TRUMPF - P4 -PTS Service

09-09/Eng-P4-V7 PTS / Multi Bed Mover / P4 1

Maintenance manual

Multi Bed Mover



Contents

1. SAFETY ............................................................................................................ p6

1.1. General .................................................................................................... p6

1.2. Causes of danger ..................................................................................... p6

1.3. Treatment of the batteries ........................................................................ p7

1.4. Use for the intended purpose ................................................................... p7

1.5. Transport / Storage .................................................................................. p8

1.6. For your safety ......................................................................................... p8

2. DESCRIPTION .................................................................................................. p9

2.1. Parts of the machine ................................................................................ p9

2.2. Technical data........................................................................................ p10

2.3. Classification ........................................................................................ p11

2.4 CE-label ................................................................................................. p11

2.5 Important warning regarding charging procedure .................................. p11

3. OPERATION ................................................................................................... p12

3.1. Parts for operation ................................................................................. p12

3.1.1.Remote control .............................................................................. p12

3.1.2.Operation Panel ............................................................................ p13

3.1.3.Relay compartment ............................................................................. p14

3.1.4. Charger display (on relay compartment) ...................................... p14

3.1.5.Chassis ......................................................................................... p15

3.1.6.Claw unit ............................................................................................... p15

3.2. Annual maintenance .......................................................................... p16

3.2.1.Points to be checked according maintenace list ...................... p16-17

3.2.2.Battery check ................................................................................ p18

3.2.3.Claw check.................................................................................... p19

3.2.4.Suspension check ......................................................................... p20

3.2.5.Engine check ........................................................................... p21-23

3.2.6.Handle check ................................................................................ p24

3.2.7.Remote control ......................................................................... p25-27

3.2.8.Relay compartment check............................................................. p28


Contents

4. Troubleshooting ............................................................................................ p29

4.1.1. LED on remote control does not light up ..................................... p29

4.1.2. Button on operating panel heats up (and melts) ......................... p29

4.1.3. Green starter switch does not light up ......................................... p29

4.1.4. Green starter switch only lights up when kept pressed ............... P30

4.1.5. Green starter switch lights up intensely when switching off ........ p30

4.1.6. White push button of the claws does not light up ........................ p30

4.1.7. Claws do not move when pressing the push buttons .................. p30

4.1.8. Device starts and steers but does not move forward/backward .. p31

4.1.9. When device is pushed it can only move half a meter .................. 31

4.1.10.Device does not steer left or right ............................................... p31

4.1.11.Device can only be steered to one side ...................................... p32

4.1.12.Device starts but does not move forward/backward

steer left or right ......................................................................... p32

4.1.13. Device starts but does not move forward/backward or steer

left or right and the claws do not move ....................................... p32

4.1.14.Device moves with jerks ............................................................. p32

4.1.15.Device suddenly swerves left or right .......................................... p33

4.1.16.Emergency stop cannot be switched off .................................... p33

4.1.17.Emergency stop cannot be switched on ..................................... p33

4.1.18.Half/full power only works in one position or does not work ........ p33

4.1.19.Handle switch does not work ...................................................... p34

4.1.20.Beeper does not work ................................................................. p34

4.1.21.Device has no power .................................................................. p34

4.1.22.Device battery runs out quickly ................................................... p34

4.1.23.Charging LED's on relay department do not light up ................... p34

4.1.24.Battery meter does not work ....................................................... p34

4.1.25.Device suddenly switches off ...................................................... p35

4.1.26.Device only works for half a day ................................................. p35


Contents

5. Appendices .................................................................................................... p36

5.1. Maintenance file ................................................................................ p36-39

5.2. Fuses ..................................................................................................... p40

5.3. Exploded views ................................................................................. p41-62

5.4. Electrical diagram .................................................................................. p63


Safety

1 Safety

1.1 General

In case of a defect first contact the distributor or manufacturer, even if you are carrying out the repairs yourself. This manual is intended for the repairer. Please read the instructions and recommendations contained in this text thoroughly before using the device. This will ensure safe operation and optimal use of the device. The care and maintenance instructions contained in this manual are intended for your safety and at the same time they will help you keep the device in good condition. The manufacturer cannot be held responsible for any personal or material damage that may result from the improper use of the device through failure to comply with this manual. This device was manufactured in compliance with the requirements of Directive 93/42 EEC. This device works with 24V DC with a current intensity of max. 25 A! Before starting any activity on the device, always make sure all safety rules are being observed and that this is the case throughout the whole intervention. In case of a defect it is worthwhile to first determine the defect using the troubleshooting section. After that, always read the function description of the parts in question before starting any repair or maintenance activities.

1.2 Causes of danger

Do not touch the underside of the device during use. During use, special care must be taken when other persons are near. Always leave sufficient stopping distance when operating the machine. Careful: the machine has an electric brake! In order to reduce speed, release the speed lever to brake. In cases of emergency the emergency stop can be used to brake. (see 3.2.9) Manoeuvre the machine carefully over thresholds and elevations. The wheels or other parts could be damaged. Slow down when going up or down slopes. Electromagnetic radiation (EMC). The device meets the requirements of the EMC standards. During its use possible interferences with other medical devices with a higher sensitivity than the limits described in the EMC standards should be taken into account at all times.


