Encore Medical 4779, 4759 User guide

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Page 1

SERVICE MANUAL

Tru-Trac® Traction Unit- Model 4779

TX® Traction Unit- Model 4759

Applies to Serial numbers 1000 and above

ISO 13485 Certiﬁ ed

Page 2

TABLE OF CONTENTS

Tru-Trac and TX® Therapeutic Traction Unit

FOREWORD.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 1

1 THEORY OF OPERATION.. .. .. .. .. .. .. .. .. .. .. .. .. 2

1.1 OVERVIEW . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..2

2 SAFETY PRECAUTIONS . .. .. .. .. .. .. .. .. .. .. .. .. 35

2.1 PRECAUTIONARY DEFINITIONS .. .. .. .. .. .. 3

2.2 PRECAUTIONARY INSTRUCTIONS .. .. .. .35

3 NOMENCLATURE .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 6

3.1 TRUTRAC AND TX UNIT

EXTERNAL COMPONENTS .. .. .. .. .. .. .. .. .. ..6

3.2 INTERNAL COMPONENTS .. .. .. .. .. .. .. .. .. ..7

4 SPECIFICATIONS .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 8

4.1 PHYSICAL SPECIFICATIONS .. .. .. .. .. .. .. .. ..8

5 TROUBLESHOOTING.. .. .. .. .. .. .. .. .. .. .. .. .. 926

5.1 TRUTRAC AND TX

ERROR MESSAGES .. .. .. .. .. .. .. .. .. .. .. ..9-13

5.2 TRUTRAC AND TX TRACTION UNIT

TESTING .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 14

5.3 VISUAL INSPECTION . .. .. .. .. .. .. .. .. .. .. .. 15

5.4 GROUND RESISTANCE TEST .. .. .. .. .. .. .. 15

5.5 LEAKAGE TESTS .. .. .. .. .. .. .. .. .. .. .. .. .. .. 15

5.6 ON/OFF SWITCH TEST . .. .. .. .. .. .. .. .. .. .. 16

5.7 ON/OFF SWITCH TROUBLESHOOTING . 16

5.8 PATIENT INTERRUPT SWITCH TEST . .. .. 17

5.9 CORD RELEASE AND RETRACT TEST.. .. 18

5.10 CORD RELEASE

TROUBLESHOOTING . .. .. .. .. .. .. .. .. .. 19-20

5.11 LOAD CELL TEST .. .. .. .. .. .. .. .. .. .. .. .. .. .. 21

5.12 LOAD CELL TROUBLESHOOTING .. .. 22-23

5.13 TOUCH SCREEN TEST .. .. .. .. .. .. .. .. .. .. .. 24

5.14 TOUCH SCREEN TROUBLESHOOTING .. 25

5.15 POWER SUPPLY TROUBLESHOOTING .. 26

6 REMOVAL & REPLACEMENT . .. .. .. .. .. .. .. .2751

6.1 SIDE COVER

REMOVAL & REPLACEMENT .. .. .. .. .. .. .. .. 27

6.2 TOP AND CORD GUIDE COVER

REMOVAL & REPLACEMENT .. .. .. .. .. .. .. .. 28

6.3 REAR COVER

REMOVAL & REPLACEMENT .. .. .. .. .. .. .. .. 29

6.4 FRONT COVER

REMOVAL & REPLACEMENT .. .. .. .. .. .. 30-31

6.5 MOTOR CONTROL BOARD

REMOVAL & REPLACEMENT .. .. .. .. .. .. .. .. 32

6.6 TOUCH SCREEEN ASSEMBLY

REMOVAL & REPLACEMENT .. .. .. .. .. 33-34

6.7 LOAD CELL ASSEMBLY

REMOVAL & REPLACEMENT .. .. .. .. .. 35-36

6.8 CLAMP SPRING ASSEMBLY

REMOVAL & REPLACEMENT .. .. .. .. .. .. .. 37

6.9 TRACTION CORD

REMOVAL & REPLACEMENT .. .. .. .. .. 38-43

6.10 CORD TENSION SPRING

REMOVAL & REPLACEMENT .. .. .. .. .. 44-45

6.11 SOLENOID ASSEMBLY

REMOVAL & REPLACEMENT .. .. .. .. .. .. .. 46

6.12 POWER SUPPLY

REMOVAL & REPLACEMENT .. .. .. .. .. 47-48

6.13 MOTOR ASSEMBLY

REMOVAL & REPLACEMENT .. .. .. .. .. 49-50

6.14 MOTOR DRIVE GEAR

REMOVAL & REPLACEMENT .. .. .. .. .. .. .. 51

7 CALIBRATION .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .5256

7.1 UNIT CALIBRATION .. .. .. .. .. .. .. .. .. .. .. 52-54

7.2 TOUCH SCREEN CALIBRATION .. .. .. .. .. .. 55

7.3 UNIT BURN IN . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 56

8 PARTS.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .5764

8.1 TOP COVER ASSEMBLY .. .. .. .. .. .. .. .. .. .. .. 57

8.2 SIDE COVERS .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 58

8.3 FRONT AND REAR COVERS . .. .. .. .. .. .. .. .. 59

8.4 BASE AND EXTRUSION ASSEMBLY . .. .. .. 60

8.5 CHASSIS ASSEMBLY . .. .. .. .. .. .. .. .. .. .. .. .. 61

8.6 TRACTION CORD SPRING ASSEMBLY

AND POWER SUPPLY .. .. .. .. .. .. .. .. .. .. .. .. 62

8.7 SOLENOID AND CLAMP ASSEMBLIES.. .. 63

8.8 LARGE DRIVEN GEAR AND

SPOOL ASSEMBLY.. .. .. .. .. .. .. .. .. .. .. .. .. .. 64

9 SCHEMATICS . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .6573

9.1 TRUTRAC AND TX TRACTION UNIT

SCHEMATICS .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 65-73

CONTROL BOARD . .. .. .. .. .. .. .. .. .. .. .. .. 66-68

MOTOR CONTROL BOARD . .. .. .. .. .. .. .. 69-70

PATIENT INTERRUPT SWITCH.. .. .. .. .. .. .. .. 71

SERIAL INTERFACE .. .. .. .. .. .. .. .. .. .. .. .. .. .. 72

SMART CARD .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 73

BLOCK DIAGRAM .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 74

10- SPECIAL FIXTURES . .. .. .. .. .. .. .. .. .. .. .. .. .. 75-78

CALIBRATION FIXTURE .. .. .. .. .. .. .. .. .. .. .. 75-78

11 WARRANTY . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .79

Page 3

FOREWORD

Tru-Trac and TX® Therapeutic Traction Unit

Read, understand, and follow the Safety Precautions and all other information contained in this manual.

This manual contains the necessary safety and field service information for those field service technicians, certified by Chattanooga Group, to perform field service on the Tru-Trac and TX unit.

At the time of publication, the information contained herein was current and up-to-date. However, due to continual technological improvements and increased clinical knowledge in the field of traction therapy, as well as Chattanooga Group’s policy of continual improvement, Chattanooga Group reserves the right to make periodic changes and improvements to their equipment and documentation without any obligation on the part of Chattanooga Group.

It is the sole responsibility for certified field technicians to stay informed and trained in the latest technology utilized in the Tru-Trac and TX units by Chattanooga Group. From time to time, as significant improvements are incorporated, service bulletins will be produced and made available on our web site (chattgroup.com) in lieu of reprinting a complete manual prematurely. These service bulletins will provide updated service information and technological improvements to the Tru-Trac and TX unit for use by certified service technicians.

Due to the complex nature of the technology utilized by Chattanooga Group, the recommended troubleshooting techniques are to determine “Bad Board” and board replacement only. No board component level troubleshooting is recommended, nor will information or parts be supplied by Chattanooga Group.

Any board component level troubleshooting performed will be at the sole risk and liability of the certified field service technician performing such troubleshooting techniques. Performance of such techniques may render the warranty null and void.

Tru-Trac and TX® are prescription devices to be used only under the supervision of and by the order of a physician or other licensed health care provider.

©2006 Encore Medical Corporation or its affiliates, Austin, Texas, USA. Any use of editorial, pictorial, or layout composition of this publication without express written consent from the Chattanooga Group of Encore Medical, L.P. is strictly prohibited. This publication was written, illustrated, and prepared for print by the Chattanooga Group of Encore Medical, L.P.

Page 4

1 THEORY OF OPERATION

1.1 OVERVIEW

The Tru-Trac and TX traction unit is comprised of several pieces of proprietary hardware and software causing the unit to function as required allowing administration of traction therapy under the prescription and supervision of a licensed medical practitioner.

The Touch Screen Assembly houses the necessary hardware and software to communicate to the Motor Control Board. Communicates commands and limits as established by the user through use of the Touch Screen. The Touch Screen Assembly, in conjunction with the Motor Control Board, monitors the functionality of the entire system during the course of the traction therapy being administered. Should the unit malfunction or a communication error occur, the unit will stop treatment and generate an error message to notify the operator of a possible problem.

The Touch Screen Assembly communicates to the Motor Control Board Assembly via a proprietary bus.

The Motor Control Board communicates to the Touch Screen Assembly throughout the therapy session all parameters via feedback from the Motor Assembly and the Load Cell Assembly.

The Touch Screen Assembly incorporates a Patient Data Card Reader/Writer for the purpose of storing Patient Treatment Data that can then be downloaded to a PC equipped with the optional PDMS System.

Tru-Trac and TX® Therapeutic Traction Unit

Page 5

2 SAFETY PRECAUTIONS

Tru-Trac and TX® Therapeutic Traction Unit

2.1 PRECAUTIONARY DEFINITIONS

The precautionary instructions found in this section and throughout this manual are indicated by specific symbols. Understand these symbols and their definitions before operating this equipment. The definition of these symbols are as follows:

A. Caution

Text with a “CAUTION” indicator will explain possible safety infractions that could have the potential to cause minor to moderate injury or damage to equipment.

B. Warning

Text with a “WARNING” indicator will explain possible safety infractions that will potentially cause serious injury and equipment damage.

C. Danger

Text with a “DANGER” indicator will explain possible safety infractions that are imminently hazardous situations that would result in death or serious injury.

D. Dangerous Voltage

Text with a “Dangerous Voltage” indicator serves to inform the technician of possible hazards resulting in the electrical charge disbursement from certain components if handled or serviced improperly.

E. NOTE

Throughout this manual, “NOTE” may be found. These Notes are helpful information to aid in the particular area or function being described.

2.2 PRECAUTIONARY INSTRUCTIONS

A. Cautions

•

Read, understand, and practice all precautionary instructions found in this manual. Know the limitations and hazards associated with using any electrical traction device. Observe the precautionary and operational decals placed on the unit.

•

Do not use accessories other than those supplied with the unit or recommended by Chattanooga Group. The safety of other products has not been established, and their use could result in injury to the patient.

•

This unit should be transported and stored in temperatures between 0°F and 140°F (-18°C and 60°C) to prevent damage to the unit or its components.

•

DO NOT operate this unit in an environment where other devices are being used that intentionally radiates electromagnetic energy in an unshielded manner. Portable and mobile RF communications equipment can affect Medical Electrical Equipment.

•

This unit generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to other devices in the vicinity. However, there is no guarantee that interference will not occur in a particular installation. Harmful interference to other devices can be determined by turning this (table, unit, device, etc.) on and off. Try to correct the interference using one or more of the following: reorient or relocate the receiving device, increase the separation between the equipment, connect the equipment to an outlet on a different circuit from that which the other device(s) are connected and consult the Chattanooga Group Service Department for help.

The unit should be routinely checked before each

•

use to determine all controls function normally. Handle the unit with care. Inappropriate handling

•

of the unit may adversely affect its characteristics. Before each use, inspect the Traction Cord for

•

wear. Prolonged wear on the cord will cause it to break, which may cause sudden release of traction pressure on a patient.

Test the Patient Interrupt Switch before each use

•

for power operation.

Page 6

2 SAFETY PRECAUTIONS

2.2 PRECAUTIONARY INSTRUCTIONS (continued)

•

Do not remove the cover. This may cause unit damage, malfunction, electrical shock, fire, or personal injury. There are no user-serviceable parts inside the unit. If a malfunction occurs, discontinue use immediately, disconnect the Mains Power Cord from the outlet, and consult the dealer for repair service.

•

Do not use sharp objects such as a pencil point or ballpoint pen to operate the buttons on the LCD base as damage may result.

•

Do not permit any foreign materials or liquids to enter the unit. Take care to prevent any foreign materials including, but not limited to, inflammables, water, and metallic objects from entering the unit. These may cause unit damage, malfunction, electrical shock, fire, or personal injury.

•

Do not disassemble, modify, or remodel the unit or accessories. This may cause unit damage, malfunction, electrical shock, fire, or personal injury.

•

Do not use the traction unit near devices such as X-ray units or diathermy units. These units may emit high frequency noise that may affect the operation of the unit.

•

Failure to use and maintain the traction unit and its accessories in accordance with the instructions outlined in this manual will render the warranty void.

•

In the event of a loss of power to the unit or when quick release is needed, traction tension should only be released by having the patient move towards the traction head to release the tension on the rope. Once the tension on the rope has been released, loosen the patient harness adjustment straps.

•

The tool, lubrication, and locking compound requirements listed are critical to component removal and replacement of the unit.

•

The hardware, bolts, nuts, and screws used to assemble the Tru-Trac and TX are SAE and Metric. Therefore, it will be necessary to obtain both SAE and Metric tools for removal and replacement of components.

•

The lubricant and locking compound listed are crucial in the assembly of certain components to ensure patient safety and efficient operation of the unit.

Tru-Trac and TX® Therapeutic Traction Unit

B. Warnings

Use of controls or adjustments or performance of

•

procedures other than those specified herein may result in a hazardous traction related injury.

Before connecting the unit to an electrical outlet,

•

make certain the unit is electrically grounded by connecting only to a grounded electrical service receptacle conforming to the applicable national and local electrical codes.

Do not use a damaged Mains Power Cord. Using

•

a damaged Mains Power Cord may cause unit damage, malfunction, electrical shock, fire, or personal injury. If the Mains Power Cord becomes damaged, discontinue use immediately and contact the dealer for replacement of the Mains Power Cord.

This device should be kept out of the reach of

•

children. Always hand tighten the Lock Knob securely to

•

avoid any slippage.

