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INSTALLATION PROCEDURE

1. Within the aforementioned time period of three 3 years from date of shipment Medical Illumination will evaluate the returned product repair as appropriate and ship the product back to you with freight costs prepaid by the Company In the event that non warranty damage or failure is discovered you will be contacted before any repairs are performed EXCLUSIONS This Limited Warranty does not cover the following Any field labor or outside services electricians contractors installation services routine maintenance or other repair services Damage to the product resulting from tampering accident abuse negligence alteration or other causes unrelated to problems with material and or workmanship Damage due to improper installation use cleaning or maintenance as outlined in the Installation and Service Manual for the product Labor costs associated with removing re packaging for shipment or reinstalling product PRODUCT RETURNS Please contact the authorized dealer from whom the product was purchased to inquire about a product return Additional terms and conditions set by the dealer may apply for any returned items SHIPMENT DAMAGE If the initial shipment of your purchased product arrived in damaged condition please file a claim with the carrier and contact Medical Illumination immediately
2. box Dual trolley Model No 044012 will have two trolley assemblies and two wire harness cables Some disassembly of the unit is required before mounting it to the ceiling Trolley Assembly Junction Box Track Assembly Wire Harness FIGURE 1 Page2 SPECIAL NOTE INSTALLATION AND REPAIR OF THIS EQUIPMENT SHOULD BE PERFORMED BY QUALIFIED PERSONS ONLY MEDICAL ILLUMINATION INTERNATIONAL INC DOES NOT WARRANTY ANY DAMAGE OR INJURIES AS A RESULT OF IMPROPER INSTALLATION PRE INSTALLATION REQUIREMENTS Before installation check to insure the following conditions are provided and in place e A structural ceiling mount meeting the specifications of the architectural plans or suggested structural mounting shown in Figures 2 through 5 The installation must be capable of supporting a weight of at least 200 pounds and a load of 167 pounds at 30 off center The track mount should not be mounted higher than 9 feet 6 inches 9 1 2 feet above the floor The track mount must be mounted at the finished ceiling level whether the ceiling surface is solid or dropped type Mounting the unit higher than 9 1 2 feet may result in instability of the light system and the arm assembly mounted too high to be accessable Check the length of the ceiling rod supplied Located in the carton with the light Head and Arm The rod lengths available for the ChuttleTrak are 16 long for a mounting height of 7 feet 6 inches to 8 feet 6 inches A 25 long rod
3. is available for a mounting height of 8 feet 7 inches to 9 feet 6 inches If a problem occurs contact our customer service department at 818 838 3025 The mounting bolts used to fasten the track must be able to support a minimum of 200 pounds each 3 8 diameter bolts are required Perpindicular Joists Looking Upward Parallel Joists Looking Upward A4 Bracing Joist Mounting Hole 6 Places AV ww ru A A Mounting Hole 6 Places MOUNTING PALLET PERPINDICULAR TO WOOD JOISTS Bracing Joists FIGURE 2 MOUNTING PALLET PARALLEL TO WOOD JOISTS FIGURE 3 Cross Bracing Joists Sub Pallet Support Pe SN y4 Nut ae Wood Sub Pallet Washer a zb a j Flush With Ceiling Level Sub Pallet Support A MM UZZZAI EZZZZA A Sub me Flush With 3 8 Hex Lag Screw Ceiling Level Ceiling Level Or Bolt Pallet MOUNTING PALLET TO A SUSPENDED CEILING FIGURE 4 Flat Washer 3 4 To 1 OD Track Channel SUSPENDED CEILING WOOD BRACING DETAIL FIGURE 5 END VIEW Page 3 DISASSEMBLY OF THE TRACK MOUNT BEFORE INSTALLATION NOTE For installations where there are 2 trolley assemblies on a single track Dual Trolley Model No 044012 The left and right trolley must be removed from the track from their respective side When disassembling the track remove both end plates from the unit Remove the right trolley from the the right side and the left trolley from th
4. Flat Head Screw FIGURE 8 FIGURE 9 Page 4 TRACK MOUNT INSTALLATION PROCEDURE WARNING IMPROPER FASTENING OF THE TRACK MOUNT CAN CAUSE SERIOUS INJURY AND OR PROPERTY DAMAGE MAKE CERTAIN THE INSTALLATION IS CAPABLE OF SUPPORTING A WEIGHT OF AT LEAST 200 POUNDS ON CENTER AND A LOAD OF 167 POUNDS AT 30 OFF CENTER Step 1 Refer to Figures 2 3 amp 10 It is recommended that the head of each mounting bolt be recessed flush or just below the surface of the plywood pallet This will allow for easier assembly of the side panels once the track is mounted Drill 6 7 16 diameter clearance holes in the plywood pallet for the bolts Counterbore the holes to 1 diameter x 3 8 deep The holes should be evenly spaced along the pallet at the outside edge of the track base extrusion NOTE The fasteners can also be placed in the interior of the track extrusion if ceiling conditions do not allow mounting the fixture at the plywood pallet Step 2 Mark the hole locations on the ceiling structure to match the hole locations on the plywood pallet Drill the proper sized pilot or clearance holes in the ceiling structure depending on the type of fastener that has been chosen Step 3 Refer to Figure 11 This step requires two people to mount the track base One person is needed to support the fixture at the ceiling while the other person fastens the bolts IMPORTANT NOTE Proper movement of the trolley requires the track must be mounted to a level ceiling struc
