4,3 DIN 9021-A2
20 4 214 515 Transition piece (WA), pair
21 4 145 358 Pad upper leg support, right X
22 4 145 359 Pad upper leg support, left X
23 4 145 361 Pad lower leg support, left X
24 4 145 360 Pad lower leg support, right X
25 4 214 501 Spar, welded assembly (pair)
26 4 212 602 Bar
DIN 7991
31 4 214 517 Gas spring KOB1V93-104-346/600N, complete X
32 4 230 787 Lever
33 1 215 540 Locking washer 10x1 DIN 471-A2
35 4 210 602 Seat
36 4 101 011 Bowden cable leg support, four parts X
37 4 230 575 Adjusting screw
38 4 210 475 Slotted nut
39 4 083 018 Cylinder pin 4M6x10 DIN 7-A2

Leg support, four parts, 4 544 482
22
21
23
20
47
30
29
49 24
50
27 42 39
39
40
28 43
41 46
44
27 45
26
28 51
25
31
32
34 33
35
38
37
36
1 2 3 6
5
4 9
7
8
10
11
12
48
19
18
13 17
14
15
16
13


42 4 230 631 Lever
43 4 230 531 Handle, complete (welded assembly)
44 4 230 632 Bearing block
45 4 081 032 Raised countersunk head screw M4x12 DIN 966-A2
46 4 144 935 Lamella stopper
48 4 212 616 Disc
Fastening of the padding upper leg support:
DIN 7991
DIN 7991
Fastening of the padding lower leg support:

Sensors and remote control
View on the height and

Sensors sensors (partial)
remote control Figure without seat and bellows
Sensor tilting
2
1
Sensor height
1 1
Sensor height
3 4
5 6


1 4 211 632 Slot sensor
2 4 144 463 Bushing
3 4 545 603 Cable remote control X*
4 4 545 645 Infrared remote control GE X*
5 4 100 006 Spiral cable
6 1 219 218 Spiral cable with plug X
7 4 545 605 Cable remote control GR/GS** X*
8 4 545 646 Infrared remote control GR/GS** X*
9 4 545 607 Cable remote control GY** X*
10 4 545 647 Infrared remote control GY** X*
11 4 145 175 Remote control upper part** X
12 4 145 176 Remote control lower part** X
13 4 144 502 Accumulator for Infrared remote control (9 V/160 mA)** X
** not in the figure

Guiding of hydraulic tubes and cables
Guiding of hydraulic tubes and cables
Z3A
Z1A
Z2B
Z1B
Z3B
Z2A
Z1A
Z1B
Z3B
Z2B
1
2
Z3A
Z2A
Z3B
Z3A
Z2B
Z2A
Z1B
Z1A


1 4 144 320 Cylinder 2 (Trendelenburg) X
2 4 144 321 Cylinder 3 (Tilting) X
Gaskets
Mat. no. Description SP

1 216 328 Gasket for ring type nipple G1/8" X
1 216 329 Gasket for ring type nipple M8x1 X
Banjo bolt
Mat. no. Description SP

1 216 325 Banjo bolt 1/8" for 2 ring type nipple (GY) X
1 216 326 Banjo bolt 1/8" X
1 216 327 Banjo bolt M8x1 X
Connections of the hydraulic tubes
Mat. no. Description Length SP

4 145 080 Control unit Z1A G1/8" lifting cylinder Z1A, M8x1 670 mm X
4 145 082 Control unit Z1B G1/8" lifting cylinder Z1B, M8x1 580 mm X
4 145 082 Control unit Z2A G1/8" Trendelenburg Z2A, M8x1 580 mm X
4 145 080 Control unit Z2B G1/8" Trendelenburg Z2B, M8x1 670 mm X
4 145 082 Control unit Z3A G1/8" tilting Z3A, M8x1 580 mm X
4 145 080 Control unit Z3B G1/8" tilting Z3A, M8x1 670 mm X
ATTENTION!
Insert two sealing rings per banjo bolt!

Hydraulic pump and fittings
5 6
2
M3
M4


1 4 144 332 O-ring 2,9x1,78, 2-006 X
2 4 144 500 Control unit, complete X
3 4 214 119 Hydraulic aggregate with pressure switch X*
4 4 102 048 Pressure switch X
5 4 142 074 Electrovalve X
6 4 144 280 Regulating valve X
Meaning of the plugs and labels of the cables
Description Fitting Description Mat. no.

