Stryker Endoscopy

5900 Optical Court, San Jose, CA 95138

APPROVALS DATE TITLE

DRAWN BY:

A. Infanger 02/28/07 X8000 Light Source

ORIGINATOR Service Guide
A. Infanger 02/28/07
SIZE REV. DOCUMENT NO. SHEET OF

A A 1000-400-933 1 71
REVISIONS REVISIONS
LTR ECN NO. DATE APPROVED LTR ECN NO. DATE APPROVED
A ECO 104650 02/28/07 A. Infanger
B
Printing Instructions:
C
D 1. 8.5 × 11” portrait
2. Front and back
E 3. Color printing
F 4. Select binding and paper weight based on cost
G
H
J Global Source:

K Archive this document as a service/repair guide.

L
M
N
P
R
T
U
V
W
Y
 X8000 Light Source
220-200-000

Service Guide

2007/02 www.stryker.com 1000400933 A

Contents
Warnings and Cautions ..................................................................................................................4

Introduction ..........................................................................................................................................5
Service Options ....................................................................................................................................5
Required Skills, Tools, and Components .............................................................................................5
Reference Documents .........................................................................................................................5

Device Description ...........................................................................................................................6

Technical Specifications.......................................................................................................................6
Device Diagrams ..................................................................................................................................7

Basic Maintenance .........................................................................................................................10

Cleaning the X8000 ............................................................................................................................10
Caring for the Bulb Module ................................................................................................................10
Replacing the Bulb Module ................................................................................................................10
Replacing the Fuses...........................................................................................................................11
Disposing of the X8000 ......................................................................................................................11

Troubleshooting ................................................................................................................................12
Error Code Definitions ........................................................................................................................13

Diagnosis ..............................................................................................................................................14
Control Board Diagrams ....................................................................................................................18

Repair/Replacement ......................................................................................................................19
1.0 Chassis Cover ..............................................................................................................................20
2.0 Control Board ...............................................................................................................................21
3.0 Ballast ..........................................................................................................................................25
4.0 Bulb Mount Board .......................................................................................................................32
5.0 AC Inlet Board .............................................................................................................................35
6.0 Jaw Handle ..................................................................................................................................38
7.0 LED power switch .......................................................................................................................39
8.0 Display Board ..............................................................................................................................43
9.0 Front Panel Membrane.................................................................................................................45
10.0 Shutter........................................................................................................................................47
11.0 Hot Mirror ...................................................................................................................................49
12.0 Motor ..........................................................................................................................................51
13.0 Jaw Assembly ............................................................................................................................53
14.0 Integrating Rod .........................................................................................................................55
15.0 AC Inlet Filter..............................................................................................................................57
16.0 Ballast Fan .................................................................................................................................60
17.0 Bulb Fan .....................................................................................................................................62

Final Testing and Inspection .....................................................................................................65

Tools Needed .....................................................................................................................................65
Hi-Pot/Di-Electric Breakdown Test ....................................................................................................67

Warranty ................................................................................................................................................67

3
 Warnings and Cautions 4. Ensure that readjustments, modifications, and/
or repairs are carried out exclusively by Stryker
Endoscopy or other authorized personnel.
Please read this manual and follow its instructions carefully.
The words warning, caution, and note carry special 5. Ensure that the electrical installation of the relevant
meanings and should be carefully reviewed: operating room complies with the applicable IEC,
CEC, and NEC requirements.
Warning Warnings indicate risks to the safety Federal law (United States of America) restricts this device
of the patient or user. Failure to follow to use by, or on order of, a physician.
warnings may result in injury to the
patient or user.

Caution Cautions indicate risks to the IMPORTANT SAFETY NOTICE

equipment. Failure to follow cautions
may result in product damage. Before operating or performing any maintenance or
repairs on the X8000 Light Source, read the user guide
Note Notes provide special information to and service guide thoroughly and carefully. When using
clarify instructions or present additional any light source, such as the X8000, fire and/or severe
useful information. injury may result to the patient, user or inanimate
objects, if the instructions in this manual are not
followed.
All light sources, including the X8000, can generate
An exclamation mark within a triangle significant amounts of heat at the scope tip, the scope
is intended to alert the user of special light post, the light cable tip, and/or near the light cable
warnings or important operating and adapter. Higher levels of brightness from the light source
maintenance instructions in the manual. result in higher levels of heat.
To avoid the risk of burns and/or fire:
• Always adjust the brightness level of the camera
and the monitor before adjusting the brightness
A lightning bolt within a triangle is level of the light source.
intended to warn of the presence of • Adjust the brightness level of the light source to
hazardous voltage. Refer all service to the minimum brightness necessary to adequately
authorized personnel. illuminate the surgical site.
The incorrect use of any of the required tools and/or • Adjust the internal shutter of the camera higher
techniques may risk damage to the equipment or injury to in order to run the light source at a lower
the person carrying out the procedure, subsequent operators, intensity.
or patient. Perform the repair ONLY if you have been • Avoid touching the scope tip or the light cable
specifically trained in the use of all pertinent equipment tip to the patient, and never place them on top
and techniques. Stryker Endoscopy cannot continue to of the patient, as doing so may result in burns to
guarantee compliance to UL, CSA, TUV, or other labeled the patient or user.
safety standards if service is performed by anyone other than • Never place the scope tip, the scope light post,
Stryker Endoscopy personnel. the light cable adapter, or the light cable tip on
To help avoid potential serious injury to the user and the the surgical drapes or other flammable material,
patient and/or damage to this device: as doing so may result in fire.
1. Read this manual thoroughly, especially the • Always place the light source in Standby mode
warnings, and be familiar with its contents prior to whenever the scope is removed from the light
using this equipment. cable or the device is unattended. The scope
2. Never sterilize any part of the X8000 console. tip, scope light post, light cable adapter, and
light cable tip will take several minutes to cool
3. Disconnect the X8000 from the electrical outlet off after being placed in Standby mode, and
when inspecting the fuses. therefore may still result in fire or burns to the
patient, user, or inanimate objects.

4
Introduction Required Skills, Tools, and Components

This manual is intended to be used as a service guide for The repair procedures described in this manual require a
Stryker repair technicians in the installation, maintenance, basic set of skills, tools, and replacement components.
and repair of the Stryker X8000 Light Source. It is meant
to be used in conjunction with the X8000 Light Source Skills
User Manual (1000-400-885) and does not replace existing Stryker recommends diagnostic and repair procedures be
documentation. performed by authorized, qualified technicians with training
or experience in the following:
Service Options • Basic electronics • Vectorscope operation
techniques • BioTek Safety Analyzer
Factory Service • Multimeter operation operation
Due to the complexity of the X8000 Light Source, Stryker • Oscilloscope operation
recommends that any malfunctioning system be returned
to Stryker Endoscopy for repair or replacement, where
specialized equipment and technicians are available to Tools
perform repairs while maintaining full product quality and Most of the procedures described in this manual can be
safety. If service is needed either during or after the warranty performed using a basic tool kit that includes the items listed
period: below.
1. Contact Stryker Endoscopy at 1-800-624-4422,
or contact your local Stryker Endoscopy sales
Basic tools Advanced tools
representative.
• Phillips screwdriver • Multimeter
2. Package all the components carefully in the original
shipping container, if possible. • Flathead screwdriver • Oscilloscope
• 8˝ adjustable wrench (20 Mhz or higher)
3. Ship the X8000 Light Source, prepaid and insured, to:
• Needlenose pliers • NTSC/Pal Vectorscope
Stryker Endoscopy Customer Service • Color video monitor • BioTek Model 601
Attention: Repair Department PRO Safety Analyzer
• Glass fuse puller
5900 Optical Court or equivalent current
San Jose, California 95138 leakage tester
You may request a loaner unit during the repair period.
Components
On-Site Service Replacement parts are identified in the “Device Diagrams”
Stryker Endoscopy accepts responsibility for the effects on section of this manual. Certain components are for in-house
safety, reliability, and performance of the equipment only if use only and will not be available to any non-Stryker entity.
readjustments, modifications, and repairs have been carried Before any parts are purchased, an Indemnification Letter
out exclusively by a person specifically authorized by Stryker must be signed and submitted to Stryker Endoscopy,
Endoscopy to do so. available from Customer Service at 1-800-624-4422.
On-site repair should be carried out only by qualified Stryker reserves the right to incorporate improvements
technicians with the proper test equipment listed in this to the X8000 without notice and will inform customers of
manual, so that the safety of operators and patients is not any significant upgrades. All updated parts will be fully
compromised. interchangeable with older versions and will offer at least the
In no event shall Stryker Endoscopy be liable for incidental same level of quality and performance.
or consequential damages in connection with or arising from For up-to-date information on upgrades to the product or to
the performance or use of its products after unauthorized this manual, contact your Stryker representative.
modification or repair.
Reference Documents

None of the in-house Manufacturing Assembly Procedures

(MAPs), Quality Inspection Procedures (QIPs), specialty
tools, jigs, or fixtures listed in this manual are available for
purchase.

