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ZOLL 731 Series Service Manual
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ZOLL 731 Series Service Manual

ZOLL 731 Series Service Manual

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731 Series Ventilator Service Manual
Models: Z Vent, EMV+, Eagle II, and AEV
906-0731-04-01 Rev. C

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Summary of Contents for ZOLL 731 Series

  • Page 1 731 Series Ventilator Service Manual Models: Z Vent, EMV+, Eagle II, and AEV 906-0731-04-01 Rev. C...
  • Page 2 The issue date for the ZOLL Ventilator Service Manual (REF 906-0731-04-01 Rev. C) is April 2024. Copyright © 2024 ZOLL Medical Corporation. All rights reserved. ZOLL, Z Vent, EMV+, AEV, Eagle II, Smart Help are registered trademarks and/or trademarks of ZOLL Medical Corporation in the United States and/or other countries.
  • Page 3 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual...
  • Page 4 Functional Descriptions ....................2-8 Chapter 3 Maintenance Schedule & Procedures Introduction ........................3-1 731 Series Ventilators Maintenance Schedule ............3-2 Annual & 4 Year Service Kits..................3-3 RCS Procedures (Remote Calibration System)............3-4 Process Overview......................3-5 Stockpile Warm-Up Procedure ..................3-7 An Overview of Discrete Tests ..................
  • Page 5 Setup Diagram K ....................... 3-28 Chapter 4 Service Kit Installation Procedures About Service Kits ....................... 4-1 Service Kit Installation Guidelines, Cautions and Warnings ........4-1 Service Kits Requiring Electrical Safety Testing............4-3 Identifying 3rd and 4th Edition Ventilators..............4-3 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 6 Procedure for Front Case Kits ................. 4-99 Chapter 5 Electrical Safety Testing Warnings: ........................5-2 Electrical Safety Testing Procedure ................5-4 Chapter 6 Ventilator & Calibration Troubleshooting Introduction ........................6-1 Part I — Troubleshooting Overview ................6-2 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual...
  • Page 7 Part II — Ventilator Troubleshooting................6-6 Troubleshooting — Communication & Preventive Maintenance Alarms ..... 6-7 Troubleshooting — Front Panel................. 6-11 Troubleshooting — Pulse Oximeter Subsystem ............6-12 Troubleshooting — Power and Battery ..............6-13 Troubleshooting — Smart Pneumatic Module (SPM) Hardware ....... 6-14 Troubleshooting —...
  • Page 8 The ZOLL Ventilator Service Manual provides information that ZOLL-trained service technicians need for the safe and effective repair of ZOLL ventilators. It is important that all persons servicing this device read and understand all information contained within. Before performing service procedures, please thoroughly read the information found in this manual related to the following topics.
  • Page 9 Service Manual Updates A revision level (A, B, C, ...) and publication date (month/year) for this manual appears on the inside of the front cover. Contact ZOLL to determine the latest manual release and make sure to use the latest revision. 1–2 www.zoll.com...
  • Page 10 HMEF - Heat and Moisture Exchanger/Bacterial Viral filter VDC - Volts DC combined HP O - High Pressure Oxygen - Tidal Volume Hz – Hertz (as in frequency, cycles per second) WOB – Work Of Breathing 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 1–3...
  • Page 11 Do Not Discard: Follow all governing regulations regarding the disposal of any part of this medical device. Defibrillation Proof: Indicates the degree of protection against electrical shock. BF Symbol: Protection against electric shock, Type B with floating (F-type) parts. 1–4 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 12 Exhalation Valve (Top Faceplate, Note: The appearance of this label may be different depending on ventilator age). Exhaust Do Not Occlude (top faceplate icon). 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 1–5...
  • Page 13 Transducer (Top Faceplate, Note: The appearance of this label may be different depending on ventilator age). Gas Output -- Patient Circuit Connector (top faceplate icon). Non-Sterile High Priority Alarm Medium Priority Alarm Low Priority Alarm External Power: Indicates the device is operating using an external power source.
  • Page 14 The information contained herein is restricted for use by personnel trained by ZOLL Medical Corporation in the care and servicing of this product. ZOLL does not authorize or assume any obligations resulting from unauthorized servicing of its products nor will it be held liable for any injuries or damages incurred therefrom.
  • Page 15 Purchase order for a device with an expired warranty Returning A Ventilator For Service Before sending a ventilator to the ZOLL Technical Support Department for repair, obtain a service request (SR) number from a service representative. The Li-ion battery should remain secured inside the ventilator. Follow any additional local or international shipping protocols regarding Lithium Ion batteries if required.
  • Page 16 Mississauga, Ontario, L4Z3E6, Canada In Canada Attention: Technical Support Department (SR number) Telephone: 1-866-442-1011 The nearest authorized ZOLL Medical Corporation representative. To locate an authorized service center, contact ZOLL International In other locations technical support at: tservice_master@zoll.com 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 1–9...
  • Page 17 Device Overview & Architecture Introduction This chapter provides a general overview of the various models within the 731 Series of ventilators along with detailed information covering system and pneumatic architectures. The below list of topics are covered in the following pages: •...
  • Page 18 Eagle II The AEV model’s is designed for managing ventilator support patients during ambulance transport. Its ventilation modes (AC, CPAP with PS, and BL) are specifically chosen to be consistent with pre-hospital care provider's operating procedures. 2–2 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 19 Lights to indicate ventilator status and a visible alarm indicator. External Power Input Connector Enables connection to an external power source. Enables connection to a USB compatible device for servicing the USB Connector ventilator. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 2–3...
  • Page 20 Provides user access to the ventilator settings. Battery Compartment Bottom Holds the ventilator’s rechargeable Li-ion battery. Enables the ventilator internal compressor to use ambient air and Fresh Gas/Emergency Air Intake Side acts as an anti-asphyxia valve. Handle Side 2–4 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 21 Secondary Parameter, Context Menu item, and Menu item. Values accelerate with speed of turning. The Mute/Cancel button mutes the audible alarm allowing the user time to change Mute/Cancel button parameters. It can also be used to cancel parameter entries. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 2–5...
  • Page 22 Note: Plateau Pressure is an optional ventilator control. Indicators The ventilator’s indicators consist of the following: Indicator Description LCD Display Displays settings, patient data, and alarm information. LED Array Indicates operational status (Red, Yellow, or Green). 2–6 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 23 Device Overview & Architecture Pneumatic Diagram 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 2–7...
  • Page 24 The intake is designed to accept additional filters through an integrated 22mm connection and also incorporates a connection for a C2A1 style chemical/biological filter. The assembly acts as a means to entrain supplemental low flow oxygen using ZOLL's O2 Reservoir kit. See the Operators guide for detailed use. Environmental Sensing The 731 ventilator incorporates sensors for ambient and device temperatures and barometric pressure/altitude.
