Welch Allyn 4802D Service Manual
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Welch Allyn 4802D Service Manual

Pediatric/infant scale with usb
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Welch Allyn Pediatric/Infant Scale with USB
Service Manual
Model 4802D – Pediatric/Infant Scale
For Serial Numbers Beginning with: U1072 only

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Summary of Contents for Welch Allyn 4802D

  • Page 1 Welch Allyn Pediatric/Infant Scale with USB Service Manual Model 4802D – Pediatric/Infant Scale For Serial Numbers Beginning with: U1072 only...
  • Page 2 © 2018 Welch Allyn. All rights are reserved. To support the intended use of the product described in this publication, the purchaser of the product is permitted to copy this publication, for internal distribution only, from the media provided by Welch Allyn. No other use, reproduction, or distribution of this publication, or any part of it, is permitted without written permission from Welch Allyn.

  • Page 3: Table Of Contents

    ONTENTS Introduction ..............................4 Intended use ............................. 4 Indications for use ............................. 4 Intended clinical care environments......................4 Symbols ..............................5 Safety ................................7 About warnings and cautions ........................7 General warnings and cautions ........................ 8 Electrostatic discharge (ESD) ........................9 Overview ...............................

  • Page 4: Introduction

    Pediatric scales can make contact with a patient’s head, neck, back, arms, legs, and side. Contact duration is intended to be limited to less than 30 seconds. Intended clinical care environments The Welch Allyn Pediatric/Infant Scales are intended to be used in the following clinical care environments: ...

  • Page 5: Symbols

    Symbols...

  • Page 7: Safety

    Caution statements can appear on the Welch Allyn Pediatric Scales, the packaging, the shipping container, or in this Service manual. The Welch Allyn Pediatric Scales are safe for patients and trained clinicians when used in accordance with the instructions and caution statements presented in this Service manual.

  • Page 8: General Warnings And Cautions

    General warnings and cautions...

  • Page 9: Electrostatic Discharge (Esd)

    This service manual is a reference for periodic preventive maintenance and corrective service procedures for the Welch Allyn Pediatric Scales. It is intended for use only by trained and qualified service personnel. Corrective service is supported to the level of field-replaceable units. These include circuit-board...

  • Page 10: Technical Support Services

    Welch Allyn service center. Technical support services If you have a problem with the device that you cannot resolve, call the Welch Allyn Technical Support Center nearest you for assistance. A representative will assist you in troubleshooting the problem and will make every effort to solve the problem over the phone, potentially avoiding an unnecessary return.

  • Page 11: Non-Warranty Service

    To ensure safe receipt of your device by the service center and to expedite processing and return of the device to you, thoroughly clean all residue from the device before you ship it to Welch Allyn. For cleaning requirements, see the Cleaning instruction in the Directions for Use.

  • Page 12: Recommended Service Intervals

    4. Write the Welch Allyn RMA number with the Welch Allyn address on the outside of the shipping carton. Recommended service intervals To confirm that the device is functioning within the design specifications, perform periodic service as indicated below. Customers can perform the basic functional verification and calibration procedures referenced below by following the instructions in this manual.

  • Page 13: Battery Replacement

    Battery replacement Scale setup You can customize the scale to best suit your needs using the Custom Modes. The custom modes on the scale are Setup, Service, Factory, Calibration. 1. Press and hold ZERO and REWEIGH while pressing the power button to enter Custom mode. 2.

  • Page 14: Enter Setup Mode

    the previous setting option. Set the selected option and move to the next setting with the LB/KG key. Enter Setup Mode Device will enter setup mode by entering PIN 9821. The scale will cycle through these parameters by pressing LB/KG key. Some of these options may be turned off or on through the Factory Mode SOFt displays the software version.

  • Page 15: Enter Service Mode

    Prtunt* allows the user to configure which unit (pounds or kilograms) will be used in the send data function when the scale is connected to a computer or a Welch Allyn device. Press REWEIGH or RECALL to switch between the following options: PrtOPt* Press REWEIGH or RECALL to switch between the following options: Set-UP This option is displayed when you have cycled through all the options.

  • Page 16: Factory Mode

    bn ¯ iS (BMIs) displays the number of times of the Height/BMI key has been pressed. OFFS displays the number of times the scale has manually been powered off. PrintS displays the number of dockets that have been printed from the scale. SEndS displays the number of the SendData key has been pressed.
  • Page 17 Prtunt* allows the user to configure which unit (pounds or kilograms) will be used in the send data function when the scale is connected to a computer or a Welch Allyn device. Press REWEIGH or RECALL to switch between the following options: Printing is not available on this unit, changing this setting will not change functionality.
  • Page 18 Default Factory Settings Test Setting 4802 Standard(lb/Kg) Display 4802 Kg Only Display Factory Func SOFt U x.x.x dAtE xx.xx.xx SCALE 4802 AutOFF ACCont FCt.UNt KG LED (On) KG LED (On) LB OZ LEDs (On) LB OZ LEDs (Off) LB LED (On) LB LED (Off) UnitS OZ (On)

  • Page 19: Calibration Of Scale

    Traction or physical therapy weights are NOT acceptable since their actual weight can often be in error as much as +/-10%. Calibration weights may be purchased from WELCH ALLYN or a local scale dealer. An alternative to calibration weights is the weight comparison method. This requires a known accurate, calibrated scale.