5
 Device Description Technical Specifications

The Stryker X8000 Light Source is a light-generating unit Electrical

designed to illuminate surgical sites during endoscopic Primary: 100 – 120 VAC, 50/60 Hz, 450 W
applications. The X8000 uses a 300-watt xenon bulb to 220 – 240VAC, 50/60 Hz, 450 W
generate light, which it delivers to the surgical site via a Fuses (2): 5.0A, 250V
fiberoptic light cable. Dimensions
The X8000 is compatible with all Stryker light cables, and, Height: 4.75˝ (12.1 cm)
with the proper light cable and adapters, can connect to any Width: 12.5˝ (31.8 cm)
flexible or rigid endoscope. Depth: 16.8˝ (42.7 cm)
The X8000 is equipped with Electronic Scope Sensing Weight: 16.0 lbs (7.3 kg)
Technology (ESST), a special safety feature that helps Fiberoptic Cable Range
prevent accidental burns caused by a light cable that is 2 – 6.5 mm diameter
not connected to the scope. When operated with an ESST Bulb
light cable, the X8000 senses when the scope and the light Type: 300 Watt Xenon (Elliptical)
cable are separated and places the light source in Standby Life: Approximately 500 hours
mode. In Standby mode, the X8000 will reduce light output Operating Conditions
to a minimum, preventing the light cable from generating 10 – 40°C
excessive heat. 30 – 75% Relative Humidity
Transportation and Storage
-20 – 50°C
10 – 75% Relative Humidity
700 – 1060 hPa
Classifications and Approvals
Complies with medical safety standards:
• IEC 60601-1:2005
• CAN/CSA C22.2 No.601.1-M90
• UL 60601-1: 2003

Complies with medical EMC standard:

• IEC 60601-1-2:2001

Class 1 Equipment

Type CF applied parts

Water Ingress Protection, IPX0 — Ordinary

Equipment

Continuous Operation
Patent Protection
U.S. #5,850,496; 6,110,107; and 6,689,050.
Other patents pending.

6
Device Diagrams

The individual components of the X8000, which are referred to throughout this manual, are identified in the
following diagrams.

Top Chassis Assembly

7
 Bottom Chassis Assembly

8
9
 Basic Maintenance Replacing the Bulb Module

Replace the bulb module when the LCD indicates 500 hours
Cleaning the X8000 or when the bulb no longer sufficiently illuminates the
surgical site. If possible, replace the bulb module between
surgical procedures.
Caution Unplug the X8000 before cleaning the
unit.
Warning During operation, the bulb and the
1. As needed, clean the external surfaces of the X8000
housing around the bulb may be hot.
using a cloth or sponge dampened with a mild
Wait at least three minutes for the bulb
detergent or disinfectant.
to cool before handling it.
2. Clean and maintain the light cable according to the
manufacturer’s instructions.

Caution Do not use any abrasive cleaners. Do not To replace the bulb module,
allow any liquid to drip into the unit. 1. Power down the X8000 and wait at least three
minutes for the bulb to cool.
Caution Do not sterilize or immerse the X8000. 2. Open the bulb door.
3. Rotate the bulb module handle to the right, grasp it,
and withdraw the bulb.
Caring for the Bulb Module

The X8000 uses a Xenon bulb, which has a guaranteed Warning Do not reach inside the bulb door for
life of 500 hours when used properly. Always follow these any reason other than replacing the bulb
guidelines to ensure maximum bulb life: module. Touching parts other than the
bulb module may cause burns or product
1. If the bulb is touched, clean the bulb face with
damage.
alcohol and a cotton swab. Dirt or oil on the bulb
face will cause the bulb to heat unevenly and fail.
2. Do not power on and off the bulb in rapid Warning Do not touch any part of the bulb module
succession. Allow the bulb to run for at least five except for the handle. The module may be
minutes once it has been powered on. Failure to do very hot and cause burns.
so can cause the bulb to rapidly darken and fail.

Caution The X8000 has been designed to start the

bulb under most conditions, even when
it is hot. However, if the bulb does not 4. Insert the new bulb module (Stryker part number
start within 10 seconds after the X8000 220-201-000) along the guide rails until it is fully
has powered on, turn the unit off and seated on the mating connectors.
wait at least five minutes for the bulb to 5. Rotate the handle to the left to secure the bulb
cool before restarting. Further attempts module within the light source.
to start the bulb can damage the bulb and 6. Close and latch the bulb door.
possibly the internal circuitry.
7. Power on the unit.
8. Power on the bulb (if not already on) and verify that
the LCD displays the bulb hours as “0.”

Note Using a non-Stryker replacement bulb

module will result in no light output.

Caution Do not operate the X8000 with a burned-

out bulb or with no bulb installed.

10
Replacing the Fuses

1. Unplug the light source from the AC outlet and

remove the power cord from the rear of the unit.
2. Unlatch the fuse holder and remove the fuse(s).
3. Replace the fuse(s) with fuse(s) of the same
value and rating.
Warning To help avoid the risk of fire, use only
5.0A 250V fuses.

4. Reinstall the fuse holder.

Disposing of the X8000

This product is considered electronic

equipment. It must not be disposed of
as unsorted municipal waste and must
be collected separately. Please contact
the manufacturer or other authorized
disposal company to decommission
your equipment.

11
 Troubleshooting
Problem Possible Solution
No light output • Ensure the AC power cord is properly connected to a hospital-grade power outlet and
the inlet on the rear console panel.
• Ensure the power switch on the front panel is powered on. (It will illuminate when
powered on.)
• Ensure all fuses are operating.
• Ensure the bulb is properly seated in the bulb housing. The bulb handle should be
turned all the way to the left within the light source.
• Ensure the bulb is in operating condition. Replace the bulb if necessary.
• Ensure the light cable is correctly engaged with the cable port. As a safety feature, the
X8000 will provide no light output unless a fiberoptic light cable is properly seated in
the cable port.
• Ensure the bulb access door is completely shut.
• Check for error codes E-1, E-2, E-3, E-4 or E-5. See the Error Code Definitions section
of this manual for details.
• Check that vents are not obstructed.
• If the safety shutoff has been activated, please return the X8000 for service. Please see
the Component Replacement section of this manual for additional information.

Too much or too little • Ensure the light cable is correctly engaged with the cable port.
light output • Ensure the bulb has adequate bulb life remaining. The bulb has a warranty of 500 hours.
• Ensure the X8000 is in Run mode. (The Run LED should be illuminated.) If necessary,
press the Mode button to switch from Standby to Run. If the unit remains in Standby:

1. Ensure the light cable is correctly engaged with the cable port.
2. If an ESST cable is connected to the X8000, ensure the cable is attached to the scope
using an ESST scope adapter.
• Use the up/down buttons to adjust the brightness.
• Ensure the fiberoptic cable is transmitting light properly. Hold the light-source end of
the cable to an overhead room light and look into the scope end of the light cable. If
the pattern contains any black spots, the light cable may be worn out and may require
replacement.
• Ensure the light cable is of an adequate size for the application. The cable diameter may
be too small to provide adequate light transmission for the medical video camera in the
endoscopic application.

Excessive glare in the • Ensure the electronic shutter on the camera is operating properly to control the video
video signal brightness. If further light reduction is required, decrease the light source
brightness with the down button.

12
Error Code Definitions

The X8000 displays error codes when one of the following conditions occurs. Follow the recommended action to correct the
error.

Code Definition Recommended Action

E-1 All conditions are met for the bulb to illuminate, yet it Consult the Diagnosis section of this manual.
remains off.

E-2 All conditions are not met for the bulb to illuminate, yet it Consult the Diagnosis section of this manual.
remains on.

E-3 The bulb has higher than expected current or voltage Consult the Diagnosis section of this manual.
applied to it.

E-4 The bulb is kept off because the ballast fan is not working Consult the Diagnosis section of this manual.
properly.

E-5 The bulb is kept off because the bulb fan is not working Consult the Diagnosis section of this manual.
properly.

Blinking The bulb has exceeded its recommended lifetime of 500 Install a new Stryker bulb.
500 hours.

Replace The bulb has reached 1000 hours and has exceeded its Install a new Stryker bulb.
Bulb recommended lifetime of 500 hours.

