Chattanooga Group OptiFlex 2030 User manual

ISO 9001/ISO 13485 CERTIFIED
®
SERVICE MANUAL
Models:
2030
(Serial Numbers- 5000 and above)
2060
(Serial Numbers- 5000 and above)

OptiFlex® 2030 & 2060
TABLE of CONTENTS
©2002 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.
Forword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1- Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
1.1 Precautionary Symbol Definitions . . . . . . . . . . . . . . . .2
1.2 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2- Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3- Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
4- Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
5- Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-11
6- Removal & Replacement Procedures . . . . . . . . . . . .12-17
8-Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-19
9- Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-23

OptiFlex® 2030 & 2060
FOREWORD
1
Read, understand and follow the Safety Precautions and information contained in this manual.
This manual contains the necessary safety, and field service information for those Field Service Technicians, approved by
Chattanooga Group, to perform field service on the OptiFlex CPM Models 2030 and 2060 units.
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 electrotherapy, 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 field technicians to stay informed and trained in the latest technology utilized in the OptiFlex
CPM Models 2030 and 2060 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 (www.chattgroup.com) in lieu of reprinting a complete
manual prematurely. These Service Bulletins will provide updated service information and technology improvements to the
OptiFlex CPM Models 2030 and 2060 for use by approved service technicians.
“Approved Service Technician” Definitions;
1. Level I- Those Field Service Technicians that have successfully completed the minimal training required by Chattanooga
Group, in basic service techniques.
2. Level II- Those Field Service Technicians that have successfully completed Level I Training as well as Level II training as
required to perform specific troubleshooting and repair techniques and procedures.
3. Level III- Those Field Service Technicians that have successfully completed Levels I & II Training as well as Level III
Advanced Training as required to perform all necessary Troubleshooting and Repair techniques. The Technician
having successfully completed the three levels of training and coupled with experience should have the ability to
train other technicians in Level I and Level II Training with the necessary Training Materials from Chattanooga
Group.
4. Temporary- Chattanooga Group, at its discretion and based on known experience of the technician, may grant a
“Temporary Approval” to a field technician for particular troubleshooting and repair of a specific unit requiring
immediate attention. This “Temporary Approval” in no fashion acknowledges the training level of a technician
as defined above. This “Temporary Approval” is utilized only in unique situations for a specific unit for a
specific service technique only and is documented as such.
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 sole
risk and liability of the Service Technician performing such troubleshooting techniques.
This equipment is to be sold and used only under the prescription and supervision of a licensed medical practitioner.
This equipment is to be serviced only by an “Approved Service Technician”.
For Additional Service Contact:
Chattanooga Group
CPM Support Department
Toll Free: 1-866-266-0026
Outside USA: [phone]

OptiFlex® 2030 & 2060
2
SAFETY PRECAUTIONS
Precautionary Symbol Definitions
The precautionary instructions found throughout this
manual are indicated by specific symbols.
Understand these symbols and their definitions before
operating or servicing this equipment. The definitions 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. EXPLOSION HAZARD
Do not use this equipment in the presence of
flammable anesthetics. This symbol is also
prominently displayed on the serial number plate of
the unit.
E. NOTE:
Throughout this manual “NOTE” may be found.
The Notes are helpful information to aid in the
particular area or function being described.
Safety Precautions
Read, understand and follow all safety precautions
found in this manual. Below are general safety
precautions that must be read and understood before
attempting any service techniques on these units.
Throughout this manual specific safety precautions will
be found. Read, understand and follow all safety
precautions.
•Read this manual before assembling or using OptiFlex.
•Only use OptiFlex on solid, flat surfaces.
•Extreme caution should be taken when in use around
children.
•Use OptiFlex only as described in this manual.
•Keep hair, loose clothing, fingers and all parts of body
away from moving parts of OptiFlex.
•DO NOT use OptiFlex outdoors or on wet surfaces.
•Materials may become flammable or combustible if
exposed to a source of ignition.
•Disconnect electrical supply before servicing or
cleaning. Failure to do so could result in electrical
shock or personal injury.
•DO NOT use OptiFlex while smoking or around
open flame.
•Exercise caution when using accessories and auxiliary
devices such as muscle stimulators, ColPaCs and
other modalities.
•Turn power off before unplugging.
•Unplug the power supply by grasping the plug not
the cord.
•Damage may occur to OptiFlex if not transported and
stored between 0° and 140°F (-18° to 60°C).
•Unplug power supply when not in use.
•DO NOT use if cord or plug is damaged.
•Use extra care when touching metal of OptiFlex after
exposure to cold or heat.
•DO NOT handle any electrical apparatus with wet
hands.
•Condensation could result and damage OptiFlex if unit
is subjected to
periods of low temperatures followed by
periods of high temperatures.
•DO NOT use on unstable surfaces or liquid filled
devices such as water mattresses or flotation pads.
!
CAUTION
WARNING
!
!
DANGER
!
CAUTION