5. WM INTERNATIONAL i INC 547 Library Street San Fernando CA 91340 U S A Phone 818 838 3025 Fax 818 838 3725 INSTALLATION PROCEDURE CHUTTLETRAK CEILING TRACK MOUNT FOR 21 CENTURY SERIES LIGHTS Track Pictured With Lights Installed P N 1003055 Rev C 10 01 Page 1 ChuttleTrak CEILING TRACK MOUNT SPECIAL NOTE INSTALLATION AND REPAIR OF THIS EQUIPMENT SHOULD BE PERFORMED BY QUALIFIED PERSONS ONLY MEDICAL ILLUMINATION INTERNATIONAL INC DOES NOT WARRANTY ANY DAMAGE ORINJURIES AS A RESULT OF IMPROPER INSTALLATION PRE INSTALLATION INFORMATION TRACK MOUNT SPECIFICATIONS Dimensions Assembled 5 10 5 8 Long x 10 1 2 Wide x 5 High Weight 44 Ibs Approx Power Requirements Power cable exiting the track can be connected to 115 120 VAC 60 Hz or 230 240 VAC single phase 50 60 Hz power The power supply line routed to the track must be a 3 wire grounded type capable of supplying 1400 Watts at 12 Amperes Refer to the Model Serial label lo cated on the arm assembly to be mounted for proper voltage to supply to the track GENERAL INFORMATION Refer to Figure 1 The shipping carton contains the track mount fully assembled Carefully remove the track from the container and take off the protective wrap and cardboard covering Check it for any visible damage or missing components The major components provided are the track assembly trolley assembly a wire harness and junction
6. e left side of the track IMPORTANT Care must be taken to avoid mixing the right and left trolley assemblies The cord bracket within each trolley is positioned to make electrical connection for the right and left light fixtures respectively Temporarily mark each trolley if needed to make sure they are assembled onto the track in the proper location and orientation When performing this procedure DO NOT disassemble the components of the trolley assembly or remove the track extrusion channel from the plywood pallet Step 1 Refer to Figure 6 Take the end plate off of one side of the track by removing the 2 screws Step 2 Refer to Figure 7 Take off the 2 side panels by removing the wood screw at the end of each panel Step 3 Refer to Figure 8 Loosen the 3 set screws along each side of the track channel extrusion Use the hex Allen wrench provided Remove both dress covers Keep the side panels and dress covers in a safe place to prevent damage until reassembly Step 4 Refer to Figure 9 Remove the 2 stop pins and the flat head screws holding them in place from the track end that has the end plate removed Secure all screws and hardware until it is time for reassembly Step 5 Slide the trolley assembly off of the track Track Extrusion Channel Trolley Assembly s End Plate Screws Side Panel Wood Screw FIGURE 6 FIGURE 7 3 4 Plywood Pallet Dress Cover Stop Pin With Protective Cover Set Screw 3 Places each side
7. e roll pin to rest in the indentation in the trolley WARNING Failure to install the roll pin correctly can cause serious injury and or property damage Secure the ceiling rod by tightening the 4 set screws in the trolley hub Insert the wire harness through the ceiling rod The large Molex connector must be located at the roll pin end Insert the Molex connector into the cord bracket until it locks in place Step 6 Slide the trolley and rod onto the track The cord mounting bracket in the trolley should be positioned so it is next to the Molex connector on the power cord Insure that the trolley rolls freely along the track If adjustment is necessary refer to Figure 14 Loosen the adjustment screws and position the side rollers against the base track extrusion Tighten the screws Step 7 Refer to Figure 15 IMPORTANT NOTE When performing this step it is critical that the power cord does not get twisted when attaching it to the cord bracket Make sure the power cord lays flat within the track Make a simple radius turn in the cord then attach the Molex connector to the mating connector from the wire harness The power cord should maintain the radius as the trolley is rolled along the track If this does not occur check the cable for twists or pinching It is important to correct the problem before proceeding with the installation If the cord does become twisted loosen the cable clamp at the center of the track Rotate the cord until it lies flat in