Safety

1.3 Treatment of the batteries

Charging is forbidden while a bed is attached to the device. Before charging the batteries inspect the charging cable. Smoking is forbidden while the batteries are being charged. Avoid flames and sparks and do not charge near a source of ignition. When charging, the device must be switched off (it switches off automatically when the charger is connected to the mains). Food and beverages are forbidden in rooms where batteries are charged.

1.4 Use for the intended purpose

The machine is intended exclusively for the transport of hospital beds within hospitals. Any other uses are not in accordance with the intended purpose. The manufacturer cannot be held responsible for any damage as a result of such uses. The risk of such uses shall be borne exclusively by the user. Only use the machine in sufficiently lit rooms. The normal temperature during operation should be between +15°C and +30°C (59 and 86 F). Use for the intended purpose shall also include compliance with the conditions of use and maintenance as provided by the manufacturer. The applicable legislation on accident prevention as well as the generally accepted safety regulations and guidelines regarding health and safety at work must be complied with. The manufacturer cannot be held liable for any damage resulting from non-authorized modifications to the machine. The machine may only be serviced and repaired by persons who have the necessary technical and organisational responsibility. Before starting to use the machine familiarise yourself with its movements, if possible in an open space, especially with regard to turning and braking, with and without a bed connected to it. The standard position of the machine is at the foot of the bed; the position of the user is at the head. (See picture on p. 14.)


Safety

1.5 Transport & storage of the machine

Always disconnect the machine. (see 3.2.7). Make sure the machine is adequately propped up when transporting it in order to prevent sudden changes in position! Place a suitable warning sign! Only use appropriate transport vehicles with sufficient loading capacity! During transport, the machine should always be placed upright, be kept dry and marked as a fragile object. The temperature during transport should be between +0° C and +40° C (32 and 104 F). The temperature during storage should be between +10° C and +30° C (50 and 86 F). When transporting the machine, the relevant instructions for use and safety precautions must be observed, especially regarding the loading capacity of the transport vehicle.

1.6 For your safety Before using the Multi Bed Mover or working on it, it is imperative to read this manual. Keep this manual in a place that is easily accessible to everyone in the technical service, in order for them to be able to reread it whenever necessary. The device may only be used or maintained by persons who have been trained to do so and who have received explicit orders to work on it. The device may transport a maximum of 1 bed with a maximum of 1 person at a time, and it must not be used for any other kind of transport without the written permission of the designer. The machine is only suitable for indoor use on even surfaces. The machine is not suitable for use in sterile operating rooms. The machine is only suitable for the transport of beds on swivel castors. Remove the key whenever you leave the machine unattended. Always leave sufficient stopping distance when operating the machine. The machine may only be used on slopes of up to 5%. The maximum permitted lateral incline is 5%. Do not drive over electric cables. Beside the manual and the national regulations on accident prevention, the general technical guidelines for a correct and safe operation must be observed as well. Any potentially dangerous actions must be avoided. The machine has not been registered for use on the public highway.


Description

2 Description

2.1 Parts of the machine

1/ Handle 7/ Relay compartment 13/ Manual claw operation

2/ Shop position lever 8/ Charger display 14/ Nose

3/ Spiral cable 9/ Battery compartment 15/ Wheel cap

4/ Remote control 10/ Chassis 16/ Charging plug

5/ Remote control holder 11/ Claw 17/ CE label

6/ Operating panel 12/ Claw magnet 18/ Warning


Description

2.2 Technical data° (Standard version P4)

Dimensions Length 530 mm

Width 815 mm

Height 1,130 mm

Wheel diameter 150 mm

Clearance 30 mm

Weight 130 kg

Engine/Power Drive engine 130W / S2

Speed 4.6 Km/h

Maximum load to be moved 350 kg

Maximum gradient 5%

Maximum lateral incline 5%

Battery Number 2

Tension 24 VDC

Capacity (maintenance-free gel batteries) 56Ah

Hours of operation ± 8 hours

Battery charger Input 230V / 50Hz / 1A

Output 24VDC / 6A

Control Electronic

Materials Frame Stainless steel + powder-

coated steel

Drive wheel Vulkolan

° = Subject to technical modifications.


Description

2.3 Classification - Class II isolation (during use the machine runs on batteries). - Protection against water: IP 12 - The machine is suitable for continued use.

2.4 CE label

Explanation

Multi Bed Mover: commercial name Model P4: technical name Operating Voltage 24VDC: operating voltage (low tension) Serial n°: a coded serial number Charging voltage 230VAC – 50Hz – 1A: operating voltage of the charging installation : see CE conformity declaration : symbol for double isolation (no earthing)

2.5 Important warning regarding charging procedure

It is prohibited to charge the machine with a bed still attached to it, with or without a patient.


Operation

3 Operation

3.1 Parts for operation

3.1.1 Remote control

1 – Stand-by LED Indicates that the device is ready for use. Also indicates to the user that the emergency stops have not been activated.

2 – Beeper This press button enables the user to let all persons in the immediate vicinity know that he or she is approaching (e.g. in places where it is difficult to pass or when leaving a room).

3 – Switch for full (II) or half (I) speed. Halves the power of the device so that it reacts less strongly to the speed lever.

4 – Remote support Thanks to this support the remote control can be hung either on the right or on the left side of the device. This allows both right and left-handed users to always take the best position.

5 – Steering lever By tilting the lever to the left or the right the device will move accordingly.

6 – Speed lever This is a lever that increases and decreases speed according to how far it is pushed in.

7 – Forward/reverse switch On this switch forward and reverse are marked by means of arrows. Before starting to move the machine the right direction must be determined.