OptiFlex® 2030 & 2060
3
SAFETY PRECAUTIONS
Safety Precautions Continued
•OptiFlex has been designed for maximum protection
against the exposure of urinary incontinence.
Precautionary measures should still be taken, when
any type of liquid comes in contact with an electrical
apparatus.
•OptiFlex is made from high impact materials. However,
structural failure or hidden damage can be caused by
shock, impact or dropping the unit. Use care when
transporting and storing unit to avoid equipment
damage.
•To isolate the unit from the power source, disconnect
the power cord at the wall outlet.
•OptiFlex should only be used after the operator has
thoroughly read and understands the User Manual.
•Rapid increases in ROM can cause complications.
•OptiFlex is not to be used in the presence of flammable
anesthetic mixture with air or with oxygen or
nitrous oxide.
•
Make certain that the unit is electrically grounded by
connecting
only to a grounded electrical service
receptacle conforming to
the applicable national and
local electrical codes.
•Keep hair, loose clothing, loose bedding, fingers and
toes away from the hinge components of the unit.
•Do not use the OptiFlex outdoors, on wet or gel filled
surfaces. Use only on firm, flat, stable level surfaces to
ensure stability of the unit while in operation.
•Materials of the unit may become flammable or
combustible if exposed to a source of ignition.
•Heat generated within the pendant may cause ignition
of the pendant if wrapped in bedding or other materials.
•DO NOT use OptiFlex while smoking or around open
flame.
•OptiFlex has been designed for maximum protection
against the exposure of urinary incontinence.
Precautionary measures should still be taken when any
type of liquid comes in contact with an electrical
apparatus.
•Always turn off and unplug unit from electrical source
before servicing or cleaning. Failure to do so could
result in electrical shock or personal injury.
• Handle the unit only when unit is dry and hands are dry
to prevent electrical shock.
• Do not use the OptiFlex as a toy.
!
CAUTION
WARNING
!
•Explosion hazard if used in the presence of
flammable anesthetics. The warning symbol for
this hazard is prominently displayed on the serial
number plate.
•Exercise caution when using accessories and auxiliary
devices such as muscle stimulators, ColPaCs and
other modalities. Route lead wires, hoses, tubes, etc
away from the working mechanism of the OptiFlex to
help prevent damage to the Optiflex and any other
modality used with it.
•Unconscious patients or patients under heavy
influence of medication must be constantly attended
and monitored while the OptiFlex is in use.
•The OptiFlex unit must be completely visible at all
times during use. Never cover the unit with bedding or
any other means of concealment while in operation.
•If the OptiFlex is used in conjunction with the optional
OptiFlex “T” trolley, make certain the OptiFlex unit is
resting on the mattress of the bed and the OptiFlex “T”
is suspended with no weight on the casters to prevent
possible movement of the unit and or possible injury
to patient.
•OptiFlex is a prescription device used under the
supervision of or by the order of a physician or other
licensed healthcare provider.
DANGER