  • Page 20: Usb Details

    LB/KG key to exit back to the Calibration options. Retry the calibration. If an error occurs, press If the error continues see the Disassembly and repair and Troubleshooting sections to identify. USB Details For detailed help and information regarding the data output capabilities, consult Welch Allyn for details.

  • Page 21: Disassembly And Repair

    Disassembly and repair These procedures provide instructions for device disassembly and board removal, as well as component replacement and reassembly. Each part’s disassembly instructions might include one or both of the following: Reassembly notes This subsection contains information specific to reassembly. •...

  • Page 22: Required Tools

    Required tools: Scale Cart T25 Torx 7/16” socket and open-end wrench #0 Phillip screwdriver Phillips head torque screwdriver T25 socket driver #1 Phillip screwdriver Phillips head torque screwdriver 3/8" socket T25 socket driver Torque socket wrench Allen socket driver 5/64" Pickle fork Allen socket driver 1/8"...

  • Page 23: Cart Disassembly

    Cart Disassembly 1. Remove cradle from scale...
  • Page 24 2. Remove scale from top plate 3. Remove Top Plate nuts (7)
  • Page 25 4. Remove Top Plate 5. Remove Paper Shelf Nuts (4)
  • Page 26 6. Remove Paper Shelf 7. Remove Column Top Plate adaptor screws (4) and Column Top Plate...
  • Page 28 8. Tip the base over to access the bottom to remove the wheel base assembly mounting bolts (3), nuts (3), and washer (1). Note: The base is to be installed in the center mounting hole for correct height 9. Remove the column from the wheel base assembly 10.
  • Page 29 Cart Torque Specification Values Use this table to determine how much torque to apply to screws by type and location when reassembling the device (See table in the Cart Exploded Repair Parts View Diagrams for identifiers). Welch-Allyn Part Number Welch-Allyn Part Number Description Torque spec (in-lb) 719962 SCREW, T25 - 2 1/4"...
  • Page 30 Unique Welch-Allyn Qty Welch-Allyn Part Number Description Identifier Part Number 719206 LPC FOUR LEG CAST BASE 719390 CASTER 5IN TWIN WHEEL WITH BRAKE 718936 LPC EXTRUSION 719962 SCREW, T25 - 2 1/4" -20 703775 NUT, T, 1/4-20 15 SERIES 718935 LPC COLUMN ADAPTER 719686 SCREW, 1/4-20 X .50 LG FHP VIBRA TITE...
  • Page 31 703832 ROLL PIN, 3/16 X .75 STL Cart Accessories/Kits Welch-Allyn Welch-Allyn Part Number Description Part Number 48217 SCALE LINERS (500 PER CARTON) 412589 4802D PEDIATRIC SCALE CART TOP PACKAGE (Parts 1-7) 412588 4802D PEDIATRIC SCALE CART BASE PACKAGE (Parts 8-14)