•

Care must be taken when operating this unit, adjacent to or stacked with other equipment. Potential electromagnetic or other interference could occur to this or other equipment. Try to minimize this interference by not using other equipment in conjunction with it.

•

In the event of a loss of power to the unit, traction tension should only be released by gradually lengthening the patient harness adjustment straps.

•

Dispose of all products in accordance with local and national regulations and codes.

In the event that an Error message or Warning

•

appears beginning with a 2 or 3, immediately stop all use of the system and contact the dealer or Chattanooga Group for service. Errors and Warnings in these categories indicate an internal problem with the unit that must be tested by Chattanooga Group or a Field Service Technician certified by Chattanooga Group before any further operation or use of the unit. Use of a unit that indicates an Error or Warning in these categories may pose a risk of injury to the patient, user, or may cause extensive internal damage to the unit.

Unit failing Dielectric Withstand and/or Leakage

•

Tests could indicate serious internal problems. DO NOT place the back into service! Send unit to factory for repair! DO NOT attempt to repair the unit in the field!

Unplug the unit from the power source before

•

attempting removal or replacement procedures to prevent electrical shock.

When performing Unit Calibration Procedure, the

•

Calibration Fixture Load Cell must be set to US lbs.

Page 7

2 SAFETY PRECAUTIONS

2.2 PRECAUTIONARY INSTRUCTIONS (continued)

Use only accessories that are specially designed

•

for this unit. Do not use accessories manufactured by other companies on this (table, unit, device, etc.). Chattanooga Group is not responsible for any consequence resulting from using products manufactured by other companies. The use of other accessories or cables may result in increased emissions or decreased immunity of this (table, unit, device, etc.).

This component removal and replacement

•

procedure requires that the following be performed after component or assembly replacement to ensure proper alignment and operation of the unit:

COMPLETE CALIBRATION OF UNIT

Refer to Section 7

AND

MINIMUM OF 2 HOUR BURN IN OF UNIT AFTER

SUCCESSFUL CALIBRATION Refer to Section 7

Failure to perform either of these procedures, after

a component or assembly replacement will void warranty and may result in injury to patients and/or severe equipment damage.

It is not recommend tying a new knot in a cord that

• has frayed or failed in use or is worn in an area from constant use. The cord must be replaced.

C. Dangers

DO NOT connect the unit to an electrical

• supply without first verifying that the power supply is the correct voltage. Incorrect voltage may cause unit damage, malfunction, electrical shock, fire, or personal injury. Your unit was constructed to operate only on the electrical voltage specified on the Voltage Rating and Serial Number Plate. Contact the Chattanooga Group dealer if the unit is not properly rated.

Power Supplies retain High Voltage!

• Discharge the C4 Capacitor prior to

• complete removal of the Power Supply.

Discharge the C4 Capacitor prior to

• handling of the new Power Supply.

Tru-Trac and TX® is a prescription device to

• be used only under the supervision of and by the order of a physician or other licensed health care provider.

Do not use any other knot styles in the

• Cord other than those specified in this manual. Use of other knot styles could cause Cord to completely disengage from the system and may cause serious injury to patient and personnel.

Tru-Trac and TX® Therapeutic Traction Unit

Page 8

3 NOMENCLATURE

3.1 TRUTRAC AND TX UNIT EXTERNAL COMPONENTS

The nomenclature graphics below, Figure 3.1, indicate the general locations of the major external components of the Tru-Trac and TX traction unit.

Know the components and their functions before performing any operation of or service to the Tru-Trac and TX traction unit.

Tru-Trac and TX® Therapeutic Traction Unit

FIGURE 3.1

Touch Screen Assembly

Top and Cord Guide Cover

Traction Cord Knuckle

Front Cover

Patient Interrupt Switch Receptacle

Side Cover

Clamp Assembly Knob

Rear Cover

Mains Power Cord Receptacle

On/Off Power Switch

10.

Page 9

3 NOMENCLATURE

3.2 INTERNAL COMPONENTS

The nomenclature graphics below, Figure 3.2, indicate the locations of the major internal components of the Tru-Trac and TX traction unit.

Tru-Trac and TX® Therapeutic Traction Unit

Know the components and their functions before performing any operation of or service to the Tru-Trac and TX traction unit.

FIGURE 3.2

Chassis

Load Cell

Top Front Traction Cord Guide

Traction Cord

Front Cover Mounting Bracket

Motor Control Board

Motor Assembly

Power Supply

Cord Tension Spring and Housing

Clamp Spring Assembly

10.

Large Driven Gear

11.

Solenoid Assembly

12.

Page 10

4 SPECIFICATIONS

PARAMETERS

MINIMUM

MAXIMUM

INCREMENTS

4.1 PHYSICAL SPECIFICATIONS

DEPTH

Tru-Trac and TX® Therapeutic Traction Unit

HEIGHT

WIDTH

FIGURE 4.1

Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 cm (9.5 in)

Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 cm (17.5 in)

Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 cm (17.5 in)

Weight

Traction Modes. . . . . . . . . . . . . . . . . Static, Intermittent,

Cyclic, and their combinations.

Traction Type . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical

LCD Display . . . . . . . . . . . . .High contrast monochrome

Standard Weight . . . . . . . . . . . . . . . . . . . . . . . .14 kg (30 lbs)

Shipping Weight . . . . . . . . . . . . . . . . . . . . . . . .18 kg (40 lbs)

Power

Voltage. . . . . . . . . . . . . . . . . . . . . . . . 100 V-240 V (50/60 Hz)

Power Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 VA

Regulatory Compliance

Meets Directive 93 /42 /EEC IEC/UL/EN: 60601-1 and 60601-1-2 CAN C22.2 No. 601.1-M90w/AZ

Current Consumption . . . . . . . . . . . . . . . . . . . . . . 3.2 A Max

Electrical Class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Class I

0413

Electrical Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Type B

TRACTION TENSION SPECIFICATIONS

PARAMETERS

MINIMUM

MAXIMUM

INCREMENTS

Traction Period 1 minute 99 minutes 1 minute

Hold Period 0 seconds 99 seconds 1 second

Rest Period 0 seconds 99 seconds 1 second

Traction Tension 0 kg (0 lb/0 N) 90 kg (200 lb/890 N) 1 kg (1 lb/5 N)

Progrssive and

1 step 9 steps 1 step

Regressive Steps

Touch Screen

Page 11

5 TROUBLESHOOTING

5.1 TRUTRAC AND TX ERROR MESSAGES

A. The following information is provided

as an aid in defining the Software Error Messages of the Tru-Trac and TX traction unit. Once a particular Error Message is defined, the information will also list probable causes and possible remedies. Once the problem area is determined, subsequent tests for verification will be necessary to determine the subassembly or PC Board to be replaced.

Tru-Trac and TX® Therapeutic Traction Unit

In the case of PC Boards, all troubleshooting

and tests will be to validate a “Bad Board” only. No component level troubleshooting information is or will be provided by Chattanooga Group for field troubleshooting of PC board components.

B. Once a particular subassembly or PC Board

has been determined as bad, refer to the appropriate Removal & Replacement Section for the board affected and follow the instructions for replacement of the board.

ERROR

CODE

ERROR

TYPE

DEFINITION PROBABLE CAUSES POSSIBLE REMEDY

USER CORRECTABLE WARNING MESSAGES

100 WARNING Treatment has been running for 8 seconds,

but no tension is detected on the Cord.

101 WARNING Patient pressed Patient Switch. Patient Interrupt Switch button pressed. Touch the Touch Screen to clear message.

102 WARNING Patient Switch is unplugged. Patient Interrupt Switch not properly connected to unit. Properly connect Patient Interrupt Switch and touch Touch

104 WARNING User selected Patient Card button on

utilities screen, but no traction treatments were found on the card.

105 WARNING User selected save to card, but no card is

inserted into the unit.

106 WARNING User selected save to card, but the card

currently inserted is not a Patient Card.

107 WARNING User selected save to card, but the card

currently inserted is full.

108 WARNING User typed in a blank patient name. No Patient ID assigned. Enter Patient ID.

109 WARNING User typed in a blank protocol name. No Protocol name entered. Enter Protocol name.

110 WARNING User attempted to access a MMC function,

but no MMC is inserted into the unit.

111 WARNING User attempted to upgrade software, but

the MMC in the unit is not a software upgrade MMC.

112 WARNING Error upgrading Control Board software. Unknown Contact Dealer or Chattanooga Group for Service.

113 WARNING Error upgrading motor board software. Unknown Contact Dealer or Chattanooga Group for Service.

114 WARNING User pressed START, but has not yet set

the Max Level value to a value greater than zero.

115 WARNING User pressed HOME button from treatment

review screen while a treatment was running.

Too much slack in Traction Cord Remove Traction Cord Slack.

Screen to clear message.

Wrong or bad Patient Data Card inserted into unit. Insert correct Patient Data Card.

No Patient Data Card inserted. Properly insert correct Patient Data Card into unit.

Wrong or bad Patient Data Card inserted into unit. Insert correct Patient Data Card.

Memory full on Patient Data Card used. Save Data to PDMS and erase Patient Data Card.

No Multimedia Card (MMC) inserted into unit. Insert Multimedia Card (MMC) into unit.

Wrong Multimedia Card (MMC) inserted into unit. Insert proper Mutimedia Card (MMC).

User has not completed Treatment Set Up. Complete Treatment Set Up prior to pressing START.

Home button has been pressed. Press STOP to end treatment prior to pressing HOME.

Page 12

5 TROUBLESHOOTING

Tru-Trac and TX® Therapeutic Traction Unit

5.1 TRUTRAC AND TX ERROR MESSAGES (continued)

In the event that an Error message or Warning appears beginning with a 2 or 3, immediately stop all use of the unit and contact the dealer or Chattanooga Group for service. Errors and Warnings in these categories indicate an internal problem with the unit that must be tested by Chattanooga Group or a Field Service Technician certified by Chattanooga Group before any further operation or use of the unit. Use of a unit that indicates an Error or Warning in these categories may pose a risk of injury to the patient, user, or may cause extensive internal damage to the unit.

ERROR

CODE

ERROR

TYPE

DEFINITION PROBABLE CAUSES POSSIBLE REMEDY

ERROR MESSAGES (200-223) REQUIRING TECHNICAL ASSISTANCE

200 ERROR The motor PCB has reset. Motor Control Board is bad. If the Error repeats routinely, replace Motor Control Board.

201 ERROR Error communicating with the realtime clock

chip.

202 ERROR The motor PCB returned an error while

performing the zero Load Cell function.

203 ERROR Timeout waiting for the motor PCB to perform

the zero Load Cell calibration.

204 ERROR Timeout waiting for the motor PCB to perform

the motor current calibration.

205 ERROR A Motor fault error has occurred while a

treatment was running.

206 ERROR The Motor PCB cannot get to the desired tension. Internal Mechanical Jam of unit.

207 ERROR We have detected a motor current error

(MC_MON pin on motor PCB).

208 ERROR We have detected a Load Cell limit error

(LC_MON pin on motor PCB).

209 ERROR Error erasing a patient card. Bad Patient Data Card.

210 ERROR CRC not correct on treatment just read from

Patient Card.

211 ERROR Error reading default protocol on power up so

must rebuild protocols to factory presets.

212 ERROR The Motor PCB ﬂ agged a comm watchdog error. Touch Screen Assembly did not poll Motor Control

213 ERROR Motor PCB has indicated that the zero calibration

value is invalid and needs to be calibrated.

Control Board Communication Error. If the Error repeats routinely, replace Touch Screen Assembly.

Bad Load Cell Assembly Motor Control Board Communication Error.

Bad Load Cell Bad Motor Control Board

Motor Control Board Communication Error. 1. Ensure there is no slack in the Cord.

Internal mechanical jam of unit. Bad Motor Control Board or Motor Assembly.

Bad Motor Control Board or Motor Assembly.

Unit out of calibration. Perform Unit Calibration and Burn In procedures.

Unit is out of calibration. Bad Motor Control Board. Bad Load Cell Assembly.

Bad Touch Screen Assembly.

Bad Patient Data Card. Bad Touch Screen Assembly.

EEPROM is corrupt. If the Error repeats routinely, replace Touch Screen Assembly.

Board in a reasonable amount of time.

Unit is out of calibration. Perform Unit Calibration and Burn In procedures.

1. Check Cables and Harnesses for proper seating and connection on Motor Control Board.

2. Replace Load Cell Assembly.

3. Replace Motor Control Board.

4. Replace Touch Screen Assembly.

1. Ensure there is slack in the Cord.

2. Check Cables and Harnesses for proper seating and

connection on Motor Control Board.

3. Replace Load Cell.

4. Replace Motor Control Board.

2. Check Cables and Harnesses for proper seating and

connection on Motor Control Board.

3. Replace Load Cell.

4. Replace Motor Control Board.

1. Correct any internal mechanical jam.

2. Replace bad Motor Control Board or bad Motor Assembly.

1. Correct any internal mechanical jam.

2. Replace bad Motor Control Board or bad Motor Assembly.

1. Perform Unit Calibration and Burn In procedures.

2. Replace Motor Control Board.

3. Replace Load Cell Assembly.

1. Try known good Patient Data Card.

2. Check Cables and Harnesses for proper seating and

connection on Motor Control Board.

3. Replace Touch Screen Assembly.

1. Try known good Patient Data Card.

2. Replace Touch Screen Assembly.

1. Check Cables and Harnesses for proper seating and

connection on Motor Control Board.

2. If the Error repeats routinely, replace Touch Screen Assembly.

Page 13

5 TROUBLESHOOTING

Tru-Trac and TX® Therapeutic Traction Unit

5.1 TRUTRAC AND TX ERROR MESSAGES (continued)

ERROR

CODE

ERROR

TYPE

DEFINITION PROBABLE CAUSES POSSIBLE REMEDY

ERROR MESSAGES (200-223) REQUIRING TECHNICAL ASSISTANCE (continued)

214 ERROR User has conﬁ gured a treatment such that it takes

too much memory to compute the treatment steps. Unit will default back to the default power up protocol.

215 ERROR Internal error, unit cannot get the next treatment

step information, treatment is terminated.