8 - Emergency stop This should be pressed in case of danger: the device will immediately come to a halt. (By lifting the red part, the starting procedure can be repeated.)

9 – Spiral cable This cable connects the remote control to the device.


Operation

3.1.2 Operating panel

1 – Key switch When you turn the key to the right the device is on standby. This is the first step to activating the machine. At this point it is not ready to be moved yet.

2 – Start button In order to be able to start moving, the green lamp below this symbol should light up. Press this button in order to activate the Multi Bed Mover.

3 – ‘Claw open’ push button

This push button, with a white lamp, opens the claws. When this lamp lights up after turning the key it means that the machine is on stand-by.

4 – ‘Claw closed’ push button This push button, with a white lamp, closes the claws. When this lamp lights up after turning the key it also means that the machine is on stand-by.

5 – Battery meter (see 3.2.8) On the display a ‘b’ of battery can be seen and at the bottom a pictogram of a battery. In between there are three LEDs: red, yellow and green, each reflecting a different battery situation.

- Green = batteries in good condition - Yellow = batteries not in optimal condition - Red = urgently charge batteries (also when the red lamp suddenly lights up during

transport of a heavy load!)

6 - Emergency stop This should be pressed in case of danger: the device will immediately come to a halt. By pulling up the red part, the starting procedure can be repeated.


Operation

3.1.3 Relay compartment

The relay compartment contains the complete electronic control unit of the device:

1 - MCDrive

Drive module which provides the drive engine with power from 0 to 20 A (standard version) or 30 A (Heavy Duty version). The MCDrive is driven via the PSUPP by the JMU in the remote control.

2 - MCSteer Steering module which provides the steering engine with power (max. 6A). The MCSteer is driven via the PSUPP by the JMU in the remote control.

3 - PSUPP Takes care of the communication between the remote control (JMU) and both modules. All ports on the PSUPP are parallel.

4 - Limiter Power limiter for the claw engine (3A).

5 - Main relay Checks the power circuit.

6 - Starter relay Checks the starter key circuit.

7 - Claw relay Switches the claw movement.

8 - Fuses Secure the different power circuits.

9 - Undervoltage relay Monitors battery voltage and switches the entire device off if the battery voltage drops below 21.5 Volt. Charger relay: connects the charger to the batteries during the charging process and disconnects it from the batteries when the power supply to the charger is interrupted.

3.1.4 Charger display (on relay compartment)

1 – Hour counter

Displays the number of hours the machine has been working.

2 – Charging LED Indicates that the battery charger has been activated. Both LEDs flash when the device is connected to the 230V mains.

3 – Float charge LED Indicates that the battery charger has entered into float charge mode; this means that at least 80% of the charging process has been completed. Both LEDs are now lit continuously.


Operation

3.1.5 Chassis

The chassis is the basic structure onto which the rest of the device is mounted.

It comprises:

1 - The drive engine

This engine is driven by the MCDrive in the relay compartment and is equipped with an electromagnetic brake.

2 - The steering engine, which is attached to a crown wheel on the drive engine, makes the engine turn on its axis with respect to the chassis. The steering engine is driven by the MCSteer in the relay compartment.

3 - The potentiometer is also connected to the crown wheel of the drive engine and continuously reports the position of the drive engine to the remote control

4 - The swivel castors

Underneath the device 2 springy swivel castors are responsible for balance, manoeuvrability and the spring function of the device. There is also 1 antistatic castor in the front, to conduct possible static electricity.

5 - The cable reel, which is in charge of the connection between the mains current (220V) and the battery charger.

6 - The battery charger, which charges the batteries in 2 phases: first fast charging, followed by float charging which completes the battery charging process.

3.1.6 Claw unit

The claw unit is in charge of the connection of the bed to the device. It consists of 2 spindles

with opposite threads and spindle nuts. The claws for the bed legs are attached to these

spindle nuts. The spindles are driven by a 24V DC engine, with a current consumption limited

to 3A by a limiter in the relay compartment. The course of the spindle nuts is limited by 2

end-of-course contacts connected to 2 relays in the relay compartment.


Annual maintenance

3.2 Annual maintenance

3.2.1 Points to be checked according to the list in the maintenance file (see appendix)

1 - Lacquer damage Always relate lacquer damage to possible direct or indirect problems. Always repair damage with lacquer stick.

2 - Key switch

Is it attached well? Is the key position right? Is the play of the key in the slot acceptable? Are the white lamps of the claw operation and the green LED on the remote control on?

3 - Starter switch

(only after pressing!) Is the lamp on, is it not damaged, do you hear the main relay being activated when pressing it?

4 - Emergency stops

Press separately and together: does the system switch off and is the emergency brake activated? Does the system start again normally when the emergency stop(s) are pulled up and the green start button is pushed again?

5 - Power

Test the switch on full and half speed and make sure there actually is a difference in top speed.

6 - Horn / beeper Does it work when pressing the push button on the remote control? Is the sound continuous?

7 - Forward/reverse switch Does the forward/reverse switch work properly?

8 - Speed lever Test the mechanical movement and speed evolution of the speed lever.

9 - Claw open

(lights up immediately after pressing the start button), attachment okay? Is the reaction of the claws when pressing the switch good (always let the claws reach the furthest position)? Do the claws automatically stop in the furthest positions (outside)?