  • Page 32: Scale Disassembly

    Scale Disassembly Cradle Disassembly 1. Remove the Mounting Posts (Banana clips) (4) from the cradle. 2. Remove the set screws (4) from the cradle. Then remove from the cradle by lifting it upward.
  • Page 33 Scale Disassembly 1. Remove battery door screws (2) and battery door 2. Remove batteries (6) 3. Remove Cover plate screws (8)
  • Page 35 4. Lift Cover Plate and disconnect wiring harnesses from display board to remove it completely 5. Turn over Cover Plate and remove display mounting screws (4) and display board 6. Disconnect the wire connection and wire tiedown from the PCBA board...
  • Page 36 7. Remove PCBA screws (4) and PCBA Board 8. Remove Power Jack Mounting screws (2) 9. Remove Power Jack...
  • Page 37 10. Remove Battery Bracket Mounting screws (4) and Battery Bracket a. Battery Holder Disassembly i. Disconnect the Power Jack ii. Remove the battery holder mounting screws (6) and the battery holder from the mounting plate 11. Remove the USB assembly a.
  • Page 38 c. Remove USB assembly i. USB Assembly disassembly 1. Remove the USB PCBA board mounting screws (2) and then carefully remove the PCBA board from the bracket by using the snap fit. 12. Remove Overload Screws (2) and Nuts (2). Note: Reassembly will require Loctite 242.
  • Page 39 13. Remove Load Beam Mounting screws (4) and washers (4). Remove Load Beam and Load Beam spacers (4). Note: The load beam can be replaced as an assembly and is recommended due to the sensitivity of the components. Individual parts of the load beam can be serviced but with caution. 14.
  • Page 40 15. Remove Loading Block Mounting bolts (8) and Loading Blocks (4) from the two loading arms 16. Remove overload stop set screws (4) from the loading arms. When installing these they MUST be set with a 0.09” Feeler Gauge. 17. Remove overload stop set screws from loading beam (2). When installing, these they MUST be set with a 0.032”...
  • Page 41 18. Remove the rear bumper mounting nuts (3) and washers (3). Then remove rear bumper mounting bolts (3), spacers (3) and plate 19. Tip the cabinet onto its back and while supporting the beam support remove the mounting screws (6) and washers (6) and the beam support...
  • Page 42 20. Remove handle mounting screws (4), washers (4), channel plates (4), handle (2), and ferrules (4) one side at a time 21. Remove the feet lock nuts (4), screws (4), washers (4) and feet (4)
  • Page 43 Torque Specification Values Use this table to determine how much torque to apply to screws by type and location when reassembling the device. Cradle Welch-Allyn Part Welch-Allyn Part Number Description Torque spec Bit Type Number (in-lb) 3/32” Hex Bit 130250 SCW, 10-32 X 1-1/4"...
  • Page 44 USB Assembly Welch-Allyn Part Welch-Allyn Part Number Description Torque spec Bit Type Number (in-lb) 727161 SCW, 3-24 X 1/4, PHILLIPS, PHP PLASTITE 3.0 ± 0.7 Phillips #1 Bit Battery Holder Assembly Welch-Allyn Part Welch-Allyn Part Number Description Torque spec Bit Type Number (in-lb) 24014...
  • Page 45 4802D Exploded Repair Parts View Diagrams To see an overall exploded view and BOM for the entire scale assembly see the Scale Full Exploded View in the appendix. To see the details of fasteners, see the Fastener Reference in the appendix.
  • Page 46 SCW, 10-32x 1/4 SOC BUTTON, NICK 700076 "D" CELL BATTERY 412632 ASSY, COVER BATTERY 4802, SCALE-T 726534 SCREW, 10/32 X 1/4 PHILLIP PHP 726588 LBL 4802D CONTROL PANEL SCALE-T 726551 POWER SUPPLY, EXT, 12VDC Scale Labels Welch-Allyn Qty Welch-Allyn Part Number Description Part Number 726636...
  • Page 47 726640 LBL ST TRANSPORT CAUTION 4802D AND CART 727304 LBL SCALE-T PED CART BASE 727305 LBL SCALE-T PED CART TOP 727712 LABEL 4802D CART WEIGHT SCALE-T 727882 LBL, 4802D CART SAFETY WT SHELF, SCALE-T 727883 LBL, 4802D CART SAFETY WT TOP, SCALE-T...
  • Page 48 412432 HARNESS, POWER JACK, DC, 2-5MM, SCALE-T 726494 SCREW, 1-32 X 3/8”, RH, TORX, THREADFORM 412417 BRACKET, ASSY, USB PCBA, SEE TABLE 5 726746 SCREW, 6-32X7/16", HEX RHS, ZINC STEEL 412418 POWER ASSY BATTERY & DC, SEE TABLE 6 48611 SCW, 6-32 X ¼”...
  • Page 49 Battery Holder Assembly Repair Parts Table 6 Battery Holder Assembly Repair Parts Unique Welch-Allyn Qty Welch-Allyn Part Number Description Identifier Part Number 726556 TRAY, BATTERY HOLDER, SCALE-T 412431 HARNESS, BATT HOLDER, W/GRD, SCALE-T 24014 SCW, 6-32 X 1/4 " PHIL PAN STEEL NICKEL Load Beam Assembly Mounting Repair Parts Table 7 Load Beam Mounting Repair Parts Unique...
  • Page 50 412416 LOAD BEAM ASSEMBLY SEE TABLE 8 106105-4 SPLIT RING WASHER 48511 SCW, 10-32 X 1.5" SHCS, SS 33003 SCW, 1/4-20 X 1/2" PAN HD MACH 715680 NUT, HEX 1/4-20...
  • Page 51 Load Beam Assembly Repair Parts Table 8 Load Beam Assembly Repair Parts Unique Welch-Allyn Qty Welch-Allyn Part Number Description Identifier Part Number 48503 LOADING ARM 726743 SET SCREW, 10-32X1" CUP-PT NYL PATCH 48504 LOADING BLOCK 50511 SCW, 5/16" X 5/8" SHOULDER, SOC, CHROME 726557 LOAD CELL, DEBBW, 100LB, SCALE-T 726745...
  • Page 52 Cabinet Body Assembly Repair Parts Table 9 Cabinet Body Assembly Repair Parts Unique Welch-Allyn Qty Welch-Allyn Part Number Description Identifier Part Number 726536 CABINET, 4802 WITH USB 66011 FOOT RUBBER 726730 WASHER, FLAT 3/16 ID X .56 OD X .049 THK 20108W SCW, 10-32 X 1/2"...
  • Page 53 Wiring Repair Parts Table 10 Wiring Repair Parts Unique Welch-Allyn Qty Welch-Allyn Part Number Description Identifier Part Number 412432 HARNESS, POWER JACK, DC, 2-5MM, SCALE-T 727162 ADHESIVE BACKED, LATCHING, WIRE CLIP 412431 HARNESS, BATT HOLDER, W/GRD, SCALE-T 412419 HARNESS, DISPLAY-MEASUREMENT, SCALE-T 412430 HARNESS, USB INTERFACE, SCALE-T 726557...