OptiFlex® 2030 & 2060
THEORY of OPERATION
4
2.1 Overview
The OptiFlex 2030 & 2060 CPM products are comprised of two PC Board assemblies housed within the head section of
the unit along with the Motor and Gearbox Assembly. These components are linked to a Pendant via a cable connection
that provides the operator access for set up and operation of the unit. The basic components of the OptiFlex CPM units
are Frame Base, Motor and Gearbox Assembly, Power Transformer, Motor Control Board, Power Supply Circuit,
Adjustable Femur Bar, Adjustable Foot Plate and User Interface (Pendant). The units are designed for patient use only
with the Patient Softgoods Kit (Part Number 20533). This single patient use softgoods kit is designed specifically for the
OptiFlex 2030 & 2060 CPM units and provides proper installation and support to the patient during therapy.See Figure 2.1.
If necessary, two units may be used simultaneously for patients that have been prescribed dual therapy by a licensed
professional. If two units are prescribed for use simultaneously, use with the optional bed mount to secure the units in
position during therapy.
UNIT
HEAD
ADJUSTABLE
FOOT REST
*PATIENT
SOFTGOODS KIT
PART NUMBER 20533
*Single Patient Use
FRAME
BASE
ADJUSTABLE
TIBIAL TUBES
USER INTERFACE
(PENDANT)
FLEXION ANGLE
POTENTIOMETER
FIGURE 2.1
ADJUSTABLE
FEMUR BAR

OptiFlex® 2030 & 2060
NOMENCLATURE
5
3.1 OptiFlex Familiarization
The nomenclature graphics below, Figure 3.1, indicate the
general locations of the major components of the OptiFlex
CPM unit.
Know the components and their functions before performing
any operation of or service to the OptiFlex 2030 or 2060
CPM unit.
ADJUSTABLE
FOOT REST
FOOT REST
PIVOT
ADJUSTMENT TIBIAL
ADJUSTMENT
KNOB
UNIT
HEAD
FRAME
BASE
FLEXION ANGLE
POTENTIOMETER
(KNEE POT)
FEMUR BAR
ADJUSTMENT
SCALE
ADJUSTABLE
FEMUR BAR
USER INTERFACE
(PENDANT)
SEE PAGE 6
MAIN
PC BOARD
DRIVE BELT
AND GEARS MOTOR & GEARBOX
ASSEMBLY
MOTOR
CONTROL
BOARD
FIGURE 3.1
Power Supply not illustrated.

OptiFlex® 2030 & 2060
NOMENCLATURE
6
3.2 OptiFlex Pendant Familiarization
The Pendant nomenclature graphics below, Figure 3.2,
indicate the location and functions of the OptiFlex CPM
Pendant (user interface).
Know the components and their functions before performing
any operation of or service to the OptiFlex 2030 or 2060
CPM unit.
MMOODDEE
Used with Fast Back, Oscillation
Zone and Progressive ROM*
FFAASSTTBBAACCKK™™
Carriage will slow down within
15° of the flexion angle.
RREESSEETT
Clear previous treatment
settings and completed cycles
EEXXTTEENNSSIIOONN
Displays the extension angle.
FFLLEEXXIIOONN
Displays the flexion angle.
SSPPEEEEDD
Displays the speed of operation.
EEXXTTEENNSSIIOONN//FFLLEEXXIIOONNDDEELLAAYY
Allows user to program carriage to stop at both the
extension and flexion angle for the time programmed.
OOSSCCIILLLLAATTIIOONNZZOONNEE™™
Carriage will oscillate three times between the
flexion angle and 10° less than the flexion angle.
**PPRROOGGRREESSSSIIVVEERROOMM™™
Unit will automatically increase the programmed flexion
angle by 1° every hour up to a maximum of 5° per day.
UUPPAARRRROOWW
Allows user to increase treatment parameters.
DDOOWWNNAARRRROOWW
Allows user to decrease treatment parameters.
CCOOMMFFOORRTTZZOONNEE™™
Temporarily decreases the flexion ROM* when
discomfort is experienced.
EEMMEERRGGEENNCCYYSSTTAARRTT//SSTTOOPP
Start or Stop Treatment
*Range Of Motion
FIGURE 3.2

