KaVo SURGmatic S201 L Pro User manual

Technician's instructions
SURGmatic S201 L - 1.009.0470
Always be on the safe side.

Distributed by:
KaVo Dental GmbH
Bismarckring 39
D-88400 Biberach
Phone [phone]
Fax [phone]
Manufacturer:
Kaltenbach & Voigt GmbH
Bismarckring 39
D-88400 Biberach
www.kavo.com

Table of contents
1 User instructions ........................................................................................................................................ 2
1.1 User guide ....................................................................................................................................... 2
1.1.1 Abbreviations ...................................................................................................................... 2
1.1.2 Symbols .............................................................................................................................. 2
1.1.3 Target group ....................................................................................................................... 2
1.1.4 Product name ..................................................................................................................... 2
2 Disassembly .............................................................................................................................................. 3
2.1 Disassembly of the SURGmatic S201 L .......................................................................................... 3
2.1.1 Removing the head from the elbow sleeve ........................................................................ 3
2.1.2 Disassembling the head casing .......................................................................................... 3
2.1.3 Disassembling the drive insert ........................................................................................... 4
2.1.4 Removing the insert and gear from the elbow sleeve ........................................................ 5
2.1.5 Disassembling the gearing ................................................................................................. 6
2.1.6 Disassembling the axle ...................................................................................................... 6
2.1.7 Disassembling the insert .................................................................................................... 7
2.1.8 Disassembling the elbow sleeve ........................................................................................ 7
3 Assembly ................................................................................................................................................... 9
3.1 Assembly of the SURGmatic S201 L .............................................................................................. 9
3.1.1 Assembly instructions ......................................................................................................... 9
3.1.2 Assembling the drive insert ................................................................................................ 9
3.1.3 Assembling the head casing .............................................................................................. 9
3.1.4 Assembling the elbow sleeve ........................................................................................... 11
3.1.5 Assembling the insert ....................................................................................................... 11
3.1.6 Assembling the axle ......................................................................................................... 12
3.1.7 Assembling the gearing .................................................................................................... 12
3.1.8 Fitting the gear and insert in the elbow sleeve ................................................................. 13
3.1.9 Insert head into elbow sleeve ........................................................................................... 15
4 Testing ..................................................................................................................................................... 16
4.1 Test of the SURGmatic S201 L ..................................................................................................... 16
4.1.1 Test set-up ....................................................................................................................... 16
4.1.2 Test instructions ............................................................................................................... 16
Technician's instructions SURGmatic S201 L - 1.009.0470
Table of contents
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1 User instructions
1.1 User guide
1.1.1 Abbreviations
Abbre‐
viation
Explanation
GA
(IfU)
Instructions for use
PA
(CI)
Care instructions
MA
(AI)
Assembly instructions
TA (TI) Technician's instructions
STK
(SC)
Safety checks
IEC International Electrotechnical Commission
RA
(RI)
Repair instructions
EMV
(EMC)
Electromagnetic compatibility
1.1.2 Symbols
Important information for users and service technicians
1.1.3 Target group
Note
Have any repair and maintenance work on the device performed by KaVo-
trained technicians only.
1.1.4 Product name
Note
The present repair instructions are for the
SURGmatic contra-angle handpiece S201 L (Mat. no. 1.009.0470).
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2 Disassembly
2.1 Disassembly of the SURGmatic S201 L
2.1.1 Removing the head from the elbow sleeve
▶ Pull the spray tube ② off at the taper sleeve ③ and remove it from the head
①.
▶ Open the clamping ring ④ by turning clockwise and remove the head ① from
the elbow sleeve ⑤.
2.1.2 Disassembling the head casing
Tool Name
Screwdriver (Mat. no. 0.308.0004)
Screwdriver bit (Mat. no. 0.410.0784)
Circlip pliers (Mat. no. 0.411.2421)
Wrench (Mat. no. 0.411.2371)
Universal bit holder
(Mat. no. 1.002.4577)
Torque handle (Mat. no. 1.002.4578)
100 Ncm
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▶ Use the screwdriver and screwdriver bit to unscrew and remove the screw ⑥
from the head casing ⑦.