10 - Claw closed

(lights up immediately after pressing the start button), attachment okay? Is the reaction of the claws when pressing the switch good (always let the claws reach the furthest position)? Do the claws automatically stop in the furthest positions (inside)?


Annual maintenance

11 - Claw spring

If the claw is horizontal, it can be pushed down without being damaged. For claws of more than a certain length the claw can be folded and remain in vertical position by means of a magnet. Does the spring work properly in both directions? Are the magnets still in the right place?

12 - Handle switch

Check the play of the brake grip and the play of the handle itself.

13 - Bed mode

Position when the handle is in vertical position. Does the device go left and right? Is there not too much noise when steering? Does the magnet of the remote control work? (if you put the device in the forward position, it should automatically be in the reverse position when disconnecting the remote control, and vice versa)

14 - Shop mode

Position when the handle is in the backward position. Does the device move perfectly straight? (steering is not possible in this position. The magnet of the remote control must not work now (so if the device is in the forward position, it keeps going forward even after disconnecting the remote control).

15 - Check battery meter

Does the battery meter correctly indicate the battery condition? Check this by also testing the battery yourself using a multimeter.

16 - Test drive

Make a test drive and note down any deviations! Make sure you test all functions and note down all deviations before doing any work on the device.


Annual maintenance

3.2.2 Battery check

Battery meter On the display a ‘b’ of battery can be seen and at the bottom a pictogram of a battery. In between there are three LEDs: red, yellow and green, each reflecting a different battery situation.

- Green = batteries in good condition - Yellow = batteries not in optimal condition (discharged to approx. 50%) - Red = urgently charge batteries (also when the red lamp suddenly lights up during transport

of a heavy load!) (discharged to approx. 20%)

Battery

-Rest voltage: completely charged batteries = > +/- 26V

-Voltage when loaded: Place the resistance tester on battery 1 and switch it on for 10 seconds.

Repeat with the second battery. In both cases the meter should remain in the green zone

(according to the type of tester).

-Voltage recovery: parallel to the resistance tester, measure the voltage with a multimeter and

check whether the battery voltage increases to rest voltage again after loading.

-Battery general:

1/ Check all connections (no oxidation of battery poles, no loose or damaged

wires, etc.).

2/ Check the fastening clamps (screws sufficiently tight, does the pressure bar

exert sufficient pressure on the battery to keep it firmly in position, etc.).

3/ Never replace batteries with another type just like that: the charging

voltage differs from one battery to another and the charger must be adjusted to

this!

Battery charger

-Charging voltage: connect the multimeter to the incoming voltage distribution bar (0V) and

the main fuse (24V) in the relay compartment and then activate the charger. Check whether

the voltage goes up and does not exceed 28.5Volt. When the charger reaches float charge

level the voltage must be around 27.6Volt.

It can take some time before the charger switches to float charge mode.


Annual maintenance

3.2.3 Claw check

(Points to be checked: see list)

Tools: - Cleaning agent / degreaser

- Compressed air

- Brush, cleaning paper or cloth

- Teflon oil (does not hold dust)

- Safety Clean

- Cross screwdriver

Mode of operation: Check whether there is not too much dirt in the spindle tube. If this is the case, remove the

gearbox and slightly unscrew the 2 countersunk bolts on both sides of the claw tube. Now you

can remove the protective strip from the spindles so that the spindles can be reached. Wipe

old grease off both threaded rods of the claw system and clean thoroughly using compressed

air, brush, paper and Safety Clean. Move the claws left and right several times during

cleaning so that the nuts are cleaned on the inside as well: dirty nuts affect the smooth

functioning of the device and produce more noise during use due to the higher resistance.

Blow everything dry with compressed air and apply Teflon oil (always check instructions on

product) to threaded rods and nuts. Always move the claws in different directions so that the

oil can properly reach the inside of the nuts!!

Replace the protective strip onto the spindle tube and fasten all screws again.

Remove the gearbox on the side of the claw tube and check the state of the drive belt and the

alignment of the timing-belt pulleys. Also check whether there is sufficient tension on the

drive belt. If this is not the case: unscrew the 4 bolts with which the claw engine is fixed to the

engine plate and pull the engine back until there is sufficient belt tension. Tighten the engine

screws again. Screw the gearbox back onto the timing-belt pulleys.

Check the state of the claws:

- position (horizontal)

- form (deformed during use)

- state of the rubber (damage, changed position, etc.)

- etc.


Annual maintenance

3.2.4 Suspension check

Tools:

- Compressed air

- Circlip ring

- Spanner set (socket wrench, open-end/ring spanner, hex key)

- 2 wooden blocks (200x70x50mm)

- Safety Clean

- Cleaning cloth

- Silicone / teflon spray

Test:

Pull the device back without a bed so that the springs (hidden behind the synthetic caps) are

compressed. Let the device slowly go back to vertical position. This movement should be

smooth and simultaneous on both sides (except: in the Heavy Duty version 1 castor is

equipped with a heavier spring).

Mode of operation for cleaning and maintenance:

Lay the device on its back: be careful with the wheel caps at the back – always place 1 or 2

wooden/synthetic blocks with the thickness of the wheel caps underneath the device to avoid

damage to the synthetic caps.

Unscrew both suspensions by unscrewing the 4 nuts. Blow the spring clean with compressed

air. Check for play or wear on the bearing bushes, replace if necessary. Clean all parts with

Safety Clean before fitting.

Check:

- The tension on all bolts and nuts

- The state of the castors: course, manoeuvrability, rolling capacity, etc.