13
 Diagnosis • PD2—reads 3.3 volts if the door reed switches
are closed. If PD2 reads 0 volts,
- Check if the reed switches on the bulb
To diagnose system errors, follow the strategies provided
mount boards are soldered properly. If
below. For steps that involve test points on the control
necessary, repair the soldering.
board, refer to the control board diagram at the end of the
- Check for shorts using the magnet on the
Diagnosis section.
reed switch. Repair/replace as necessary.
Diagnosis strategies are grouped by symptom: - Check if the cable wire colors are
correctly oriented. Adjust as necessary.
A. Bulb does not turn on • PD3—reads 3.3 volts if the fans are functioning
B. Bulb does not turn off properly
• PD4—reads 3.3 volts if a regular light cable is
C. Bulb ignites immediately upon system startup
inserted. If PD4 reads 0 volts, remove the front
D. LCD display is blue or completely dark panel and check if the beam sensor is properly
E. Fan does not run positioned and connected to the display board.
F. Light source does not switch from STANDBY to Adjust as necessary.
RUN mode • PD5—reads 3.3 volts if an ESST light cable is
inserted. If PD5 reads 0 volts, remove the front
G. Brightness cannot be adjusted
panel and check if the beam sensor is properly
H. E-1 error appears on the LCD display positioned and connected to the display board.
I. E-2 error appears on the LCD display Adjust as necessary.
J. E-3 error appears on the LCD display 6. If none of these help, contact Technical Support at
+1.800.624.4422.
K. E-4 error appears on the LCD display
L. E-5 error appears on the LCD display
B. Bulb does not turn off
M. Bulb hours value does not display
If the bulb turns on immediately after AC power is applied
N. Shutter makes noise or does not move properly.
to the light source, proceed to diagnosis strategy C, “Bulb
ignites immediately upon system startup.”
A. Bulb does not turn on If the bulb ignites after the regular startup sequence but then
1. Check the voltages on the control board test points will not turn off, perform the following steps until the source
TP22 and TP23. of the problem is identified.
• If the test points read 12V and 0V respectively, 1. Remove the light cable from the jaw.
then the ballast is faulty. Replace the ballast. 2. Open the bulb door or remove the magnet from the
• If the voltages are in the vicinity of 5.5V and reed switches.
7V respectively, proceed to step 2.
3. Using a multimeter, check the following test points
2. Visually check if the bulb door is properly on the control board:
closed with the cover or a stand-alone magnet. If
• PD2—If PD2 reads 3.3 volts, the reed switches
necessary, close the door.
are faulty. Replace the reed switches.
3. Visually check if the light cable is properly inserted • PD4 and PD5—If either PD4 or PD5 reads 3.3
into the jaw. If necessary, reinsert the cable. volts, the light cable sensor (beam sensor) is
4. Visually check if the bulb has the one-wire memory faulty. Replace the light cable sensor.
chip. If it does, ensure the chip makes contact with 4. If PD4 or PD5 reads 0 volts, measure the voltage
the bulb mount board connector. If necessary, difference between TP22 and TP23.
adjust contact between the chip and the connector. • If the voltage difference is around -1.3 volts,
5. Using a multimeter, electronically check the replace the ballast.
following test points on the control board. Each test • If the voltage difference is around 12 volts,
point should read 3.3 volts. proceed to step 5.
• PD1—reads 3.3 volts if the one wire chip is 5. Measure the voltage level for TP32.
detected by the control board. If PD1 reads 0 • If TP32 reads 0 volts, replace the control board.
volts (and PD2 reads 3.3 volts), try a different (See the Repair/Replacement Procedures
bulb. Push the bulb firmly towards the plastic section of this manual.)
separator panel to ensure contact. • If TP32 reads 3.3 volts, proceed to step 6.

14
 6. Measure the voltage for TP34. 4. Make sure that the 6-pin power cable from the
• If TP34 reads 0 or 1.6 volts, replace the control board. ballast to the control board is connected.
(See the Repair/Replacement section of this • If the power button lights up, perform steps
manual.) 1 – 3.
• If TP34 reads otherwise, contact Technical • If the power button still does not light up,
Support at +1.800.624.4422. replace the control board (See the Repair/
Replacement section of this manual.).
C. Bulb ignites immediately upon system
startup E. Fan does not run
1. Check if the jumpers on the ballast (JP300) are 1. If one or both fans are not working, an E-4 (ballast)
properly installed. When the ballast is viewed from or E-5 (bulb) error should display on the LCD
the bulb side, the jumpers should read 0 I I 0 I 0 0. screen. Confirm this.
Adjust as necessary. 2. If both fans do not work, measure the voltage on the
2. Check the voltage difference between TP22 and 10.2V test point on the control board (underneath
TP23 on the control board: lamp status connector).
• Turn off system power • If it does not read around 10.2 volts, replace
• Connect the positive multimeter probe to TP22 the control board (See the Repair/Replacement
and the negative probe to TP23 section of this manual.).
• Turn on system power 3. If only one fan works, switch the fan connectors
• If the voltage difference is around 12V, proceed between the working and non-working fans.
to step 3 • If non-working fan still fails to run, then it is
• If the voltage difference is around -1.3 volts, faulty. Replace it. (See the Repair/Replacement
replace the ballast (See the Repair/Replacement section of this manual.)
section of this manual.). • If the non-working fan begins to run, but the
3. Check the voltage of TP32. If it does not read 3.3 working fan stops running, then the control
volts, replace the control board (See the Repair/ board is faulty. Replace it. (See the Repair/
Replacement section of this manual.). Replacement section of this manual.).

D. LCD display is blue or completely dark F. Light source does not switch from
Power on the light source: STANDBY to RUN mode
• If you hear the fans running, or if the power 1. Check if the bulb is lit. If it is lit, go to step 2. If it is
button is lighted, perform steps 1 – 3. not lit, then go to diagnosis strategy A.
• If you don’t hear the fans running, and the 2. Press the brightness up and brightness down buttons
power button is not lighted, perform step 4. on the membrane. Check if the mini brightness
1. Check if the cable between the control board and meter in the top right corner of the display increases
front display board is connected properly. Adjust as or not.
necessary. • If the meter does not change, remove the front
2. Insert the bulb, close the bulb door, and measure the panel and check if the front panel membrane
voltages of PD1 and PD2 on the control board. connector is fully connected to the display
• If they do not read 3.3 volts, replace the control board. Adjust as necessary.
board. (See the Repair/Replacement section of • If the meter does change and the membrane
this manual.) is properly connected, cycle the light source
• If they do read 3.3 volts, proceed to step 3. power.
3. Measure the voltage across the C47 and C48 - As the LCD powers up, check the software
capacitors (directly beneath the display board cable version numbers. They should read at
on the control board side). least SW REV P 1. 2 and SW REV P.1.2
consecutively. (The revision numbers may
• If they read 3.3 volts and 12.3 volts respectively,
be higher if newer software versions are
replace the display board (See the Repair/
installed.)
Replacement section of this manual.).
- If the version numbers are not at least
• If not, replace the control board (See the
1.2, contact Technical Support at
Repair/Replacement section of this manual.).
+1.800.624.4422 for software updates.
- If the version numbers are adequate,
contact Technical Support.

15
 G. Brightness cannot be adjusted J. E-3 error appears on the LCD display
1. Switch the light source between STANDBY and 1. Probe TP13 with a multimeter.
RUN modes by pressing on the membrane switch. • If it reads 3.3 volts, and E-3 still appears on the
(Make sure to use a non-ESST cable, or an ESST display, replace the control board.
cable that has the ESST adaptor at the tip.) • If the voltage on TP13 is low, replace the
• If the light source does not switch between ballast.
modes, replace the control board (See the
Repair/Replacement section of this manual.) K. E-4 error appears on the LCD display
• If the light source switches between modes, but
1. Verify that the ballast fan is not running.
brightness cannot be increased or decreased,
proceed to step 2. 2. Ensure the ballast fan is connected to the control
2. Remove the jaw handle and the plastic front panel. board.
Ensure that the front panel membrane is properly 3. If the fan seems to be working, visually compare the
connected to the front LCD display board. Adjust as speed of the ballast fan to the bulb fan.
necessary. • If the ballast fan seems to be running slower,
3. If the membrane is properly connected, but replace the fan and verify that the E-4 error
brightness still cannot be adjusted, replace the disappears.
membrane. • If the E-4 error does not disappear with the
4. If the new membrane does not work, check for new fan, replace the control board.
proper connection between the control board and
the display board. Adjust as necessary. L. E-5 error appears on the LCD display
5. If the membrane works after checking the 1. Check to verify that the bulb fan is not running.
connections, replace the front LCD display board 2. Ensure the ballast fan is connected to the control
(See the Repair/Replacement section of this board.
manual.) 3. If the fan seems to be working, visually compare the
speed of the bulb fan to the ballast fan.
H. E-1 error appears on the LCD display • If the ballast fan seems to be running slower,
1. Make sure that the light cable is inserted, the bulb replace the fan and verify that the E-5 error
door is closed with a bulb inside, and the lamp is disappears.
not lit. • If the E-5 error does not disappear with the
2. Check the voltages on TP22 and TP23. new fan, replace the control board.
• If the voltage difference between TP22 and
TP23 is not 12V, replace the control board. M. Bulb Hours value does not display
• If the voltage difference between these two test 1. Connect a regular light cable to the light source.
points is 12V, ensure the J3 cable is connected 2. Make sure there is a bulb in the light source, close
properly to the ballast and that the individual the door, and verify that it is lit.
wires are not crossed. 3. Verify that there is a one-wire memory properly
- Ensure that L3 and L4 ferrites, located attached.
underneath the J3 connector, are
soldered properly to the control board. 4. Verify that the one-wire memory is making contact
- If these ferrites are missing, broken, or with the connectors on the bulb mount board.
not soldered properly, repair or replace 5. If the bulb does not light, perform diagnosis
the control board. strategy A.
3. If none of the above steps resolves the problem, 6. If you are unsure about the proper contact, insert a
replace the ballast. new bulb to see if the hours will display.
7. If the hours still do not display, verify that the cable
I. E-2 error appears on the LCD display between the bulb mount board and the control
1. Make sure that the bulb is lit and the light is on. board is properly connected.
2. Repeat diagnosis strategies B and C, respectively. 8. If the cables are properly connected, but the hours
still do not display, replace the control board.