▶ Use the assembly pliers to turn the adapter ⑧ slightly and pull it out; then re‐
move the spring ⑨.
▶ Unscrew the cover ① with the wrench, the universal bit holder and the torque
handle (turn anticlockwise).
▶ Take the spring washer ④ out of the cover ①.
▶ Remove the ball spring ③ and button ②.
▶ Remove the assembled head drive ⑤ from the head casing ⑦.
2.1.3 Disassembling the drive insert
Tool Name
Tweezers (Mat. no. 0.308.1410)
▶ Use the tweezers to take off the wire ring ① and remove the slide ③.
▶ Remove the ball bearing ② from the head drive ⑤.
▶ Remove segment ④ with the tweezers.
▶ Remove the ball bearings ⑥ from head drive ⑤.
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2.1.4 Removing the insert and gear from the elbow sleeve
Tool Name
Assembly pliers (Mat. no. 0.411.3921)
Wrench (Mat. no. 0.411.1881)
Universal bit holder
(Mat. no. 1.002.4577)
Torque handle (Mat. no. 1.003.1524)
180 Ncm
Clamping sleeve (Mat. no. 0.411.4451)
▶ Take hold of the elbow sleeve ① with the circlip pliers and turn the wrench,
universal bit holder and torque handle anticlockwise to unscrew the threaded
ring ④.
▶ Slide the adapter sleeve into the insert ③ and push the spring pin into place.
▶ Pull the insert ③ out of the elbow sleeve ① and remove the adapter sleeve.
▶ Completely remove the gear ② from the elbow sleeve ①.
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2.1.5 Disassembling the gearing
▶ Remove parts ② to ⑧ entirely from the bearing cartridge ① or press out using
an extending mandrel.
▶ Remove the planetary gear support ②, ball bearing ③, pressure spring ④,
planetary gears ⑤, and outer wheel ⑥ from axle ⑦.
▶ Remove bearing cartridge ⑧ from the axle ⑦.
2.1.6 Disassembling the axle
Tool Description
Tweezers (Mat. no. 0.308.1410)
▶ Squeeze the pressure spring ③ and sleeve ④ together and remove the pin ⑥
using the tweezers.
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▶ Pull the driver ⑤, sleeve ④, pressure spring ③, and ball bearing ② off the
drive axle ①.
2.1.7 Disassembling the insert
▶ Take out the slide ② and pressure spring ①.
2.1.8 Disassembling the elbow sleeve
Tool Name
Circlip pliers (Mat. no. 0.411.3921)
Puller (Mat. no. 0.411.2381)
Note
Take care not to damage the fibre-optic conductor when disassembling the el‐
bow sleeve.
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▶ Take hold of the elbow sleeve ⑧ with the circlip pliers and use a hot-air blow‐
er to heat up the glued joint on the fibre-optic bundle.
▶ Insert the puller into the front of the sleeve ② and slowly screw in the threa‐
ded spindle of the puller to loosen and extract the sleeve ②.
▶ Screw back the threaded spindle of the puller and remove the puller.
▶ Remove the tension ring ③ and spring ④ from the elbow sleeve ⑧.
▶ Pull the fibre-optic bundle ① forward and take it out.
▶ Remove the ball ⑥, ball ⑦ and wire ring⑤ from the elbow sleeve ⑧.
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3 Assembly
3.1 Assembly of the SURGmatic S201 L
3.1.1 Assembly instructions
Material numbers for spare parts are listed in the separate spare parts sheet.
See also: Spare parts sheet for the SURGmatic S201 L.
Requirement
All parts must be cleaned thoroughly.
The glued joint must be clean; there must be no traces of grease or adhesive
residue.
Note
Once assembled, the contra-angle handpiece has to be sprayed thoroughly with
KAVOspray.
3.1.2 Assembling the drive insert
Tool Name
Mounting mandrel
(Mat. no. 0.411.0961)
▶ Place the ball bearing ⑥ on the head drive ⑤.
▶ Insert the segment ④ into the head drive ⑤.
▶ Place the ball bearing ② on the head drive ⑤.