J1 accumulator accumulator cable 4 100 029
J2 motor 1 motor cable 4 100 028
J3 valves electrovalves 4 100 027
J4 sensors and IR-receiver

J5 sensors
J6 Cable remote control foot end 4 100 025

J7 Cable remote control head end 4 100 026
ATTENTION!
1 Plug connector of the hydraulic motor in J2, left!
2 Tighten screws of J6 and J7!
3 Clamp screens of the cables under the plates!

5 6
2
M3
M4

Pin assignment J4
Pin Connection Colour sensor connector

1 +12 V white
2 Sensor Tilting green
3 Ground brown
4 +12 V white
5 Sensor Trendelenburg green
6 Ground brown
7 +12 V white
8 Sensor height 1 (bottom)) green
9 Ground brown
10 +12 V white
11 Sensor height 2 (top) green
12 Ground brown
13 +12 V white
14 IR input green
15 Ground brown
Pin assignment J5
Pin Connection Cable for membrane keyboard

6 +12 V marked lead
7 E_0 Tast all other leads are to be connected
in order
Pin Connection Cable pressure switch

8 ground
9 E_Druck


Connection diagram
8 Connection diagram

78
white
yellow Cable remote control feed end white Pin 1
green brown brown
Sensor Sensor grey green Pin 2
Pressure switch hydraulic brown Cable 10 x 0,14 qmm, shielded yellow green
Tilting Trendelenburg Pin 3
white grey yellow
black red Pin 4
pink violet grey
blue only with 24 V / 3,2 Ah Pin 5
red SF model Pin 6
violet
shield Pin 7
red
shield Pin 8
brown
white pink Pin 9
white
green
brown
white
green
brown
Cable remote control shield Pin 1
blue
Don´t connect white 12 V, 12 Ah 12 V, 12 Ah Pin 2
head end black
white
green
brown
shield! brown
Pin 3
white
Connection diagram
brown motor
green black
L1
yellow shield
grey N
red
white
brown
green yellow
Connection diagram
yellow green
grey
red grey M1
brown Pin 1
violet white brown M2
black black Pin 2
Pin 1 cable 10 x 0,14 qmm, shielded M3
blue pink
Pin 2 blue Pin 3
M4
pink red Pin 4
Pin 3 violet green M5
shield Pin 5
M6
shield Pin 6
green/yellow yellow M7
Pin 7
M8
Pin 8
grey M9
Pin 9
M 10
Pin 10
3 x 0,75 qmm pink
Pin 11
Jul 1B Pin 12
shield
Pin 13
Pin 14
Jul 1A J 20
Pin 15
pink GND
Pin 25
GND
Pin 24
GND
Pin 23
GND
Pin 22
GND
Pin 21
GND
Pin 20
primary 230 V black GND
Pin 19
blue
GND
Pin 18
GND
Pin 17
brown black GND
Pin 16
blue white
brown white Hydraulic unit

blue
brown
blue
Connection 115 V
primary
brown
Service Manual SATURN GE, GR, GS, GY 4 900 305 - 10/03

Hydraulic diagram control unit
9 Hydraulic diagram control unit

80
Lifting = 350 Lifting = 103 Lifting = 63
A1 = 4,90 qcm A1 = 12,56 qcm A1 = 12,56 qcm
A2 = 3,14 qcm A2 = 9,42 qcm A2 = 9,42 qcm
Lifting Trendelenburg Tilting
Z1B Z1A Z2B Z2A Z3B Z3A
ca. 80 µm ca. 80 µm ca. 80 µm
Filter
Chock Choke
M5 M6 M7 M8 M9 M10
Magnetic valve
Blind plate
M2 M1 M4 M3
Magnetic valve
Hydraulic aggregate

Second-hand parts SATURN Family
10 Second-hand parts SATURN Family

Pos. Mat. no. Description
1 1 222 715 Electronic unit IR SATURN SX, GE, GR 1.0
2 1 222 847 Cable remote control SATURN GE
3 1 222 848 Infrared remote control SATURN GE
4 1 222 849 Cable remote control SATURN GR/GS
5 1 251 171 Infrared remote control SATURN GR/GS
6 1 251 172 Cable remote control SATURN GY
7 1 251 173 Infrared remote control SATURN GY
8 1 219 288 Hydraulic aggregate with pressure switch

Service Manual Operating Table SATURN GR
11 Service Manual Operating Table SATURN GR

NOTE!
No replacement of gas spring in back section of SATURN GR necessary!
11.1 Replacing Cylinder (1 219 289) in Back Section
433 mm
3 2 1
Figure 10: Cylinder

1 Protector 3 Locknut
2 Hydraulic tube
1. Remove circlip and lower bolt of cylinder.

2. Remove tube protector [1].
3. Unscrew side spar plate in the back section.
4. Disassemble upper bearing block of the cylinder (2 screws from underneath).
5. Tear out cylinder from the baring to the front and take it out downward through the
spar.
ENVIRONMENT!
Capture leaking oil, pay attention to the regulations for environmental
safety!
6. Unscrew hydraulic tubes [2], capture hydraulic oil.
7. Unscrew seat and locknut [3] from cylinder and reassemble at new cylinder.
8. Adjust length of 433 mm with nut at piston rod.
NOTE!
Bleed the system:
- Lift back section to highest position.
- Use the function “Back section up/down” several times.
Then the system is automatically bleeded.
TEST!
Check all functions!