217 ERROR Error reading a MMC. Bad Mutimedia Card (MMC).

218 ERROR Error upgrading Control Board software. Bad Mutimedia Card (MMC).

219 ERROR Error upgrading Control Board software. Bad Mutimedia Card (MMC).

220 ERROR Error upgrading Motor Control Board software. Bad Mutimedia Card (MMC).

221 ERROR Error upgrading Motor Control Board software. Bad Mutimedia Card (MMC).

222 ERROR Patient switch is shorted. Patient Interrupt Switch not completely seated in

223 ERROR Beta version evaluation period has expired. Unit is designated BETA Test Unit. Immediately return unit to Chattanooga Group.

Under normal operating conditions, this Error should never appear.

Multimedia Card (MMC) Data is corrupt. Multimedia Card (MMC) interface not working.

Improper cable connection to Motor Control Board. Bad Touch Screen Assembly.

Improper cable connection to Motor Control Board. Bad Motor Control Board. Bad Touch Screen Assembly.

connector. Bad Patient Interrupt Switch. Bad Patient Interrupt Switch Connector.

Remove unit from service and report exact treatment parameters to Chattanooga Group.

1. Try known good Multimedia Card (MMC).

2. Remove unit from service and report exact treatment

parameters to Chattanooga Group.

1. Try known good Multimedia Card (MMC).

2. Check Cables and Harnesses for proper seating and

connection on Motor Control Board.

3. Replace Touch Screen Assembly.

1. Try known good Multimedia Card (MMC).

2. Check Cables and Harnesses for proper seating and

connection on Motor Control Board.

3. Replace Touch Screen Assembly.

1. Try known good Multimedia Card (MMC).

2. Check Cables and Harnesses for proper seating and

connection on Motor Control Board.

3. Replace Touch Screen Assembly.

1. Try known good Multimedia Card (MMC).

2. Check Cables and Harnesses for proper seating and

connection on Motor Control Board.

3. Replace Motor Control Board.

4. Replace Touch Screen Assembly.

1. Try known good Multimedia Card (MMC).

2. Check Cables and Harnesses for proper seating and

connection on Motor Control Board.

3. Replace Motor Control Board.

4. Replace Touch Screen Assembly.

1. Properly connect Pateint Interrupt Switch to unit.

2. Use a known good Pateint Interrupt Switch.

3. Replace Patient Interrupt Switch Connector on unit.

Page 14

5 TROUBLESHOOTING

Tru-Trac and TX® Therapeutic Traction Unit

5.1 TRUTRAC AND TX ERROR MESSAGES (continued)

ERROR

CODE

300

through

CRITICAL

307

308 CRITICAL

309 CRITICAL

310 CRITICAL

311 CRITICAL

312 CRITICAL

313 CRITICAL

314 CRITICAL

TYPE

ERROR

DEFINITION PROBABLE CAUSES POSSIBLE REMEDY

CRITICAL ERRORS (300-314) DEMANDING TECHNICAL SERVICE

Communication Error between Touch Screen and Motor Control Board.

We are supposed to be increasing tension, but tension is not increasing.

We are supposed to be decreasing tension, but tension is actually increasing.

We are reading > 0 tension when we should be reading zero.

We are reading < 0 tension when we should be reading zero.

We have detected that the motor is running too fast. Bad Motor Control Board.

Internal memory error. Bad Touch Screen. Replace Touch Screen Assembly.

Error reading EEPROM. Bad Touch Screen. Cycle power to unit. If the Error repeats, then replace

Communication Error. 1. Check Cables and Harnesses for proper seating and

Slack in Cord. Bad Load Cell. Bad Motor Control Board.

Unit out of calibration. Bad Harness connection. Bad Load Cell. Bad Motor Control Board.

Unit out of calibration. Perform Unit Calibration and Burn In procedures.

Unit out of calibration. Bad Load Cell. Bad Motor Control Board.

Bad Motor Assembly.

connection on Motor Control Board.

2. Replace Motor Control Board.

3. Replace Touch Screen Assembly.

1. Remove slack in Cord.

2. Check Cables and Harnesses for proper seating and

connection on Motor Control Board.

3. Replace Load Cell.

4. Replace Motor Control Board.

1. Perform Unit Calibration and Burn In procedures.

2. Check Cables and Harnesses for proper seating and

connection on Motor Control Board.

3. Replace Load Cell.

4. Replace Motor Control Board.

1. Perform Unit Calibration and Burn In procedures.

2. Check Cables and Harnesses for proper seating and

connection on Motor Control Board.

3. Replace Load Cell.

4. Replace Motor Control Board.

1. Replace Motor Control Board.

2. Replace Motor Assembly.

Touch Screen Assembly.

Page 15

NOTES

Tru-Trac and TX® Therapeutic Traction Unit

Page 16

5 TROUBLESHOOTING

5.2 TRUTRAC AND TX TRACTION UNIT TESTING

A. General- Electronic

1. Information within this section in respect to electronic components is intended to aid in troubleshooting the PCB's of the Tru-Trac and TX units to “Board Level” only. These tests are the standard testing procedures and methods used at the factory before shipment of the unit.

2. Due to the complex nature of the technology utilized by Chattanooga Group, the recommended PCB troubleshooting techniques are to determine “Bad Board” and board replacement only. No PCB component level troubleshooting is recommended nor will information or parts be supplied by Chattanooga Group. Any PC board component level troubleshooting performed will be at the sole risk and liability of the Service Technician performing such troubleshooting techniques.

3. Once a particular PCB has been determined as bad, replace the PCB. Use only Chattanooga Group replacement parts and hardware.

B. General- Replacement Components

Critical component replacement parts for the

traction unit are available as subassemblies only. This is due to the accuracy required and the critical nature of the subassembly within the unit for power function and operation. Individual components of these subassemblies will not be made available by Chattanooga Group.

C. General- Tests and Repair Procedures

1. Certain tests and repair procedures require the use of special tools and/or fixtures. These will be listed at the particular test where they are required. Testing with any other special tool or fixture other than those stated could give erroneous readings or test results. Always perform the tests exactly as stated to ensure accurate results.

2. Test equipment settings will be listed for each test performed prior to the respective test to ensure the test is performed to Chattanooga Group standards and ensure power readings.

3. The troubleshooting and repair of the units are to be performed only by authorized technicians trained and certified by Chattanooga Group.

D. Tools, Fixtures, and Equipment Required

1. Dielectric Withstand (Hi-Pot) and ground resistance tester.

Tru-Trac and TX® Therapeutic Traction Unit

NOTE:

Adjust Dielectric Withstand tester to indicate fault with 120 kOhm load across the output when at specified test voltage.

2. Milliohm Meter

3. Digital Multimeter

4. Required Hand Tool

•

#1 Phillips Screwdriver

•

#2 Phillips Screwdriver

•

Flat Blade Screwdriver

•

Calibrated Torque Wrench- 200 inch

pound or 2,500 Newton meter minimum capacity.

Allen Wrenches

•

SAE- 3/32, 5/32, and 9/64 in

•

Metric- 3 mm

• Hex Key Sockets for Torque Wrench

•

SAE- 3/32 and 5/32 in

• Metric- 4 mm

•

Needle Nose Pliers

• Tape Measure- 12 ft (3 meter) minimum

• Ratchet

• 7mm Box End Wrench

• Pick for removing connector wires.

•

5. Touch Screen to Cover Assembly Jig

6. Calibration Fixture with calibrated Strain Meter.

7. Solenoid Assembly Mounting Jig. P/N 48139.

The tool, lubrication, and locking compound requirements listed are critical to component removal and replacement of the unit.

The lubricant and locking compound listed are crucial in the assembly of certain components to ensure patient safety and efficient operation of the unit.

Page 17

5 TROUBLESHOOTING

Tru-Trac and TX® Therapeutic Traction Unit

5.3 VISUAL INSPECTION

A. General

Visually inspect the unit. A visual inspection can, to an experienced Technician, indicate possible abuse of the unit and internal problems.

5.4 GROUND RESISTANCE TEST

A. Voltage Specifications

Models 4759 and 4779 . . . . . . . . .

B. Specification

Maximum Acceptable Resistance: 100 milliohms

C. Equipment Required

Milliohm Meter

D. Tes t

Place unit on level work surface. Place one meter probe on the ground prong of

power supply and the other to any exposed metal or screw on the unit. See Figure 5.1.

Input: 100-240 VAC

50/60 Hz, 75 VA

5.5 LEAKAGE TESTS

UNIT FAILING DIELECTRIC WITHSTAND AND/OR LEAKAGE TESTS COULD INDICATE SERIOUS INTERNAL SYSTEM PROBLEMS. DO NOT PLACE UNIT BACK INTO SERVICE! SEND UNIT TO FACTORY FOR REPAIR! DO NOT ATTEMPT TO REPAIR IN THE FIELD!

Test Voltage Spec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Conduct all necessary leakage tests as required per “Chapter 7 Electrical Equipment” of the 1999, or later, edition of the NFPA (National Fire Protection Association) “Health Care Facilities” standards. See Figure 5.2.

1000 V

FIGURE 5.1

NOTE:

U.S.A. Power Cord Illustrated. Unit is illustrated on its side.

EXPOSED METAL

FIGURE 5.2

GROUND PRONG

NOTE:

The NFPA "Health Care Facilities" standards are specific to the U.S.A. All other technicians should verify their country's requirements for these tests.

Page 18

5 TROUBLESHOOTING

5.6 ON/OFF SWITCH TEST

A. Specification

Unit turns Off and On

B. Equipment Required

None

C. On/Off Switch Test Procedure

1. Place unit on level work surface.

2. Plug Power Cord into grounded power source with appropriate voltage. See Specifications on page 8.

3. Turn unit Off and back On with Power Switch. See Figure 5.3.

D. Test Result

1. If unit turns Off and On, unit passed test.

2. If unit does not turn Off and On, unit failed test. Refer to: 5.7 On/Off Switch Troubleshooting below.

5.7 ON/OFF SWITCH TROUBLESHOOTING

A. Specification

Appropriate AC voltage.

B. Equipment Required

Digital Multimeter

3/32 in Allen Wrench

C. On/Off Switch Troubleshooting Procedure

1. Disconnect unit from power source.Remove Side Covers. Refer to 6.1 Side Cover Removal & Replacement.

2. Remove Top Cover. Refer to 6.2 Top and Cord Guide Cover Removal & Replacement.

3. Remove Rear Cover leaving harnesses connected. Refer to 6.3 Rear Cover Removal and Replacement.

4. Disconnect the Blue and Red wires from the Power Supply to the Power Switch. See Figure 5.4.

5. Set Multimeter to AC and to the appropriate voltage setting. Connect Multimeter Leads to the Blue and Brown wire Connectors from the Power Switch. See Figure 5.5.

6. Plug unit into a grounded power source with appropriate voltage. Turn Power Switch On and take reading from Multimeter.

D. Test Result

1. If Multimeter reads appropriate voltage, unit passed test. If unit will not power up, refer to

5.15 Power Supply Troubleshooting.

2. If Multimeter does not read appropriate voltage.

Replace Power Switch.

Tru-Trac and TX® Therapeutic Traction Unit

ON/OFF SWITCH

FIGURE 5.3

DISCONNECT RED AND BLUE

POWER SUPPLY WIRES

FIGURE 5.4

ON/OFF SWITCH

MULTIMETER

CONNECTED TO BLUE

AND BROWN WIRES

FIGURE 5.5

Page 19

5 TROUBLESHOOTING

5.8 PATIENT INTERRUPT SWITCH TEST

A. Specification Unit displays Error 101 or 102 at the respective test.

B. Equipment Required None C. Patient Interrupt Switch Test Procedure

1. Place unit on level work surface. Plug Power Cord into grounded power source with appropriate voltage.

2. Connect Patient Interrupt Switch to unit making certain it is completely seated in the Patient Interrupt Switch connector. See Figure 5.6.

3. Turn unit On with Power Switch. After unit has completely booted up, disconnect the Patient Interrupt Switch. Unit should display Error 102. See Figure 5.7.

4. Reconnect the Patient Interrupt Switch. Touch the Touch Screen anywhere to clear the Error.

5. Turn unit Off. with Patient Interrupt Switch connected to the unit, turn unit On with Power Switch.

6. After unit has completely booted up, depress the Patient Interrupt Switch button. The unit should display Error 101. Touch the Touch Screen anywhere to clear the Error. See Figure 5.8.

D. Test Result

1. If unit displays Errors 101 or 102 at the respective test, unit passed test.

2. If unit does not display Errors 101 or 102 at the respective test, unit failed test. Repeat test with a known good Patient Interrupt Switch.

3. If known good Patient Interrupt Switch resolves the problem, replace existing Patient Interrupt Switch with new part.

4. If the known good Patient Interrupt Switch does not remedy the problem, Replace Patient Interrupt Switch Jack.

Tru-Trac and TX® Therapeutic Traction Unit

FIGURE 5.6

FIGURE 5.7

FIGURE 5.8

Page 20

5 TROUBLESHOOTING

5.9 CORD RELEASE AND RETRACT TEST

A. Specification

Release . . . . . . . . . . . . . . . . . . . . Cord releases with less

than 5 lbs tension

Retract . . . . . . . . . . . . . . . . . .Cord completely retracts

B. Equipment Required Calibration Fixture with calibrated Strain Meter.

C. Cord Release and Retract Test Procedures

1. Secure unit to the Calibration Fixture. See Figure 5.9.

2. Plug unit into approved power source and turn unit On.

3. After unit has completely booted, press and hold Rope Release on Touch Screen, and pull Cord out. Release Rope Release while holding Cord out. See Figure 5.10.

NOTE:

It may be necessary to pull and release slight tension on the Cord to allow the internal mechanism to release the stop on the Cord.

4. While holding on to extended Cord, press Rope Release on the Touch Screen and guide Cord back into unit.

5. Repeat step 3 above to connect the Cord to the Calibration Fixture. See Figure 5.11.

6. Set up unit for a static pull of 100 lbs. Refer to User Manual if necessary.

7. Press the START button. After the 100 lbs has been reached, press the STOP Button and view the Rope Release on the Touch Screen, it should be inactive.

8. Watch as the tension decreases. Once the tension decreases to below 5 lbs, the Rope Release should become active. Immediately press the Rope Release on the Touch Screen, pull enough Cord out to facilitate disconnection from the Calibration Fixture. Release the Rope Release control. Disconnect the Cord from the Calibration Fixture.

NOTE:

It may be necessary to apply and release slight tension on the Cord to allow the internal mechanism to release the stop on the Cord.