  • Page 54: Troubleshooting

    Board. The proper resistance values are listed below: WIRE COLORS (PIN NO.) RESISTANCE WHT(4)/RED(5) 350 ± 3 Ω GRN(1)/BLK(2) 386 ± 50 Ω Pin to Ground ≥5000 MΩ Full Scale Output 3.0mV/V ±0.1% Consult Welch Allyn if readings differ from those shown.

  • Page 55: Symptoms And Solutions

    NOTE: Ohmmeters will not indicate a change in resistance of the load cell transducer when weights are applied to scale. This is due to the extremely small change in resistance of the strain gauges employed (<1 ohm) and the fact that the bridge configuration presents a constant value of resistance when measured from its terminals.

  • Page 56: Appendix

    PACKING, CARTON BOX, PEDIATRIC, SCALE-T 726744 PACKAGING 4802 CART SIDE SUPPORT 726748 PACKAGING 4802 CART FRONT-BACK INSERT 726750 PACKAGING 4802D CART FILLER INSERT 727286 PACKING, INSERT TOP, PEDI-CART, SCALE-T 727385 PACKING, D-CELL BATT, BOX, SCALE-T 727386 PACKING, SIDE SLEEVE, 4802, SCALE-T...

  • Page 57: Scale Full Exploded View

    Scale Full Exploded View...
  • Page 59 Unique Welch-Allyn Welch-Allyn Part Description Identifier Part Number 726536 CABINET, 4802 WITH USB 66011 FOOT RUBBER 726730 WASHER, FLAT 3/16 ID X .56 OD X .049 THK 20108W SCW, 10-32 X 1/2" BHMS, SS PASSIVATED 106137-4 NUT,10-32 EXTLOCK 48106 HANDLE SIDE 48118 FERRULE FOR 3/8"...
  • Page 60 SCW, 10-32x 1/4 SOC BUTTON, NICK 700076 "D" CELL BATTERY 412632 ASSY, COVER BATTERY 4802, SCALE-T 726534 SCREW, 10/32 X 1/4 PHILLIP PHP 726588 LBL 4802D CONTROL PANEL SCALE-T 48220W CRADLE 4 SIDED ACRYLIC 48200W CRADLE. STANDARD 25" 48222 CRADLE, OVERSIZED 32" ACRYLIC 130250 SCW, 10-32 X 1-1/4"...

  • Page 61: Fastener Reference (Not To Scale)

    Fastener Reference (NOT TO SCALE) Welch-Allyn Welch-Allyn Part Description and Image Part Number 24014 SCW 6-32 X 1/4 PHIL PAN STEEL NICKEL 33003 SCW, 1/4-20 X 1/2" PAN HD MACH 48112 SCW, 1/4-20 X 1/2" BHCS, SS, PASSIVATED 48138 SCW, 1/4-20 X 3" FHMS, SOC, SS PASSIVATE 48205 MOUNTING POST 48508 SCW, 1/4-20 X 1/2"...
  • Page 62 130250 SCW, 10-32 X 1-1/4" CUP PT SET SCRW SOC 703775 NUT, T, 1/4-20 15 SERIES 715680 NUT, HEX 1/4-20 719683 NUT, 1/4-20 SERRATED FLANGE 719684 SCREW, 1/4"-20 X 1.25" SERRATED FLANGE 719686 SCREW, 1/4-20 X .50 LG FHP VIBRA TITE 719962 SCREW, T25 - 2 1/4"...
  • Page 63 726747 SCREW, 10-32X1/2", TROX RHS, ALLOY STEEL 727161 SCW, 3-24 X 1/4, PHILLIPS, PHP PLASTITE 106137-4 NUT, 10-32 EXTLOCK 20108W SCW, 10-32 X 1/2" BHMS, SS PASSIVATED...

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