  • Page 25 The panel is the pathway for the exhalation valve's pressure to exhaust to atmosphere. Power input and power filtering are connected to the control panel. Located to the front and right of the Control Panel is the USB port for calibration and diagnostics and the pulse oximeter connector. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 2–9...
  • Page 26 Device Overview & Architecture 2–10 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 27 The ventilator has a built in function generating an alarm to remind the user of the PM/Calibration Due date (#3120). Refer to the respective alarm codes in the troubleshooting section of this manual. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 3–1...
  • Page 28 Maintenance Schedule & Procedures 731 Series Ventilators Maintenance Schedule Year After Initial Purchase of Ventilator * Maintenance Schedule Replace the high pressure oxygen inlet and compressor foam and disk filters Perform a periodic maintenance check using the RCS tool. Replace the main battery...
  • Page 29 Maintenance Schedule & Procedures Annual & 4 Year Service Kits The following tables provide part numbers for PM kits across the line of 731 Series ventilators. See the Service Kits chapter information additional options. (Click Jump) Z Vent, EMV+, Eagle II, and AEV...
  • Page 30 If you have not been trained on the RCS procedures, or do not have access to an RCS, ventilators can be returned to ZOLL for calibration or calibration may be performed on- site...
  • Page 31 12. Connect the TSI High Flow Module to PC 13. Select Get TSI Connect Device 14. Once TSI check is complete, select 731 Series Ventilator and Proceed 15. Select the Service Sequence, then proceed. 16. Connect to device via USB service Port (See RCS User Manual) TCE 7.X - Select the “Read”...
  • Page 32 Note: Do NOT change the original configuration without prior authorization. Contact technical support to change configuration or for authorization. Test Records & Calibration Upon completion of the testing and calibration sequences, ensure calibration Reports reports are printed, signed and filed. Table 3 3–6 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 33 On the vent set Mode: AC(V), Breath Rate= 20 BPM, Vt= 450ml, PIP High alarm=50cmH2O, FIO2=60% run for 5 minutes. Set FIO2 to 100%. Run for 5 minutes. End of Procedure 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 3–7...
  • Page 34 Masimo Tester Model # 1593 (or equivalent simulator) is used to test the Pulse Oximeter Pulse Ox Sp02 & Heart Rate SpO2 and Heart Rate on the 731 series ventilator. The device software continuously checks to see that the hardware has not failed. The...
  • Page 35 Verify UUT and Reference device UUT and/or reference device are not swapped. Conditional PM Due Reset The TCE resets the PM due date, if the calibration and functional checks are successful. End of Discrete Test List 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 3–9...
  • Page 36 Compressor Bypass Protection ● ● Breath Performance Check ● Date and Time Set ● Date and Time Check ● Download Calibration Tables ● Verify UUT and Reference Device ● ● ● Conditional PM Due Reset ● 3–10 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 37 Date and Time Set ● Date and Time Check ● ● Download Calibration Tables ● ● ● Verify UUT and Reference Device ● Conditional PM Due Reset Erases Forensic Memory ● Final Configuration ● 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 3–11...
  • Page 38 Hardware Maintenance Routines The following pages cover the required annual hardware replacement procedures. Service kits for annual and 4 year cycles can be purchased from ZOLL medical. See the section above titled “Annual & 4 year service kits” for additional information,...
  • Page 39 Removal Instructions To begin, unscrew the oxygen inlet cap. Using a #2 Phillips head screwdriver remove the three 8-32 flat head screws securing the oxygen inlet fitting to the ZOLL 731 Ventilator. Next, lift and remove the oxygen inlet fitting. Step Replacement Instructions Before replacing the oxygen inlet fitting, be sure to insert the center rubber O ring into its recess.
  • Page 40 Lift and remove the foam filter. Step Replacement Instructions Lower the foam filter into the compressor intake housing. To complete, lightly tap the foam filter into place, allowing it to expand into the fresh gas intake housing. 3–14 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 41 Insert the fresh gas intake into the device, making sure that its alignment pin mates. The O-Ring and gasket should be checked and replaced if damaged. Using a torque driver set to 14 in lbs/1.58 newton meter replace the four 8-32 flathead screws. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 3–15...
  • Page 42 Main Battery Replacement (Every 4 Years) ZOLL 731 Series Ventilators are internally powered by a 6.6 Ah, 14.8 V, Lithium-Ion Battery. Only trained technicians should replace the Main battery within the unit. Note that new batteries are shipped at a 30% charge per IATA/DOT 38.3...
  • Page 43 RTC Battery Replacement (Every 4 Years) The RTC Battery within ZOLL 731 Series ventilators should be replaced Every 4 years, or when prompted by the device. Service Code 3110 “RTC Battery Low” will display on start up if the RTC battery is less than or equal to 2.5 VDC.
  • Page 44 The following setup illustrations are listed below: • Setup A • Setup A2 • Setup B • Setup C • Setup D • Setup E • Setup F • Setup G • Setup I • Setup K 3–18 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 45 Maintenance Schedule & Procedures Setup Diagram A 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 3–19...
  • Page 46 Maintenance Schedule & Procedures Setup Diagram A2 3–20 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 47 Maintenance Schedule & Procedures Setup Diagram B 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 3–21...
  • Page 48 Maintenance Schedule & Procedures Setup Diagram C 3–22 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 49 Maintenance Schedule & Procedures Setup Diagram D 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 3–23...
  • Page 50 Maintenance Schedule & Procedures Setup Diagram E 3–24 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 51 Maintenance Schedule & Procedures Setup Diagram F 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 3–25...
  • Page 52 Maintenance Schedule & Procedures Setup Diagram G 3–26 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 53 Maintenance Schedule & Procedures Setup Diagram I 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 3–27...
  • Page 54 Maintenance Schedule & Procedures Setup Diagram K 3–28 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 55 Maintenance Schedule & Procedures Setup Diagram L 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 3–29...
  • Page 56 About Service Kits Service kits are factory-tested sub-assemblies used to facilitate ventilator servicing and repair. Service kits are available only to ZOLL trained and certified service personnel. For additional information on availability of ZOLL Technical training programs, please contact techtraining@zoll.com.
  • Page 57 NOTE: Screws are coated with anti-vibration compound. When reusing screws clean, then reapply the anti-vibration compound (Part No. 602-0006-00). Some kits require the RTV silicone sealant be reapplied (Part No. 602-0001-00) 4–2 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 58 Identifying 3rd and 4th Edition Ventilators. When servicing 731 series ventilators, it is important to differentiate between 3rd and 4th edition devices. The tables on the following pages identify service kits for each product along with specific columns for 3rd and 4th edition kits.