9. Repeat step 4.

D. Test Result

1. If Cord fails to release, unit failed test. Refer to 5.10 Cord Release Troubleshooting.

2. If Cord fails to completely retract, unit failed test. Adjust Cord Retraction Spring. Refer to page 42 beginning with step 13 for adjustment procedures.

Tru-Trac and TX® Therapeutic Traction Unit

FIGURE 5.9

FIGURE 5.10

FIGURE 5.11

Page 21

5 TROUBLESHOOTING

5.10 CORD RELEASE TROUBLESHOOTING

A. Specification

Solenoid Supply Voltage . . . . . . . 24 VDC ±5%

Solenoid Gear . .Properly engages Driven Gear B. Equipment Required

1. Digital Multimeter

2. #1 Phillips Screwdriver

3. 3/32 in Allen Wrench

4. Solenoid Assembly Mounting Jig C. Cord Release Troubleshooting Procedure

1. Solenoid Assembly a. Remove Side Covers. Refer to 6.1 Side

Cover Removal & Replacement. b. Manually move solenoid shaft in and out

to ensure gears are not locked and the Solenoid Shaft moves and properly engages the large Driven Gear. See Figure 5.12. If Solenoid moves and engages properly, procede to step c. below.

If Solenoid Shaft will not move or properly mesh with the Large Driven Gear, adjust Solenoid Assembly. Refer to page 46, parts A-D for adjustment. If problem persists, replace Solenoid Assembly. Refer to 6.11 Solenoid Assembly Removal & Replacement procedures.

c. With unit connected to an approved power supply and turned on, press the Rope Release on the Touch Screen. Repeat several times to ensure the solenoid properly engages and disengages the large Driven Gear.

1) Touch Screen Control does not activate Solenoid. Troubleshoot Motor Control Board. Refer to page 20 for instructions.

2) Solenoid Gear does not properly engage the large Driven Gear. See Figure 5.13. Adjust Solenoid Assembly. Refer to page 46, parts A through D for adjustment.

Tru-Trac and TX® Therapeutic Traction Unit

FIGURE 5.12

FIGURE 5.13

Page 22

5 TROUBLESHOOTING

5.10 CORD RELEASE TROUBLESHOOTING (continued)

2. Motor Control Board a. Disconnect Solenoid Harness from J8 on

Motor Control Board. See Figure 5.14. b. Make certain unit is connected to an

approved power supply outlet and turn unit On with Power Switch.

c. Set Multimeter to read 24 VDC and connect leads to the J8 connector pins. See Figure 5.15.

d. Push and hold the Rope Release on the Touch Screen and take reading from Multimeter.

1. If no voltage is present or low voltage is present, replace Motor Control Board. Refer to 6.5 Motor Control Board Removal & Replacement.

2. If proper voltage is present and problem persists, replace Touch Screen Assembly. Refer to 6.6 Touch Screen Removal & Replacement.

Tru-Trac and TX® Therapeutic Traction Unit

FIGURE 5.14

FIGURE 5.15

Page 23

5 TROUBLESHOOTING

5.11 LOAD CELL TEST

A. Specification

Touch Screen Reading ±10% B. Equipment Required

1. Calibration Fixture with calibrated Load Cell C. Load Cell Test Procedure

1. Secure unit to the Calibration Fixture. See Figure 5.16.

2. Plug unit into an approved power source and turn unit On with Power Switch.

3. After unit is completely booted, Press Cord Release on the Touch Screen and pull out enough Cord to connect Cord to the Load Cell. See Figure 5.16.

4. After connecting Cord to Load Cell, allow any slack Cord back into the unit. Release the Rope Release on the Touch Screen.

5. Set up unit for a 100 lbs static pull. Refer to User Manual if necessary.

6. Zero the Load Cell according to the manufacturer's instructions.

7. Press the START button just below the Touch Screen. See Figure 5.17.

8. During the pull, compare and record the reading on the Touch Screen to the reading on the Load Cell at 25, 50, 75, and 100 lb intervals.

9. After 100 lbs has been reached, press the STOP button. See Figure 5.18. Allow unit to release the Cord.

D. Test Result

1. If reading of Load Cell is within ±10% of the Touch Screen reading, unit passed test.

2. If readings are higher or lower than the ±10% tolerance, unit failed test. Calibrate unit and re-test. Refer to Section 7 Calibration for Procedures.

3. If problem persists, perform Load Cell Troubleshooting. Refer to 5.12 Load Cell Troubleshooting for procedures.

Tru-Trac and TX® Therapeutic Traction Unit

FIGURE 5.16

FIGURE 5.17

FIGURE 5.18

Page 24

5 TROUBLESHOOTING

5.12 LOAD CELL TROUBLESHOOTING

A. Specification

Voltage to Load Cell . . . . . . . . . . . . . . . . . .10 VDC

Voltage from Load Cell . . . . . . . . . . . . . . Variable

Motor Control Board Voltage (U3) . . . Variable

B. Equipment Required

1. Calibration Fixture with calibrated Load Cell

2. 3/32 in Allen Wrench

3. Digital Multimeter

4. Pick for removing wires from connectors. C. Voltage to Load Cell Test

1. Remove Side Covers. Refer to 6.1 Side Cover Removal & Replacement.

2. Secure unit to the Calibration Fixture. See Figure 5.19.

3. Plug unit into an approved power source and turn unit On with Power Switch.

4. After unit is completely booted, press Cord Release on the Touch Screen and pull out enough Cord to connect Accessory Clip to the Load Cell. See Figure 5.19.

5. Guide any Cord slack back into unit. Release the Rope Release on the Touch Screen.

6. Remove Load Cell Connector from J11 on Motor Control Board. See Figure 5.20.

7. Set Multimeter to read 10 VDC and connect leads to Pins 1 and 2 of the J11 connector on the Motor Control Board. See Figure 5.21.

8. Multimeter should read 10 VDC. If reading is 10 VDC, procede to step 9. If reading is not 10 VDC, replace Motor Control Board. Refer to 6.5 Motor Control Board Removal & Replacement.

9. Reconnect Load Cell Connector to J11 on Motor Control Board. Make certain the Pink Wire on the Connector is positioned onto Pin 1 of the Motor Control Board. See Figure 5.22.

10. Set Multimeter to read 10 VDC. Make connection with Pins 1 and 2 from the side of the connector with Multimeter Leads and take reading. See Figure 5.22.

11. If reading is not 10 VDC, replace unit Load Cell. Refer to 6.7 Load Cell Removal and Replacement. If reading is 10 VDC procede to step D.

Tru-Trac and TX® Therapeutic Traction Unit

FIGURE 5.19

FIGURE 5.20

FIGURE 5.21

FIGURE 5.22

Page 25

5 TROUBLESHOOTING

5.12 LOAD CELL TROUBLESHOOTING (continued)

D. Voltage from Load Cell Tests NOTE:

It will be necessary to have two people available for the following test.

1. Set Multimeter to read 10 VDC. Make connection with Pin 3 (Blue wire) and Pin 4 (Green wire) from the side of the connector with Multimeter Leads. See Figure 5.23.

2. Press the START button. The voltage reading on Multimeter should increase as Cord Tension increases.

3. Press the STOP button. The voltage reading on Multimeter should decrease as Cord Tension decreases.

4. If voltage does not increase and decrease as described in steps 2 and 3, continue with test.

5. Turn unit Off. Using the Pick, remove Blue wire and Green wire from connector. See Figure 5.24.

6. Connect the Multimeter Leads to the Blue and Green wires. Repeat steps 2 and 3.

7. If voltage does not increase or decrease as described in steps 2 and 3, replace unit Load Cell. Refer to 6.7 Load Cell Removal and Replacement.

8. If voltage does increase and decrease as described in steps 2 and 3, replace wires into connector. Make certain the Blue wire is in the Pin 3 position and the Green wire is in the Pin 4 position. Repeat steps 2 and

3. If problem persists, proceed to step 9.

9. Locate U3 on Motor Control Board. Connect the Red (+) Multimeter Lead to Pin 7 of U3 and the Black (-) Lead to Pin 4 of U3. See Figure 5.25.

10. Repeat steps 2 and 3. If voltage does not increase and decrease as described in steps 2 and 3, replace Motor Control Board. Refer to 6.5 Motor Control Board Removal & Replacement.

Tru-Trac and TX® Therapeutic Traction Unit

RED LEAD TO PIN 4

BLACK LEAD TO PIN 3

FIGURE 5.23

USE PICK TO REMOVE WIRES

FIGURE 5.24

FIGURE 5.25

Page 26

5 TROUBLESHOOTING

5.13 TOUCH SCREEN TEST

A. Specification

Contrast Control . . . . . . . . . . Touch Screen Dims

and Brightens

Touch Screen . . . . . . . . . Displays proper Screen

B. Equipment Required

None C. Touch Screen Test Procedure

1. Place unit on level work surface.

2. Plug Power Cord into grounded power source with appropriate voltage. See Specifications on page 8.

3. Turn unit On with Power Switch. After the unit has completely booted, adjust the Touch Screen Contrast with the Contrast Control on the back of the Touch Screen Housing. See Figure 5.26.

4. Press Touch Screen controls to verify the Touch Screen responds and displays the correct screen. See Figure 5.27.

D. Test Result

1. If when adjusting, Contrast Control dims and brightens Touch Screen, unit passed test. If Contrast Control does not dim and brighten Touch Screen, refer to 5.14 Touch Screen Troubleshooting.

2. If when pressing controls on Touch Screen the proper screen does not display, unit failed test. Calibrate Touch Screen. Refer to 7.2 Touch Screen Calibration.

3. If nothing is visible on Touch Screen, adjust Contrast Control. If problem persists, unit failed test. Refer to 5.14 Touch Screen Troubleshooting.

Tru-Trac and TX® Therapeutic Traction Unit

CONTRAST KNOB

FIGURE 5.26

FIGURE 5.27

Page 27

5 TROUBLESHOOTING

Tru-Trac and TX® Therapeutic Traction Unit

5.14 TOUCH SCREEN TROUBLESHOOTING

A. Specification Voltage to Touch Screen:

J6 Connector . . . . . . . . . . . . . . . . .5 VDC ±5%

Display Connector . . . . . . . . . . .24 VDC ±5%

B. Equipment Required

1. 3/32 in Allen Wrench

2. Digital Multimeter C. Touch Screen Troubleshooting Procedure

1. Remove Side Covers. Refer to 6.1 Side Cover Removal & Replacement.

2. Plug unit into an approved power source and turn unit On with Power Switch.

3. Observe Motor Control Board LEDs. The "5V OK" LED should be illuminated and LED 3 should be flashing. See Figure 5.28.

a. If LEDs are not working properly, proceed to step 4.

b. If LEDs are working properly, proceed to steps 5 through 9.

4. Turn unit Off. Remove Touch Screen Ribbon Cable from "Display" on Motor Control Board. See Figure 5.29. Turn unit On.

a. If LEDs begin working properly, replace Touch Screen assembly. Refer to 6.6 Touch Screen Assembly Removal and Replacement.

b. If LEDs are not working properly, refer to

5.15 Power Supply Troubleshooting. c. If Power Supply is functioning properly,

replace Motor Control Board. Refer to 6.5 Motor Control Board Removal and Replacement.

5. Turn unit Off. Remove Touch Screen Ribbon Cable from "Display" on Motor Control Board. See Figure 5.29. Turn unit On.

6. Set Multimeter to VDC. On Connector J6, connect the Red (+) Multimeter Lead to Pin 1 and the Black (-) Lead to Pin 2. See Figure 5.28. Take reading from Multimeter. Reading should be +5 VDC.

7. Connect the Red (+) Multimeter Lead to Pin 6 and the Black (-) Lead to Pin 1 on the Motor Control Board "Display" Connector. See Figure 5.30 reading on Multimeter should be 24 VDC.

8. If the voltage reads correctly from steps 5 and 6, replace the Touch Screen Assembly. Refer to 6.6 Touch Screen Removal and Replacement.

9. If either of the voltages are not reading properly as in steps 6 and 7, replace Motor Control Board. Refer to 6.5 Motor Control Board Removal & Replacement.

PIN 1

LED 3

PIN 2

5V OK LED

FIGURE 5.28

FIGURE 5.29

Make certain Multimeter Leads are on the

correct pins and do not short across any

other pins to prevent destruction of the

CAUTION

Motor Control Board.

FIGURE 5.30

Page 28

5 TROUBLESHOOTING

5.15 POWER SUPPLY TROUBLESHOOTING

A. Specification Power Supply Input . . 100 V-240 V (50/60 Hz)

Power Supply Output . . . . . . . . . . .24 VDC ±5%

B. Equipment Required

1. 3/32 in Allen Wrench

2. Digital Multimeter C. Power Supply Troubleshooting Procedure

1. Remove Side Covers. Refer to 6.1 Side Cover Removal & Replacement.

2. Plug Power Cord into grounded power source with appropriate voltage. See Specifications on page 8.

3. Set Multimeter to read appropriate VAC.

4. Connect Multimeter Leads to the Power Supply Fuses at the rear of Power Supply. See Figure 5.31. Multimeter should read same voltage as the approved power source. a. If reading is the same as approved power source, proceed to step 5.

b. If VAC reading is not the same as approved power source, replace Power Supply. Refer to 6.12 Power Supply Removal & Replacement.

5. Remove Power Supply Output Harness from Motor Control Board J5. See Figure 5.32.

6. Set Multimeter to read VDC. Connect Multimeter Leads to the Power Supply Output Harness. See Figure 5.33. Multimeter reading should be 24 VDC ±5%.

a. If reading is within the specified range as stated above, unit passed test.

b. If reading is not within the specified range as stated above, replace Power Supply. Refer to 6.12 Power Supply Removal & Replacement.

Tru-Trac and TX® Therapeutic Traction Unit

FIGURE 5.31

FIGURE 5.32

FIGURE 5.33

Page 29

6 REMOVAL & REPLACEMENT

6.1 SIDE COVER REMOVAL & REPLACEMENT

Unplug the unit from the power source before attempting removal or replacement procedures to prevent electrical shock.

A. Part Numbers

Side Cover (2 Req'd) . . . . . . . . . . . . . . . . . . . 47857

B. Equipment Required

3/32 in Allen Wrench

• Flat Blade Screwdriver

• #1 Phillips Screwdriver

•

C. Removal of Side Covers

1. Remove Patient Interrupt Switch Hook Screw Cover with a Flat Blade Screwdriver. See inset at Figure 6.1.

2. Remove Patient Interrupt Switch Hook Screw using a #1 Phillips Screwdriver. See Figure 6.1.

3. Lay unit on its side on a clean, soft work surface.

4. Using the 3/32 in Allen Wrench, remove the three Side Cover Mounting Screws from the bottom of the unit. See Figure 6.2.