- The functioning of the spring system + attachment, play of axles and bushes.

Only blow the inside clean with compressed air (the main engine has been treated with a

special protective agent). Afterwards thoroughly spray everything with silicone spray (in the wheel hole, on the spring).


Annual maintenance

3.2.5 Engine check

Tools:

- Compressed air


- Screwdriver set (posidrive, flat, Philips)

- Soldering iron

- Multimeter

- 2 wooden blocks (200x70x50mm)

- Vernier callipers

- Locking device

A/ Engine

Mode of operation:

- Switch off the main fuse.

- Take the electrical diagram (can be obtained on request) or pen and paper and systematically

note down the position + numbers of the disconnected wires.

- Pull the blade terminals (yellow and blue) of both modules loose (steering and drive engine).

- Take out the phone plug (black) from the top of the left module and remove the cover of the

cable duct. Make sure the plug and wire are completely free.

- On the starter relay unscrew position K1/6 wire number 16 (brown wire) (brake pos.),

remove the cover of the cable duct and make sure the wire is completely free.

- On the mass bar unscrew wire number 0V10 (blue wire) (brake neg.) and make sure the wire

is completely free. Put all disconnected cables through the respective holes at the bottom of

the relay compartment.

- Open the battery cover and remove the convertor with mounting plate from between the

batteries.

- Remove the batteries from the battery compartment, unscrew the 2 securing bolts and take

the battery compartment off the relay compartment.

- Now remove the stainless steel cover plate by unscrewing the 5 screws (3 in the front, 2 in

the corners at the back) so that the claw engine, the central wire duct and the cable reel (if

available) become visible.


Annual maintenance

- Remove the protective plate of the end-of-course contacts by unscrewing the 2x M5x35

Allen screws and 1x M8x40 hexagon. (Careful with the spacer bushes mounted underneath!)

- Carefully pull the disconnected wiring, which runs through the centrally located synthetic

ring, away from the relay compartment towards the front (must be free when the engine is

taken out).

- Now unscrew the 4 M8X30 countersunk Allen screws and carefully slide the metal plate and

the synthetic ring over the disconnected cabling.

- Unscrew the end-of-course contacts and attach them to the chassis with adhesive tape so that

they are not in the way.

- Now unscrew the remaining 3 M8x16 bolts of the engine: make sure the engine is

supported!!

- Slowly lower the engine, taking care that the wiring does not get crushed anywhere. The

engine can now be inspected.

B/ Electromagnetic brake

In case of normal use the brake is maintenance-free. During maintenance check the play

between the disc and the magnet.

Mode of operation:

• Remove the 3 x M4 Allen screws (side of the toothed aluminium ring).

• Take the cover with the magnetic contact off the engine.

• Measure the thickness of the brake disc: max. 5mm – min. 4.7mm. If the minimum

value is exceeded replace the disc. Careful: note down how the disc is placed on the

axle.

• Mount the cover back onto the engine.


Annual maintenance

C/ Steering engine

Bearing and engine are maintenance-free.

Check the attachment of the cogwheel onto the steering engine axle. The play between the

small and the large cogwheel must be minimal but not zero.

Mode of operation:

- Remove all dust and other remaining material with compressed air.

- Visually check the play by moving the cogwheel back and forth.

- Check the tension on the nut pressing together and locking the conical parts of the engine

axle and the cogwheel centre; this can also be reached when the engine is still mounted onto

the chassis, through a circular hole on the left side of the engine fixing plate. Not too hard,

otherwise the axle could break!

- Check the state of all cogwheels and replace if you have the least doubt.

D/ Replacing the carbon brushes

Mode of operation:

- Unscrew the protective strip

- Move the strip so that the carbon brushes become visible

- Remove all surplus carbon (with compressed air, only in a well-ventilated area!)

- Clear the grooves between the copper contacts.

- Check whether the carbon brushes smoothly run over the contacts

- Brush wear must not exceed the following values:

• new brush height = 17mm

• maximum wear = 8mm

• minimum brush height = 9mm


Annual maintenance

3.2.6 Handle check

Tools:

- Compressed air

- Teflon oil


- Screwdriver set

- Multimeter

Mode of operation:

- First remove all dust and dirt around both hinge points with compressed air.

- Check:

• The tension on all fastening bolts and nuts

• Whether the handle position block (left and right) is still firmly attached to the chassis

• Whether there is no abnormal play on the black, central hinge bushes.

• The play of the handles when using the handlebar (2mm between handlebar and

support); if necessary, adjust with an adjusting bolt (lock with locknut!)

• Whether the wire sleeves are well centred: bottom left and right of the handle

• Whether both orange magnets are thoroughly fastened to the back of the remote

control supports, are not damaged or cracked, etc.

• The whole handle system for damage and deformation

• At the bottom of the handle, whether the Reed contact and the magnet are firmly fixed

onto chassis and the handle plate, are not cracked and are adjusted well to each other.

• Fix bolt 4x, between handle & handle plates.

- After that, apply sufficient Teflon oil to all moving parts (but NOT to the area where the pin

and the position block touch!)


Annual maintenance

3.2.7 Remote control

Tools:

- Multimeter

- Screwdriver set

- Open-end spanner 22

- Socket wrench

- Test plug

Points to be checked:

Spiral cord:

- Is there damage or deformation? Repair or replace cord.

- Is the cord firmly attached to the plug on the relay board?

- Is the cord firmly attached to the remote control?