16
N. Shutter makes noise or does not move
properly.
1. Check the pinouts of the motor cable and the bulb
mount board/control board cable. Make sure the
wire colors match the drawing.
2. Make sure the connectors J1 and J2 on the bulb
mount board are not soldered in the wrong
direction.
3. Make sure the minimum shutter switch is soldered
properly. Make sure the switch lever is properly
connected to the switch itself.
4. Make sure the shutter wheel is properly connected
to the motor shaft.
5. Make sure the shutter wheel is not rubbing against
the hot mirror holder.
6. If the motor is rotating the shutter in the reverse
direction when power is applied to the light source,
replace the motor.
7. If the motor is hesitantly rotating the shutter back
and forward, then replace the motor.
8. If the shutter’s mini tab is catching the bottom
of the minimum shutter switch, replace the bulb
mount board.
9. If none of the steps above solves the problem,
contact Technical Support at +1.800.624.4422.

17
 Control Board Diagrams

18
Repair/Replacement Note For all steps that involve the application of
Loctite, apply Loctite to the threaded holes
rather than to the threads on the screws
The X8000 Light Source is a precision instrument that has
unless otherwise specified.
been engineered and manufactured with great care to ensure
the safety of operators and patients. In order to maintain the
high level of safety and reliability required in devices of this Note When using a power screwdriver, set
nature, it is important to fully understand and comply with torque setting to 3 high unless otherwise
all required procedures set forth herein. specified.
If some part of a procedure is omitted or adequate equipment
Each of the following tables provides repair/replacement
is not used, the safety and performance of the devices may
instructions for specific components of the X8000. For each
be unknowingly compromised. If any of the procedures
instruction, the required tools, equipment, and replacement
described in this manual are beyond the scope of the
part numbers are provided.
technician’s training, consult the “Service Options” section of
this manual for information on how to obtain service from
Stryker Endoscopy.
As is the case with all AC powered
devices, dangerous voltages are present.
If adequate safety precautions are not
taken, results may include damage to the
equipment, personal injury, or death. It
is imperative that these procedures are
approached only by trained technicians
with proper equipment after fully reading
and understanding the steps involved.

Caution ESD Protection is required to perform

this assembly. Failure to follow this
procedure can cause undetectable
damage to electrical components.

19
 1.0 Chassis Cover

Seq. Task Description Figure Tools Needed Parts

10 Unscrew Chassis Cover • Power • 6-32 x 0.25 PH
from Chassis. Screwdriver Ext. Sems. (2)
(Phillips) (198)
Torque setting of 5. • X8000 Cover
(407)
• X8000 Chassis
(343)

20 Remove Chassis Cover • X8000 Cover

from Chassis. (407)
• X8000 Chassis
(343)

20
2.0 Control Board

Seq. Task Description Figure Tools Needed Parts

30 Remove Chassis Cover
from Chassis (procedure
1.0).
40 Remove all Cables • 4mm Nut • 2-56 Hex Nut
connected to the Control Driver (866)
Board. Unscrew S-Bracket • S-Bracket
from Chassis as shown. (585)
• X8000 Chassis
(343)

50 Unscrew U-Bracket from • 4mm Nut • 2-56 Hex Nut

Chassis as shown. Driver (2) (866)
• U-Bracket
(584)
• X8000 Chassis
(343)

60 Unscrew Control Board • Power • 6-32 x 5/16

from lower Control Board Screwdriver PH Screw (4)
mounts as shown. (Phillips) (102)
• X8000 Control
Board (873)
Do not bend Control
Board! • X8000 Chassis
(343)

70 Unscrew Control Board • Power • 6-32 x 5/16

from Fan Support. Remove Screwdriver PH Screw (2)
Control Board from Unit. (Phillips) (102)
• Fan Support
(223)
• X8000 Control
Board (873)

21
 80 Get New Control Board. • X8000 Control
Remove Control Board Board (873)
from metal-shielded bag
and place on ESD-safe Mat.

90 Loosen the Fan Support • 5/16” Nut • 6-32 SS Nut

from the Chassis. This will Driver (489)
allow for easier reassembly. • Fan Support
(223)
• X8000 Chassis
(343)

100 Place new Control Board • X8000 Control

into Chassis and align with Board (873)
screw mounts on Chassis • X8000 Chassis
flange. (343)

Be careful not to hit the

A/C Inlet Board!

110 Connect 3-Wire Fan cable • 3-Wire Fan

from Bulb Fan to Control Cable from
Board connector J9 (BULB Bulb Fan (3-
FAN). Pin 3-Wire)
• X8000 Control
Board (873)
Do not bend Control
Board!

22
120 Connect 3-Wire Fan from • 3-Wire Fan
Ballast Fan to Control Cable from
Board connector J10 Ballast Fan (3-
(BALLAST FAN). Pin 3-Wire)
• X8000 Control
Board (873)
Do not bend Control
Board!

130 Connect 4-Pin 4-Wire • Control

Control Board/Ballast Board/Ballast
Lamp Status Cable to Lamp Status
Control Board connector J4 Cable (4-Pin
(BALLAST FAN). 4-Wire) (509)
• X8000 Control
Board (873)
Do not bend Control
Board!

140 Connect 6-Pin 4-Wire • Control

Control Board/Ballast Lit- Board/Ballast
Enable-Intensity Cable to Lit-Enable-
Control Board connector J3 Intensity Cable
(BALLAST ENABLE). (6-Pin 4-Wire)
(563)
• X8000 Control
Do not bend Control
Board (873)
Board!

150 Connect 5-Pin 5-Wire • Control

Control Board/Display Board/Display
Board Cable from Display Board Cable
Board to Control Board (5-Pin 5-Wire)
connector J12 (DISPLAY (565)
BOARD). • X8000 Control
Board (873)
Do not bend Control
Board!

23
 160 Connect 6-Pin 6-Wire • Control
Control Board/Ballast Board/Ballast
Cable from Ballast to Cable (6-Pin
Control Board connector J6 6-Wire) (567)
(DC POWER – 12V). • X8000 Control
Board (873)
Do not bend Control
Board!

170 Connect 8-Pin 8-Wire • Control

Control Board/Bulb Mount Board/Bulb
Board Cable from Bulb Mount Board
Mount Board to Control Cable (8-Pin
Board connector J14 (BULB 8-Wire) (566)
MOUNT BRD). • X8000 Control
Board (873)
Do not bend Control
Board!

180 Slide Chassis Cover onto • X8000 Cover

Chassis until flush with (407)
Chassis and secure • X8000 Chassis
(343)

190 Screw Chassis Cover to • Power • 6-32 x 0.25 PH

Chassis. Screwdriver Ext. Sems. (2)
(Phillips) (198)
• X8000 Cover
Torque setting of 5.
(407)
• X8000 Chassis
(343)

24
3.0 Ballast

Seq. Task Description Figure Tools Needed Parts

200 Remove Chassis Cover
from Chassis (procedure
1.0).

210 Disconnect all cables on the

Control Board side. • X8000 Control
Board (873)
Do not bend Control
Board!

220 Remove green Ground Post • Needlenose • Ground Post

A/C Inlet Board/Ballast Pliers AC Inlet
Cable from bottom Ballast Board/Ballast
connector GND J103. Cable (587)
• X8000 Ballast
(413)

230 Unscrew black Ballast/ • Power • Ballast/Bulb

Bulb Cathode Cable from Screwdriver Anode Cable
Ballast. (Phillips) Assembly
(568)
• X8000 Ballast
(413)

240 Unscrew red Ballast/Bulb • Power • Ballast/Bulb

Anode Cable from Ballast. Screwdriver Anode Cable
(Phillips) Assembly
(569)
• X8000 Ballast
(413)

25
 250 Unscrew Ballast from front- • Power • 6-32 x 5/16
left Chassis PEM as shown. Screwdriver PH Screw (1)
(Phillips) (102)
• X8000 Ballast
(413)
• X8000 Chassis
(313)

260 Unscrew Ballast from • Power • 6-32 x 5/16

front-right Chassis PEM as Screwdriver PH Screw (1)
shown. (Phillips) (102)
• X8000 Ballast
(413)
• X8000 Chassis
(313)

270 Unscrew Ballast from rear- • Power • 6-32 x 5/16

left Chassis PEM as shown. Screwdriver PH Screw (1)
(Phillips) (102)
• X8000 Ballast
(413)
• X8000 Chassis
(313)

280 Unscrew Ballast from • Power • 6-32 x 5/16

rear-right Chassis PEM as Screwdriver PH Screw (1)
shown (Phillips) (102)
Remove the ballast from • X8000 Ballast
the unit. (413)
• X8000 Chassis
(343)

26
290 Remove Brown and Blue • Needlenose • X8000 Ballast
lead of AC Inlet Board/ Pliers (413)
Ballast Cable from original • A/C Inlet
Ballast. Board/
Ballast Cable
Assembly
(571)

300 Remove Control Board/ • X8000 Ballast

Ballast Lamp Status Cable (413)
from original Ballast. • Control
Board/
Ballast Lamp
Status Cable
Assembly (4-
Pin) (509)

310 Remove Control Board/ • X8000 Ballast

Ballast Lit-Enable-Intensity (413)
Cable from original Ballast. • Control
Board/Ballast
Lit-Enable-
Intensity Cable
(6-Pin 4-Wire)
(563)

320 Get New Ballast. Remove • X8000 Ballast

the Ballast from metal- (413)
shielded bag and place on
ESD safe mat.

