Mortara Quinton CR60 User manual

TABLE OF CONTENTS
REF 042101-001Rev C
CR60
REHABILITATION TREADMILL
SERVICE MANUAL
Manufactured by Mortara Instrument, Inc., Milwaukee,Wisconsin U.S.A.
CAUTION: Federallaw restricts this device to sale by oron theorderofa physician.

Copyright © 2013
by Mortara Instrument, Inc.
7865 N. 86th Street
Milwaukee, Wisconsin 53224
Thisdocument contains confidential informationthat belongsto Mortara Instrument,Inc. No part ofthisdocument
may be transmitted,reproduced,used,or disclosed outside ofthe receiving organizationwithout the express written
consent of Mortara Instrument, Inc. Mortara is a registered trademark of Mortara Instrument, Inc. Quinton is a
registered trademark of Mortara Instrument, Inc.

i
TABLE OF CONTENTS
PREFACE ................................................................................................................................ 1
GENERAL STATEMENTS.......................................................................................................... 2
TECHNICAL SUP PO RT AND SERVICE ...........................................................................................................................................2
NOTICES ................................................................................................................................. 3
MANUFACTURER’S RESPONSIBILITY..........................................................................................................................................3
RESPONSIBILITY OF THE CUS TO M E R..........................................................................................................................................3
EQUI PM ENT IDENTIFICATION...................................................................................................................................................3
COPYRIGHT AND TRADEM ARK NOTICES.....................................................................................................................................3
OTHER IMPORTANT INFORMATION...........................................................................................................................................3
WARRANTY INFORMATION...................................................................................................... 5
YOUR MORTARA WARRANTY ..................................................................................................................................................5
USER SAFETY INFORMATION .................................................................................................. 7
CAUTI ONS AND WARNINGS.....................................................................................................................................................7
EQUIPMENT SYMBOLS AND MARKINGS................................................................................... 9
SYMBOL DEFINITIONS.............................................................................................................................................................9
ELECTROMAGNETIC COMPATABILITY (EMC)..........................................................................11
INTRODUCTION......................................................................................................................15
OVERVIEW..........................................................................................................................................................................15
COMPO NENTS.....................................................................................................................................................................16
Configuration Plate.....................................................................................................................................................16
Power...........................................................................................................................................................................16
Operation....................................................................................................................................................................16
Controllers...................................................................................................................................................................16
THEORY OF OPERATION ........................................................................................................17
OVERVIEW..........................................................................................................................................................................17
Controller Assembly....................................................................................................................................................17
Headframe Assembly.................................................................................................................................................17
Deck and Roller Assembly ..........................................................................................................................................17
CONTROLLER ASSEMBLY .......................................................................................................................................................18
Key Panel.....................................................................................................................................................................18
User Inputs..................................................................................................................................................................18
OutputDisplays...........................................................................................................................................................18
Additional Functions...................................................................................................................................................18
HEADFRAME AS SEM BLY........................................................................................................................................................19
Input Power Module...................................................................................................................................................19
Drive Board .................................................................................................................................................................19
Drive Motor Assemb l y ................................................................................................................................................19
Grade MotorAssembly and System..........................................................................................................................19
DECK AND ROLLER ASSEMBLY................................................................................................................................................19
TROUBLESHOOTING ..............................................................................................................21
DIAGNOSIS..........................................................................................................................................................................21

TABLE OF CONTENTS
ii
TOOLS................................................................................................................................................................................21
ELECTRICAL PROBLEM S .........................................................................................................................................................22
ELECTRONIC PROBLEM S ........................................................................................................................................................23
Error Cod es ..................................................................................................................................................................23
SERVICE MODE....................................................................................................................................................................24
Enter/Exit Service Mode.............................................................................................................................................24
Controller Keys............................................................................................................................................................24
Displays.......................................................................................................................................................................25
Speed/Grade (Open-Loop Mode)...............................................................................................................................25
S p eed ...........................................................................................................................................................................25
Grade...........................................................................................................................................................................25
Testing Pin Signalson the Communications Cable...................................................................................................26
MECHANICAL PRO BLEMS ......................................................................................................................................................26
Walking Belt................................................................................................................................................................26
Drive Belt.....................................................................................................................................................................27
Treadmill Noise...........................................................................................................................................................27
FLOW CHARTS.....................................................................................................................................................................27
Bus Voltage FlowChart..............................................................................................................................................28
Grade Error Flow Chart ..............................................................................................................................................29
Drive Motor Error Flow Chart ....................................................................................................................................30
Communications Link.................................................................................................................................................31
Grade Problems Flow Chart.......................................................................................................................................32
REPAIR/REPLACEMENT AND CALIBRATION............................................................................33
ELECTRICAL SHOCK ...............................................................................................................................................................33
BURNS ...............................................................................................................................................................................33
MECHANICAL HAZARDS ........................................................................................................................................................34
TOOLS................................................................................................................................................................................34
REMOVING THE TREADMILL HOOD.........................................................................................................................................35
REPLACING THE CONFIGURATION PLATE .................................................................................................................................37
Field Functional Test...................................................................................................................................................38
REPLACING THE POWER CO RD ...............................................................................................................................................38
Hard-wired Cords (Low Voltage Units)......................................................................................................................38
Detachable Cords (High Voltage Units).....................................................................................................................38
Field Functional Test...................................................................................................................................................38
REPLACING THE AC DRIVE MODULE .......................................................................................................................................38
Field Functional Test...................................................................................................................................................39
REPLACING THE TENSI O NER...................................................................................................................................................40
Field Functional Test...................................................................................................................................................40
REPLACING THE POLY-V DRIVE BELT ......................................................................................................................................41
Field Functional Test...................................................................................................................................................41
REPLACING THE DRIVE MOTOR..............................................................................................................................................41
REPLACING THE TRA NSFORMER .............................................................................................................................................43
Field Functional Test...................................................................................................................................................43
REPLACING THE GRADE MOTOR ............................................................................................................................................43
Field Functional Test...................................................................................................................................................44
REPLACING THE GRADE MOTOR CHAIN...................................................................................................................................45
Field Functional Test...................................................................................................................................................45
REPLACING THE GRADE POTENTIOMETER (POT).......................................................................................................................45
Grade Pot Wires..........................................................................................................................................................46
Field Functional Test...................................................................................................................................................47
REMOVING THE RACK GEARS.................................................................................................................................................47