OptiFlex® 2030 & 2060
SPECIFICATIONS
7
MODEL 2030
Input: 120 VAC~50/60 Hz, 40 Watts
Weight: 28 Lbs. (13 kg)
Length: 37 in. (94 cm)
Operation
Knee Flexion ROM Limit: 120°
Knee Extension Limit: -10° Hyper Extension
Knee Speed Range : 30°/min. to 150°/min. Nominal
Maximum Patient Weight: 350 Lbs. (159kg.)
Calf Length Range: 10 to 23.5 in. (25.4 to 59.7 cm)
(knee joint to sole of foot)
Thigh Length Range: 12 to 19 in. (30.5 to 48.3 cm)
(hip joint to knee joint)
Transportation and Storage
Unit should be transported and stored within the following conditions:
Temperature: 0° - 140°F (32° - 60°C)
Humidity: 0 - 75% Relative Humidity
MODEL 2060 (International)
Input: 230 VAC~50/60 Hz, 40 Watts
Weight: 28 Lbs. (13 kg)
Length: 37 in. (94 cm)
Operation
Knee Flexion ROM Limit: 120°
Knee Extension Limit: 10° Hyper Extension
Knee Speed Range : 30°/min. to 150°/min. Nominal
Maximum Patient Weight: 350 Lbs. (159kg.)
Calf Length Range: 10 to 23.5 in. (25.4 to 59.7 cm)
(knee joint to sole of foot)
Thigh Length Range: 12 to 19 in. (30.5 to 48.3 cm)
(hip joint to knee joint)
Transportation and Storage
Unit should be transported and stored within the following conditions:
Temperature: 0° - 140°F (32° - 60°C)
Humidity: 0 - 75% Relative Humidity

OptiFlex® 2030 & 2060
TROUBLESHOOTING
8
5.1 OptiFlex Software Error Messages
A. The information provided below is intended to
aid in troubleshooting Software Error Messages
of the OptiFlex Units to “Board Level” only. No
component level troubleshooting information is
or will be provided by Chattanooga Group for
field troubleshooting of board components.
B. Once a particular PCB has been determined as
bad, replace the suspected board.
ERROR MESSAGE PROBABLE CAUSE POSSIBLE REMEDY
RAM Test Failed Pendant Replace Pendant
Checksum Test Failed Pendant Replace Pendant
(2) Motor Failure 1. Carriage Angle <-15°
2. Carriage Angle >125°
Replace Pendant
Adjust or replace knee pot.
(3) Motor Failure Motor Speed Counter Make certain Femur Adjustment knobs are tight.
Carriage Obstruction,
Treatment Stopped
1. Motor Overcurrent
2. Carriage Stuck or in Bind
Calibrate unit. Should calibration not clear the problem,
send unit to factory for service.
Pendant is not Connected 1. Loop Around
2. DAC Speed Out
Connect Pedant to unit. If this does not correct the
problem, replace pendant
(2) Failure RTC 3V Battery (A/D Pendant) Replace pendant battery. If this does not correct
problem, replace pendant.
(3) Failure Monitor 8V (A/D Pendant) Cable
(4) Failure Monitor 24V (A/D SPI) Cable, knee pot, main PCB
(5) Failure Monitor 5V (A/D SPI) Cable
Stuck Button Sticky Deposits Remove and clean button pads, inspect switch lands. If
this does not correct problem, replace pendant.

OptiFlex® 2030 & 2060
TROUBLESHOOTING
9
55..22OOppttiiFFlleexxSSyysstteemmTTeessttiinngg
AA..GGeenneerraall
11..The following information is intended to aid in
troubleshooting the major components of the
OptiFlex Units to “Board Level” only. These
tests are OEM standard testing procedures and
methods used at the factory before shipment of
any OptiFlex unit.
22..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 sole risk and
liability of the Service Technician performing such
troubleshooting techniques.
33..Once a particular PC Board has been determined
as bad, replace the board only with Chattanooga
Group OEM replacement parts and hardware.
BB..SSppeecciiaallTToooollss,,FFiixxttuurreess&&MMaatteerriiaallssRReeqquuiirreedd
11..Certain tests 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.
22..Standard test equipment settings will be listed for
each test performed to aid in performing the test
to OEM standards and ensure proper readings.
33..The troubleshooting and repair of the OptiFlex
units, should be performed only by authorized
technicians trained and certified by Chattanooga
Group.
CC..EEqquuiippmmeennttRReeqquuiirreedd
11..Digital Multimeter
22..Dielectric Withstand (Hi-Pot) and ground
resistance tester.
33..Milliohm Meter.
NNOOTTEE::
Adjust Dielectric Withstand tester to indicate fault with
120k Ohm Load across the output when at specified test
voltage.
55..RReeqquuiirreeddSSAAEETToooollss
#1 Phillips Screwdriver
#2 Phillips Screwdriver
Preset and calibrated, 5 inch pound “T”-Handle
Torque Wrench with 1/4” square drive and 5/64”
straight hex key socket.
Preset and calibrated, 10 inch pound “T”-Handle
Torque Wrench with 1/4” square drive and 9/64”
straight hex key socket.
5/16” Socket Driver
3/32” Allen Wrench
66..RReeqquuiirreeddLLuubbrriiccaannttss
Molykote 33 Grease (Light Pink) by Dow Corning.
MolyGraph Grease (Black) by Sta-Lube.
77..RReeqquuiirreeddLLoocckkiinnggCCoommppoouunnddaannddPPrriimmeerr
Type N Primer by Loctite
Loctite 222 (Purple)
Loctite 242 (Blue)
Loctite 262 (Red)
Loctite 609 (Green)
88..Inclinometer, Protractor or Goniometer accurate
to 1°.
99..Certified, calibrated Stop Watch.
NNOOTTEE::
The tool, lubricant and locking compound requirements will
be listed at the respective removal and replacement
procedures throughout this manual.
!
CAUTION
The following tool, lubrication and locking compound
requirements are critical to the component removal and
replacement of the OptiFlex.
All hardware,bolts, nuts and screws, used to assemble the
OptiFlex are SAE Standard. Due to the size of these
components no metric equivalent is available. Therefore,
it will be necessary to obtain the proper size tools for
removal and replacement of certain components.
The lubricants and locking componds listed below are
crucial in the assembly of certain components to ensure
patient safety and efficient operation of the unit. Use only
the recommended products listed or an approved
equivalent possessing the same properties and qualities.