27
 330 Attach Control Board/ • X8000 Ballast
Ballast Cable -567 to Ballast (413)
Connector J422. • Control
Board/
Ballast Cable
Assembly
(6-Pin 6-Wire)
(567)

340 Attach Control Board/ • X8000 Ballast

Ballast Lit-Enable-Intensity (413)
Cable -563 to Ballast • Control
Connector J500. Board/Ballast
Lit-Enable-
Intensity Cable
(6-Pin 4-Wire)
(563)

350 Attach Control Board/ • X8000 Ballast

Ballast Lamp Status Cable (413)
-509 to Ballast Connector • Control
J504. Board/
Ballast Lamp
Status Cable
Assembly (4-
Pin) (509)

360 Attach Blue lead of AC Inlet • Needlenose • X8000 Ballast

Board/Ballast Cable -571 to Pliers (413)
top Ballast connector HOT • A/C Inlet
J101. Board/
Ballast Cable
Assembly
Flat end of connector
(571)
should face in towards
Ballast.

28
370 Attach Brown lead of AC • Needlenose • X8000 Ballast
Inlet Board/Ballast Cable Pliers (413)
-571 to middle Ballast • A/C Inlet
connector NEUT J102 on Board/
Ballast. Ballast Cable
Assembly
(571)
Flat end of connector
should face in towards
Ballast.

380 Place and align Ballast onto • X8000 Ballast

Chassis PEM’s with Heat (413)
Sink towards outside of • X8000 Chassis
Chassis. (343)

390 Screw Ballast to rear-right • Power • 6-32 x 5/16

Chassis PEM as shown. Screwdriver PH Screw (1)
(Phillips) (102)
• X8000 Ballast
(413)
• X8000 Chassis
(343)

400 Screw Ballast to rear-left • Power • 6-32 x 5/16

Chassis PEM as shown. Screwdriver PH Screw (1)
(Phillips) (102)
• X8000 Ballast
(413)
• X8000 Chassis
(313)

29
 410 Screw Ballast to front-right • Power • 6-32 x 5/16
Chassis PEM as shown. Screwdriver PH Screw (1)
(Phillips) (102)
• X8000 Ballast
(413)
• X8000 Chassis
(313)

420 Screw Ballast to front-left • Power • 6-32 x 5/16

Chassis PEM as shown. Screwdriver PH Screw (1)
(Phillips) (102)
• X8000 Ballast
(413)
• X8000 Chassis
(313)

430 Attach green Ground Post • Needlenose • Ground Post

A/C Inlet Board/Ballast Pliers AC Inlet
Cable to bottom Ballast Board/Ballast
connector GND J103. Cable (587)
• X8000 Ballast
(413)
Flat end of connector
should face in towards
Ballast.

440 Screw red Ballast/Bulb • Power • Ballast/Bulb

Anode Cable from forward Screwdriver Anode Cable
Banana Plug to Ballast (Phillips) Assembly
connector J602 LAMP + (569)
• X8000 Ballast
(413)
Screw Cable flat side
down.
Torque setting of 3!

30
450 Screw black Ballast/Bulb • Power • Ballast/Bulb
Cathode Cable from rear Screwdriver Anode Cable
Banana Plug to Ballast (Phillips) Assembly
connector J604 LAMP – (568)
• X8000 Ballast
(413)
Screw Cable flat side
down.Torque setting of 3!

460 Reconnect all the cables

to the Control Board
(procedure 2.0, seq 120
- 170).
470 Slide Chassis Cover onto • X8000 Cover
Chassis until flush with (407)
Chassis and secure. • X8000 Chassis
(343)

480 Screw Chassis Cover to • Power • 6-32 x 0.25 PH

Chassis. Screwdriver Ext. Sems. (2)
(Phillips) (198)
• X8000 Cover
Torque setting of 5.
(407)
• X8000 Chassis
(343)

31
 4.0 Bulb Mount Board

Seq. Task Description Figure Tools Needed Parts

490 Remove Chassis Cover
from Chassis (procedure
1.0). Remove the Bulb
Assembly. Unplug A/C
Inlet Board/Bulb Mount
Board Cable from A/C Inlet
Board.

500 Unplug Stepper Motor • X8000 Stepper

connector from Bulb Motor (341)
Mount Board connector J2 • X8000
as shown. Also unplug A/C Horizontal
Inlet Board/Bulb Mount Bulb Mount
Board Cable from Bulb Board
Mount Board. Assembly
(279)
• A/C Inlet
Board/Bulb
Mount Board
Cable (572
510 Unscrew Bulb Mount Board • Power • 6-32 x 5/16
Assembly from Chassis Screwdriver PH Screw (4)
PEM’s. Remove old Bulb (Phillips) (102)
Mount Board from unit. • X8000
Horizontal
Bulb Mount
Board
Assembly
(279)
• X8000 Rail
Plate (329)
520 Remove Thermal Switch • Screwdriver • 4-40 x ¼
Guard from Bulb Mount (Phillips) Nylon Phil.
Board. PH Screws (2)
(448)
• Thermal
Use a manual
Switch Guard
screwdriver!
(596)

32
530 Get New Bulb Mount • Thermal
Board. Place Thermal Switch Guard
Switch Guide over Thermal (596)
Switch and A/C Inlet • Bulb Mount
Board/Bulb Mount Board Board (279)
Cable as shown.

Pass Thermal Switch

through opening in
Thermal Switch Guard as
shown!
540 Screw Thermal Switch • Screwdriver • 4-40 x ¼
Guard onto Bulb Mount (Phillips) Nylon Phil.
Board. PH Screws (2)
(448)
• Thermal
Use a manual
Switch Guard
screwdriver!
(596)

550 Get new Bulb Mount • Power • 6-32 x 5/16

Board. Screw Bulb Mount Screwdriver PH Screw (4)
Board Assembly to Chassis (Phillips) (102)
PEM’s above Rail Plate until • X8000
secure. Horizontal
Bulb Mount
Board
Assembly
(279)
• X8000 Rail
Plate (329)
560 Plug Stepper Motor • X8000 Stepper
connector into Bulb Mount Motor (341)
Board connector J2 as • A/C Inlet
shown. Also, plug in A/C Board/Bulb
Inlet Board/Bulb Mount Mount Board
Board Cable -572 into Bulb Cable (572)
Mount Board and A/C Inlet
• X8000
Board.
Horizontal
Bulb Mount
Board
Assembly
(279)

33
 570 Slide Chassis Cover onto • X8000 Cover
Chassis until flush with (407)
Chassis and secure. • X8000 Chassis
(343)

580 Screw Chassis Cover to • Power • 6-32 x 0.25 PH

Chassis. Insert Bulb back Screwdriver Ext. Sems. (2)
in unit. (Phillips) (198)
• X8000 Cover
(407)
Torque setting of 5.
• X8000 Chassis
(343)

34
5.0 AC Inlet Board

Seq. Task Description Figure Tools Needed Parts

590 Remove Chassis Cover
from Chassis (procedure
1.0). Remove the Bulb
Assembly.

600 Disconnect all cables from • A/C Inlet

A/C Inlet Board. Board (121)

610 Unscrew A/C Inlet Board • Power • 6-32 x 5/16

from Chassis PEM’s. Screwdriver PH Screw (3)
Remove AC Inlet board and (Phillips) (102)
AC Inlet Shield from unit. • A/C Inlet
Board (121)
• X8000 Chassis
(343)
• AC Inlet
Shield (014)

620 Get new A/C Inlet Board. • A/C Inlet

Remove A/C Inlet Board Board (121)
from metal-shielded bag
and place on ESD-safe mat.