  • Page 59 Selector Knob Kit 712-0731-27 712-0731-27 712-0731-27 Smart Pneumatic Module (SPM)/ 712-0731-02 712-0731-02-01 712-0731-02-04 Vent Assembly Kit UIM Adapter PCB Assembly Kit 712-0731-38 712-0731-38 712-0731-38-04 USB Connector Kit 712-0731-15 712-0731-15 712-0731-15 USB Connector Plate Kit 712-0731-07 712-0731-07 712-0731-07 4–4 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 60 712-0731-27 Smart Pneumatic Module (SPM)/ 712-0731-02 712-0731-02-01 712-0731-02-04 Vent Assembly Kit UIM Adapter PCB Assembly Kit 712-0731-38 712-0731-38 712-0731-38-04 USB Connector Kit 712-0731-15 712-0731-15 712-0731-15 USB Connector Plate Kit 712-0731-07 712-0731-07 712-0731-07 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–5...
  • Page 61 Power Knob Kit 392-0071-00 392-0071-00 Selector Knob Kit 712-AEV1-27 712-AEV1-27 Smart Pneumatic Module (SPM)/ 712-0731-02 712-0731-02-01 Vent Assembly Kit UIM Adapter PCB Assembly Kit 712-0731-38 712-0731-38 USB Connector Kit 712-0731-15 712-0731-15 USB Connector Plate Kit 712-0731-07 712-0731-07 4–6 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 62 Selector Knob Kit 712-EGL2-27 712-EGL2-27 Smart Pneumatic Module (SPM)/ 712-EGL2-02 712-EGL2-02-01 Vent Assembly Kit UIM Adapter PCB Assembly Kit 712-0731-38 712-0731-38 USB Connector Kit 712-0731-15 712-0731-15 USB Connector Plate Kit 712-EGL2-07 712-EGL2-07 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–7...
  • Page 63 Power Knob Kit 392-0071-01 392-0071-01 Selector Knob Kit 712-EGL2-27 712-EGL2-27 Smart Pneumatic Module (SPM)/ 712-EGL2-02 712-EGL2-02-01 Vent Assembly Kit UIM Adapter PCB Assembly Kit 712-0731-38 712-0731-38 USB Connector Kit 712-0731-15 712-0731-15 USB Connector Plate Kit 712-EGL2-07 712-EGL2-07 4–8 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 64 712-EMBP-27 Smart Pneumatic Module (SPM)/ 712-EMBP-02-01 712-EMBP-02-01 712-EMB4-02-04 Vent Assembly Kit UIM Adapter PCB Assembly Kit 712-0731-38 712-0731-38 712-0731-38-04 USB Connector Kit 712-0731-15 712-0731-15 712-0731-15 USB Connector Plate Kit 712-EMBP-07 712-EMBP-07 712-EMBP-07 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–9...
  • Page 65 Power Knob Kit 392-0071-02 392-0071-02 Selector Knob Kit 712-EMBP-27 712-EMBP-27 Smart Pneumatic Module (SPM)/ 712-EMBP-02-01 712-EMB4-02-04 Vent Assembly Kit UIM Adapter PCB Assembly Kit 712-0731-38 712-0731-38-04 USB Connector Kit 712-0731-15 712-0731-15 USB Connector Plate Kit 712-EMBP-07 712-EMBP-07 4–10 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 66 Service Kit Installation Procedures Bulk Supplies Refer to the table below for a list of supplies to have on hand if regularly servicing 731 series ventilators. Bulk Supplies - Screws & Nuts Location Type 0163-000460 Z-Vent Power Input Plug Hex Socket...
  • Page 67 Flow Manifold to Compressor Output #4 Split ring washer Bulk Supplies - Components Part Number Part Type Location Picture O-Ring Compressor 340-0106-00 Inlet/Outlet O-Ring 340-0020-00 Snap Cover O-Ring 340-0113-00 Mix Manifold 490-0005-00 Leaf Valve BV Filter Holder Base 4–12 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 68 Service Kit Installation Procedures 340-0118-00 O-Ring BV Filter Holder 340-0107-00 Gasket Intake Adaptor 340-0055-00 O-Ring Intake Adaptor 340-0023-00 O-Ring Manifold/ Connector Panel 340-0059-00 O-Ring Gas Out 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–13...
  • Page 69 Bumper Foot Back Cover / Battery Cover 602-0006-00 Vibratite All Screws 600-0005-00 Loctite High Pressure O2 Hose 602-0001-01 RTV Silicone SPO2 / USB Connectors 540-0215-00 High Pressure O2 O2 Manifold / Tubing O2 Tank XDCR 4–14 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 70 Service Kit Installation Procedures 540-0217-00 SPM Tubing SPM Board 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–15...
  • Page 71 Front Bezel 4-40 X 1/4" Buzzer 4-40 X 1/4" Masimo Plug (SPO2 M2.5 X 5mm Cable) UIM Stack to Front Case 2 6-32 X 5/16" UIM Adapter Board 4-40 X 1/4" USB Cable 4-40 X 3/16" 4–16 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 72 6-32 X 1/2" Mix Manifold Foam Filter Holder 4-40 X 1/4" Screen to B/V Holder Green cap & chain to O2 4-40 X 3/16 Fitting O2 Fitting 8-32 X 7/16 Gas Output Fitting 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–17...
  • Page 73 4-40 X 5/16" Compressor Output 15mm Compressor 4-40 X 1/2" Input Port to Compressor Back Cover to Dovetail 6-32 X 5/16" Bracket Compressor to Pump 6-32 X 1.5" Bracket Pump Bracket to Chassis 4 6-32 X 1/4" 4–18 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 74 Loosen and remove the two 10-32 Keps nuts and the four 6-32 x 2 screws. Save these screws and Keps nuts. Remove the back case by lifting from the ventilator. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–19...
  • Page 75 Save these screws. Loosen and remove the two 4-40 x 1 1/4 screws and nylon spacers that support the Power Input assembly within the chassis. Save these screws and spacers. 4–20 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 76 Disconnect the Power Input cable from the PIM board by pressing on the locking latch and pulling the cable straight up from the connector. Remove the PIM board by loosening the five 4-40 x 1/4 screws. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–21...
  • Page 77 6-32 x 5/16 screws. Secure the Power Input assembly to the Chassis using the two spacers and two 4-40 x 1 1/4 screws. Note: Do not over-tighten the screws. (Maximum torque - 3.5 in.- lb.) 4–22 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 78 Insert and tighten the four 6-32 x 2” screws and then the two 10-32 Keps nuts (provided in the kit). Tighten the four 8-32 x 3 screws on the outer air intake. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–23...
  • Page 79 Service Kit Installation Procedures Step Action Use the RCS "Write" function to update the new part's serial number. Re-certify the ventilator using the RCS tool 4–24 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 80 6-32 x 2 1/4 screws. Re-assemble the battery compartment cover by tightening the four 6-32 x 5/16 screws. Re-certify the ventilator using the RCS tool 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–25...