TABLE OF CONTENTS
iii
Reassembling the Rack Gears....................................................................................................................................48
Field Functional Test...................................................................................................................................................49
REPLACING A JAMMED RACK GEAR ........................................................................................................................................49
Field Functional Test...................................................................................................................................................50
REPLACING THE PI NI ON SHAFT...............................................................................................................................................50
Field Functional Test...................................................................................................................................................51
ADJUSTING THE GRADE LIMIT SWITCHES.................................................................................................................................51
Field Functional Test...................................................................................................................................................52
WALKI NG DECK ASSEMBLY ...................................................................................................................................................52
REPLACING ROLLERS.............................................................................................................................................................52
Field Functional Test...................................................................................................................................................53
REPLACING THE WALKING BELT .............................................................................................................................................53
Field Functional Test...................................................................................................................................................54
REPLACING COMPRESSION MOUNTS ......................................................................................................................................54
Field Functional Test...................................................................................................................................................54
REPLACING THE DECK ...........................................................................................................................................................55
Field Functional Test...................................................................................................................................................55
ADJUSTI NG THE WALKI NG BELT .............................................................................................................................................55
Belt Tension.................................................................................................................................................................55
Method 1: Using Calipers..........................................................................................................................................55
Method 2: WithoutCalipers......................................................................................................................................56
Walking Belt Tracking................................................................................................................................................56
CONTROLLER ASSEMBLY .......................................................................................................................................................57
Removing the Enclosure.............................................................................................................................................57
Field Functional Test...................................................................................................................................................58
Replacing the PCBA....................................................................................................................................................58
Configuring the Controller..........................................................................................................................................58
Field Functional Test...................................................................................................................................................58
Removing the Key Panel.............................................................................................................................................59
Replacing the Controller Cable..................................................................................................................................59
Field Functional Test...................................................................................................................................................59
Cumulative Use...........................................................................................................................................................59
Distance.......................................................................................................................................................................59
Time.............................................................................................................................................................................60
Limited Access Switch.................................................................................................................................................60
Disabling the Limited Access Switch..........................................................................................................................60
CALIBRATION PROCEDURES ...................................................................................................................................................60
Grade Potentiometer (Pot) Calibration.....................................................................................................................60
Speed Calibration........................................................................................................................................................61
Grade Calibration .......................................................................................................................................................61
PREVENTATIVE MAINTENANCE ..............................................................................................63
RECOMMENDED SERVICE......................................................................................................................................................63
ROUTINE MAINTENANCE ......................................................................................................................................................63
Visual Inspection.........................................................................................................................................................63
CLEANING THE TREADMILL SURFACES .....................................................................................................................................63
Disinfection.................................................................................................................................................................64
VACUUM I NG UNDER THE TREADMILL HOOD ...........................................................................................................................64
Frequency....................................................................................................................................................................64
REPLACEMENT SCHEDULES ....................................................................................................................................................64
ELECTRICAL TESTI NG ............................................................................................................................................................64