35
 630 Screw A/C Inlet Board • Power • 6-32 x 5/16
to Chassis PEM’s with Screwdriver PH Screw (3)
connector GND J4 to front (Phillips) (102)
of Chassis. Attach AC Inlet • A/C Inlet
Shield to single screw on Board (121)
left side of board.
• X8000 Chassis
(343)
• AC Inlet
Shield (014)

640 Connect 3-Pin 2-Wire • A/C Inlet

A/C Inlet Board/Ballast Board/Ballast
Cable from Ballast to A/C Cable (3-Pin 2
Inlet Board connector J3 –Wire) (571)
BALLAST. • A/C Inlet
Board (121)

650 Connect green A/C Inlet • A/C Inlet

Board/Ballast Ground Post Board/Ballast
Cable from Ballast to A/C Ground Post
Inlet Board connector J4 Cable (1-Wire)
GND. (571)
• A/C Inlet
Board (121)

660 Connect 3-Pin 2-Wire • A/C Inlet

A/C Inlet Board/Bulb Board/Bulb
Mount Board Cable to A/C Mount Board
Inlet Board connector J2 Cable (3-Pin
B.MOUNT. 2-Wire) (572)
• A/C Inlet
Board (121)

36
670 Connect 8-Pin 8-Wire • Control
Control Board/Bulb Mount Board/Bulb
Board Cable to Bulb Mount Mount Board
Board connector J1. Cable (8-Pin
8-Wire) (566)
• Bulb Mount
Board (279)

680 Slide Chassis Cover onto • X8000 Cover

Chassis until flush with (407)
Chassis and secure. • X8000 Chassis
(343)

690 Screw Chassis Cover to • Power • 6-32 x 0.25 PH

Chassis. Insert Bulb back Screwdriver Ext. Sems. (2)
in unit. (Phillips) (198)
• X8000 Cover
(407)
Torque setting of 5.
• X8000 Chassis
(343)

37
 6.0 Jaw Handle

Seq. Task Description Figure Tools Needed Parts

700 Remove Jaw Handle from • 1/16” Hex • #6 x ¼ FLPT
Jaw Handle Key and Pinion Wrench SS BLK Set
Shaft as shown. Screw (002)
Make sure the Jaw • Jaw Handle
Handle Key remains in the (554)
Pinion Shaft groove • Jaw Handle
Key (641)
• X8000 Pinion
Shaft (298)

710 Place small amount of • 1/16” Hex • #6 x ¼ FLPT

Loctite 222 onto threaded Wrench SS BLK Set
shaft of new Jaw Handle, • Loctite 222 Screw (002)
then place Jaw Handle onto • Jaw Handle
Jaw Handle Key and Pinion (554)
Shaft as shown and screw
• Jaw Handle
into place until secure.
Key (641)
• X8000 Pinion
Make sure that Loctite Shaft (298)
does not get on the plastic
of Jaw Handle or damage
can occur.

38
7.0 LED power switch

Seq. Task Description Figure Tools Needed Parts

720 Remove Chassis Cover
from Chassis (procedure
1.0).

730 Remove Jaw Handle from

Jaw Handle Key and Pinion
Shaft (procedure 6.0, seq
700).
740 Remove Jaw Handle Key • Jaw Handle
from Pinion Shaft groove. Key, X7000
(641)
• X8000 Pinion
Shaft (298)

750 Unsnap Front Panel from • X8000 Front

Chassis as shown. Panel (337)
• X8000 Chassis
(343)

760 Unplug Control Board/ • Control

Display Board Cable Board/Display
-565 from Display Board Board Cable
connector J20. Assembly
(5-Pin 5-Wire)
(565)
• X8000 Display
Board (336)

39
 770 Unplug 3mm LED • X8000 3mm
connector from Display LED (594)
Board connector as shown. • Display Board
(336)

780 Pull 3mm LED from rear of • X8000 3mm

Power Button. LED (594)
• Power Button
(226)

790 Get new 3mm LED. Insert • X8000 3mm

3mm LED into rear of LED (594)
Power Button and push • Power Button
forward until it stops. (226)

800 Plug 3mm LED connector • X8000 3mm

into Display Board LED (594)
connector as shown. • Display Board
(336)
Dress LED wires neatly
against Front Panel.

Connect LED
connector with metal pins
facing up.

40
810 Plug Control Board/Display • Control
Board Cable -565 into Board/Display
Display Board connector Board Cable
J20 and pass through front Assembly
of Chassis as shown. (5-Pin 5-Wire)
(565)
• X8000 Display
Dress LED Cable under
Board (336)
Display Board!

820 Snap Front Panel to Chassis • X8000 Front

as shown. Panel (337)
• X8000 Chassis
(343)

830 Insert Jaw Handle Key into • Jaw Handle

Pinion Shaft groove. Key, X7000
(641)
• X8000 Pinion
Shaft (298)

840 Attach Jaw Handle onto

Jaw Handle Key and Pinion
Shaft (procedure 6.0, seq
710).
850 Slide Chassis Cover onto • X8000 Cover
Chassis until flush with (407)
Chassis and secure. • X8000 Chassis
(343)

41
 860 Screw Chassis Cover to • Power • 6-32 x 0.25 PH
Chassis. Screwdriver Ext. Sems. (2)
(Phillips) (198)
• X8000 Cover
Torque setting of 5.
(407)
• X8000 Chassis
(343)

42
8.0 Display Board

Seq. Task Description Figure Tools Needed Parts

870 Remove Chassis Cover
from Chassis (procedure
1.0).
880 Disconnect front panel
from unit (procedure 7.0,
seq 730 - 770).
890 Unplug Front Panel Overlay • Front Panel
Cable from Display Board Overlay Cable
connector J20. • Display Board
(336)

900 Unplug Beam Sensor-ESST/ • Beam Sensor-

Display Board Cable from ESST/Display
Display Board connector Board Cable
J17 as shown. (573)
• Display Board
(336)

910 Unsnap Display Board • Display Board

from Front Panel as shown. (336)
Remove Display Board • Front Panel
from unit. Assembly

920 Peel off LCD Cover and • Display Board

snap on new Display Board (336)
to Front Panel with LCD • Front Panel
facing out of Front Panel as Assembly
shown.

43
 930 Plug Beam Sensor-ESST/ • Beam Sensor-
Display Board Cable into ESST/Display
Display Board connector Board Cable
J17 as shown. (573)
• Display Board
(336)

940 Plug Front Panel Overlay • Front Panel

Cable into Display Board Overlay Cable
connector J20. • Display Board
(336)
Tuck ribbon under
Display Board to protect
from abrasion from Jaw
Assembly.

950 Complete the reassemble of

the unit (procedure 7.0, seq
800-860).

44
9.0 Front Panel Membrane

Seq. Task Description Figure Tools Needed Parts

960 Remove Chassis Cover
from Chassis (procedure
1.0).
970 Disconnect Front Panel
from unit (procedure 7.0,
seq 730 - 770).
980 Remove Display Board
from front panel
(procedure 8.0, seq 890
- 910).
990 Unpeel the Front Panel • Front Panel
Membrane from Front Membrane
Panel. (292)
• X8000 Front
Panel (337)

1000 Pull Front Panel Membrane • Front Panel

cable through Front Panel Membrane
as shown. (292)
• X8000 Front
Panel (337)

1010 Get new Front Panel • Front Panel

Membrane. Peel adhesive Membrane
backing off Front Panel (292)
Membrane.

Ensure 2nd Backing

Piece behind flex cable is
removed

1020 Pass Front Panel Membrane • Front Panel

cable through Front Panel Membrane
as shown. (292)
• X8000 Front
Panel (337)
Leave film on outside of
display to protect it from
scratching.

45
 1030 Press Front Panel • Front Panel
Membrane flush against Membrane
Front Panel until adhesive (292)
backing is secure. • X8000 Front
Panel (337)
Check alignment before
securing. Once it is on the
front panel it cannot be
adjusted.

1040 Reinstall Display Board and

cables (procedure 8.0, seq
920 - 940).
1050 Complete the assemble of
the unit (procedure 7.0, seq
800 – 860).

46
10.0 Shutter

Seq. Task Description Figure Tools Needed Parts

1060 Remove Chassis Cover • X8000 Bulb
from Chassis (procedure Assembly
1.0). Remove Bulb (331)
Assembly.

1070 Unscrew set screw from • 1/16” Hex • 6-32 x 1/8

Shutter and motor shaft. Wrench Socket HD Set
Screw (001)
• X8000 Shutter
(577)
• X8000 Stepper
Motor (341)

1080 Slide Shutter off shaft with

cutout passing over the rail
plate protrusion.
1090 Place new Shutter onto • 1/16” Hex • 6-32 x 1/8
Stepper Motor and screw Wrench Socket HD Set
into burr hole on Motor • Loctite 290 Screw (001)
shaft until secure. • X8000 Shutter
(577)
Start screw in Shutter • X8000 Stepper
before mounting to Motor. Motor (341)
Slide Shutter on shaft
with cutout passing over
the rail plate protrusion.