  • Page 81 FILTER, DISK, FRESH GAS/EMERGENCY AIR 465-0027-00 INTAKE,INDIVIDUALLY BAGGED FILTER, FOAM INLET 465-0028-00 Instructions Disk Filter Replacement Oxygen Filter Replacement Foam Filter Replacement Scan or Click for Video Scan or Click for Video Scan or Click for Video 4–26 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 82 Service Kit” within this Chapter. (Click to Jump) RTC Battery Replacement See instructions below on the following pages, Scan or Click for Video or scan / click the QR Code to watch a video of this procedure. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–27...
  • Page 83 2 1/4 screws and detaching the plug from its locking latch. Save these screws. Disconnect the Power Input Cable from the PIM board by pressing on the locking latch and pulling the cable straight up from the connector. 4–28 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 84 Remove the corrugated hose connecting the Compressor Air Intake Base to the Compressor intake port. Remove the 4 4-40 x ¼" screws holding the SPM PCB to the SPM. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–29...
  • Page 85 Reattach the Dovetail Mounting Bracket using the 4 6-32 x 1/4" flathead screws on the ends and 2 4-40 x ¼" flathead located towards the middle of the bracket. Caution: Make sure to insert the SPO insulator between the chassis and Dovetail Support bracket. 4–30 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 86 Insert and tighten the four 6-32 x 2” screws and then the two 10-32 Keps nuts (provided in the kit). Tighten the four 8-32 x 3 screws on the outer air intake. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–31...
  • Page 87 Service Kit Installation Procedures Step Procedure Power cycle the ventilator three times, and then re-certify the ventilator using the RCS. Note: A PM Due Alarm (SC#3120) may occur and will be reset when the device is recalibrated. 4–32 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 88 6-32 x 5/16 screws. Save these screws. Remove the battery by unscrewing the four 6-32 x 2 1/4 screws and detaching the plug from its locking latch. Save these screws. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–33...
  • Page 89 (pull lightly on cable to ensure it is locked in place) then tightening the four 6-32 x 2 1/4 screws. Re-assemble the battery compartment cover by tightening the four 6-32 x 5/16 screws. Re-certify the ventilator using the RCS. 4–34 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 90 Loosen and remove the two 10-32 Keps nuts and the four 6-32 x 2 screws. Remove the back case by lifting from the ventilator. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–35...
  • Page 91 Loosen and remove the two M2.5 x 5mm screws holding the SpO cable to the front case. Loosen and remove the two 6-32 x 5/16 screws that hold the CPU/UIM & SpO Stack to the front case. 4–36 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 92 Flex Cable lays flat against the front case and is assembled correctly into the UIM Bracket and SpO Isolation Shield. Insert and tighten the two M2.5 x 5mm screws holding the SpO cable to the front case. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–37...
  • Page 93 Insert and tighten the four 6-32 x 2” screws and then the two 10-32 Keps nuts. Tighten the four 8-32 x 3 screws on the outer air intake. Perform PM processPM process testing then re- certify the ventilator using the RCS 4–38 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 94 Screw, Phillips, Pan Head, SS, 6-32 x 5/16 Bumper, Rubber, Foot, P/S, Round, 1/2" Dia. x 1/8", Blk Instructions Step Action Remove the damaged cover by unscrewing the four 6-32 x 5/16 screws. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–39...
  • Page 95 Rotate cover to align with the battery compartment, then insert and tighten the four 6- 32 x 5/16 screws. Re-certify the ventilator using the RCS. 4–40 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 96 Quantity Description Depiction EMV Chassis Assembly Screw, Phillips, Pan Head, SS, 6-32 x 5/16 Screw, Phillips, Flat Head, 8-32 x 1/4, Undercut, ZP Screw, Phillips, Flat Head, 6-32 x 1/4, Undercut Insulator 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–41...
  • Page 97 Remove the battery compartment cover by unscrewing the four 6-32 x 5/16 screws. Save these screws. Remove the battery by unscrewing the four 6-32 x 2 1/4 screws and detaching the plug from its locking latch. Save these screws. 4–42 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 98 Insert screwdriver through the holes on the chassis to loosen and remove the two 6-32 x 5/16 screws holding the chassis to the ventilator module. Lift the damaged chassis from the ventilator module. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–43...
  • Page 99 Place the front case assembly over the ventilator module and tighten the two 4-40 x 1/4 screws to the dovetail mounting bracket. Reconnect the ribbon cable unto the PIM board. Make sure the two ejector latches are secured. 4–44 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 100 Insert and tighten the four 6-32 x 2” screws and then the two 10-32 Keps nuts. Tighten the four 8-32 x 3 screws on the outer air intake. Re-certify the ventilator using the RCS. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–45...
  • Page 101 Torque driver with #1 and #2 Phillips bits • Nut driver set • Needle-nosed pliers • 5/16” open-ended wrench Kit Contents Quantity Description Depiction Connector Panel Assembly 8-32 x 1/4 Screw 6-32 Keps Nut O-Ring ½” OD x 3/8” ID 4–46 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 102 Loosen and remove the three 8-32 x 1/4 screws. Loosen and remove the gas output fitting (GAS OUTPUT) using a socket wrench that has a 1 in. deep well socket. Save the fitting. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–47...
  • Page 103 3 tubing on these fittings: • “Transducer” • “Exhaust Do not Occlude” • “Exhalation Valve” Do not discard the tubing. Loosen and remove the two 6-32 Keps nuts using a 5/16 open-end wrench. 4–48 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 104 Connect the Power Input cable by inserting into connector. Insure that locking latch engages. Insert the 3 tubing to their correct connectors. • “V_BACKUP” to “Exhalation Valve” • “V_ACAL” to “Transducer” • “Exhaust Do Not Occlude” (smallest tubing) 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–49...
  • Page 105 Attach the back case to the ventilator module, then align the cover with the handle, air intake housing and dovetail mounting studs. Insert and tighten the four 6-32 x 2” screws and then the two 10-32 Keps nuts. 4–50 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 106 Service Kit Installation Procedures Step Action Tighten the four 8-32 x 3 screws on the outer air intake. Re-certify the ventilator using the RCS. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–51...
  • Page 107 Loosen and remove the two 10-32 Keps nuts and the four 6-32 x 2 screws. Remove the case by lifting from the ventilator. Save these screws. 4–52 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 108 Insert and tighten the two 10-32 Keps nuts (provided in the kit) and the four 6-32 x 2” screws. Tighten the four 8-32 x 3 screws on the outer air intake. Re-certify the ventilator using the RCS 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–53...
  • Page 109 Remove the back case by lifting it from the ventilator. Remove the two 4-40 x 1/4 screws on the dovetail mounting bracket. Save these screws. Disconnect the ribbon cable on the PIM board by simultaneously applying pressure on the two ejector latches. 4–54 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 110 Note: Do not fold the SpO Insulator. Lift the defective PIM Board out of the ventilator module. Place the new PIM Board Note: Make sure male header pins are inserted correctly into the mating header. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–55...