▶ Insert the assembly mandrel into the drive insert from above, insert the slide
③ in the assembled head drive ⑤ and push the new wire ring ① over the as‐
sembly mandrel until the wire ring ① slots into place in the groove.
3.1.3 Assembling the head casing
Tool Name
Wrench (Mat. no. 0.411.2371)
Universal bit holder
(Mat. no. 1.002.4577)
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Tool Name
Torque handle A (Mat. no. 1.002.4578),
100 Ncm
Torque handle B (Mat. no. 1.006.9911)
with 5 Ncm
Blade holder (Mat. no. 0.411.2271)
Assembly pliers (Mat. no. 0.411.2421)
603
Loctite 603 adhesive
(Mat. no. 0.359.2009)
Screwdriver (Mat. no. 0.308.0004)
Screwdriver bit (Mat. no. 0.410.0784)
▶ Insert the assembled head drive ⑤ in the head casing ⑦ and insert the spring
washer ④.
▶ Insert the button ② into the cover ① and insert the ball spring ③.
▶ Screw the cover ⑦ completely into the head casing and tighten to 100 Ncm
with the wrench, the universal bit holder and the torque handle.
▶ Insert the spring ⑨ (curvature upwards) into the milled edge on the adapter
⑧.
▶ Use the assembly pliers to slide the adapter ⑧ into the head casing ⑦, lining
up the threaded bore for the screw ⑥ at the same time.
▶ Insert the screwdriver bit in the blade holder and affix it.
▶ Insert the blade holder in the universal bit holder.
▶ Wet the screw ⑥ with the adhesive and use the screwdriver insert and torque
handle B to screw it into the head casing ⑦ and tighten it to 5 Ncm.
▶ Allow the adhesive to harden for 5 minutes at 120 °C.
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3.1.4 Assembling the elbow sleeve
Note
Take care not to damage the fibre-optic bundle when assembling the elbow
sleeve.
▶ Press the wire ring ⑤ into the groove on the elbow sleeve ⑧ and insert ball ⑥
and ball ⑦ into the elbow sleeve ⑧.
▶ Insert the fibre-optic bundle ① into the elbow sleeve ⑧.
▶ Insert the spring ④ into the small drilled hole on the tension ring ③.
▶ Add the tension ring ③, secure the spring ④ in the drilled hole on the elbow
sleeve ⑧ and turn the tension ring ③ until it locks into place.
▶ Carefully position the taper sleeve ② and press it into place making sure that
the fibre-optic bundle ① sits flush with the front of the taper sleeve ②.
3.1.5 Assembling the insert
▶ Insert the slide ② and pressure spring ①.
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3.1.6 Assembling the axle
▶ Place the ball bearing ②, pressure spring ③, sleeve ④, and driver ⑤ on the
drive axle ①.
▶ Insert the pin ⑥ into the driver ⑤.
3.1.7 Assembling the gearing
▶ Place the bearing cartridge ⑧ on the axle ⑦.
▶ Insert the ball bearing ③ into the planet gear carrier ②.
▶ Place the three planetary gears ⑤ and the outer wheel ⑥ on the planetary
gear support ② and then on the axle ⑦.
▶ Remove the planetary gear support ② including ball bearing ③.
Please note that the three planetary gears ⑤ including the outer wheel ⑥
need to be positioned on the axle.
▶ Place the pressure spring ④ on axle ⑦.
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▶ Place the planetary gear support ② including the ball bearing ③ on the pre-
mounted axle ⑦.
▶ Insert parts ② to ⑧ into the bearing cartridge ① and hold them in place.
Note
Make sure that the planet wheels ⑤ are positioned with their undercut on the
planar side opposite to the planar surface of the planet gear carrier ② or in the
direction of the tappet.
3.1.8 Fitting the gear and insert in the elbow sleeve
Tool Name
Assembly pliers (Mat. no. 0.411.3921)
Wrench (Mat. no. 0.411.1881)
Universal bit holder
(Mat. no. 1.002.4577)
Torque handle (Mat. no. 1.003.1524)
180 Ncm
Assembly pliers (Mat. no. 0.411.2421)
Loctite 306 adhesive
(Mat. no. 0.359.2044)
Gluing device (Mat. no. 0.411.2981)
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5
6
▶ Insert the insert ⑤ into the gear ④ make sure that the fixing noses latch into
place correctly
on the insert ⑤.