1100 Slide Chassis Cover onto • X8000 Cover

Chassis until flush with (407)
Chassis and secure. • X8000 Chassis
(343)

47
 1110 Screw Chassis Cover to • Power • 6-32 x 0.25 PH
Chassis. Insert Bulb back Screwdriver Ext. Sems. (2)
in unit. (Phillips) (198)
• X8000 Cover
(407)
Torque setting of 5.
• X8000 Chassis
(343)

48
11.0 Hot Mirror

Seq. Task Description Figure Tools Needed Parts

1120 Remove Chassis Cover
from Chassis (procedure
1.0). Remove the Bulb
Assembly.
1130 Remove Shutter (procedure
10.0, seq 1070 - 1080).
1140 Unscrew Hot Mirror • 5/64” Hex • 2-56 x 0.250
Holder from Motor Mount Wrench Socket HD
as shown. Screw (2)
(344)
• Hot Mirror
Unscrew bottom screw
Holder (632)
first and then top screw.
• X8000 Motor
Mount (339)

1150 Remove Hot Mirror from • X8000 Hot

Hot Mirror Holder. Mirror (576)
• Hot Mirror
Holder (632)

1160 Place new Hot Mirror in • X8000 Hot

Hot Mirror Holder. Mirror (576)
• Hot Mirror
Holder (632)
Handle Hot Mirror
with Adept Wipes.

1170 Screw Hot Mirror Holder • 5/64” Hex • 2-56 x 0.250

to Motor Mount as shown. Wrench Socket HD
Screw (2)
(344)
Screw in top screw first
• Hot Mirror
and then bottom screw.
Holder (632)
• X8000 Motor
Mount (339)

49
 1180 Reinstall the Shutter
(procedure 10.0, seq 1080
– 1090).
1190 Slide Chassis Cover onto • X8000 Cover
Chassis until flush with (407)
Chassis and secure. • X8000 Chassis
(343)

1200 Screw Chassis Cover to • Power • 6-32 x 0.25 PH

Chassis. Insert Bulb back Screwdriver Ext. Sems. (2)
in unit. (Phillips) (198)
• X8000 Cover
(407)
Torque setting of 5.
• X8000 Chassis
(343)

50
12.0 Motor

Seq. Task Description Figure Tools Needed Parts

1210 Remove Chassis Cover
from Chassis (procedure
1.0). Remove the Bulb
Assembly.
1220 Remove Shutter (procedure
10.0, seq 1070 - 1080).
1230 Unplug Stepper Motor • X8000 Stepper
connector from Bulb Motor (341)
Mount Board connector J2 • X8000
as shown. Horizontal
Bulb Mount
Board
Assembly
(279)

1240 Unscrew Stepper Motor • Power • M2.5 x 8 mm

from Motor Mount. Screwdriver PH Head
(Phillips) Screw (4)
(071)
• X8000 Stepper
Motor (341)
• X8000 Motor
Mount (339)

1250 Get new Stepper Motor. • Power • M2.5 x 8 mm

Screw in new Stepper Screwdriver PH Head
Motor to Motor Mount. (Phillips) Screw (4)
(071)
• X8000 Stepper
Make sure the Motor
Motor (341)
wire pointed towards
outside of Chassis. • X8000 Motor
Mount (339)

1260 Plug Stepper Motor • X8000 Stepper

connector into Bulb Mount Motor (341)
Board connector J2 as • X8000
shown. Horizontal
Bulb Mount
Board
Assembly
(279)

51
 1270 Reinstall the Shutter
(procedure 10.0, seq 1080
– 1090).
1280 Slide Chassis Cover onto • X8000 Cover
Chassis until flush with (407)
Chassis and secure. • X8000 Chassis
(343)

1290 Screw Chassis Cover to • Power • 6-32 x 0.25 PH

Chassis. Insert Bulb back Screwdriver Ext. Sems. (2)
in unit. (Phillips) (198)
• X8000 Cover
(407)
Torque setting of 5.
• X8000 Chassis
(343)

52
13.0 Jaw Assembly

Seq. Task Description Figure Tools Needed Parts Needed

1300 Remove Chassis Cover
from Chassis (procedure
1.0). Remove the Bulb
Assembly.
1310 Remove Shutter (procedure
10.0, seq 1070-1080).
1320 Remove Hot Mirror Holder
(procedure 11.0, seq 1140).
! Make sure the Hot Mirror
remains in the Hot Mirror
Holder.
1330 Disconnect Front Panel
from unit (procedure 7.0,
seq 730 - 770).
1340 Unscrew Lower Integrating • Screwdriver • 2-56 x ¼ FH
Rod Holder from Motor (Phillips) PH Screw (2)
Mount. (645)
• X8000 Motor
Mount (339)
• Lower
Integrating
Rod Holder
(276)

1350 Unscrew Jaw Assembly • Power • 6-32 x 3/8

from front of Chassis. Screwdriver PH Screw (4)
Remove Jaw Assembly. (Phillips) (441)
• Completed
X8000 Jaw
Assembly
• X8000 Chassis
(343)

1360 Get new Jaw Assembly. • Screwdriver • 2-56 x ¼ FH

Screw Lower Integrating (Phillips) PH Screw (2)
Rod Holder to Motor (645)
Mount until secure. • X8000 Motor
Mount (339)
• Lower
Integrating
Rod Holder
(276)

53
 1370 Screw Jaw Assembly to • Q-Tips • 6-32 x 3/8
front of Chassis until • Loctite 290 PH Screw (4)
secure. (441)
• Power
Screwdriver • Completed
(Phillips) X8000 Jaw
Torque setting of 5!
Assembly
• X8000 Chassis
Apply enough Loctite (343)
290 so that it is visible on
Chassis threads.

1380 Reinstall Hot Mirror

Holder (procedure 11.0, seq
1170).
1390 Reinstall the Shutter
(procedure 10.0, seq 1080
– 1090).
1400 Complete the assembly of
the unit (procedure 7.0, 810
– 860).

54
14.0 Integrating Rod

Seq. Task Description Figure Tools Needed Parts

1410 Remove Chassis Cover
from Chassis (procedure
1.0)
1420 Remove Shutter, Hot
Mirror Holder, Front
Panel and Jaw Assembly
(procedure 13.0, seq 1310
– 1350).
1430 Unscrew Upper Integrating • 5/64” Hex • 2-56 x 0.250
Rod Holder from Lower Wrench Socket HD
Integrating Rod Holder and Screw (2)
remove rod. (344)
• Upper
Integrating
Rod Holder
(277)

1440 Slide new Integrating Rod • X8000

into Lower Integrating Rod Integrating
Holder and push forward Rod (314)
until flush with end of • Lower
Holder. Integrating
Rod Holder
(276)
Do Not Touch Ends.

Make sure new Rod has

no chips.
1450 Salvage silicone strip • Silicone Strip
from original assembly 2in x 1/8 in
unless adhesive on strip is (595)
longer affective. Replace if • Upper
necessary. Press Silicone Integrating
Strip into Upper Integrating Rod Holder
Holder. (277)

55
 1460 Screw Upper Integrating • 5/64” Hex • 2-56 x 0.250
Rod Holder to Lower Wrench Socket HD
Integrating Rod Holder. Screw (2)
(344)
• Upper
Ensure Integrating Rod
Integrating
is flush with end of Lower
Rod Holder
Integrating Rod Holder.
(277)

1470 Complete assembly of the

unit (procedure 13.0, seq
1360 – 1400).

56
15.0 AC Inlet Filter

Seq. Task Description Figure Tools Needed Parts

1480 Remove Chassis Cover
from Chassis (procedure
1.0).
1490 Remove Control Board
(procedure 2.0, seq 50
– 80).
1500 Remove Ballast
(procedure 3.0, seq 230
– 280).
1510 Remove Ground Post Cable • X8000 Ground
from outermost single Post Cable
flange of A/C Inlet Filter. (591)
• A/C Inlet
Filter (575)

1520 Remove A/C Filter/AC • A/C Filter/AC

Inlet Board Cables from Inlet Board
A/C Inlet Filter. Cable (570)
• A/C Inlet
Filter (575)

1530 Unscrew A/C Inlet Filter • A/C Inlet • 4-40 SS B KEP

from Chassis. Filter Nuts (2) (484)
Tightening • A/C Inlet
Tool Filter (575)
• ¼” Nut Driver • X8000 Chassis
(343)

57
 1540 Remove fuse holder from • Tweezers • 5A SLO-BLO
A/C Inlet Filter. Fuse (2) (435)
• A/C Inlet
Filter (575)

1550 Take out original 5A SLO- • Screwdriver • 5A SLO-BLO

BLO fuses from A/C Inlet (Flathead) Fuse (2) (435)
Filter fuse holder. Put fuses • A/C Inlet
in fuse holder a new AC Filter (575)
Inlet Filter.

Open holder using a

Screwdriver (Flathead).

1560 Screw new A/C Inlet Filter • A/C Inlet • 4-40 SS B KEP
to Chassis with single prong Filter Nuts (2) (484)
facing out of Chassis as Tightening • A/C Inlet
shown. Tool Filter (575)
• ¼” Nut Driver • X8000 Chassis
Attach lower nut first! (343)

1570 Attach A/C Filter/AC Inlet • A/C Filter/AC

Board Cable to A/C Inlet Inlet Board
Filter with Blue Wire on top Cable (570)
flange and Brown Wire on • A/C Inlet
bottom flange. Filter (575)

Flat side of Cable

should face out of Chassis.