- Does it not touch the floor with the handle in shop position? (Attach higher on the handle or

provide more spiral rings between device and handle.)

Magnetic contact:

- Open the back cover of the remote control (careful with the cable of the Reed contact which

is fixed to both parts).

- Check the Reed contact for cracks, attachment and plug connection.

- Are both parts firmly attached? Check with screwdriver (careful: the blue casing is very

fragile, do not screw on too tight!!).

- In case you have the least doubt, replace the parts.

- Check functioning again.

Adjustment of play and/or resistance on steering lever:

- Remove the back cover of the remote control

- With a no. 22 open-end spanner you can adjust the play by tightening or loosening the

locknut. Be careful: the bearing bush and cogwheel are clasped onto the axle of the handle; to

loosen the handle a little, after unscrewing the nut, carefully but forcefully pull the handle

back out of the casing in order to be able to inspect the result.

- Careful: make sure there is a balance between play and smooth movement of the steering

lever!!


Annual maintenance

Wheel alignment General: Always first check and adjust wheel alignment in shop position and then in bed position. The reason for this is that adjustment of the alignment in shop position influences adjustment in bed position, and not the other way round.

(also never change remote controls without adjusting them: they have been adjusted to the

original device)

1/ Complete misadjustment of the shop position or adjustment after installation of a new

turn potentiometer

- Open the relay compartment

- Remove the black phone plug on the left module (MCSteer – POT position)

- Place the test plug (special tool) in its place.

- Lay the device on its back. Careful with the wheel caps at the back, place 2 blocks under the

device!

- Unscrew the cover of the potentiometer.

- Partly unscrew both locknuts (only release tension) and slide the potentiometer cogwheel

out of the crown wheel, pull away the white cap and the attachment plate of the crown wheel.

- Connect one of the multimeter probes to the centre position of the green plug (special tool),

put the scale on Ohm (measurement=max 20K).

- Both the measurement on the left position and that on the right position must be balanced =

+/- 5K (of the green plug).

- The correction is done by very softly turning the cogwheel of the potentiometer until the

multimeter indicates +/-5K. Check both positions again!

- Carefully slide the potentiometer cogwheel, the attachment plate and the cover back onto the

crown wheel. In doing so, pay attention to the multimeter data = 5K. If there is a slight

deviation from +/-5K because the teeth of both cogwheels do not come out entirely, correct

this with the trimmer in the remote control as mentioned above.

- Tighten both locknuts again.

- Check the play between the potentiometer cogwheel and the crown wheel!!! There must

not be any physical tension on the potentiometer cogwheel!! So always make sure you can

turn the potentiometer cogwheel about 1-2 mm independently from the crown wheel.

- Mount the cover of the potentiometer.

- Connect the black plug to the MCSteer POT position again.

- Start the device and check the adjustment. If necessary fine-tune with the trimmer in the

remote control.

2/ Deviation in shop position

- Activate the device.

- Check the forward position of the drive wheel with an inclined handle. If not:

- Carefully turn the trimmer on the PCB and direct the wheel.

(the trimmer is located in the middle of the PCB and can be reached by unscrewing the plastic

bolt at the bottom of the stainless steel back plate of the remote control.

- Now check the forward position with a straight handle. (steering lever in position zero).


Annual maintenance

3/ Deviation in bed position

- Remove the back cover of the remote control.

- Be careful with the magnetic contact on the back cover.

- Slightly unscrew the fastening screws of the potentiometer and place this so that the drive

wheel is positioned upright.

- Tighten the fastening screws and mount everything again.

- In case of complete misadjustment the lower potentiometer must be adjusted first:

Locking buttons

- On the back cover of the remote control there are 2 round black buttons. The purpose of

these is to lock the remote control onto the device and ensure the electronic switching of the

operation.

- Carefully check the attachment bolts for tension.

- Check the state of the buttons for breakage, deformation and damage.

- In case of doubt replace the buttons!

LED

- The LED only works when the key has been turned and the emergency stops have been

pulled up.

- Push in the emergency stops one by one and check whether the LED goes out; then pull

them back up.

- If this does not work, measure the voltage on the poles, if OK replace the LED.


Annual maintenance

3.2.8 Relay compartment check

Tools:

- Multimeter

- Screwdriver set

- Spanner set

- Dry compressed air

Mode of operation:

- Check attachment.

- Check whether all built-in components are firmly attached.

- Remote control connection plug must be tight.

- Check all plug connections, disconnect and reconnect.

- Remove dust if necessary.

- Tighten 4 locking bolts in chassis.


Troubleshooting

4 Troubleshooting

4.1 Troubleshooting

4.1.1 LED on remote control does not light up.

• emergency stop(s) have not been pulled up

• key malfunction

• LED defect

• poor connection between relay compartment and remote control, check spiral cable

and maintenance file

• fuse defect

• discharged battery (undervoltage relay switched on)

• poor contact on battery clamp (loose or broken)

• plug loose on remote PCB

4.1.2 Button on operating panel heats up (and melts).

• wrong lamp used (normally 24V; 1.2W)

• the lamp is not positioned straight in the holder

4.1.3 Green starter switch does not light up.

• emergency stop(s) have not been pulled up

• switch lighting defect

• key malfunction

• starter button or contact element do not work properly

• fuse defect

• relay defect (undervoltage relay)