5. Slide side cover from under Top Cover.

6. Turn unit over onto opposite side and repeat steps 2-5.

D. Replacement of Side Covers

1. Position Side Cover Top Mounting Tab between plastic of Top Cover and Touch Screen Mounting Plate. See Figure 6.3.

2. Slide cover into position and secure with three socket head screws using the 3/32 in Allen Wrench. Refer to Figure 6.2.

NOTE:

Do not overtighten mounting screws.

Tru-Trac and TX® Therapeutic Traction Unit

FIGURE 6.1

SIDE COVER

MOUNTING SCREWS

FIGURE 6.2

FIGURE 6.3

Page 30

6 REMOVAL & REPLACEMENT

6.2 TOP AND CORD GUIDE COVER REMOVAL & REPLACEMENT

Tru-Trac and TX® Therapeutic Traction Unit

Unplug the unit from the power source before attempting removal or replacement procedures to prevent electrical shock.

A. Part Numbers

•

Top Co ver . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47856

•

Cord Guide Cover . . . . . . . . . . . . . . . . . . . . 47872

B. Equipment Required

•

3/32 in Allen Wrench

•

#2 Phillips Screwdriver

•

Touch Screen to Cover Assembly Jig

C. Removal of Top and Cord Guide Covers

1. Remove Side Covers. Refer to 6.1 Side Cover Removal & Replacement.

2. Position unit upright on base and untie Traction Cord from Knuckle. Refer to page 41, step 11 Traction Cord Removal & Replacement.

3. Disconnect the Touch Screen Ribbon Cable from the Motor Control Board. See Figure 6.4.

4. Using the #1 Phillips Screwdriver, remove the two Top Cover Mounting Screws from each side of the unit. See Figure 6.5.

NOTE:

To remove the Touch Screen Assembly from the Top Cover refer to 6.6 Touch Screen Removal & Replacement.

5. Carefully lift the Top Cover away from unit and position into Touch Screen to Cover Assembly Jig. See Figure 6.6.

6. Using the #2 Phillips Screwdriver, remove the four Cord Guide Cover Mounting Screws. See Figure 6.6.

D. Replacing Top and Cord Guide Covers

1. With Top Cover positioned onto the Touch Screen to Cover Assembly Jig, place the Cord Guide Cover into position. Secure with the four Cord Guide Cover Mounting Screws. See Figure 6.6.

2. Position the Top Cover Assembly onto the unit chassis. Secure into position on the standoffs with the four Top Cover Mounting Screws (two on each side). See Figure 6.5.

3. Connect the Touch Screen Ribbon Cable to the "Display" Connector on the Motor Control Board. See Figure 6.4.

4. Install Side Covers. Refer to 6.1 Side Cover Removal & Replacement.

WHEN INSTALLING, RIBBON CABLE BLACK STRIP MUST BE

TOWARD THE TOP OF THE MOTOR CONTROL BOARD.

FIGURE 6.4

TOP COVER MOUNTING SCREWS

TWO ON EACH SIDE

FIGURE 6.5

CORD GUIDE COVER

MOUNTING SCREWS

FIGURE 6.6

Page 31

6 REMOVAL & REPLACEMENT

6.3 REAR COVER REMOVAL & REPLACEMENT

Unplug the unit from the power source before attempting removal or replacement procedures to prevent electrical shock.

A. Part Numbers

Rear Cover Assembly . . . . . . . . . . . . . . . . . .48110

B. Equipment Required

3/32 in Allen Wrench

•

Touch Screen to Cover Assembly Jig

•

C. Removal of Top and Cord Guide Covers

1. Remove IEC Connector Cover. See Figure 6.7.

2. Remove Side Covers. Refer to 6.1 Side Cover Removal & Replacement.

3. Remove Top Cover Assembly. Refer to 6.2, part C, steps 1-5.

4. Using the 3/32 in Allen Wrench, remove the four Rear Cover Mounting Screws. See Figure 6.8.

NOTE:

To replace the Rear Cover with a new part, remove the Power Switch, Mains Connector, and USB Board from the old Rear Cover for re-installation onto the new part. See Figure 6.9.

It is not necessary to remove Harnesses from Power Switch, Mains Connector, or USB Board unless these components are to be replaced.

D. Replacing Rear Cover

1. Replace existing Rear Cover a. Secure Rear Cover to chassis with four

Rear Cover Mounting Screws. See Figure 6.8.

b. Install Top Cover Assembly. Refer to 6.2, part D, steps 2 and 3.

c. Install Side Covers. Refer to 6.1, part D, steps 1 and 2.

2. Replace with new Rear Cover a. Install existing Power Switch, Mains

Connector, and USB Board to new Rear Cover.

b. Secure Rear Cover to chassis. See Figure 6.8.

c. Install Top Cover Assembly. Refer to 6.2, part D, steps 2 and 3.

d. Install Side Covers. Refer to 6.1, part D, steps 1 and 2.

NOTE:

Do not overtighten mounting screws.

Tru-Trac and TX® Therapeutic Traction Unit

IEC CONNECTOR COVER

FIGURE 6.7

REAR COVER

MOUNTING SCREWS

FIGURE 6.8

USB BOARD

POWER SWITCH

MAINS CONNECTOR

FIGURE 6.9

Page 32

6 REMOVAL & REPLACEMENT

6.4 FRONT COVER REMOVAL & REPLACEMENT

Tru-Trac and TX® Therapeutic Traction Unit

Unplug the unit from the power source before attempting removal or replacement procedures to prevent electrical shock.

A. Part Numbers

Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . .47858

B. Equipment Required

3/32 in Allen Wrench

•

Touch Screen to Cover Assembly Jig

•

Needle Nose Pliers

•

C. Removal of Front Cover

1. Remove Side Covers. Refer to 6.1 Side Cover Removal & Replacement.

2. Remove Top Cover Assembly. Refer to 6.2, part C, steps 2-5.

3. Disconnect the Patient Interrupt Switch Jack from the Motor Control Board. See Figure 6.10.

4. Using the 3/32 in Allen Wrench, remove the four Front Cover Mounting Screws. See Figure 6.11.

NOTE:

To replace the Front Cover with a new part, remove the Patient Interrupt Switch Jack from the old Front Cover for re-installation onto the new part. See Figure 6.12.

D. Replacing Front Cover

1. Replacing existing Front Cover a. Connect Patient Interrupt Switch Jack to

the Motor Control Board. See Figure 6.10. b. Secure the Front Cover to the chassis

with the four Front Cover Mounting Screws. See Figure 6.11.

c. Install Top Cover Assembly. Refer to 6.2, part D, steps 2 and 3.

d. Install Side Covers. Refer to 6.1, part D, steps 1 and 2.

2. Replacing with new Front Cover a. Install Patient Interrupt Switch Jack into

new Front Cover. See Figure 6.12. b. Perform steps 3-4 above in reverse order. c. Install Top Cover Assembly. Refer to 6.2,

part D, steps 2 and 3. d. Install Side Covers. Refer to 6.1, part D,

steps 1 and 2.

NOTE:

Do not overtighten mounting screws.

PATIENT INTERRUPT

SWITCH HARNESS

FIGURE 6.10

FRONT COVER

MOUNTING SCREWS

FIGURE 6.11

PATIENT INTERRUPT

SWITCH JACK

FIGURE 6.12

Page 33

6 REMOVAL & REPLACEMENT

Tru-Trac and TX® Therapeutic Traction Unit

The remaining removal and replacement procedures in this section require that the following be performed after component or assembly replacement to ensure proper alignment and operation of the unit:

1. COMPLETE CALIBRATION OF UNIT AND

2. MINIMUM OF 2 HOUR BURN IN OF UNIT AFTER SUCCESSFUL CALIBRATION

Failure to perform either of these procedures after a component or assembly replacement will void warranty and may result in injury to patients and severe equipment damage.

Page 34

6 REMOVAL & REPLACEMENT

6.5 MOTOR CONTROL BOARD REMOVAL & REPLACEMENT

Tru-Trac and TX® Therapeutic Traction Unit

Unplug the unit from the power source before attempting removal or replacement procedures to prevent electrical shock.

A. Part Numbers

Motor Control Board . . . . . . . . . . . . . . . . . .47803

B. Equipment Required

3/32 in Allen Wrench

•

#2 Phillips Screwdriver

•

C. Removal of Motor Control Board

1. Remove Side Covers. Refer to 6.1 Side Cover Removal & Replacement.

2. Disconnect all seven harnesses from the Motor Control Board. See Figure 6.13.

3. Using the #2 Phillips Screwdriver, remove the four Motor Control Board Mounting Screws. See Figure 6.14.

D. Replacing Motor Control Board

1. Position Motor Control Board over chassis standoffs and secure into position with the screws removed in step 3 above.

2. Install Harnesses to the Motor Control Board. See Figure 6.13.

3. Perform complete Calibration and Burn In of unit.

NOTE:

Do not overtighten mounting screws.

LOAD CELL HARNESS

USB HARNESS

TOUCH SCREEN

HARNESS

SOLENOID HARNESS

MOTOR HARNESS

PATIENT INTERRUPT

SWITCH HARNESS

POWER SUPPLY

HARNESS

FIGURE 6.13

This component removal and replacement procedure requires that the following be performed after component or assembly replacement to ensure proper alignment and operation of the unit:

COMPLETE CALIBRATION OF UNIT Refer to

Section 7

AND

MINIMUM OF 2 HOUR BURN IN OF UNIT AFTER

SUCCESSFUL CALIBRATION Refer to Section 7

Failure to perform either of these procedures, after a component or assembly replacement will void warranty and may result in injury to patients and/or severe equipment damage.

MOTOR CONTROL

BOARD MOUNTING

SCREWS

FIGURE 6.14

Page 35

6 REMOVAL & REPLACEMENT

6.6 TOUCH SCREEEN ASSEMBLY REMOVAL & REPLACEMENT

Tru-Trac and TX® Therapeutic Traction Unit

Unplug the unit from the power source before attempting removal or replacement procedures to prevent electrical shock.

A. Part Numbers

Touch Screen Assembly . . . . . . . . . . . . . . .48063

B. Equipment Required

3/32 in Allen Wrench

•

Flat Blade Screwdriver

•

Touch Screen to Cover Assembly Jig

•

C. Removal of Touch Screen Assembly

1. Remove Side Covers. Refer to 6.1 Side Cover Removal & Replacement.

2. Remove the Top Cover. Refer to 6.2 Top and Cord Guide Cover Removal & Replacement, part C, steps 2-5.

3. Using the Flat Blade Screwdriver, remove the four Top Moulding Plate Mounting Screws. When removing the Top Moulding Plate, guide the Touch Screen Ribbon Cable through the opening. See Figure 6.15.

4. Using the Flat Blade Screwdriver, remove the four Turn Table Plate Retaining Screws. See Figure 6.16.

5. Squeeze the two Touch Screen Assembly Tabs and push the Touch Screen Assembly out of the Top Cover. See Figure 6.17.

TOP MOULDING PLATE

MOUNTING SCREWS

FIGURE 6.15

TURN TABLE PLATE

MOUNTING SCREWS

FIGURE 6.16

FIGURE 6.17

Page 36

6 REMOVAL & REPLACEMENT

6.6 TOUCH SCREEN ASSEMBLY REMOVAL & REPLACEMENT (continued)

Unplug the unit from the power source before attempting removal or replacement procedures to prevent electrical shock.

D. Replacing Touch Screen Assembly

1. Place new Touch Screen Assembly into Touch Screen to Cover Assembly Jig.

2. Position Top Cover over the Touch Screen Assembly aligning the mounting hole to the Touch Screen Assembly.

3. Slide the Top Cover over the Touch Screen Assembly until the Mounting Tabs click into position. See Figure 6.18.

4. Position the Turntable Plate and secure the four screws with the #2 Phillips Screwdriver. See Figure 6.19.

5. Position the Top Moulding Plate. Thread the Touch Screen Ribbon Cable through the opening in the Top Moulding Plate as shown in Figure 6.20. Secure the four Top Moulding Plate screws with the #2 Phillips Screwdriver. Refer to Figure 6.15.

6. Install Top Cover Assembly. Refer to 6.2, part D, steps 2 and 3.

7. Install Side Covers. Refer to 6.1, part D, steps 1 and 2.

8. Perform complete Calibration and Burn In of unit.

NOTE:

Do not overtighten mounting screws.

FIGURE 6.18

Tru-Trac and TX® Therapeutic Traction Unit

TURN TABLE PLATE

MOUNTING SCREWS

This removal and replacement procedure requires that the following be performed after component or assembly replacement to ensure proper alignment and operation of the unit:

1. COMPLETE CALIBRATION OF UNIT Refer to Section 7

AND

2. MINIMUM OF 2 HOUR BURN IN OF UNIT AFTER SUCCESSFUL CALIBRATION

Refer to Section 7

Failure to perform either of these procedures after a component or assembly replacement will void warranty and may result in injury to patients and severe equipment damage.

FIGURE 6.19

FIGURE 6.20

Page 37

6 REMOVAL & REPLACEMENT

6.7 LOAD CELL ASSEMBLY REMOVAL & REPLACEMENT

Unplug the unit from the power source before attempting removal or replacement procedures to prevent electrical shock.

A. Part Numbers

Load Cell Assembly . . . . . . . . . . . . . . . . . . . .48009

B. Equipment Required

3/32 in Allen Wrench

•

4 mm Hex Key Socket and Ratchet

•

Calibrated Torque Wrench- 200 inch pound

•

or 2,500 Newton meter minimum capacity.

C. Removal of Load Cell Assembly

1. Remove Side Covers. Refer to 6.1 Side Cover Removal & Replacement.

2. Remove the Top Cover. Refer to 6.2 Top and Cord Guide Cover Removal & Replacement, part C, steps 2-5.

3. Remove Rear Cover. Refer to 6.3 Rear Cover Removal & Replacement.

4. Remove the Clamp Spring Assembly. Refer to 6.8 Clamp Spring Assembly Removal & Replacement.

5. Disconnect the Load Cell Harness from the Motor Control Board. See Figure 6.21.

6. Using the 4 mm Hex Key Socket and Ratchet, remove the two Load Cell Mounting Screws and Flat Washers from each side of the Chassis. See Figure 6.22.