58
1580 Attach Ground Post • X8000 Ground
Cable to outermost single Post Cable
flange of A/C Inlet Filter (591)
by running Cable under • A/C Inlet
Ballast Duct. Filter (575)

Flat side of Green Cable

should face out of Chassis

1590 Reinstall Ballast (procedure

3.0, seq 380 – 450).

1600 Reinstall Control Board and

Chassis Cover (procedure
2.0, seq 100 – 190).

59
 16.0 Ballast Fan

Seq. Task Description Figure Tools Needed Parts

1610 Remove Chassis Cover,
Control Board, Ballast, and
AC Inlet Filter (procedure
15.0, seq 1480 - 1530).
1620 Use a screwdriver to pop • Flathead • Nylon Snap
ballast duct rivets free and screwdriver Rivets (4)
remove duct. (816)
• Ballast Duct
(326)
• 3-Wire Fan
(507)

1630 Unscrew nuts from Ballast • 11/32” • #8-32 KEP

side PEM’s. Remove Wrench Nuts (3) (491)
connector from control • 3-Wire Fan
board and remove fan. (507)
• Fan Duct
(498)
• X8000 Chassis
(343)

1640 Place new 3-Wire Fan onto • 3-Wire Fan

Ballast side onto Chassis (507)
PEM’s with sticker facing • Fan Duct
out of Chassis and plug (498)
connector into control
• X8000 Chassis
board.
(343)

Looking from the rear

of the chassis, wire should
be located at 7:00.

60
1650 Screw nuts to 3-Wire Fan • Loctite 290 • #8-32 KEP
for Ballast side to PEM’s • 11/32” Nuts (3) (491)
until secure against Fan Wrench • 3-Wire Fan
Duct as shown. (507)
• Fan Duct
Do not bend fan flange (498)
by over-tightening. • X8000 Chassis
Leave lower inside nut (343)
off.
Use Loctite 290 on
standoffs.
1660 Secure Ballast Duct to • Needlenose • Nylon Snap
3-Wire Fan on Ballast side pliers Rivets (4)
using Nylon Snap Rivets. (816)
• Ballast Duct
(326)
Turn Chassis on side to
set rivets in place. • 3-Wire Fan
(507)

It may help to use

Needlenose Pliers for hard
to reach spaces!
1670 Connect 3-Wire Fan from • 3-Wire Fan
Ballast Fan to Control Cable from
Board connector J10 Ballast Fan (3-
(BALLAST FAN). Pin 3-Wire)
• X8000 Control
Board (873)
Do not bend Control
Board!

1680 Complete assembly of the

unit (procedure 15.0, seq
1560 - 1600).

61
 17.0 Bulb Fan

Seq. Task Description Figure Tools Needed Parts

1690 Remove Chassis Cover
from Chassis (procedure
1.0). Remove the Bulb
Assembly.
1700 Disconnect 3-Wire Fan • 3-Wire Fan
cable from Control Board Cable from
connector J9 (BULB FAN). Bulb Fan (3-
Pin 3-Wire)
• X8000 Control
Board (873)

1710 Use a screwdriver to pop • Flathead • Nylon Snap

rivets on the bulb duct free Screwdriver. Rivets (4)
and remove duct. (816)
• Bulb Duct
(325)
• 3-Wire Fan
(507)

1720 Remove nuts from PEMs • 11/32” • #8-32 KEP

and remove fan. Wrench Nuts (3) (491)
• 3-Wire Fan
(507)
• Fan Duct
(498)
• X8000 Chassis
(343)

1730 Remove wire tie securing • Cable Tie • Standard

3-Wire Fan cable from Bulb Cutters Cable Tie
Fan to Separator as shown. (873)
Remove Fan and get new • Separator
Fan. (328)
• Bulb Fan
Cable (507)

62
1740 Place new 3-Wire Fan for • 3-Wire Fan
Bulb side onto Chassis (507)
PEM’s with sticker facing • Fan Duct
out Chassis . (498)
• X8000 Chassis
Looking from the rear (343)
of the chassis, wire should
be located at 2:00.

1750 Screw nuts to 3-Wire Fan • Loctite 290 • #8-32 KEP

for Bulb side to PEM’s until • 11/32” Nuts (3) (491)
secure against Fan Duct as Wrench • 3-Wire Fan
shown. (507)
• Fan Duct
Do not bend fan flanges (498)
by over-tightening. • X8000 Chassis
Leave lower inside nut (343)
off.
Use Loctite 290 on
standoffs.
1760 Connect 3-Wire Fan cable • 3-Wire Fan
from Bulb Fan to Control Cable from
Board connector J9 (BULB Bulb Fan (3-
FAN) Pin 3-Wire)
• X8000 Control
Board (873)
Do not bend Control
Board!

1770 Secure 3-Wire Fan cable • Cable Tie • Standard

from Bulb Fan to Separator • Cutters Cable Tie
as shown. (873)
• Separator
(328)
Secure using a loop of
excess wire in Cable Tie! • Bulb Fan
Cable (507)

63
 1780 Slide Chassis Cover onto • X8000 Cover
Chassis until flush with (407)
Chassis and secure. • X8000 Chassis
(343)

1790 Screw Chassis Cover to • Power • 6-32 x 0.25 PH

Chassis. Insert Bulb back Screwdriver Ext. Sems. (2)
in unit. (Phillips) (198)
• X8000 Cover
(407)
Torque setting of 5.
• X8000 Chassis
(343)

64
Final Testing and Inspection

Tools Needed

•Torque Wrench
•Fiber Optic Light Cable
•Arthroscopes
•Sidne Voice Activation System
•6 ft. Serial USB Cable
•BioTek Safety Analyzer
•240 V Transformer
•120V Transformer
•X8000 Fan Direction Fixture

Cosmetic Inspection
1. Replace the front panel, chassis, and chassis cover to fit snugly with no
visible gaps.
2. Check that the logos and printing on the back panel are clear.

3. Check that the logos and printing on the front panel are clear.

4. All connectors should be properly oriented with no visible gaps.

5. All surfaces should be smooth and free of scratches or dents.

Bulb Inspection
1. The bulb should be clean with no fingerprints, cracks, or thermal paste
compound on the glass surface.
2. Verify that the serial number is above the handle on the bulb.
3. Tighten the female connectors with the torque wrench set to 18 in-lbs.
4. The bulb module should slide and lock into place on the rail plate.

Power on Test
1. Connect the X8000 to the 120 V power supply.
2. Press the power button on and verify that the bulb does illuminate.
3. Insert the optical fiber light cable in the jaw. The bulb should ignite and
stay lit.

65
 Front Panel Functional Test
1. While the light source is turned on, the standby LED should be lit and the
display should read “Standby”. There should be a brightness display on the
top right hand corner of the LED display

2. Press the up/down brightness membrane button to increase/decrease the

brightness number in the upper right hand corner. The light source should
not come off standby.
3. Press the run/standby membrane button. The light source should go into
run mode and the run LED should be lit. The brightness percentage should
be the same as the number previously in the top right hand corner.

Brightness step-up/down
1. Press the brightness membrane button multiple times to go once all the
way from either 0 to 100% or 100% to 0%. The brightness display should
increase or decrease without skipping.

Door Switch Test

1. Open the bulb side door and verify that the bulb turns off, the light source
goes into standby, the standby LED is lit, and the LED display reads
standby with the current brightness setting in the upper right hand corner.

2. Close the bulb side door and verify that the bulb turns on but the light
source stays in standby with the same displays on the LED.

Fan Test
1. Verify that the fans are blowing out of the unit by using the fan flow
direction fixture.

Jaw Test
1. Remove the light cable by turning the knob clockwise on the jaw assembly.
The jaw should lock open. Verify that the bulb turns off, the lgihtsource
goes into standby, and the standby LED is lit when the light cable is
removed.

66
Hi-Pot/Di-Electric Breakdown Test Warranty
1. Energize the Hi-Pot tester and adjust the test voltage This Stryker Endoscopy product is warranted to the
to 1.8 kV. original purchaser to be free from defects in material and
2. Plug the test fixture into the back of the unit. workmanship for the following times:
3. Connect the alligator clip to the ground post of the One year following shipment.
unit... This warranty extends to all purchases and is limited to the
4. Touch the positive (red) probe to the Hi-Pot test repair or replacement of the product without charge when
fixture and press test on the Hi-Pot tester for 1 returned in the original shipping case to:
second.

Note Always check the hi-pot tester for proper Stryker Endoscopy
functionality prior to use by hitting the test 5900 Optical Court
butoon and touching the leads. The hi-pot San Jose, CA 95138
tester should emit the “fail” alarm.
Stryker Endoscopy cannot accept responsibility for returns
Caution Do not test the unit for more than 1 or replacements which have not been authorized. This
warranty does not cover damages caused by misuse or by
second or internal damage can occur. failure to follow the procedures outlined in this manual or
demonstrated by Stryker Endoscopy representatives.
There are no other expressed warranties.

67
68
Stryker Endoscopy
5900 Optical Court
San Jose, California 95138
+1.800.624.4422
+1.408.754.2000

2007/02 www.stryker.com 1000400933 A