• poor wire connection in the relay compartment or the operating panel


• poor connection between relay compartment and remote control, check spiral cable

and maintenance file

• check the plugs on the switch in the operating panel



Troubleshooting

4.1.4 Green starter switch only lights up when kept pressed.


• undervoltage relay does not work properly


4.1.5 Green starter switch lights up intensely when switching off the device.

• diode defect on main relay K1

4.1.6 White push button of the claws does not light up.

• key switch does not work properly

• switch lighting defect

• fuse defect

• relay defect (undervoltage relay)

• switch defect (starter switch)

• poor wire connection in the relay compartment or the operating panel

• battery voltage too low (undervoltage relay switched on)

• check the plugs on the switch in the operating panel

4.1.7 Claws do not move when pressing the push buttons.

• Can they be moved manually with the black knob?

no => mechanical problem (object blocks nut movement)

yes => see below


• switch defect

• timing-belt pulley loose (covered on the side of the claw tube)

• drive belt broken

• too little tension on drive belt

• wire connection interrupted

• end-of-course switch defect or poorly adjusted; check manually and listen whether

you hear the switches switch on and off

• limiter defect (you hear the relay switch but the claws do not move)

• fuse defect

• relay defect in relay compartment

• claw engine defect


Troubleshooting

4.1.8 Device starts and steers but does not move forward or backward.

• green push button does not light up

• Can you push the device along manually? => electronic brake OK

• brake relay does not work

• forward/reverse switch in remote control defect

• slide potentiometer in handle defect

• poor connection between device and remote control

• check whether all LEDs on MCDrive and MCSteer work

• check whether all plugs on MCDrive, MCSteer and PSUPP work

• check whether the MCDrive IC has been pressed properly into its base

• PSUPP module defect

• plug connection in remote control has come loose

• check the drive engine

• MCDrive module defect

• blade terminals not mounted correctly onto the MC Drive module, resulting in

poor contact

• wire loose on the speed potentiometer or the half-full speed switch

4.1.9 Device starts and steers but does not move forward or backward. When pushed forward the device can move half a metre.

• carbon brushes not in correct position (or not flat)

4.1.10 Device starts and moves forward/backward but does not steer left or right.

• check whether all LEDs on MCDrive and MCSteer work

• check all plugs on MCDrive, MCSteer and PSUPP

• check whether the MCSteer IC has been pressed properly into its base

• magnetic contact at the bottom of the handle defect or damaged

• distance between magnet sensor and magnet too big

• MCSteer module defect

• cogwheel connection in remote control has come loose

• defect potentiometer in remote control

• cogwheel on steering engine has come loose

• steering engine defect

• breakage in feeder cables between steering engine and MCSteer

• breakage in data cable between engine potentiometer and MCSteer (engine is in

furthest position left or right, immediately switch off the device and measure the

cable)

• blade terminals not mounted correctly onto MC Steer module, resulting in poor

contact


Troubleshooting

4.1.11 Device can only be steered to one side, not or hardly to the other side.

• cogwheel in remote control has moved with respect to cogwheel of steering

potentiometer (as a result of a fall)

• MC Steer defect

4.1.12 Device starts but does not move forward or backward or steer left or right.

• middle LED flashes on both modules but outer LED does not: communication

problem

• no LEDs lit up on either module: 12V power supply problem.

• cable breakage

• PSUPP plug loose

• 12V converter defect

• fuse defect

• poor contact on port 3-4 of K2 (voltage loss)

• middle LED flashes at normal frequency, outer LEDs normal (depending on

version)

• engine deviation (depending on the version)

• potentiometer plug (6-pole) has come loose in remote

4.2.13 Device starts but does not move forward or backward or steer left or right and the claws do not move.

• poor contact on main relay K1

4.2.14 Device moves with jerks. Only at full speed does the device (with bed) slow down or stop brusquely (without bed), after which it continues moving at full speed.

• slide potentiometer in remote control worn

• MC Drive defect (following a short circuit)


Troubleshooting

4.1.15 Device suddenly swerves left or right for a moment and/or suddenly swerves left or right and continues moving in that direction.

• cogwheel on potentiometer has come loose at the bottom

• potentiometer axle stuck

• check the wiring of the remote control

• check the wiring of the 2 potentiometers, especially check the phone cable of the

lower potentiometer for exaggerated torsion

• cogwheel connection in remote control has come loose

• defect potentiometer in the remote control or in the engine

• cogwheel on steering engine has come loose

• steering engine defect

• breakage in feeder cables between steering engine and MCSteer

• poor contact on convertor connection

4.1.16 Emergency stop(s) cannot be switched off.

• switch defect

• starter relay defect

• poor wire connection (orange or brown) in operating panel to handle, relay

compartment, remote control or spiral cord of remote control

• remote control plug not connected properly to relay compartment plug

• defect brake system

4.1.17 Emergency stop(s) cannot be switched on.

• switch defect

• contact element on switch defect

• contact element has come loose from the switch

• brake defect

4.1.18 Half/full power only works in one position or does not work.

• switch defect

• loose wire connection

• speed potentiometer in handle defect


Troubleshooting

4.1.19 Handle switch does not work, steering keeps working in shop position.

• magnetic contact loose, cracked or broken; check sensor distance

• wire connection between magnetic contact and relay compartment interrupted

• green plug at the top of the Drive module has come loose

4.1.20 Beeper does not work.

• beeper defect

• wire interrupted

• push button defect

• horn sounds husky

• interference on horn feeder cable (ask for information)

4.1.21 Device does not have power.


• castor on device defect

• castor on bed defect

• Mc Drive module defect

• problem with electromagnetic brake

• engine problem

4.1.22 Device battery runs out quickly according to battery meter and charges quickly when charged.

• battery meter defect

• poor contact in handle cable (black wire near terminal block)

• battery defect

4.1.23 Charging LEDs on relay compartment do not light up.

• no voltage on 220V socket

• wire interrupted

• LED defect

• charger defect

• (LED wiring may need to be adapted to a new type of charger)

4.1.24 Battery meter does not work.


• check plug connection


• battery meter defect


Troubleshooting

4.1.25 Device suddenly switches off.

• battery voltage too low, charge urgently!! (undervoltage relay switched on)

• check adjustment of the undervoltage relay

• fuse defect (find cause!)