Service Manual Operating Table SATURN GR
11.2 Spare parts
7
1
A
5
8 6 6
5
2
34 6 5
5 6
A
9
10
Figure 11: Spare parts operating table SATURN GR
• Item Number: 4 544 072

• Manual valid from serial number: 950449
• Differences from SATURN GE: Back section hydraulically adjustable
• Release of horizontal shifting: Release handle

1 1 219 289 Cylinder, complete (incl. pos. 2, 3, 4) X
2 4 144 388 Hydraulic cylinder LC-20-0200-3 X
3 4 083 113 Dowel pin X
4 4 213 024 Seat X
5 4 145 098 Hydraulic tube IK-6 1/8 inch / M8x1, 1600 mm X
6 4 145 097 Hydraulic tube IK-6 1/8 inch / M8x1, 1500 mm X
7 4 213 112 Tube protector, left X
8 4 213 111 Tube protector, right X
9 4 144 379 Auxiliary block 17-05658-00 X
10 1 216 325 Banjo bolt G 1/8 inch for 2 banjo unions X
4 545 605 Cable remote control GR X
ATTENTION!
For SATURN GR do not use any other cable remote control than
item no. 4 545 605!

Service Manual Operating Table SATURN GS
12 Service Manual Operating Table SATURN GS
12.1 Replacing the bowden cable - longitudinal shift
1. Remove H-lever in the seat:

- Loosen 4 spherical heads and 4 cylinder screws.
- Tilt adapter (lobe) downwards.
- Pull out H-lever towards the foot end.
- Unhinge bowden cable.
2. Locknut of the adjustment screw loosen and unscrew.
4. Unhinge bowden cable.
NOTE!
Insert new bowden cable using the old one to pull!
5. The position in the spar must be as with the old bowden cable!
Reassemble in reversed order
TEST!
Check after check list!
Load on one side 70 kg.

Service Manual Operating Table SATURN GS
12.2 Spare parts
2
1
Figure 12: Spare parts operating table SATURN GS

• Manual valid from serial number: 001 034423
• Differences from SATURN GE: Back section suitable for x-raying
and hydraulically adjustable
• Release of horizontal shifting: Release handle at right spar

1 4 213 682 Bowden cable for horizontal shifting X
2 4 213 677 Release handle X

Service Manual Operating Table SATURN GY
13 Service Manual Operating Table SATURN GY

NOTE!
From serial number 001 034061 SATURN GY has the following additional
function:
- Synchronization of the leg sections in highest position.
Synchronization can be carried out as follows:
1. Lift leg sections to highest position.

2. Hold the function “Lift leg sections” in highest position for 20 seconds.
3. The leg sections are synchronized exactly at the same hight and the hydraulic system is
bleeded automatically.
13.1 Replacing Hydraulic Cylinder 4 144 183 and 4 144 182

ATTENTION!
Relieve hydraulic system of leg sections before starting by taking off both leg
sections!
1
Figure 13: SATURN GY without pads
1 Toggle link socket
1. Remove standard rail.

2. Unscrew 3 countersunk screws on top, 1 countersunk screw underneath and 1 hexagon
socket screw inside the spar.
3. Remove circlip and bolt at toggle link socket [1].
4. Pull off spar.
5. Tear out upper bolt at cylinder.
6. Take out cylinder.
ENVIRONMENT!
Capture leaking oil, pay attention to the regulations for environmental
safety!
7. Unscrew hydraulic tubes, capture hydraulic oil.
8. Unscrew toggle link socket [1] with locknut from the cylinder and lock at new cylinder.

Reassemble in reversed order with following instructions:
TEST!
Synchronize positions of both leg sections at lower stop (in lowest position)!
Adjust at thread of toggle link socket.
• Lock toggle link socket at piston rod with a locknut.