TABLE OF CONTENTS
iv
S P ECIF I CAT I ONS ....................................................................................................................66
MEDTRACK CR60 REHABI LITATION TREADM I LL.......................................................................................................................66
POWER REQUIREMENTS .......................................................................................................................................................66
SPEED VS.WEIGHT RANGE ...................................................................................................................................................67
MEDTRACK CONTROLLER......................................................................................................................................................67
PERCENT VS ANGLE RELATIONSHIP FOR TREADMILL GRADE .......................................................................................................69
PART NUMBERS.....................................................................................................................70
FINAL ASSEMBLIES...............................................................................................................................................................70
PART NUMBERS BY CATEGO RY...............................................................................................................................................70
PART NUMBERS BY LOCATION................................................................................................................................................71
FIELD FUNCTIONAL TESTS.....................................................................................................76
COMPLETE FIELD FUNCTI O NAL TEST.......................................................................................................................................76
Test A: Test the Controller Displays..........................................................................................................................76
Test B: Test the Multi Display ...................................................................................................................................77
Test C: Test the Controller Operation.......................................................................................................................77
Test D: Test the Grade Operation.............................................................................................................................78
Test E: Test Speed Operation ....................................................................................................................................78
Test F: Test the Deck Friction ....................................................................................................................................79
Test G: Test the Walk Belt Operation.......................................................................................................................79
Test H: Shut Down the Treadmill..............................................................................................................................79
FIELD TEST NO.1 ................................................................................................................................................................79
FIELD TEST NO.2 ................................................................................................................................................................79
FIELD TEST NO.3 ................................................................................................................................................................81
FIELD TEST NO.4 ................................................................................................................................................................81
FIELD TEST NO.5 ................................................................................................................................................................81
DRAWINGS.............................................................................................................................83
WIRING DIAGRAMS..............................................................................................................................................................83

1
PREFACE
This manualcontainsinformationfor servicing andrepairingthe Quinton®CR60 Rehabilitation treadmill to the
module level. The manualcovers domestic andinternationalversions of the treadmill.
The manual is written for authorized service personnelwith propertraining. There are no user-serviceable parts in
the tread mills . A ny attempt by non-authorized personnelto service the treadmillcan void the warranty. For service
information,callMortara-Quinton Technical Support: 888-MORTARA.
Use this manualonly forservicing the CR60treadmill. Do not use this manualforservicingother
Qu inton treadmills .

2
GENERAL STATEMENTS
Technical Support and Service
Headquarters
Mortara Instrument, Inc.
7865 North 86th Street
Milwaukee, WI 53224
U.S.A.
Tel: [phone]
Tel: [phone]
Fa x: 414.354.4760
Internet: http://www.mortara.com
European Union
Representative
Mortara Rangoni Europe, S rl
(European Headquarters)
Via Cimarosa 103/105
40033 Casalecchio diReno (BO)
Italy
Tel: [phone]
Fa x: +39.051.613.3582
Service/Technical
Support Group
Mortara Instrument, Inc.
7865 North 86th Street
Milwaukee, WI 53224
U.S.A.
Tel: [phone]
Service: 888.MORTARA
(888.667.8272)
Fa x: 414.354.4760
E-mail: [e-mail]
Sales Support/
Supplies & Accessories
Mortara Instrument, Inc.
7865 North 86th Street
Milwaukee, WI 53224
U.S.A.
Tel: [phone]
Fa x: 414.354.4760
HospitalCustomers: [e-mail]
Physician Practice: [e-mail]
US Distribution: [e-mail]
Mortara InstrumentGermany
Bonifaciusring15
45309 Es s en
Germany
Tel: [phone]
Fa x: +49.201.18 55 69 77
Mortara InstrumentNetherlands
Postbus 324
5680 AH Best
Indus trieweg 160b
5683 CG Best
Netherlands
Tel: [phone]
Fa x: +31.499.377908
Mortara InstrumentAustralia
PO Box 7568
Baulkham Hills NSW 2153
Unit 28, 9 Hoyle Avenue
Cas tle Hill NSW 2154
Aus tralia
Tel: [phone]
Fa x: [phone]
Mortara Dol by UK Ltd.
Units 11 & 12, Scion House
Stirling University Innovation Park
Stirling FK9 4NF
Scotland
Tel: [phone]
Fa x: +44.1786.446630

3
NOTICES
Manufacturer’s Responsibility
Mortara Ins trument, Inc. is responsible for the effects on safety and performance only if:
•Assembly operations,extensions,readjustments,modifications,orrepairs are carried out by persons authorized
by Mortara Instrument,Inc.
•The device is used in accordance with the instructions foruse.
•The electricalinstallationofthe relevantroomcomplies with the requirements of appropriate regulations.
Responsibility of the Customer
The user of this device is responsible for ensuringthe implementationof a satisfactory maintenance schedule.
Failure to do so may cause unduefailure and possible healthhazards.
Equipment Identification
Mortara Instrument,Inc. equipment is identified by a serialand reference numberon the backof the device. Care
shouldbe taken so that thesenumbers are notdefaced.
Copyright and Trademark Notices
This document contains information that is protected bycopyright. Allrights are reserved. No part ofthis
documentmay be photocopied, reproduced,ortranslated to anotherlanguagewithout priorwritten consent of
Mortara Ins trument, Inc.
Other Important Information
The information in this documentis subjectto change without notice.
Mortara Instrument,Inc.makes no warrantyofany kind with regard to this materialincluding,butnotlimited to,
implied warranties of merchantability and fitnessfor a particular purpose. Mortara Instrument, Inc. assumes no
responsibility forany errors oromissions that may appearin this document. Mortara Instrument,Inc.makes no
commitment to update orto keep currentthe information containedin this document.

NOTICES
4