Encore Medical Chattanooga Tru-Trac Model 4779 User manual

© 2006 Encore Medical, L.P.
Tru-Trac® Traction Unit- Model 4779
TX® Traction Unit- Model 4759
Applies to Serial numbers 1000 and above
SERVICE MANUAL
/
ISO 13485 Certified

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
TABLE OF CONTENTS

1
Tru-Trac andTX®TherapeuticTraction 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.
FOREWORD
©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.
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.

2
Tru-Trac andTX®TherapeuticTraction Unit
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.

3
Tru-Trac andTX®TherapeuticTraction Unit
2 SAFETY PRECAUTIONS
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:
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.
Text with a “WARNING” indicator will explain
possible safety infractions that will potentially
cause serious injury and equipment damage.
Text with a “DANGER” indicator will explain
possible safety infractions that are imminently
hazardous situations that would result in death
or serious injury.
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.
Throughout this manual, “NOTE” may be found.
These Notes are helpful information to aid in
the particular area or function being described.
2.1 PRECAUTIONARY DEFINITIONS
A. Caution
B. Warning
C. Danger
D. Dangerous Voltage
E. NOTE
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.
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