▶ Squeeze the tongues on the insert ① together using the assembly pliers.
▶ Push the insert ⑤ and the gear ④ into the elbow sleeve ③.
▶ Take hold of the elbow sleeve ③ with the circlip pliers and turn the threaded
ring ⑥ clockwise to screw into place.
▶ Screw the threaded ring ⑥ tight to 180 Ncm using the wrench, universal bit
holder, and torque handle.
▶ Apply a layer of adhesive to the the fiber-optic conductor and the inside of the
sleeve ①.
▶ Open the tension ring ② and attach the reducing shank to the gluing device.
▶ Place the gluing device in a hot-air furnace and allow the adhesive to set for
30 minutes at 120 °C.
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3.1.9 Insert head into elbow sleeve
▶ Open the clamping ring ④ and insert the head ① into the elbow sleeve ⑤.
▶ Stick the spray tube ② through the head and affix it to the taper sleeve ③.
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4 Testing
4.1 Test of the SURGmatic S201 L
4.1.1 Test set-up
① Test device 2182 KL
(Mat. no. 0.411.8540)
④ Pressure gauge
(Mat. no. 1.003.1050)
② Leakage air hose ⑤ Motor
③ Motor hose
4.1.2 Test instructions
Note
The following evidence must be documented:
- Customer's address and repair dates
- Material number or sales number of the product
- Serial number of the product
- Spare parts material numbers
- Name, date, signature or personnel number of repair/test engineer
Requirement
- Amount of cooling air: 28 ± 4 Nl/min
- Spray water pressure: 2 ± 0.1 bar
- Drive speed: max. 40,000 min-1
- The pressures are to be set on the test device.
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Test equipment Name
Test drill A (Mat. no. 0.410.1802)
Test drill B (Mat. no. 0.410.1733)
Spray test drill (Mat. no. 1.003.1255)
Meter tube (Mat. no. 0.411.4441)
Testing Test equipment Procedure
Check repair documents and ID ▶ Check product ID, type, and
serial number.
Carry out a visual inspection ▶ Carry out a general visual in‐
spection.
No external damage
visible.
There should be no spots on
the fibre-optic bundle.
Check head tension ring ▶ Insert the head into the reduc‐
ing shank as far as the stop
and unscrew.
It can be inserted and pulled
out easily.
The head tension ring resets
automatically.
Check that the head is correctly
positioned and firmly seated.
▶ Measure the chucking capacity
of the head tension ring.
The chucking capacity is 90°
±30°.
Check handpiece connection ▪ Motor ▶ Attach the contra-angle hand‐
piece to the motor coupling and
pull it off.
Connection, locking and dis‐
connection can be done with‐
out much force.
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Testing Test equipment Procedure
Check chuck system ▪ Test drill A ▶ Insert test drill A into the chuck
system, run briefly, apply radial
and axial load and remove.
Test drill A should be able to
enter the chuck system easily
without the pushbutton being
activated.
Test drill A can be removed
with ease.
▪ Test drill B ▶ Insert test drill B into chuck
system.
Test drill B locks securely.
Check running characteristics ▪ Motor ▶ Operate contra-angle hand‐
piece under test conditions in
clockwise and counter-clock‐
wise direction subjecting it to
axial and radial load.
The load must not exceed a
power consumption by motor
plus contra-angle handpiece of
1.2 A.
There should be no noticeable
vibrations or running noise.
Under axial load, the adapter
does not graze the push-button
and the push-button does not
heat up.
Check concentricity ▪ Test drill A ▶ Run the angle piece with test
drill off-load at 40,000 rpm.
There should be no noticeable
vibrations or running noise.
Check power consumption ▪ Test drill A ▶ Measure the power consump‐
tion under test conditions with
head and test drill.
Power consumption: max. 60
mA
Check for absence of leakage ▪ Leakage air hose ▶ Apply pressure to the media
chamber (2 bar) and pressure-
test the spray bore hole for 15
seconds.
The pressure of the com‐
pressed air must remain con‐
stant.
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