55..33VViissuuaallIInnssppeeccttiioonn
AA..GGeenneerraall
Visually inspect the OptiFlex unit. A visual inspection
can, to an experienced Technician, indicate possible
abuse of the unit and/or internal problems.
55..44GGrroouunnddRReessiissttaanncceeTTeesstt
AA..VVoollttaaggeeSSppeecciiffiiccaattiioonnss
MMooddeell22003300. . . . .
Input: 120 VAC~50/60 Hz, 40 Watts
MMooddeell22006600. . . . Input: 230 VAC~50/60 Hz, 40 Watts
BB..SSppeecciiffiiccaattiioonn
Maximum Acceptable Resistance: 500 milliohms
CC..EEqquuiippmmeennttRReeqquuiirreedd
Milliohm Meter
DD..TTeesstt
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.
FFIIGGUURREE55..11
55..55LLeeaakkaaggeeTTeessttss
TTeessttVVoollttaaggeeSSppeecc. . . . . . . . . . . . . . . . . . . . . . . . . . . .
1000V
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.
55..66FFlleexxiioonnAAnnggllee&&CCaalliibbrraattiioonnTTeesstt
SSppeecc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
90° ± 2°
AA..EEqquuiippmmeennttRReeqquuiirreedd
Inclinometer, Protractor or Goniometer accurate to 1°
BB..TTeesstt
Place unit on level work surface.
Plug unit transformer into grounded wall outlet with .
appropriate voltage. See Specifications on page 7.
Connect Pendant to Unit and turn unit power ON.
Press and hold the Extension button. While holding
the Extension button down, press the Down arrow
until -10 is displayed on the Pendant. See Figure 5.3.
Press and hold the Flexion button. While holding the .
Flexion button down, press the Up arrow until 120 is .
displayed on the Pendant. See Figure 5.4.
Press and hold the Speed button. While holding the
Speed button down press the Up or Down arrow
button until 90 is displayed on the Pendant. See
Figure 5.5.
Press the Emergency Start/Stop button on the
Pendant. When the number on the Pendant display
reads 90, press the Emergency Start/Stop button to
stop movement of the unit.
OptiFlex® 2030 & 2060
TROUBLESHOOTING
10
FFIIGGUURREE55..33FFIIGGUURREE55..55
FFIIGGUURREE55..44
!
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!
WARNING
FFIIGGUURREE55..22