7. Lift Load Cell Assembly out of Chassis. See Figure 6.23.

LOAD CELL HARNESS

MOUNTING SCREWS

Tru-Trac and TX® Therapeutic Traction Unit

LOAD CELL HARNESS

FIGURE 6.21

2 EACH SIDE

FIGURE 6.22

LOAD CELL ASSEMBLY

FIGURE 6.23

Page 38

6 REMOVAL & REPLACEMENT

6.7 LOAD CELL ASSEMBLY REMOVAL & REPLACEMENT (continued)

Unplug the unit from the power source before attempting removal or replacement procedures to prevent electrical shock.

D. Replacement of Load Cell Assembly

1. Place Load Cell Assembly into Chassis and hold in position while hand starting the Load Cell Mounting Screws and Flat Washers. See Figure 6.24.

2. Hand tighten the Load Cell Mounting Screws.

3. Install the Clamp Spring Assembly. Refer to 6.8 Clamp Spring Assembly Removal & Replacement.

4. Use the Torque Wrench and 4 mm Hex Key Socket to torque the Load Cell Mounting Screws to 35 Nm (84 in lbs).

5. Route Load Cell Harness through Harness Clips on the Chassis and connect to Motor Control Board. See Figure 6.25.

6. Route Traction Cord through the Load Cell Assembly Pulley and through the Chassis Upper Guide Pulley. See Figure 6.26.

7. Install Rear Cover. Refer to 6.3 Rear Cover Removal & Replacement.

8. Install Top Cover. Refer to 6.2 Top and Cord Guide Cover Removal & Replacement.

9. Install Side Covers. Refer to 6.1 Side Cover Removal & Replacement.

10. Perform complete Calibration and Burn In of unit.

Tru-Trac and TX® Therapeutic Traction Unit

FIGURE 6.24

FIGURE 6.25

This removal and replacement procedure requires that the following be performed after component or assembly replacement to ensure proper alignment and operation of the unit:

1. COMPLETE CALIBRATION OF UNIT Refer to Section 7

AND

2. MINIMUM OF 2 HOUR BURN IN OF UNIT AFTER SUCCESSFUL CALIBRATION

Refer to Section 7

Failure to perform either of these procedures after a component or assembly replacement will void warranty and may result in injury to patients and severe equipment damage.

FIGURE 6.26

Page 39

6 REMOVAL & REPLACEMENT

6.8 CLAMP SPRING ASSEMBLY REMOVAL & REPLACEMENT

Unplug the unit from the power source before attempting removal or replacement procedures to prevent electrical shock.

A. Part Numbers

Clamp Spring Assembly . . . . . . . . . . . . . . .48023

B. Equipment Required

3/32 in Allen Wrench

C. Clamp Spring Assembly Removal

1. Remove Side Covers. Refer to 6.1 Side Cover Removal & Replacement.

2. Remove the Top Cover. Refer to 6.2 Top and Cord Guide Cover Removal & Replacement, part C, steps 2-5.

3. Remove Rear Cover. Refer to 6.3 Rear Cover Removal & Replacement.

4. Remove the four Clamp Spring Assembly Mounting Screws. See Figure 6.27.

5. Turn the Clamp Knob Counterclockwise until it is completely disengaged from the Clamp Plate. See Figure 6.28.

D. Clamp Spring Assembly Replacement

1. Position the Clamp Spring Assembly at the Chassis and rotate Clamp Knob until the threaded portion is fully engaged in the Clamp Plate and the Clamp Spring Assembly Mounting Bracket is aligned with the respective mounting holes in the Chassis. Secure with the four Clamp Spring Assembly Mounting Screws.

2. Install Rear Cover. Refer to 6.3 Rear Cover Removal & Replacement.

3. Install Top Cover. Refer to 6.2 Top and Cord Guide Cover Removal & Replacement.

4. Install Side Covers. Refer to 6.1 Side Cover Removal & Replacement.

5. Perform complete Calibration and Burn In of unit.

This removal and replacement procedure requires that the following be performed after component or assembly replacement to ensure proper alignment and operation of the unit:

2. MINIMUM OF 2 HOUR BURN IN OF UNIT

Tru-Trac and TX® Therapeutic Traction Unit

CLAMP SPRING

ASSEMBLY

SCREWS

2 EACH SIDE

FIGURE 6.27

CLAMP KNOB

CLAMP SPRING

ASSEMBLY

MOUNTING SCREWS

2 EACH SIDE

CLAMP PLATE

FIGURE 6.28

1. COMPLETE CALIBRATION OF UNIT Refer to Section 7

AND

AFTER SUCCESSFUL CALIBRATION

Refer to Section 7

Failure to perform either of these procedures after a component or assembly replacement will void warranty and may result in injury to patients and severe equipment damage.

Page 40

6 REMOVAL & REPLACEMENT

6.9 TRACTION CORD REMOVAL & REPLACEMENT

Unplug the unit from the power source before attempting removal or replacement procedures to prevent electrical shock.

A. Part Numbers

Traction Cord . . . . . . . . . . . . . . . . . . . . . . . . . .48031

B. Equipment Required

3/32 in Allen Wrench

•

5/32 in Allen Wrench

•

Needle Nose Pliers

•

Tape Measure

•

C. Clamp Spring Assembly Removal

1. Remove Side Covers. Refer to 6.1 Side Cover Removal & Replacement.

2. Remove the Top Cover. Refer to 6.2 Top and Cord Guide Cover Removal & Replacement, part C, steps 2-5.

3. Remove Rear Cover. Refer to 6.3 Rear Cover Removal & Replacement.

4. Remove the Clamp Spring Assembly. Refer to 6.8 Clamp Spring Removal and Replacement.

5. While holding the Cord Tension Spring Housing in position with one hand, loosen the retaining screw with the other hand. See Figure 6.29.

6. Gradually release the spring tension by allowing the Spring Housing to slowly rotate in the hand. Leave the Housing Retaining Screw loose.

7. Manually release the Solenoid from the Large Driven Gear and simultaneously pull the Traction Cord through the unit front until the Traction Cord stops. See Figure 6.30.

NOTE:

Make certain the Traction Cord Knot is facing the rear of the unit.

8. Release the Solenoid, making certain it fully engages the teeth of the Large Driven Gear.

NOTE:

It may be necessary to slightly jog the Large Driven Gear to facilitate tooth engagement.

9. Remove the Traction Cord Knuckle. Refer to page 41, step 11. Using the Needle Nose Pliers, pull the Traction Cord Knot from the Traction Cord Spool and completely pull the Traction Cord out of unit. See Figure 6.31.

Tru-Trac and TX® Therapeutic Traction Unit

FIGURE 6.29

FIGURE 6.30

FIGURE 6.31

Page 41

6 REMOVAL & REPLACEMENT

6.9 TRACTION CORD REMOVAL & REPLACEMENT (continued)

D. Traction Cord Replacement

1. Route Traction Cord through the Traction

Unplug the unit from the power source before

• attempting removal or replacement procedures to prevent electrical shock. It is not recommend tying a new knot in a cord that

• has frayed or failed in use or is worn in an area from constant use. The cord must be replaced.

TOP GUIDE PULLEY

Cord Spool, Load Cell Pulley, and Top Guide Pulley. See Figure 6.32

NOTE:

The left side of the Chassis incorporates a Window to facilitate proper routing of the Traction Cord.

Tru-Trac and TX® Therapeutic Traction Unit

LOAD CELL PULLEY

TRACTION CORD SPOOL

TRACTION CORD ROUTING WINDOW

FIGURE 6.32

Page 42

6 REMOVAL & REPLACEMENT

6.9 TRACTION CORD REMOVAL & REPLACEMENT (continued)

Unplug the unit from the power source before attempting removal or replacement procedures to prevent electrical shock.

2. Pull enough of the Traction Cord through the Traction Cord Spool to allow the knot to be tied.

3. Tie a Figure Eight (Flemish, Savoy) Knot in the end of the Cord passing through the Traction Cord Spool. See Figure 6.33.

Do not use any other knot styles in the Cord other than those specified in this manual. Use of other knot styles could cause Cord to completely disengage from the system causing serious injury to patient and personnel.

Tru-Trac and TX® Therapeutic Traction Unit

4. Trim any fraying from the Traction Cord leaving 19 mm (0.75 in) of Cord outside the Figure Eight (Flemish, Savoy) Knot.

5. Singe the Cord end until the outer jacket and inner core of the Traction Cord melt together. See Figure 6.34A.

6. Pull other end of Traction Cord until the Figure Eight (Flemish, Savoy) Knot is completely seated within the Traction Cord Spool. See Figure 6.34B.

NOTE:

It may be necessary to use a long, thin tool such as a Flat Blade Screwdriver to properly tuck the Figure Eight (Flemish, Savoy) Knot into the Traction Cord Spool.

FIGURE 6.33

FIGURE 6.34A

FIGURE 6.34B

Page 43

6 REMOVAL & REPLACEMENT

6.9 TRACTION CORD REMOVAL & REPLACEMENT (continued)

Unplug the unit from the power source before attempting removal or replacement procedures to prevent electrical shock.

7. Route Traction Cord through the Front Cord Guide Support.

8. Route Traction Cord through the Top Cover and place the Top Cover in Position on the Chassis. See Figure 6.35. Do not secure Top Cover at this time.

9. Inspect Traction Cord Knuckle for damage and wear. Replace if damaged or worn.

10. Route Traction Cord through Traction Cord Knuckle Cover and Cord Knuckle. Tie an Overhand or Half Knot in the end of the Traction Cord leaving 25.5 mm (1.00 in) of Traction Cord outside the knot. See Figure 6.36.

11. Trim any fraying from the end of the Traction Cord and singe the Cord end until the outer jacket and inner core of the Traction Cord melt together. Make certain at least 19 mm (0.750 in) of Traction Cord still remains outside the knot. See Figure 6.36 inset.

Tru-Trac and TX® Therapeutic Traction Unit

FIGURE 6.35

Do not use any other knot styles in the Cord other than those specified in this manual. Use of other knot styles could cause Cord to completely disengage from the system and may cause serious injury to patient and personnel.

12. Secure the knot inside the Traction Cord Knuckle ensuring the loose end enters the Bore inside the Traction Cord Knuckle. See Figure 6.37. Slide Traction Cord Knuckle Cover into position over the knot. See Figure 6.37 inset.

NOTE:

It may be necessary to use a long, thin tool such as a Flat Blade Screwdriver to properly tuck the loose end of the Traction Cord into the Bore of the Traction Cord Knuckle.

FIGURE 6.36

FIGURE 6.37

Page 44

6 REMOVAL & REPLACEMENT

6.9 TRACTION CORD REMOVAL & REPLACEMENT (continued)

Unplug the unit from the power source before attempting removal or replacement procedures to prevent electrical shock.

NOTE:

If adjusting Spring Tension only and not replacing the Traction Cord, it will be necessary to remove the Side Covers and have available the Tools required in 6.9, B.

13. Manually release the Solenoid and simultaneously fully extend the Traction Cord. Release Solenoid and make certain the Solenoid Gear fully engages the Large Driven Gear. See Figure 6.38.

14. With the Cord fully extended, rotate the Cord Spring Housing clockwise until the Cord Spring is completely wound, then rotate counterclockwise 1/4 to 1/2 turn. Hold the Cord Spring Housing in position and tighten the Retaining Screw using the 5/32 in Allen Wrench. See Figure 6.39.

NOTE:

Overtightening of the Cord Spring Housing Retaining Screw will break the housing and cause the spring to lose tension.

15. While holding on to the Traction Cord, manually release the Solenoid and allow the Traction Cord to retract.

16. Manually release the Solenoid and simultaneously fully extend the Traction Cord. Release Solenoid and make certain it fully engages the Large Driven Gear.

17. Using Tape Measure, measure the length of the Cord from the Cord Guide Cover to the end of the Harness Clip. See Figure 6.40. Measurement should be

96.5 cm to 106.5 cm (38 in to 42 in). a) If measurement is less than 96.5 cm

(38 in), Spring Tension is too tight. Loosen the Spring Housing Retaining Screw and allow the housing to release no more than 1/2 revolution of tension. Tighten Spring Housing Retaining Screw and repeat steps 15 and 16.

b) If measurement is more than 106.5 cm (42 in), increase Traction Cord Spring Tension by no more than 1/2 revolution.

18. Repeat step 17 a or b until Cord dimension is correct.

Tru-Trac and TX® Therapeutic Traction Unit

FIGURE 6.38

FIGURE 6.39

FIGURE 6.40

Page 45

6 REMOVAL & REPLACEMENT

6.9 TRACTION CORD REMOVAL & REPLACEMENT (continued)

Unplug the unit from the power source before attempting removal or replacement procedures to prevent electrical shock.

19. Install Clamp Spring Assembly. Refer to

6.8 Clamp Spring Assembly Removal & Replacement.

20. Install Rear Cover. Refer to 6.3 Rear Cover Removal & Replacement.

21. Install Top Cover. Refer to 6.2 Top and Cord Guide Cover Removal & Replacement.

22. Install Side Covers. Refer to 6.1 Side Cover Removal & Replacement.

23. Perform complete Calibration and Burn In of unit.

Tru-Trac and TX® Therapeutic Traction Unit

This removal and replacement procedure requires that the following be performed after component or assembly replacement to ensure proper alignment and operation of the unit:

1. COMPLETE CALIBRATION OF UNIT Refer to Section 7

AND

2. MINIMUM OF 2 HOUR BURN IN OF UNIT AFTER SUCCESSFUL CALIBRATION

Refer to Section 7

Failure to perform either of these procedures after a component or assembly replacement will void warranty and may result in injury to patients and severe equipment damage.

Page 46

6 REMOVAL & REPLACEMENT

6.10 CORD TENSION SPRING REMOVAL & REPLACEMENT

Unplug the unit from the power source before attempting removal or replacement procedures to prevent electrical shock.

A. Part Numbers

Cord Tension Spring . . . . . . . . . . . . . . . . . . .80653

B. Equipment Required

3/32 in Allen Wrench

•

5/32 in Allen Wrench

•

C. Cord Tension Spring Removal

1. Remove Side Covers. Refer to 6.1 Side Cover Removal & Replacement.

2. Remove the Top Cover. Refer to 6.2 Top and Cord Guide Cover Removal & Replacement, part C, steps 2-5.

3. While holding the Cord Tension Spring Housing with one hand. Loosen the retaining screw with the other hand using the 5/32 in Allen Wrench. See Figure 6.41.