• Synchronize the system and so automatically bleed it.
Repeat synchronization/bleeding several times.
13.2 Spare parts
A
5
4 4
6
3 13
A 8
6 13
2
4
4 11
5 12 9
10
7
1
Figure 14: Spare parts operating table SATURN GY

• Manual valid from serial number: 001 034061
• Differences from SATURN GE: Back section hydraulically adjustable
no horizontal shifting


1 4 144 277 Electronic unit, complete for SATURN GY X
2 4 144 183 Hydraulic cylinder, right X
3 4 144 182 Hydraulic cylinder, left X
4 4 145 080 Hydraulic tube G 1/8 inch / M8x1, 670 mm X
5 4 145 084 Hydraulic tube G 1/8 inch / M8x1, 980 mm X
6 1 216 312 Hydraulic tube M8x1 X
7 1 216 310 Hydraulic tube M8x1, 230 mm X
8 1 216 327 Banjo bolt M8x1 X
9 1 216 326 Banjo bolt for banjo union G 1/8 inch X
10 1 216 325 Banjo bolt G 1/8 inch for 2 banjo unions X
11 4 145 404 Adjusting block GY X
12 4 144 379 Auxiliary block 17-05658-00 X
13 4 144 174 Toggle link socket ZL 10 GS X
4 545 607 Cable remote control X
CAUTION!
For SATURN GY do not use any other cable remote control than
item no. 4 545 607!



Postfach 1263
D-07303 Saalfeld, Germany
Telephone:+49 3671 586-0 e-mail: [email protected]
Telefax: +49 3671 586 166 www.trumpf-med.com

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Operating table SATURN GE, GR, GS, GY

TRUMPF Medizin Systeme GmbH

TRUMPF Medizin Systeme GmbH

Sales and Phone +49 3671 586-0

Service Phone +49 3671 586 172

We are constantly working on further developments.

© 10/03 TRUMPF Medizin Systeme GmbH

4 Disposal and recycling of the parts

Service Manual SATURN GE, GR, GS, GY 4 900 305 - 10/03 1

6 Course offers Equipment

7 Spare Parts SATURN GE

9 Hydraulic diagram control unit

10 Second-hand parts SATURN Family . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

2 Service Manual SATURN GE, GR, GS, GY 4 900 305 - 10/03

11 Service Manual Operating Table SATURN GR

12 Service Manual Operating Table SATURN GS

13 Service Manual Operating Table SATURN GY

Service Manual SATURN GE, GR, GS, GY 4 900 305 - 10/03 3

4 Service Manual SATURN GE, GR, GS, GY 4 900 305 - 10/03

1.1 Notes for Service Personnel

Repairs may only be performed by trained personnel.

TRUMPF Medizin Systeme GmbH

Telephone +49 3671 586 172

Service Manual SATURN GE, GR, GS, GY 4 900 305 - 10/03 5

1.2 Explanation of Symbols

The measures to prevent dangers arising must be implemented without fail!

6 Service Manual SATURN GE, GR, GS, GY 4 900 305 - 10/03

1.3 General Safety Instructions

Observe the following general safety regulations:

Service Manual SATURN GE, GR, GS, GY 4 900 305 - 10/03 7

1.4 Safety Instructions for Working in the Operating Area

Instructions for endangered persons:

• Endangered persons must be inoculated against hepatitis B!

1.5 Instructions for Protecting the Environment

8 Service Manual SATURN GE, GR, GS, GY 4 900 305 - 10/03

2.1 Electrical Unit

2.1.1 Replacing the Accumulator

1. Bring lifting in upper position.

Service Manual SATURN GE, GR, GS, GY 4 900 305 - 10/03 9

2.1.2 Adjusting the column in case of breakdown of the electronic unit

1. Push cover downwards.

Figure 1: Plugs and terms above the electronic unit

3. Remove plugs J2 (motor 1) and J3 (valve) above the electronic unit.

10 Service Manual SATURN GE, GR, GS, GY 4 900 305 - 10/03

2.1.3 Replacing the Electronic Unit

5. Open electronic unit (remove 4 screws M5 in the lid).

J6 Pull reliefs (Screening plates)

J13 brown brown white

J15 brown brown Connection 115 V

J20 J17 J19 J18

Figure 2: Connectors on the PCB

7. Pull off plugs J1 through J7.

Service Manual SATURN GE, GR, GS, GY 4 900 305 - 10/03 11

Figure 3: Jumper JU 1A and JU 1B

11. Insert the jumper for the charging current correctly!

12. Assemble casing, connect plugs as in figure 1.

12 Service Manual SATURN GE, GR, GS, GY 4 900 305 - 10/03

17. Check Trendelenburg function!

18. Close lid and lock the screws!

19. Lock the cover.