Using the Inclinometer or Protractor measure the
angle of the flexion of the unit. Compare to Spec. See
Figure 5.6.
NNOOTTEE::
In Figure 5.6, a Digital Inclinometer is used to measure each
side and the two numbers are added together.
55..77TTrraavveellSSppeeeeddTTeesstt
SSppeecc. . . . . . . . . . . . . . . . . . . 0° to
90° in 65 Seconds ±8%
AA..EEqquuiippmmeennttRReeqquuiirreedd
Calibrated Stop Watch
BB..TTeesstt
Set unit up as described in the “Flexion Angle Test”
Press the Emergency Start/Stop button and start the
Stop Watch when the Pendant reads 0. The unit
should move from 0° to 90° within the specification
listed above.
Repeat and record results three times. Record
the average.
55..88EEmmeerrggeennccyySSttaarrtt//SSttooppFFuunnccttiioonnTTeesstt
SSppeecc.. . . . . . . . . . . . Unit Start or Stop upon pushing button
AA..EEqquuiippmmeennttRReeqquuiirreedd
OptiFlex®with Pendant
BB..TTeesstt
Place unit on a level work surface.
Plug unit power supply into grounded wall outlet with
appropriate voltage. See Specifications on page 7.
Connect Pendant to Unit and turn unit power ON.
Press the Emergency Start/Stop button to start and
stop the unit. Repeat several times.
55..99PPeennddaannttDDiissccoonnnneeccttTTeesstt
SSppeecc. . . . .Unit Stops immediately upon Pendant disconnect
AA..EEqquuiippmmeennttRReeqquuiirreedd
OptiFlex with Pendant
BB..TTeesstt
Place unit on a level work surface.
Plug unit power supply into grounded wall outlet
with appropriate voltage. See Specifications on
page 7.
Connect Pendant to Unit and turn unit power ON.
Press the Emergency Start/Stop button to start
the unit.
Disconnect the Pendant from the unit while moving.
Unit should stop.
OptiFlex® 2030 & 2060
TROUBLESHOOTING
11
FFIIGGUURREE55..66

66..11CCoovveerrRReemmoovvaall&&RReeppllaacceemmeenntt
AA..MMoottoorrCCoovveerrRReemmoovvaall
Remove the 11 Male Push Rivets from the Blue
Motor Cover by hand. See Figure 6.1
FFIIGGUURREE66..11
Remove the 11 Female Push Rivets from the Blue
Motor Cover by hand. See Figure 6.2.
FFIIGGUURREE66..22
Lift up and rotate the Blue Motor Cover toward the
carrying handle of the unit. Then slide the cover
over the carrying handle to completely remove from
the unit.
NNOOTTEE::
Retain both parts of the push rivets for re-installation.
BB..RReeaarrAAcccceessssCCoovveerr
Remove the 6 Male Push Rivets from the Blue Rear
Access Cover by hand. See Figure 6.3.
FFIIGGUURREE66..33
Remove the 6 Female Push Rivets from the Blue
Front Access Cover by hand. See Figure 6.4.
FFIIGGUURREE66..44
CC..RReeppllaacceemmeennttCCoommppoonneennttPPaarrttNNuummbbeerrss
Push Rivet (Male & Female Components). . . . . J6004
Motor Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . .J2007
Front Access Cover. . . . . . . . . . . . . . . . . . . . . . J2005
DD..RReeppllaacceemmeenntt
Replace both covers in reverse order of removal.
OptiFlex® 2030 & 2060
REMOVAL & REPLACEMENT
12
!
UNPLUG THE UNIT FROM THE POWER SOURCE BEFORE
ATTEMPTING ANY REMOVAL OR REPLACEMENT
PROCEDURES TO PREVENT ELECTRICAL SHOCK.
WARNING
RREEMMOOVVEETTHHEE1111
MMAALLEEPPUUSSHHRRIIVVEETTSS
RREEMMOOVVEETTHHEE1111FFEEMMAALLEE
PPUUSSHHRRIIVVEETTSS
RREEMMOOVVEETTHHEE66
MMAALLEEPPUUSSHHRRIIVVEETTSS
RREEMMOOVVEETTHHEE66FFEEMMAALLEE
PPUUSSHHRRIIVVEETTSS