4. Gradually allow the Spring Housing to rotate in the hand releasing spring tension.

5. Rotate the Cord Tension Spring Housing until the hole in the face aligns with the Spring Mounting Screw. Remove screw with the 3/32 in Allen Wrench. See Figure 6.42.

6. Remove the Cord Tension Spring Housing Mounting Screw. See Figure 6.43.

7. Remove Cord Tension Spring and Housing from unit.

SPRING MOUNTING SCREW

Tru-Trac and TX® Therapeutic Traction Unit

FIGURE 6.41

FIGURE 6.42

FIGURE 6.43

Page 47

6 REMOVAL & REPLACEMENT

6.10 CORD TENSION SPRING REMOVAL & REPLACEMENT (continued)

Unplug the unit from the power source before attempting removal or replacement procedures to prevent electrical shock.

D. Cord Tension Spring Replacement

1. Position new Cord Tension Spring in

Housing as shown in Figure 6.44.

2. Place Spring Mounting Screw through hole in face of the Housing and through the Cord Tension Spring Mounting Loop. Leave the head of the Spring Mounting Screw protruding through the Housing. See Figure 6.45

3. Position the Spring and Housing assembly in the mounting position on the Chassis. Start the Spring Mounting Screw using the 3/32 in Allen Wrench. Tighten Mounting Screw until Cord Tension Spring Mounting Loop is secure then, back the screw out one complete revolution. See Figure 6.46.

4. Position the Spring and Housing so that the Housing Mounting Screw can be started. Start screw with the 5/32 in Allen Wrench.

5. Adjust Spring Tension. Refer to page 42.

6. Install Top Cover. Refer to 6.2 Top and Cord Guide Cover Removal & Replacement.

7. Install Side Covers. Refer to 6.1 Side Cover Removal & Replacement.

8. Perform complete Calibration and Burn In of unit.

Tru-Trac and TX® Therapeutic Traction Unit

FIGURE 6.44

FIGURE 6.45

This removal and replacement procedure requires that the following be performed after component or assembly replacement to ensure proper alignment and operation of the unit:

1. COMPLETE CALIBRATION OF UNIT Refer to Section 7

AND

2. MINIMUM OF 2 HOUR BURN IN OF UNIT AFTER SUCCESSFUL CALIBRATION

Refer to Section 7

Failure to perform either of these procedures after a component or assembly replacement will void warranty and may result in injury to patients and severe equipment damage.

FIGURE 6.46

Page 48

6 REMOVAL & REPLACEMENT

6.11 SOLENOID ASSEMBLY REMOVAL & REPLACEMENT

Unplug the unit from the power source before attempting removal or replacement procedures to prevent electrical shock.

A. Part Numbers

Solenoid Assembly . . . . . . . . . . . . . . . . . . . . 48014

B. Equipment Required

•

9/64 in Allen Wrench

•

Solenoid Assembly Mounting Jig(P/N 48139)

C. Solenoid Assembly Removal

1. Remove Side Covers. Refer to 6.1 Side Cover Removal & Replacement.

2. Make certain the Cord is fully retracted. If necessary, manually retract. Refer to Figure 5.12.

3. Disconnect the Solenoid Assembly Harness from Motor Control Board. See Figure 6.47.

4. Using the 9/64 in Allen Wrench, remove the two Solenoid Assembly Mounting Screws. See Figure 6.48.

D. Solenoid Assembly Replacement

1. Position the Solenoid Assembly Mounting Jig onto the Shafts of the Large Driven Gear and the Motor Gear. See Figure 6.49.

2. Position the Solenoid Assembly so gears are fully seated and the front and bottom of the Bracket are against the Solenoid Assembly Mounting Jig. Secure with screws. See Figure 6.49.

3. Connect Solenoid Assembly Harness to Motor Control Board. See Figure 6.47.

4. Install Side Covers. Refer to 6.1 Side Cover Removal & Replacement.

5. Perform complete Calibration and Burn In of unit.

Tru-Trac and TX® Therapeutic Traction Unit

FIGURE 6.47

SOLENOID MOUNTING SCREWS

FIGURE 6.48

SOLENOID ASSEMBLY MOUNTING JIG P/N 48139

This removal and replacement procedure requires that the following be performed after component or assembly replacement to ensure proper alignment and operation of the unit:

1. COMPLETE CALIBRATION OF UNIT Refer to Section 7

AND

2. MINIMUM OF 2 HOUR BURN IN OF UNIT AFTER SUCCESSFUL CALIBRATION

Refer to Section 7

Failure to perform either of these procedures after a component or assembly replacement will void warranty and may result in injury to patients and severe equipment damage.

SOLENOID MOUNTING SCREWS

FIGURE 6.49

Page 49

6 REMOVAL & REPLACEMENT

6.12 POWER SUPPLY REMOVAL & REPLACEMENT

Unplug the unit from the power source before attempting removal or replacement procedures to prevent electrical shock.

A. Part Numbers

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . .27265

Power Supply Shield . . . . . . . . . . . . . . . . . . 27592

B. Equipment Required

3/32 in Allen Wrench

•

#2 Phillips Screwdriver

•

Digital Multimeter (Set to VDC)

•

C. Power Supply Removal

1. Remove Side Covers. Refer to 6.1 Side Cover Removal & Replacement.

2. Remove the Top Cover. Refer to 6.2 Top and Cord Guide Cover Removal & Replacement.

3. Remove Rear Cover. Refer to 6.3 Rear Cover Removal & Replacement.

4. Disconnect the Power Supply Input Harnesses from the Mains Connector. See Figure 6.50A.

5. Disconnect Power Supply Output Harness from the Motor Control Board. See Figure 6.50B.

6. Using the 3/32 in Allen Wrench, remove the Ground Harnesses from the Chassis. See Figure 6.51.

7. Using the Multimeter set to VDC discharge the Power Supply Capacitor at C4. See Figure 6.52.

POWER SUPPLY INPUT HARNESSES

FIGURE 6.50A

Tru-Trac and TX® Therapeutic Traction Unit

FIGURE 6.50B

FIGURE 6.51

Power Supplies retain High Voltage!

• Discharge the C4 Capacitor prior to

• complete removal of the Power Supply.

8. Using the #2 Phillips Screwdriver, remove the four Power Supply Mounting Screws.

9. Grasp the sides of the Power Supply and carefully remove from the chassis.

FIGURE 6.52

Page 50

6 REMOVAL & REPLACEMENT

6.12 POWER SUPPLY REMOVAL & REPLACEMENT (continued)

POWER SUPPLY MOUNTING SCREWS

Tru-Trac and TX® Therapeutic Traction Unit

Unplug the unit from the power source before attempting removal or replacement procedures to prevent electrical shock.

D. Power Supply Replacement

1. Prior to handling new Power Supply, discharge the Capacitor at C4. Refer to page 47.

Power Supplies retain High Voltage!

• Discharge the C4 Capacitor prior to

• handling of the new Power Supply.

2. Make certain the Shield is in place with the nonconductive (black) side toward the Power Supply. Position the Power Supply on the Chassis. Secure with the four Power Supply Mounting Screws. See Figure 6.53.

3. Using the 3/32 in Allen Wrench and Ground Harness Mounting Screw, secure the Ground Harnesses from the Power Supply and the Mains Connector to the Chassis. See Figure 6.53.

4. Connect the Power Supply Input Harnesses to the Mains Connector Harnesses. See Figure 6.54A.

5. Connect the Power Supply Output Harness to the Motor Control Board. See Figure 6.54B.

6. Install Rear Cover. Refer to 6.3 Rear Cover Removal & Replacement.

7. Install Top Cover. Refer to 6.2 Top and Cord Guide Cover Removal & Replacement.

8. Install Side Covers. Refer to 6.1 Side Cover Removal & Replacement.

9. Perform complete Calibration and Burn In of unit.

GROUND HARNESSES

SHIELD

BLACK SIDE TOWARD

POWER SUPPLY

POWER SUPPLY MOUNTING SCREWS

FIGURE 6.53

POWER SUPPLY INPUT HARNESSES

FIGURE 6.54A

FIGURE 6.54B

This removal and replacement procedure requires that the following be performed after component or assembly replacement to ensure proper alignment and operation of the unit:

1. COMPLETE CALIBRATION OF UNIT Refer to Section 7

AND

2. MINIMUM OF 2 HOUR BURN IN OF UNIT AFTER SUCCESSFUL CALIBRATION

Refer to Section 7

Failure to perform either of these procedures after a component or assembly replacement will void warranty and may result in injury to patients and severe equipment damage.

Page 51

6 REMOVAL & REPLACEMENT

6.13 MOTOR ASSEMBLY REMOVAL & REPLACEMENT

Unplug the unit from the power source before attempting removal or replacement procedures to prevent electrical shock.

A. Part Numbers

Motor Assembly . . . . . . . . . . . . . . . . . . . . . . .48019

B. Equipment Required

3/32 in Allen Wrench

•

3 mm Allen Wrench

•

7 mm Box End Wrench

•

Solenoid Assembly Mounting Jig

•

C. Motor Assembly Removal

1. Remove Side Covers. Refer to 6.1 Side Cover Removal & Replacement.

2. Make certain Traction Cord is completely retracted. If necessary, manually release Solenoid to retract Cord.

3. Loosen the Solenoid Mounting Screws enough to rotate Solenoid Gear up and off of the Motor Gear. See Figure 6.55.

4. Disconnect the Motor Harness from the Motor Control Board. See Figure 6.56.

5. Using the 3 mm Allen Wrench and 7 mm Boxed End Wrench, remove the four Motor Assembly Mounting Screws. See Figure 6.57.

6. Remove Motor Assembly from Chassis.

NOTE:

It may be necessary to remove the Motor Control Board. Refer to 6.5 Motor Control Board Removal & Replacement.

Tru-Trac and TX® Therapeutic Traction Unit

FIGURE 6.55

FIGURE 6.56

FIGURE 6.57

Page 52

6 REMOVAL & REPLACEMENT

6.13 MOTOR ASSEMBLY REMOVAL & REPLACEMENT (continued)

Unplug the unit from the power source before attempting removal or replacement procedures to prevent electrical shock.

D. Motor Assembly Replacement

1. Position new Motor Assembly into Chassis and secure with the four Motor Assembly Screws, Lock washers, and Nuts. See Figure 6.58.

2. Position and adjust the Solenoid. Refer to

6.11 Solenoid Assembly Removal & Replacement.

NOTE:

If Motor Control Board was removed, re-install before proceeding to step 3 below.

3. Connect the Motor Assembly Harness to the Motor Control Board. See Figure 6.59.

4. Install Side Covers. Refer to 6.1 Side Cover Removal & Replacement.

5. Perform complete Calibration and Burn In of unit.

Tru-Trac and TX® Therapeutic Traction Unit

FIGURE 6.58

This removal and replacement procedure requires that the following be performed after component or assembly replacement to ensure proper alignment and operation of the unit:

1. COMPLETE CALIBRATION OF UNIT Refer to Section 7

AND

2. MINIMUM OF 2 HOUR BURN IN OF UNIT AFTER SUCCESSFUL CALIBRATION

Refer to Section 7

Failure to perform either of these procedures after a component or assembly replacement will void warranty and may result in injury to patients and severe equipment damage.

FIGURE 6.59

Page 53

6 REMOVAL & REPLACEMENT

6.14 MOTOR DRIVE GEAR REMOVAL & REPLACEMENT

Unplug the unit from the power source before attempting removal or replacement procedures to prevent electrical shock.

A. Part Numbers

Motor Drive Gear . . . . . . . . . . . . . . . . . . . . . .48024

B. Equipment Required

3/32 in Allen Wrench

•

Solenoid Assembly Mounting Jig

•

Tape Measure

•

C. Motor Drive Gear Removal

1. Remove Side Covers. Refer to 6.1 Side Cover Removal & Replacement.

2. Make certain Traction Cord is completely retracted. If necessary, manually release Solenoid to retract Cord.

3. Rotate Motor until Drive Gear Set Screw is accessible. See Figure 6.60.

4. Using the 3/32 in Allen Wrench, loosen the Drive Gear Set Screw and pull the Drive Gear from Motor Shaft.

D. Motor Drive Gear Replacement

1. Install new Motor Drive Gear onto Motor Shaft. Align Set Screw with the Key Slot in the Motor Shaft. See Figure 6.61.

2. Adjust the Gear position until the face of the gear is 9.5 mm (3/8 in) from the face of the shaft. See Figure 6.61.

3. Tighten the Set Screw with the 3/32 in Allen Wrench.

4. Install Side Covers. Refer to 6.1 Side Cover Removal & Replacement.

Tru-Trac and TX® Therapeutic Traction Unit

SOLENOID REMOVED

FOR CLARITY

LOOSEN SET SCREW

FIGURE 6.60

TIGHTEN SET SCREW

9.5 MM 3/8"

FIGURE 6.61

This removal and replacement procedure requires that the following be performed after component or assembly replacement to ensure proper alignment and operation of the unit:

1. COMPLETE CALIBRATION OF UNIT Refer to Section 7

AND

2. MINIMUM OF 2 HOUR BURN IN OF UNIT AFTER SUCCESSFUL CALIBRATION

Refer to Section 7

Failure to perform either of these procedures after a component or assembly replacement will void warranty and may result in injury to patients and severe equipment damage.

Page 54

7 CALIBRATION

Tru-Trac and TX® Therapeutic Traction Unit

7.1 UNIT CALIBRATION

Certain removal and replacement procedures require that complete Unit Calibration and Burn In be performed prior to placing the unit back into service.

Failure to perform either of these procedures after certain component or assembly replacement will void warranty and may result in injury to patients and severe equipment damage.

A. General Information

1. The Calibration and Burn-In Procedures in this section must be performed annually and when field service requires removal and replacement of certain components.

2. The Calibration Procedure requires use of US lb Weight Measurements. The software is fixed and will not perform conversions of Metric Weight Measurements for this critical procedure. Therefore, when constructing and equipping the Calibration Fixture, it is required that the Electronic Load Cell Components be capable of expressing US lbs.