• check emergency stops

• check whether K1 and K2 (main and starter relay) work properly

• check spiral cable between relay compartment and remote control


4.1.26 Device only works for half a day.

• check charger function

• check battery voltage

• check adjustment of undervoltage relay


Maintenance file

5 Appendices

5.1 Maintenance file MAINTENANCE SHEET P4

Customer name

Date

Signature person responsible (customer)

Serial number

Name of repairer

Hour counter position

Visual control

Check Parts

OK NOK Art. no.

#

Lacquer damage Chassis

Relay compartment

Battery compartment

Nose

Remote

Key switch Key in/out

Turn

Starter switch Push button

Lamp

Start

Emergency stops Operating panel on/off

Remote on/off

Power Half/full

Horn Remote button function

Continuous sound

Front/back Handle switch

Speed stick Mechanical movement

Speed evolution

Claw open Push button

Lamp

Movement + sound

End-of-course

Claw closed Push button

Lamp

Movement + sound

End-of-course


Claw spring Claw spring

Fold claw

Handle switch Play of brake grip

Play of handle

Bed mode Steer left/right

Remote magnet works

Shop mode Steer straight ahead

Remote magnet does not work

Battery meter LED function

Driving test Noise driving forward

Noise driving backward

Straight in shop mode

Straight in bed mode

Noise going left/right

Battery Check 3510,0100 + 3510,0150 + 3510,0160 + 3510,0310

Check Parts

+ - Art. no. #

Battery Rest voltage V V

Voltage when loaded V V

Voltage recovery V V

Battery charger Charging voltage V V

LED function OK / NOK

Mechanical Attachment, shielding, cables OK / NOK

Remarks

Relay compartment check 3510,0100 + 3510,0300

Check Parts

OK NOK Art. no. #

Screw connections Tighten

Plug connections Check

Cabling Course and insulation

Securing bolts in chassis Tighten

Remarks

Operating panel check 3510,0120

Check Parts

OK NOK Art. no. #

Screw connections Tighten

Plug connections Check

Cabling Course and insulation

All buttons Tighten

Remarks


Finish check 3510,0010 + 3510,0011 + 3510,0030

Check Parts

OK NOK Art. no. #

Chassis Front finish

Back finish

Wheel caps

Nose Nose finish

Remarks

Handle check 3510,0050 + 3510,0120

Check Parts

OK NOK Art. no. #

Handle position plates Attachment

Cleaning

Greasing

Hinge bolts Tighten

Handle tube Tighten 4 bolts

Lock pin Does it slide smoothly?

Magnetic contact Casing

Functioning

Cable fixing screws Shop handle

Handle plate

Handle unlocking system Adjustment

Remarks

Wheel suspension check 3510,0010 + 3510,0050

Check Parts

OK NOK Art. no. #

Nose wheel Swivel bearing

Wheel bearing + overlay

Rear wheels Swivel bearing

Wheel bearing + overlay

Spring, pin, teflon greasing

Drive wheel Overlay min. 138mm dia.

Sufficient driving pressure?

Remarks


Claw check 3510,0130 + 3510,0140

Check Parts

OK NOK Art. no. #

Movement Smooth, without noise?

Spindle Clean

Axis play

Apply grease

Timing-belt pulleys Attachment

Alignment

Bearings Revolving bearings

Escoflex attachment

Manuel button Damage and attachment

End-of-course switches Functioning inside/outside

Claws Rubber parts, attachment, position

Remarks

Engine check 3510,0050

Check Parts

OK NOK Art. no. #

Cabling continuity To be measured before disassembling battery compartment

Potentiometer

Steering engine

Brake

Making dust-free Engine

End-of-course switches Functioning

Potentiometer Course and adjustment 5K

Play of cogwheels Steering engine

Potentiometer

Functioning Noise

Attachment

Protective agent Apply

Remarks

Remote control check 3510,0190 + 3510,200 + 3510,0210

Check Parts

OK NOK Art. no. #

Wiring Course, insulation

LEDs Internal and external

Magnetic contact Casing, functioning

Steering handle Attachment, play

Speed potentiometer Course resistance

Steering potentiometer Course resistance

Wheel alignment Straight?

Locking buttons Attachment?

Remarks


Fuses

5.2 Fuses


Exploded views

5.3 Exploded views


Exploded views


Exploded views


Exploded views


Exploded views


Exploded views


Exploded views


Exploded views


Exploded views


Exploded views


Exploded views


Exploded views


Exploded views


Exploded views


Exploded views


Exploded views


Exploded views


Exploded views


Exploded views


Exploded views


Exploded views



Electrical diagram

5.4 Electrical diagram

Documents

TRUMPF - P4 -PTS Service