OptiFlex® 2030 & 2060
REMOVAL & REPLACEMENT
13
66..22MMaaiinnPPCCBBooaarrddRReemmoovvaall&&RReeppllaacceemmeenntt
AA..TToooollssRReeqquuiirreedd
#2 Phillips Screwdriver
BB..MMoottoorrCCoovveerrRReemmoovvaall
Remove Motor Cover. Refer to “6.1. Cover Removal &
Replacement”.
CC..MMaaiinnPPCCBBooaarrddRReemmoovvaall
Disconnect the six wiring harnesses from the main
board. See Figure 6.5.
FFIIGGUURREE66..55
Using the #2 Phillips Screwdriver, remove the two
mounting screws securing the Main PC Board
Assembly to the unit. See Figure 6.6.
FFIIGGUURREE66..66
NNOOTTEE::
The Main PC Board is permanently mounted to the
aluminum mounting bracket.
DD..RReeppllaacceemmeennttCCoommppoonneennttPPaarrttNNuummbbeerrss
Main PC Board Assembly. . . . . . . . . . . . . . . . . .J6043
EE..MMaaiinnPPCCBBooaarrddRReeppllaacceemmeenntt
Replace in reverse order. When connecting
harnesses, each harness will only connect to their
respective locations on the board.
66..33MMoottoorrPPCCBBooaarrddRReemmoovvaall&&RReeppllaacceemmeenntt
AA..TToooollssRReeqquuiirreedd
#2 Phillips Screwdriver
BB..MMoottoorrCCoovveerrRReemmoovvaall
Remove Motor Cover. Refer to “6.1. Cover Removal &
Replacement”.
CC..MMoottoorrPPCCBBooaarrddRReemmoovvaall
Disconnect the three wiring harnesses from the
Motor PC Board. See Figure 6.7.
FFIIGGUURREE66..77
NNOOTTEE::
Memory for Calibration and Model Number are stored on
the Main PC Board. Calibration and verification of Model
Number will be necessary if the Main PC Board is replaced.
To determine Model Number, turn unit on and press the Up
and Down arrows simultaneously. If “OPTIFLEX I” is
displayed on pendant, it will be necessary to put unit in the
Calibration Mode. See Page 16.
With unit in Calibration Mode, press the “Mode” button.
The pendant display should change from “OPTIFLEX I” to
“OPTIFLEX II”. Unit is now ready for Calibration.
!
UNPLUG THE UNIT FROM THE POWER SOURCE BEFORE
ATTEMPTING ANY REMOVAL OR REPLACEMENT
PROCEDURES TO PREVENT ELECTRICAL SHOCK.
RREEMMOOVVEETTHHEE66
HHAARRNNEESSSSEESSFFRROOMMBBOOAARRDD
RREEMMOOVVEETTHHEE22
BBOOAARRDDMMOOUUNNTTIINNGGSSCCRREEWWSS
RREEMMOOVVEETTHHEE33
HHAARRNNEESSSSEESSFFRROOMMBBOOAARRDD
WARNING

Using the #2 Phillips Screwdriver, remove the two
mounting screws securing the Motor PC Board
Assembly to the unit. See Figure 6.8.
FFIIGGUURREE66..88
DD..RReeppllaacceemmeennttCCoommppoonneennttPPaarrttNNuummbbeerrss
Motor PC Board Assembly. . . . . . . . . . . . . . . . .J6010
EE..MMoottoorrPPCCBBooaarrddRReeppllaacceemmeenntt
Replace in reverse order. When connecting
harnesses, each harness will only connect to their
respective locations on the board.
66..33DDrriivveeBBeellttRReemmoovvaall&&RReeppllaacceemmeenntt
AA..TToooollssRReeqquuiirreedd
#2 Phillips Screwdriver
9/64” Allen Wrench
Preset 10 inch-pound “T”-Handle Torque Wrench
BB..MMoottoorrCCoovveerrRReemmoovvaall
Remove Motor Cover. Refer to “6.1. Cover Removal &
Replacement”.
CC..BBeellttRReemmoovvaall
Loosen the three Motor Mounting Screws. See
Figure 6.9.
FFIIGGUURREE66..99
Rotate the motor toward the center of the unit to
loosen the tension from the belt. Tighten the one
Motor Mounting Screw in the upper left hand corner.
Remove the old belt from the pulleys.
DD..DDrriivveeBBeellttRReeppllaacceemmeennttPPaarrttNNuummbbeerr
Motor Drive Belt. . . . . . . . . . . . . . . . . . . . . . . . J2000
EE..DDrriivveeBBeellttRReeppllaacceemmeenntt
Replace Drive Belt in reverse order.
Rotate motor by hand applying tension to the belt.
Make certain the belt is seated into the pulley teeth.
Torque Motor Mounting Screws using the Preset 10
inch-pound “T”-Handle Torque Wrench with 9/64”
straight hex key socket.
66..44MMoottoorrRReemmoovvaall&&RReeppllaacceemmeenntt
AA..TToooollssRReeqquuiirreedd
11/32” Open End Wrench
#2 Phillips Screwdriver
5/64” Allen Wrench
9/64” Allen Wrench
3/32” Allen Wrench
Preset 10 inch-pound “T”-Handle Torque Wrench
Preset 5 inch-pound “T”-Handle Torque Wrench
Type N locking compound primer
Loctite 222 (Purple) or approved equivalent
Molykote or approved equivalent grease
OptiFlex® 2030 & 2060
REMOVAL & REPLACEMENT
14
RREEMMOOVVEEMMOOUUNNTTIINNGG
SSCCRREEWWSSFFRROOMM
BBOOTTTTOOMMOOFFBBOOAARRDD
MMOOUUNNTTIINNGGBBRRAACCKKEETT
!
UNPLUG THE UNIT FROM THE POWER SOURCE BEFORE
ATTEMPTING ANY REMOVAL OR REPLACEMENT
PROCEDURES TO PREVENT ELECTRICAL SHOCK.
WARNING
LLOOOOSSEENNTTHHRREEEEMMOOTTOORR
MMOOUUNNTTIINNGGSSCCRREEWWSS
!
UNPLUG THE UNIT FROM THE POWER SOURCE BEFORE
ATTEMPTING ANY REMOVAL OR REPLACEMENT
PROCEDURES TO PREVENT ELECTRICAL SHOCK.
WARNING