  • Page 111 6-32 x 2” screws. Tighten the four 8-32 x 3 screws on the outer air intake. Use the RCS "Write" function to update the new part's serial number. Re-certify the ventilator using the RCS tool 4–56 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 112 Loosen by 1 full turn and do not remove the four 8- 32 x 3 screws on the outer air intake. (Additional loosening may cause the filter disk to slip out of place) 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–57...
  • Page 113 Using a sharp knife, carefully cut the RTV sealant around the SpO cable. Loosen and remove the two M2.5 x 5mm screws holding the SpO cable to the front case. 4–58 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 114 Flex Cable lays flat against the front case and is routed correctly into the UIM Bracket and SpO Isolation Shield. Insert and tighten the two M2.5 x 5mm screws holding the SpO cable to the front case. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–59...
  • Page 115 Place the front case assembly over the ventilator module and tighten the two 4-40 x 1/4 screws unto the dovetail mounting bracket. Reconnect the ribbon cable unto the PIM board. Make sure the two ejector latches are secured. 4–60 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 116 Use the RCS "Write" function to update all serial numbers on the "Front Case" fields, and the PIM board's serial number on the respective field. Re-certify the ventilator using the RCS tool. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–61...
  • Page 117 Loosen and remove the two 10-32 Keps nuts and the four 6-32 x 2 screws. Save these screws. Remove the back case by lifting from the ventilator. 4–62 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 118 Loosen and remove the two 4-40 x 3/16 screws holding the Mini USB Cable Assembly to the front case. Remove the damaged cable by pressing on locking tab and pulling cable downwards. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–63...
  • Page 119 Attach the back case to the ventilator module and align cover with the handle, air intake housing, and dovetail mounting studs. Insert and tighten the two 10-32 Keps nuts (provided in the kit) and the four 6-32 x 2” screws. 4–64 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 120 Service Kit Installation Procedures Step Action Tighten the four 8-32 x 3 screws on the outer air intake. Re-certify the ventilator using the RCS. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–65...
  • Page 121 Fitting, Patient, Outlet, SPM O-Ring, Neoprene, 1/2" ID Instructions Step Action Remove the damaged fitting by unscrewing with a socket wrench that has a 1-inch deep well socket. Place O-ring unto underside of outlet fitting 4–66 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 122 Place fitting and O-ring unto Gas Output and tighten with a socket wrench that has a 1 in. deep well socket. Torque to 75 in-lbs. Note: Do not cross thread. Re-certify the ventilator using the RCS. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–67...
  • Page 123 Step Action Loosen by 1 full turn and do not remove the four 8- 32 x 3 screws on the outer air intake. (Additional loosening may cause the filter disk to slip out of place) 4–68 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 124 2 1/4 screws and detaching the plug from its locking latch. Loosen and remove the two 4-40 x 1 1/4 Screws and nylon spacers supporting the Power Input assembly unto the chassis. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–69...
  • Page 125 Insert the new power input assembly into the connector panel socket and pull on the assembly to ensure the locking tabs have engaged. 4–70 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 126 Attach the back case to the ventilator module and align cover with handle, air intake housing and dovetail mounting studs. Insert and tighten the four 6-32 x 2” screws and then the two 10-32 Keps nuts (provided in the kit). 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–71...
  • Page 127 Service Kit Installation Procedures Step Action Tighten the four 8-32 x 3 screws on the outer air intake. Re-certify the ventilator using the RCS. 4–72 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 128 Kit Contents Quantity Description Depiction Oxygen inlet fitting with filter, cap and chain Screw, Phillips, Flat Head, 8-32 x 7/16, ZP O-Ring, Black, Neoprene, 1/2"O.D.x 3/8"I.D. (Nominal) O-Ring, Buna-N 5/16 OD X 3/16 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–73...
  • Page 129 Install the O-Rings (provided in the kit) into grooves on underside of inlet fitting. Place oxygen inlet fitting over the ventilators connector panel then insert and tighten the 3 supplied 8-32 x 7/16 screws. Re-certify the ventilator using the RCS. 4–74 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 130 • Do not keep sources of contaminate on the workbench such as soldering material. • If an oxygen clean part becomes contaminated, replace the part and do not attempt to clean it. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–75...
  • Page 131 Loosen and remove the two 10-32 Keps nuts and the four 6-32 x 2 screws. Save these screws and Keps nuts. Remove the back case by lifting from the ventilator. 4–76 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 132 The O2 valve is located on the ventilator module. The 6" corrugated tubing can be removed for easier viewing and access to the O Valve. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–77...
  • Page 133 (4-40 x 11/16) from the O Valve. Remove the O Valve with its (2) O-rings from the SPM assembly. With the new valve kit, insert two O-Rings into the Valve Assembly. Note: Ensure that the O-Rings stay firmly in place. 4–78 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 134 Connect Oxygen Flow Valve cable to J2 of SPM PCB. Test that the connector is locked in place by gently pulling up on the connector. Re-attach the 6" corrugated tubing if it was previously removed. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–79...
  • Page 135 Insert and tighten the four 6-32 x 2” screws and then the two 10-32 Keps nuts (provided in the kit). Re-certify the ventilator using the RCS. 4–80 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 136 • Do not keep sources of contaminate on the workbench such as soldering material. • If an oxygen clean part becomes contaminated, replace the part and do not attempt to clean it. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–81...
  • Page 137 ACTION STEP Remove the battery compartment cover by unscrewing the (4) 6-32 X 5/16 screws. Remove the battery by unscrewing the (4) 6-32 X 2 ¼ screws and detaching the plug from its locking latch. 4–82 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 138 X 7/16 screws. Remove and keep the O- ring(s) Loosen and remove the (3) 8-32 X ¼ screws. Loosen and remove the Gas Output fitting using a 1-inch deep-socket wrench. Remove and keep the O-ring(s) 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–83...
  • Page 139 “Exhalation Valve” fittings. Loosen and remove the (2) 6-32 Keps nuts using a 5/16 open-end wrench. Lift the damaged connector panel assembly out from the SPM. Remove the Compressor Intake Corrugated Hose ACTION STEP 4–84 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 140 Disconnect Oxygen Flow Valve cable from J2 of SPM PCB by pinching on the locking latch and pulling up on the connector. Disconnect the Hoses (6) from the Flow Manifold Assembly ACTION STEP 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–85...
  • Page 141 Manifold (+). For re-assembly: Connect tubing from XDCR_O2_FLOW (-) to the O2 Inlet Manifold (-). Disconnect tubing from the O2 Inlet Manifold (-). For re-assembly: Connect tubing from XDCR_O2_FLOW (+) to the O2 Inlet Manifold (+). 4–86 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 142 XDCR_COMP_FLOW (+) to the Mix Manifold (+). Disconnect the Flow Manifold from the Compressor ACTION STEP Loosen and remove the 4 hex screws (with washers) holding the Flow Manifold to the Compressor outlet. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–87...