8. ngle Ceiling Mount Installation section When 2 light fixtures are to be mounted to the ceiling rod refer to the Dual Ceiling Mount Installation section Medical Illumination International Inc Lighting Equipment Limited Warranty This document comprises the general terms of your product s Limited Warranty By accepting the shipment of the product the owner purchaser agrees to adhere to the warranty terms and conditions expressed herein Medical Illumination International Inc Medical Illumination Lighting Equipment is warranted against defective material and or workmanship excluding normal replacement parts e g bulbs sterilizable handles or glass items for a period of three 3 years from the date of shipment This Limited Warranty applies exclusively to the repair or replacement of parts recognized as defective by Medical Illumination are in normal use and have not been modified or repaired by unauthorized personnel This Limited Warranty extends only to the first retail purchaser of a product and is not transferable or assignable This warranty supersedes all other guarantees or warranties expressed or implied WARRANTY SERVICE amp REPAIRS Medical Illumination does not provide or give any compensation for outside repair services or field labor Therefore in the event of a failure covered under this warranty please take the following immediate action 1 Contact Medical Illumination via phone at 818 838 3025
9. side the track Tighten the cable clamp then check the trolley and cord movement Trolley Assembly Ceiling Rod Trolley Hub 2 Long Roll Pin Wire Harness FIGURE 12 FIGURE 13 1 4 Set Screw 4 Places Cord Mounting Bracket Make A Turn In Power Cord Alignment Bracket 2 Places To Form A Simple Radius Adjustment Screw Side Roller FIGURE 14 Trolley Assembly Radius in Cord Moves Ceiling Rod With The Trolley FIGURE 15 Page 6 Step 8 If the power cable and trolley move properly along the track replace the 2 stop pins and screws at the open track end Carefully slide the center dress covers through the trolley Avoid damaging the trolley components wire connections or the covers as you position them in place Tighten the 3 set screws along both sides of the track to secure the covers in place Step 9 Position each side panel and fasten in place with the wood screws The holes in the side panel have to be oriented to match the holes in the pallet before fastening NOTE If the bolt heads were not previously set flush with the plywood clearance holes need to be drilled in each panel to allow them to sit against the plywood pallet Step 10 Fasten the end plate with the 2 screws previously removed To install the light fixture to the end of the ceiling rod refer to the Installation and Service Manual for The 21st Century Series supplied with the light If 1 light fixture is to be mounted to the rod refer to Si
10. through our website at http www medillum com or by facsimile at 818 838 3725 A Be prepared to give the model number serial number and full description of the failure B Our Customer Service department will attempt to solve the problem over the phone If it becomes necessary to send the product to the factory for repair you will be provided with a Return Authorization number Products sent to the factory without a Return Authorization number will not be accepted 2 It is the retail purchaser s obligation to arrange for shipment return of a product to the factory for warranty service which shall be at the retail purchaser s expense Carefully package the light component light head arm assembly mount assembly etc and return it freight prepaid and insured with the Return Authorization number clearly marked on the outside of the box to Medical Illumination 547 Library Street San Fernando CA 91340 RA Damage resulting from inadequate packing is not covered by this warranty and shipping insurance does not cover damage due to inadequate packing We recommend that the package be insured against loss or in transit damage Medical Illumination cannot be held responsible for in transit loss Page 2 Medical Illumination Limited Warranty cont d or damage In the event that freight related damage should occur Medical Illumination will notify you immediately so that you can file a damage claim with the proper freight carrier
11. ture Check the ceiling with a leveling device in the length and width directions before mounting the base Install the base to the desired location with 6 3 8 diameter x 4 minimum length hex bolts with flat washers or hex lag screws with washers Fastening hardware is not provided If a small amount of shimming is required 1 4 or less flat washers can be placed between the track pallet and the ceiling surface to achieve a level installation Step 4 An electrical junction box is provided if one is not available in the ceiling Fasten the box as close as possible to the power cable exiting the back of the track Route the cable from the track to the junction box then connect the power source to the cable NOTE A ground wire is provided and must be fastened to an earth ground to insure proper grounding reliability for the lighting fixture s Wire routing and connections must be done in accordance to local and national electrical codes Electrical Junction Box Fasten Track To Ceiling Structure Drill Clearance Holes amp Counterbore In Pallet 6 Places Power Cable FIGURE 10 FIGURE 11 Page 5 TRACK MOUNT INSTALLATION PROCEDURE Step 5 Refer to Figure 12 amp 13 Remove the 1 4 x 2 roll pin taped down in the trolley assembly Insert the pin into the ceiling rod end that has one hole in both walls The pin should extend the same amount on both sides of the ceiling rod Install the ceiling rod into the trolley and allow th

INSTALLATION PROCEDURE

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