OptiFlex® 2030 & 2060
REMOVAL & REPLACEMENT
15
BB..MMoottoorrCCoovveerrRReemmoovvaall
Remove Motor Cover. Refer to “6.1. Cover Removal &
Replacement”.
CC..MMoottoorrPPCCBBooaarrddRReemmoovvaall
Remove Motor PC Board. Refer to “6.3 Motor PC
Board Removal & Replacement”.
DD..MMoottoorrRReemmoovvaall
Loosen three motor mounting screws. Rotate
motor to release belt tension and remove belt. See
Figure 6.10.
FFIIGGUURREE66..1100
Using the 5/64” Allen Wrench, remove the set screw
from the motor pulley. See Figure 6.11.
FFIIGGUURREE66..1111
Remove Pulley from shaft.
NNOOTTEE::
It may be necessary to use a gear puller in removing the
pulley.
Remove the three motor mounting screws using the
9/64” Allen Wrench and remove motor from unit. See
Figure 6.12.
FFIIGGUURREE66..1122
EE..RReeppllaacceemmeennttCCoommppoonneennttPPaarrttNNuummbbeerrss
Motor and Gearbox Assembly. . . . . .40101 and 40100
FF..MMoottoorrRReeppllaacceemmeenntt
Position the motor in the unit with ribbon cable
up. Install the three Motor Mounting Screws and
Nylon Lock Nuts. Do not completely tighten.
Position the pulley onto the motor shaft. Make
certain the set screw hole is aligned with the flat
area of the shaft.
Push the pulley onto the shaft until the face of the
pulley collar is flush with the end of motor shaft.
Prime the pulley set screw with the Type N primer
and apply the Loctite 222 or approved equivalent per
the manufacturer’s instructions to the threads of the
set screw.
Install the set screw until seated against motor shaft
and then torque using the Preset 5 inch-pound “T”-
Handle Torque Wrench with 5/64” straight hex
key socket.
Rotate motor and place belt onto both pulleys. Rotate
motor in the opposite direction until belt is tight.
Tighten the three motor mounting screws and torque
using the Preset 10 inch-pound “T”-Handle Torque
Wrench with 9/64” straight hex key socket.
Replace the Motor PC Board. Refer to “6.3 Motor PC
Board Removal & Replacement”.
Replace Motor Cover. Refer to “6.1. Cover Removal &
Replacement”.
LLOOOOSSEENNTTHHRREEEEMMOOTTOORR
MMOOUUNNTTIINNGGSSCCRREEWWSS
RREEMMOOVVEEPPUULLLLEEYY
SSEETTSSCCRREEWW
RREEMMOOVVEETTHHRREEEEMMOOTTOORR
MMOOUUNNTTIINNGGSSCCRREEWWSS