  • Page 143 Step Action Remove the Manifold Assembly from the Top Panel Connector and the Compressor Pump. Remove 4 screws at SPM Oxygen Inlet Manifold to separate it from the SPM Mix Manifold. Remove 4 screws at SPM Mix Manifold to separate it from the Compressor-SPM Connector. On the SPM Mix Manifold, insert the O-Ring ½"...
  • Page 144 NOTE: Ensure that it sits properly in the counter bore. Insert the Filter, Diffuser, .615 DIA (P/N 465- 0029-00) into the shoulder of the Compressor- SPM Connector. NOTE: Ensure that it sits properly and flat on the shoulder. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–89...
  • Page 145 360-0632-05) through the Compressor-SPM Connector into the SPM Mix Manifold. NOTE: Ensure the thread does not get stripped. Torque four screws in a crossing pattern to 9 in- lbs with a 7/64 ball driver hex bit. 4–90 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 146 NOTE: Ensure that it sits properly and flat on the shoulder. Insert the O-Ring ½" OD X 3/8" ID (P/N 340-0023- 00) into the SPM Oxygen Inlet Manifold with tweezers. NOTE: Ensure that it sits properly in the counter bore. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–91...
  • Page 147 NOTE: Ensure that it sits properly in the counter bore. Insert the O-Ring ½" ID X 5/8" OD X .0629 (P/N 340-0059-00) into the SPM Oxygen Inlet Manifold. NOTE: Ensure that it sits properly in the counter bore. 4–92 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 148 Insert four of Screw, Phillips, Pan Head, 4-40 X 1 ¾ (P/N 358-0440-28) into the SPM Oxygen Inlet Manifold and torque in a crossing pattern to 5 in- lbs with #1 Phillips head. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–93...
  • Page 149 Mix Manifold, SPM Oxygen Inlet Manifold, and Compressor-SPM Connector are flushed before re-install the whole Manifold Assembly to the Top Panel Connector and Compressor Pump. NOTE Once re-assembly is completed you must calibrate and test the ventilator with the RCS. 4–94 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 150 Allow the Flow Screens to air dry before re-inserting them into the Manifold. DO NOT use compressed air from an oil-based compressor. • Inspect the screen against a light to verify cleanliness before re-inserting them into the manifold 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–95...
  • Page 151 Servicing Membrane Panels and Button Boards NOTICE: There has been a design change in ZOLL Ventilators. The user interface has been changed from a Membrane Panel (MP) to Button Board (BB). The Button Board components (including knobs and bezels) are not interchangeable with the older Membrane Panel components.
  • Page 152 AEV: 712-0731-23 and 712-AEV1- Bezel 712-0731-05 (EMV+) 712-EGL2-05 Near end of life. Assembly Kit 712-AEV1-01 (AEV) Available until Zoll inventory is depleted. Convert ventilator to Button Board with kits: After that convert ventilator to EMV+: 712-0731-23 and 712-0731- Button Board with kits: 712-EGL2-15 and 712-EGL2-18.
  • Page 153 Service Kit Installation Procedures Power Knob 712-0731-06 712-EGL2-06 NEAR END OF LIFE Available until Zoll inventory is Convert ventilator to Button Board depleted. After that convert with kits: ventilator to Button Board with kits: EMV+:712-0731-23 and 712-0731- 712-EGL2-15 and 712-EGL2-18...
  • Page 154 To distinguish between a Membrane Panel and Button Board ventilator and to also determine replacement kit number needed refer to, “How to Identify a Button Board for the 731 Series Ventilator” earlier in this appendix. Note: Plastic case, Membrane Panel and Button Boards are not interchangeable.
  • Page 155 Tools/Supplies needed: • Philips Head Screwdriver, small point • 5/16” Nut Driver • 1/16” Ball Hex Driver • X-Acto® Knife • RTV- Zoll #s • 602-0001-01(3oz) • 602-0001-02(10oz) Buzzer - Kit#:712-0731-37 Remove two (2) 4-40 x ¼" Philips Pan Head screws that secure the Buzzer to...
  • Page 156 ¼" Philips Pan Head screws securing the UIM PCB to the Front Case. Carefully disconnect the Pulse Oximeter ribbon cable from Pulse Oximeter PCB. Separate the UIM Bracket from the Pulse Oximeter plastic housing. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–101...
  • Page 157 For Eagle II ventilators start by removing the Selector knob by prying the knob up from the case. Remove the seven (7) (4) 4-40 x ¼" Philips Pan Head screws securing the Front Case to the Front Panel. 4–102 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 158 Remove the two (2) 4-40 x 3/16" Philips Pan Head screws that attach the USB Adapter PCB to the USB Connector Plate Assembly and remove the cable. Remove the USB Connector Plate from the Front Case. Reassembly 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–103...
  • Page 159 Ensure proper connector key orientation and attach buzzer cable to connector J4 of UIM adapter. 1.) Make sure flex cable is aligned with the right side of J2 on UIM adapter board. 2.) Insert flex cable into J2. 4–104 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 160 Ensure that the ribbon cable is pushed down to be flattened as shown in the photo. Do not allow any bulging of the ribbon cable, as it may interfere with tubing. Ensure proper key orientation and install power knob to assembly. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–105...
  • Page 161 Note: Eagle II units will have the selector knob installed during front case assembly. Carefully unplug membrane panel/button board ribbon cable from J3 of UIM adapter board. Ensure proper key orientation and connect membrane panel/button board ribbon cable to J3 of UIM adapter. 4–106 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 162 Fasten the Front Bezel to the front case using quantity 7 of 4-40 X ¼" screws in locations indicated. Prepare connector plate assembly for installation. Hold cap and plate together and insert into case as shown. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–107...
  • Page 163 Ensure proper mating connector alignment (J4 connector of UIM/CPU board mates with J1 connector of UIM Adapter), install UIM Stack into Front Case. Fasten UIM Stack to Front Case using quantity (2) 6- 32 x 5/16" Philips pan head screws. 4–108 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 164 (2) M2.5 x 5mm Philips flat head screws. Perform after successful Pre-Test (#35) Apply a bead of RTV around the perimeter of the Masimo connector board to create a seal between Front Case and board. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 4–109...
  • Page 165 Apply a bead of RTV around the perimeter of the USB connector board to create seal between Front Case and board. Position USB cable as indicated. Re-assemble ventilator per instructions, and test/ calibrate using the RCS. 4–110 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 166 Due to the wide variety of electrical safety test equipment on the market, it is not possible to provide detailed step by step instructions for this procedure. Perform these tests at the line-power voltage and frequency used in your installation. The 731 Series Ventilator 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 5–1...
  • Page 167 Electrical Safety Testing is a Class 1 medical device, certified to IEC 60601-1 with BF applied parts. The ZOLL 731 series ventilators have been certified as Class 1 ME externally powered per IEC/EN 60601-1 Standards. The device meets the class 1 standard when operating on battery as the device is internally powered, and again when operating on AC due to the presence of a protective earth connection.
  • Page 168 An affected test operator should consult a physician for recommendations. • Do not attempt to operate the electrical safety testing device if impaired for any reason including medication, illness, alcohol, mental stress, etc. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 5–3...
  • Page 169 Leakage Testing : • The chassis of the 731 Series ventilator is electrically isolated from AC power. Enclosure leakage testing of all exposed metal components on the device should be utilized in order to verify the device remains properly insulated. Use the following values for enclosure leakage in accordance with IEC 60601-1.
  • Page 170 Electrical Safety Testing 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 5–5...
  • Page 171 Electrical Safety Testing 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 5–6...
  • Page 172 Electrical Safety Testing 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 5–7...
  • Page 173 • Observations and resolution for the RCS user. Part III - Service Codes: This section provides a numerical list of service codes for both V4 and V5 ventilators. Each code contains relevant mitigation/resolution strategies along with service kit information. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 6–1...
  • Page 174 The Complete Calibration cycle evaluates hardware for its ability to be calibrated. This test identifies device hardware faults, if they exist. Once all calibrations are completed successfully, the calibration table is applied to the device. 6–2 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 175 Resolutions are provided to direct the technical actions taken by all technicians. Service Kits and Replacement Parts The service kits and replacement parts are listed in Chapter 4 of this Service Manual. Please refer to Chapter 4 for Part Number and ordering information. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 6–3...
  • Page 176 Date and Time Set SPM – Board ● Date and Time Check SPM – Board ● Download Calibration Tables Test Station ● ● ● Verify UUT and Reference Device Test Station ● Conditional PM Due Reset Test Station/Device 6–4 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 177 Date and Time Set ● Date and Time Check ● ● Download Calibration Tables ● ● ● Verify UUT and Reference Device ● Conditional PM Due Reset Erases Forensic Memory ● Final Configuration ● 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 6–5...
  • Page 178 Communication & Preventive Maintenance Alarms Device Subsystems Front Case Assembly, I/O, CPU, Adapter Pulse Oximeter Subsystem, Masimo Embedded Module Power Subsystem Smart Pneumatic Module SPM Board Calibration Airway Pressure Calibration Compressor System Calibration Oxygen Systems Calibrations Test Station 6–6 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 179 UIM and CPU. • Consider replacement of the CPU/UIM • Replace LCD/PIM board or 1475 The contrast fault indicates replace the LCD front panel when the LCD Is not visible both are viable. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 6–7...
  • Page 180 • On the PC check the Device Manager and verify connection to both CPU and DSP. • On the PC verify Load VCP box is unchecked. • Check USB-PC Set UP • Return the device to service to evaluate the FTDI component. 6–8 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 181 Another TCE running in the background may already have an active/open connection to the device • Prompt is hidden by application. Hidden Pop Up. • Minimize Window to see Pop UP. Users waiting for Prompt. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 6–9...
  • Page 182 • Check USB Cable. WRITE TESTLOAD.BOOTLOADER.BIN • OR • Check USB-PC • Check for Device Hardware COMM The RCS does cannot read the device Serial Numbers, and the test load cannot be installed on the device. 6–10 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 183 The test is to verify the functionality of the rotary encoder in both directions. Verifies the capability of the device to sound • Replace the front panel assembly kit. Buzzer Check and audible alarm. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 6–11...
  • Page 184 Observations Observation Resolution • Replace sensor and cable with a new and known SPO2 readings are not displayed or SPO2 sensor LEDs do working cable/sensor set. not illuminate. • Replace Masimo board. 6–12 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 185 • Repair: replace PIM or Connector cable to CPU. PIM. • Disconnect external power, and verify the icon Indicates Possible faulty wiring of disappears. Try replacing your external power the external power connector. cable. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 6–13...
  • Page 186 • See the manifold calibration sheet. The slope of the airway pressure during simulated expiratory phase (no flow) shall be less than 0.5 cmH2O per second at 5 cmH2O and 25 cmH2O. 6–14 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 187 PIP: ± (2 cm H2O + 7.5% of setting) BPM: ±1 FIO2: ± (3% + 8% of setting) I Time: ± (100ms) NOTE: For mixed flows, only FIO2 is checked due to calibration issue with TSI 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 6–15...
  • Page 188 Self Check: Internal COMM – Corrupt file • Calibration required. 1176 Checks for a corrupted • Attempt recalibration. calibration file. • Note: You may need to use the write function if the default cal table is loaded. Observations Observation Resolution 6–16 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 189 • Select: No Do you want to upload a default cal file? • Attempt to perform a calibration. Selecting “Yes” will overwrite the SPM serial numbers and Write will need to be done. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 6–17...
  • Page 190 • Rapid temperature change, high vibration. Self Check: Internal COMM – Corrupt file • Calibration required. Self Check Failure 1176 Checks for a corrupted • Perform WRITE function to eliminate error and calibration file. perform calibration sequence. 6–18 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 191 • Check intake assembly for blockage Gas Intake Failure 1030 Gas intake failure, prevents • Replace filters device from delivering sufficient flow. • Change SPM board Self Check Failure 1174 Flow transducers are not behaving as expected. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 6–19...
  • Page 192 This window should always be reviewed prior to attempting to correct setup issues or re-try a test. • Prompt is hidden by application. Hidden Pop Up. • Minimize Window to see Pop UP Users waiting for Prompt. 6–20 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 193 87 psig. • Change SPM board Self Check Failure 1174 Flow transducers are not behaving as expected. • Calibration required. Self Check Failure 1176 Checks for a corrupted calibration file. Observations Observation Resolution 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 6–21...
  • Page 194 This window should always be reviewed prior to attempting to correct setup issues or re-try a test. • Prompt is hidden by application. Hidden Pop Up. • Minimize Window to see Pop UP. Users waiting for Prompt. 6–22 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 195 • Always close the tank and relieve pressure from both sides of the regulator when not in use. • Always open the tank slowly with the regulator in the completely closed position (0 PSI). Turn the regulator handle fully counter clockwise. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 6–23...
  • Page 196 O-rings. • Inspect hoses to ensure O-rings is in place and not damaged • Prompt is hidden by application. Hidden Pop Up. • Minimize Window to see Pop UP. Users waiting for Prompt. 6–24 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 197 The “DB” file, while less readable contains ntilator\ServiceActions information in a database format. Typically, “VV” files are used to assess the calibration applied to the device and assist in understanding device/Test station behavior 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 6–25...
  • Page 198 Ventilator Memory Logs: This folder will contain several files and is created when the forensic Documents\ZOLL\Ventilator_For memory is read from the ventilator. This folder is only present after the read forensic memory is executed. The files document device settings and...
  • Page 199 RCS, which is expected behavior. When communicating with the SPM, communication is broken with the EMV. The opposite is also true. Therefore, it is common and expected to have communication alarms present in forensic memory after conducting tests with RCS. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 6–27...
  • Page 200 Each time the Read Forensic Memory is run, five additional files will be written to the directory location. The file names will include the current date and time to prevent overwriting previously read Forensic Memory files. 6–28 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 201 - replace screen • Bad flow transducer -> Replace SPM Module Possible Cause: • Calibration error • Foreign substances in screen • Faulty compressor flow transducer 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 6–29...
  • Page 202 • Check SPM board ->SPM contamination near O2 flow 3012 Valve (Failure/ flow sensor to the SPM transducer-> Replace SPM Module Faults) fails. Possible Cause: • Kinked or disconnected tube • SPM contamination near O2 flow transducer • Faulty O2 flow transducer 6–30 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 203 • Check intake transducer tubing -> Kinked tubing -> Transducer Faults Signal from the Fresh correct tubing • Replace SPM Module Gas/ Intake pressure sensor is stuck High or Possible Cause: • Kinked tubing • Faulty intake pressure transducer 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 6–31...
  • Page 204 Description /Possible CODES NAME Actions Cause 1041 High O2 Supply Description: • Check O2 supply-> O2 supply pressure too high- 3041 (Failure/Fault) O2 input pressure too >Decrease O2 supply • Check O2 regulator ->Faulty regulator -> Replace O2 high regulator on O2 inlet •...
  • Page 205 • Check RTC Battery Contact -> Retention battery holder date and time returned clip -> RTC battery contact is intermittent -> Replace to default SPM Module Possible Cause: • RTC battery is drained • RTC battery contact is intermittent 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 6–33...
  • Page 206 -2000 feet if the alarm does not clear -> Replace the SPM module ATM (below -2000 feet) Possible Cause: • If this error occurs at altitudes that are above -2000 feet: • Faulty Barometric Pressure Sensor 6–34 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 207 I2C was stuck, if the problem persists -> Replace SPM with any I2C device for Module 4 consecutive attempts (on the SPM) Possible Cause: • Stuck I2C bus 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 6–35...
  • Page 208 Internal Masimo board is bad -> Replace CPU/ pulse oximeter cannot SPO2 Stack kit or the front panel assembly identify the connected sensor or the sensor has failed. Possible Cause: • Masimo Flex Cable fault • Internal Masimo board fault 6–36 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 209 > 33 VDC after the • If the above does not resolve the issue -> Faulty PIM fuse board ->Replace the PIM board Possible Cause: • faulty external power supply • faulty PIM board 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 6–37...
  • Page 210 • Replace Battery Pack Fault The battery pack has reported an internal temperature of ≥ 75 degrees C Possible Cause: • The internal temperature of the battery pack is too high and external power is plugged in 6–38 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 211 • If the above do not resolve the issue -> faulty PIM board-> Replace the PIM board Possible Cause: • Cable loose or wire dislodged • faulty Battery Pack • faulty PIM board 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 6–39...
  • Page 212 • faulty or loose PIM blinking, the SPM firmware may be corrupt-> corrupt to CPU cable SPM firmware -> reprogram SPM • SPM application • If the above do not resolve the issue-> Faulty SPM corrupted Module-Replace SPM module 6–40 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 213 -> re-conduct programing -> Use front case and SPM RCS to Write "SPM SN" and "SPM Model" in "SN To module Update" fields • Accidentally swapped assemblies • Incomplete upgrade • incorrect programming 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 6–41...
  • Page 214 Smart Pneumatic Module/ Vent Assembly Service Kit O2 Valve Failure Alarm occurs when the signal to the O valve is not delivering the required flow rate and the compressor is not available to provide ventilation. 6–42 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 215 1172 Self Check Failure Smart Pneumatic Module/ Vent Assembly Service Kit Alarm occurs when the 5 volt power bus fails to provide the required voltage. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 6–43...
  • Page 216 Alarm triggers when the internal communication bus and the host are not able to communicate with the sub-assemblies. If this failure occurs, the user should manually ventilate the patient, replace the ventilator, and contact the ZOLL Technical Service Department for additional information. 1176...
  • Page 217 Service Kit The user should manually ventilate the patient, replace the ventilator, and contact the ZOLL Technical Service Department for additional information. 1475 Self Check Failure Check Cable from PIM board...
  • Page 218 Low O2 Supply Fault Check O2 regulator output pressure Alarm triggers when the O supply pressure is < 35 psig Smart Pneumatic Module/ (241 kPa) and the compressor is able to support ventilation. Vent Assembly Service Kit 6–46 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 219 2076 Apnea Check internal/external tubing connections Alarm triggers when the spontaneous breathing rate is less than the low alarm limit. This alarm only occurs in noninvasive ventilation, CPAP and BL modes. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 6–47...
  • Page 220 Pressing the Mute/Cancel button silences the audible alarm for 30 seconds. 2301 Self Check Fault CPU/UIM and SPO Stack Service Kit Alarm triggers when the communication between the pulse oximeter module and device fails. 6–48 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 221 2423 Self Check Fault Power Interface Module Service Kit Alarm triggers when the internal power circuit has failed and external power is connected but cannot be used. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 6–49...
  • Page 222 Alarm triggers when the device is not able to communicate with the internal battery. When this occurs the device does not know the current charge of the battery and operation could stop at any time. 6–50 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 223 Alarm is triggered when the tubing compliance correction shows that it is greater than the set tidal volume, indicating that the patient may not be receiving the appropriate tidal volume. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 6–51...
  • Page 224 > 131 °F (55 °C) for the ventilator. 3141 Ambient Temperature Fault Ventilator being used outside of specification limits Alarm triggers when the ambient temperature falls below the normal operating range < 14 °F (-10 °C) for the ventilator. 6–52 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 225 CPU/UIM and SPO Stack Ambient Light Fault Service Kit Alarm triggers when there is too much ambient light on the SpO sen- sor or there is inadequate tissue covering the sensor detector. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 6–53...
  • Page 226 Alarm triggers when the external power supply has insufficient current. When this occurs, the device automatically switches to operation using the internal battery. If the external power source is known to be good, then the AC/DC Power Supply may be faulty and need replacement. 6–54 www.zoll.com 906-0731-04-01 Rev. C...
  • Page 227 Power Interface Module Service Kit 3480 Self Check Fault Recalibrate using the RCS Alarm triggers when the device software detects that it has not been calibrated with the SPM that is inside the device. 906-0731-04-01 Rev. C ZOLL Ventilator Service Manual 6–55...
  • Page 228 Ventilator & Calibration Troubleshooting 6–56 www.zoll.com 906-0731-04-01 Rev. C...

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