3. The fabrication of a Calibration Fixture is required for these units.

B. Equipment Required

FIGURE 7.1

Calibration Fixture with calibrated Strain Meter C. Unit Calibration Procedure

1. Place unit on Calibration Fixture and secure in position by tightening the unit Lock Knob. See Figure 7.1.

SLACK IN

CORD

ACCESSORY CLIP TO

LOAD CELL

STRAIN METER

2. Connect unit to an approved power source.

3. Turn unit On.

4. Release Traction Cord and connect Accessory Clip to the Strain Meter. Leave slack in Cord. See Figure 7.2.

5. Zero Strain Meter LCD.

When performing Unit Calibration Procedure, the Calibration Fixture Load Cell must be set to US lbs.

FIGURE 7.2

Page 55

7 CALIBRATION

7.1 UNIT CALIBRATION (continued)

6. Press the Clinical Resources button. See Figure 7.3.

Tru-Trac and TX® Therapeutic Traction Unit

7. Simultaneously press the START, STOP, and Clinical Resources buttons. See Figure 7.4.

8. Press "Zero the Load Cell" on Touch Screen. See Figure 7.5.

9. When the screen message appears, "Load Cell has been zero calibrated!", touch the Touch Screen anywhere to continue.

FIGURE 7.3

FIGURE 7.4

FIGURE 7.5

Page 56

7 CALIBRATION

7.1 UNIT CALIBRATION (continued)

Tru-Trac and TX® Therapeutic Traction Unit

10. Hold onto Traction Cord and press Rope Release to remove all slack from Traction Cord.

11. Press Calibrate Load Cell Bias on the Touch Screen. See Figure 7.6.

12. While watching the Strain Meter LCD, Figure 7.7A, press the Up and Down Arrow buttons, Figure 7.7B until 100 lbs is displayed on LCD.

13. Press Back icon on Touch Screen to set and accept calibration measurement.

NOTE:

Unit will display a validation message reading "Returning to zero" while releasing tension on the Traction Cord.

CALIBRATE LOAD CELL

BIAS

FIGURE 7.6

STRAIN METER LCD

14. Press Rope Release and pull enough Cord out to connect the Accessory Hook to the Lower Ring on the Calibration Fixture. See Figure 7.8.

15. Allow excess Traction Cord to feed back into unit and release Rope Release.

FIGURE 7.7A

ACCESSORY CLIP TO

LOWER RING

FIGURE 7.7B

FIGURE 7.8

Page 57

7 CALIBRATION

7.1 UNIT CALIBRATION (continued)

Tru-Trac and TX® Therapeutic Traction Unit

16. Press Calibrate Motor Current on the Touch Screen. See Figure 7.9.

17. Unit will display "Motor Current Calibration completed OK." When Motor Current Calibration is complete. Touch anywhere to continue.

7.2 TOUCH SCREEN CALIBRATION

NOTE:

If the unit is not in the Calibration Mode, refer to 7.1, C, steps 6-7 to place unit in Calibration Mode.

CALIBRATE MOTOR

CURRENT

FIGURE 7.9

A. Equipment Required None

B. Touch Screen Calibration Procedure

1. Press Touch Screen Calibration on Touch Screen. See Figure 7.10.

2. Follow instructions on Touch Screen.

FIGURE 7.10

Page 58

7 CALIBRATION

7.3 UNIT BURN IN

Certain removal and replacement procedures require that complete Unit Calibration and Burn In be performed prior to placing the unit back into service.

Failure to perform either of these procedures after certain component or assembly replacement will void warranty and may result in injury to patients and severe equipment damage.

The following Burn In procedure must be allowed to cycle for a minimum of two hours after Calibration Procedures have been performed, but prior to placing the unit back into service.

A. Specifications Burn In Intermittent Pull . . . 0-200 US lbs ±10%

Burn In Time Period . . . . . . . . .2 hours minimum

B. Equipment Required Calibration Fixture with calibrated Strain Meter. C. Burn In Set Up

1. Place unit on Calibration Fixture and secure in position by tightening the unit Lock Knob. See Figure 7.11.

2. Connect unit to an approved power source.

3. Turn unit On.

4. Release Traction Cord and connect Accessory Clip to the Load Cell. See Figure 7.2.

5. Zero Load Cell.

D. Burn In Procedure

1. Perform Burn In Set Up.

2. Press the Clinical Resources button.

3. Simultaneously press the STOP, Clinical Resources, and PAUSE buttons to access the Technical Screen.

4. Press Start Burn-In on the Touch Screen. See Figure 7.12.

5. After unit has cycled for a minimum of two hours, press the STOP button. Unit will return to the Home Screen.

6. Set up unit for a 100 lb Static pull. Start the pull and verify the readout for the Load Cell is 100 lbs ±10%.

E. Burn-In Result

1. If Load Cell Readout is outside the specified range during the Static pull, perform Unit Calibration Procedure and Burn In procedure. Refer to pages 51-55.

2. If Load Cell Readout is within Specified Range during Static pull, unit is ready to be placed into service.

START BURN IN

FIGURE 7.11

FIGURE 7.12

Tru-Trac and TX® Therapeutic Traction Unit

Page 59

8 PARTS

8.1 TOP COVER ASSEMBLY

Tru-Trac and TX® Therapeutic Traction Unit

ITEM PART

DESCRIPTION QTY

NO.

1 47856 Top Cover 1

2 48007 Top Moulding Plate 1

3 27137 Screw 10

4 60803 Screw 4

5 48063 Touch Screen Assembly 1

6 48062 Turn Table Plate 1

7 47896 Hook Cover 2

8 47872 Cord Guide Cover 1

Page 60

8 PARTS

8.2 SIDE COVERS

Tru-Trac and TX® Therapeutic Traction Unit

See Page 56

6-7

ITEM PART

DESCRIPTION QTY

NO.

1 47857 Side Cover 2

2 47884 Side Badge 2

3 47871 Knob Cap 1

4 47869 Lock Knob 1

5 27008 IEC Connector Cover 1

6 48113 Tru-Trac Badge (Model 4779) 1

7 48114 TX Badge (Model 4759) 1

Page 61

Page 62

8 PARTS

8.3 FRONT AND REAR COVERS

Tru-Trac and TX® Therapeutic Traction Unit

ITEM PART

DESCRIPTION QTY

NO.

1 47858 Front Cover 1

2 48038 Left Spring 1

3 48070 Stand Oﬀ 4

4 48110 Rear Cover Assembly (includes wiring and hardware) 1

5 47851 Screw 8

6 48054 Right Spring 1

7 47878 Front Inﬁ ll (Not Illustrated) 1

8 48040 Patient Switch Receptacle 1

Page 63

8 PARTS

8.4 BASE AND EXTRUSION ASSEMBLY

Tru-Trac and TX® Therapeutic Traction Unit

ITEM PART

DESCRIPTION QTY

NO.

1 47833 Extrusion 1

2 70208 Hex Nut 8

3 21387 Flat Washer 8

4 47832 Base Plate 1

5 60014 Anti Skid Feet 4

6 62951 Screw 8

7 48019 Motor Assembly 1

Page 64

8 PARTS

8.5 CHASSIS ASSEMBLY

Tru-Trac and TX® Therapeutic Traction Unit

ITEM PART

DESCRIPTION QTY

NO.

1 48009 Load Cell Assembly 1

2 21387 Flat Washer 4

3 48102 Shoulder Bolt 4

4 70369 Top Guide Pulley 1

5 48078 Top Guide Mounting Spacer 2

6 47998 Top Guide Pulley Axle 1

7 48031 Traction Cord 1

8 47851 Screw 4

9 47889 Spring Housing 2

10 48097 Front Cover Mounting Bracket 1

11 47850 Stand Oﬀ 4

12 47803 Motor Control Board 1

13 70777 Screw 4

14 78155 Cable Guide 2

15 48008 E-Clip 2

Page 65

8 PARTS

8.6 TRACTION CORD SPRING ASSEMBLY AND POWER SUPPLY

Tru-Trac and TX® Therapeutic Traction Unit

ITEM PART

DESCRIPTION QTY

NO.

1 54758 Snap Ring 1

2 48106 Mounting Hub 1

3 73146 Square Key 1

4 48104 Screw 4

5 71934 Bearing 1

6 80653 Traction Cord Spring 1

7 80634 Spring Cover 1

8 21384 Flat Washer 1

9 47846 Screw 1

10 47823 Spring Mounting Screw 1

11 72559 Stand Oﬀ 4

12 31768 Screw 4

13 27592 Power Supply Shield 1

14 27265 Power Supply 1

Page 66

8 PARTS

8.7 SOLENOID AND CLAMP ASSEMBLIES

Tru-Trac and TX® Therapeutic Traction Unit

ITEM PART

DESCRIPTION QTY

NO.

1 48023 Clamp Assembly 1

2 47851 Screw 8

3 48014 Solenoid Assembly 1

4 21384 Flat Washer 2

5 47851 Screw 2

6 48097 Front Traction Cord Guide 1

Page 67

8 PARTS

8.8 LARGE DRIVEN GEAR AND SPOOL ASSEMBLY

Tru-Trac and TX® Therapeutic Traction Unit

ITEM PART

DESCRIPTION QTY

NO.

1 47997 Retaining Bar 1

2 48103 Spool 1

3 72017 Set Screw 2

4 47851 Screw 2

5 80158 Clamp Foot 1

6 47840 Hub 1

7 48104 Screw 4

8 71934 Bearing 1

9 47839 Large Driven Gear with Shaft Assembly 1

Page 68

9 SCHEMATICS

9.1 TRUTRAC AND TX TRACTION UNIT SCHEMATICS

A. General Information

1. Due to the complex nature of the technology utilized by Chattanooga Group, the recommended

PCB troubleshooting techniques are to determine “Bad Board” and board replacement only. No PCB component level troubleshooting is recommended, nor will information or parts be supplied by Chattanooga Group. Any PCB component level troubleshooting performed will be at sole risk and liability of the Service Technician performing such troubleshooting techniques.

2. Once a particular PCB has been determined as bad, replace the PCB. Use only Chattanooga Group replacement parts and hardware. Refer to Section 8 Parts for replacement parts and assemblies.

Tru-Trac and TX® Therapeutic Traction Unit

Page 69

9 SCHEMATICS

Tru-Trac and TX® Therapeutic Traction Unit

Control Board- 47801

1 of 3

Page 70

9 SCHEMATICS

Tru-Trac and TX® Therapeutic Traction Unit

Control Board- 47801

2 of 3

Page 71

9 SCHEMATICS

Tru-Trac and TX® Therapeutic Traction Unit

Control Board-47801

3 of 3

Page 72

9 SCHEMATICS

Tru-Trac and TX® Therapeutic Traction Unit

Motor Control Board- 47803

1 of 2

Page 73

9 SCHEMATICS

Tru-Trac and TX® Therapeutic Traction Unit

Motor Control Board- 47803

2 of 2

Page 74

9 SCHEMATICS

Tru-Trac and TX® Therapeutic Traction Unit

Patient Interrupt Switch- 48056

1 of 1

Page 75

9 SCHEMATICS

Tru-Trac and TX® Therapeutic Traction Unit

Serial Interface- 47022

1 of 1

Page 76

9 SCHEMATICS

Tru-Trac and TX® Therapeutic Traction Unit

Smart Card- 47807

1 of 1

Page 77

9 SCHEMATICS

Tru-Trac and TX® Therapeutic Traction Unit

Block Diagram

1 of 1

Page 78

10 SPECIAL FIXTURES

Tru-Trac and TX® Therapeutic Traction Unit

Calibration Fixture

1 of 4

Page 79

10 SPECIAL FIXTURES

Tru-Trac and TX® Therapeutic Traction Unit

Calibration Fixture

2 of 4

Page 80

10 SPECIAL FIXTURES

Tru-Trac and TX® Therapeutic Traction Unit

Calibration Fixture

3 of 4

Page 81

10 SPECIAL FIXTURES

Tru-Trac and TX® Therapeutic Traction Unit

Calibration Fixture

4 of 4

Page 82

11 WARRANTY

Chattanooga Group (“Company”) warrants that the Tru-Trac and TX Traction Unit (“Product”) is free of defects in material and workmanship. This warranty shall remain in effect for two years (24 months) from the date of original consumer purchase. If this Product fails to function during the two year warranty period due to a defect in material or workmanship, Company or the selling dealer will repair or replace this Product without charge within a period of thirty days from the date on which the Product is returned to the Company or the dealer.

All repairs to the Product must be performed by a service center authorized by the Company. Any modifications or repairs performed by unauthorized centers or groups will void this warranty.

The warranty period for accessories is 180 days. Accessories consist of Patient Interrupt Switch shipped with the unit.

To participate in warranty coverage, this Product’s warranty registration card (included with Product) must be filled out and returned to the Company by the original owner within ten business days of purchase.

This Warranty Does Not Cover:

•

Replacement parts or labor furnished by anyone other than the Company, the selling dealer, or a certified Company service agent.

•

Defects or damage caused by labor furnished by someone other than Company, the selling dealer, or a certified Company service agent.

•

Any malfunction or failure in the Product caused by product misuse, including, but not limited to, the failure to provide reasonable and necessary maintenance or any use that is inconsistent with the Product User Manual.

Tru-Trac and TX® Therapeutic Traction Unit

COMPANY SHALL NOT BE LIABLE IN ANY EVENT FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. To obtain service from Company or the selling dealer under this warranty:

1. A written claim must be made within the warranty period to the Company or the selling dealer. Written claims made to the Company should be sent to:

4717 Adams Road P.O. Box 489 Hixson, TN 37343 USA Phone: USA: (800) 592-7329 Fax: (423) 875-5497 Canada: (800) 361-6661 Outside USA: +1 (423) 870-7200 Outside USA Fax: +1 (423) 870-2046

2. The Product must be returned to the Company or the selling dealer by the owner.

This warranty gives you specific legal rights and you may also have other rights which vary from state to state or location to location. The Company does not authorize any person or representative to create for it any other obligation or liability in connection with the sale of the Product. Any representation or agreement not contained in the warranty shall be void and of no effect.

THE FOREGOING WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED,

INCLUDING ANY WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

Page 83

ISO 13485 Certiﬁ ed

4717 Adams Road P.O. Box 489 Hixson, TN 37343 U.S. A.

1-423-870-2281 1-800-592-7329 U.S. A. 1-800-361-6661 CANADA

+1-423-870-7200 OUTSIDE U.S.A +1 423-870-2046 OUTSIDE U.S.A. FAX

chattgroup.com

48131A

0413