treadmill 95t-domlx-domhx-inthx-01_service_manual_m051_00k65-a003[1]

Customer Support Services

SERVICE MANUAL

95T-DOMLX-01 PCST-DOMLX-01 PCST-DOMLX-02

95T-DOMHX-01 PCST-DOMHX-01 PCST-DOMHX-02

95T-INTHX-01 PCST-INTHX-01 PCST-INTHX-02

95T-DOMLX-01, 95T-DOMHX-01, and 95T-INTHX-01 Treadmills

Table of Contents

1

TABLE OF CONTENTS INTRODUCTION USING THIS MANUAL ........................................................................... 5 CONTACTING CUSTOMER SUPPORT .......................................................... 7 THEORY OF OPERATION ....................................................................... 9 SERVICE TOOLS ................................................................................11 GLOSSARY ......................................................................................13 TROUBLESHOOTING

NO POWER TO TREADMILL ...................................................................17 NO POWER TO CONSOLE......................................................................17 TREADMILL PAUSES OR RESETS RANDOMLY ................................................18 WORKOUT SUMMARY APPEARS IN THE MIDDLE OF A WORKOUT.........................18 REDUCED MAXIMUM SPEED ...................................................................18 KNOCKING NOISE ..............................................................................19 RUBBING SOUND FROM UNDER THE TREADMILL...........................................19 SQUEAKING NOISE WHEN BELT MOVES .....................................................19 GRINDING NOISE DURING INCLINE...........................................................19 GRINDING NOISE ON FOOTFALL .............................................................19 STRIDING BELT SLIPS..........................................................................19 STRIDING BELT NOT CENTERED OR TRAVELS BEYOND TRACKING LIMITS ..............20 LIFT MOTOR WILL ONLY INCLINE ............................................................20 ABNORMALLY HIGH LIFEPULSE READINGS..................................................20 LIFEPULSE SYSTEM DOES NOT RESPOND OR DISPLAYS INCORRECT READING..........20 CONSOLE DISPLAYS A HEART RATE READING WITHOUT A SIGNAL PRESENT...........21 NO HEART RATE TRANSMITTER DETECTED.................................................21

HOW TO… HOW TO…REPLACE THE CUP HOLDERS .....................................................25 HOW TO…REPLACE THE LINE CORD ........................................................26 HOW TO…REPLACE THE REAR CONSOLE COVER...........................................27 HOW TO…REPLACE THE CONSOLE ASSEMBLY..............................................28 HOW TO…REPLACE THE CONSOLE NECK SPACER..........................................29 HOW TO…REPLACE THE ACTIVITY ZONE ASSEMBLY ......................................30 HOW TO…REPLACE THE INSIDE HANDRAIL COVERS .......................................31 HOW TO…REPLACE THE LOWER BRIDGE COVER.......................................... 32 HOW TO…REPLACE THE OUTSIDE HANDRAIL COVERS ....................................33 HOW TO…REPLACE THE UPPER BRIDGE COVER ...........................................34 HOW TO…REPLACE THE HANDRAIL..........................................................35 HOW TO…REPLACE THE HEART RATE HAND SENSORS ....................................36 HOW TO…REPLACE THE ERGO BAR ASSEMBLY.............................................37 HOW TO…REPLACE THE TOP MOTOR SHROUD COVER....................................38 HOW TO…REPLACE THE UPRIGHT COVERS.................................................39 HOW TO…REPLACE THE UPRIGHTS .........................................................40 HOW TO…REPLACE THE MAIN CABLE .......................................................42 HOW TO…REPLACE THE BOTTOM MOTOR SHROUD COVER ..............................43 HOW TO…REPLACE THE REAR END CAPS ...................................................44

95T-DOMLX-01, 95T-DOMX-01, and 95T-INTHX-01 Treadmills

Table of Contents

2

TABLE OF CONTENTS – CONTINUED HOW TO…REPLACE THE LOWER EXTRUSIONS .............................................45 HOW TO…REPLACE THE UPPER EXTRUSION/ANTI-SLIP PAD ASSEMBLIES ..............46 HOW TO…REPLACE THE FRONT ROLLER ASSEMBLY.......................................48 HOW TO…REPLACE THE DRIVE BELT ........................................................50 HOW TO…REPLACE THE IDLER BRACKET ASSEMBLY ......................................52 HOW TO…REPLACE THE DRIVE MOTOR .....................................................53 HOW TO…REPLACE THE LIFT MOTOR ...................................................... 57 HOW TO…REPLACE THE MOTOR CONTROLLER ........................................... 58 HOW TO…REPLACE THE ON/OFF SWITCH................................................. 59 HOW TO…REPLACE THE LINE FILTER ...................................................... 60 HOW TO…REPLACE THE IEC RECEPTACLE................................................. 61 HOW TO…REPLACE THE HOME SWITCH.................................................... 63 HOW TO…REPLACE THE REAR ROLLER GUARDS .......................................... 64 HOW TO…REPLACE THE REAR ROLLER ASSEMBLY........................................ 65 HOW TO…REPLACE THE STRIDING BELT AND DECK ...................................... 66 HOW TO…TENSION A STRIDING BELT ..................................................... 70 HOW TO…ADJUST THE STRIDING BELT TRACKING ...................................... 71 HOW TO…REPLACE THE LIFESPRINGS...................................................... 72 HOW TO…REPLACE THE STRIDE SENSOR ASSEMBLY ..................................... 73 HOW TO…REPLACE THE REAR TOE GUARD................................................ 75

ELECTRONICS DSP CONTROLLER BOARD ....................................................................79 POWER COMPONENTS SCHEMATIC ......................................................... 82 BLOCK DIAGRAM .............................................................................. 83

INDEX ....................................................................................................87


INTRODUCTION


Introduction

5

USING THIS MANUAL

This service manual provides safe and efficient step-by-step test and service procedures for the treadmills. