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Manufacturer
Model
What This Guide Helps With
TRS equipment that fails an applicable PM, inspection, functional, performance, or electrical safety requirement during Clinical Engineering evaluation.
Step-by-Step Troubleshooting
1. Remove Failed Equipment From Availability
If the TRS system fails a required PM, functional, or applicable electrical safety test, do not return it to clinical use simply because it appears to operate.
Separate the equipment from available surgical inventory until the failed test has been understood and resolved.
Expected outcome: Equipment with an unresolved test failure cannot inadvertently return to patient use.
2. Identify the Exact Failed Test
Document precisely what failed: visual inspection, power operation, control function, attachment retention, mechanical condition, performance verification, charger evaluation, or an applicable electrical safety measurement.
Do not treat “PM failed” as a sufficient diagnosis.
Expected outcome: The failure is tied to a specific inspection or measured test result.
3. Confirm That the Test Applies to the Component
Verify that the test procedure and acceptance criteria are appropriate for the exact TRS component being evaluated.
A battery-operated handpiece, charger, and other system components may not be evaluated identically. Do not apply an irrelevant electrical safety test merely because it is routinely performed on other equipment types.
Expected outcome: The failed requirement is confirmed to be applicable to the component under test.
4. Verify Test Equipment and Setup
Confirm that electrical safety analyzers, functional test equipment, cables, fixtures, adapters, and other measurement devices are appropriate, functioning normally, and within required calibration status.
Inspect test leads and connections before condemning the medical device.
Expected outcome: The failure is not caused by incorrect test setup or defective test equipment.
5. Repeat the Test From a Known Starting Condition
Reset the test setup and repeat the failed measurement or functional check according to the approved procedure.
If a measurement changes substantially after reconnecting the test setup, investigate the connection before assigning a device failure.
Expected outcome: The failure is either reproduced or identified as a setup-related problem.
6. Complete the Physical Inspection
Inspect the TRS component for cracks, damaged housings, loose parts, corrosion, contamination, damaged contacts, worn couplings, compromised cables on applicable equipment, or evidence of fluid ingress.
Inspect charging equipment and external power cords where present.
Expected outcome: Physical condition meets applicable requirements or a visible defect explains the failed inspection.
7. Verify Power Sources and External Components
Use known-good compatible power sources, accessories, and attachments as appropriate. For charger-related testing, verify facility power and any detachable external power connection.
Expected outcome: The failed test is not being caused by a depleted power source, damaged accessory, or external power problem.
8. Evaluate Applicable Functional Performance
Operate the TRS component under controlled no-patient conditions and verify required controls, attachment engagement, powered operation, and other functions included in the approved PM procedure.
Do not invent performance specifications or acceptance limits not provided by approved documentation.
Expected outcome: Functional requirements pass, or the failed performance area is clearly documented.
9. Evaluate an Electrical Safety Failure Carefully
For any TRS component to which electrical safety testing legitimately applies, verify the equipment class, test configuration, power connection, analyzer connections, and approved acceptance criteria before repeating the test.
Do not alter grounding, insulation, power cords, or internal wiring to force a passing result.
Expected outcome: The electrical safety measurement either passes using the correct setup or remains a confirmed failure requiring service.
10. Complete Full Post-Correction Verification
If an external defect or test-setup issue is corrected, repeat the failed portion and any other required PM or safety tests affected by the correction.
Expected outcome: All applicable inspections and tests pass before the equipment is considered eligible for return to service.
11. Escalate Any Confirmed PM or Safety Failure
If the TRS equipment continues to fail an applicable inspection, functional requirement, performance check, or electrical safety requirement, stop troubleshooting at the external level.
Expected outcome: The component remains out of service and is routed for qualified repair or manufacturer-level evaluation.
If the Problem Persists
Test setup, applicability, test equipment, external power, accessories, physical condition, and repeat measurements have been evaluated. A persistent failure may indicate an internal electrical, mechanical, motor, control, insulation, charger, or other service-level condition.
The affected equipment should be:
- Removed from service.
- Labeled Out of Service.
- Sent for repair or bench evaluation.
- Evaluated using appropriate DePuy Synthes documentation and approved test equipment.
- Repaired or adjusted only by qualified personnel.
After repair, repeat the applicable PM, performance, and electrical safety testing required by the facility and manufacturer before return to clinical use.
Knowing when to stop external troubleshooting and escalate is proper troubleshooting.
Clinical Use Tip
A device that operates normally can still fail an important PM or safety requirement; do not return it to the OR until the failed requirement is resolved.
Work Order Documentation (CCR Method)
CCR = Complaint, Cause, Resolution
Complaint
What was reported by the clinical staff.
Example:
"The DePuy Synthes TRS system failed functional inspection during scheduled preventive maintenance because powered operation was intermittent."
Cause
What was observed during troubleshooting.
Example:
"Clinical Engineering found that the intermittent operation followed a degraded power source while the handpiece operated normally with a known-good compatible power source."
Resolution
What action was taken.
Example:
"Removed the degraded power source from service, repeated the applicable functional PM checks successfully with a verified power source, and returned the handpiece to service."
Helpful Details to Include (If Known)
- Exact PM or safety test failed
- Applicable procedure used
- Initial test result
- Test equipment identification
- Test equipment calibration status
- Test configuration
- Physical inspection findings
- Power source used
- Known-good substitutions
- Charger or external power condition
- Repeat test result
- Corrective action
- Complete post-correction verification
- Final device status
Final Thought
A failed PM or safety test should be traced to a specific requirement and verified with the correct setup before internal failure is assumed. Resolve external causes, repeat affected testing after correction, escalate confirmed failures appropriately, and clearly document the evidence supporting return to service.
That is successful troubleshooting.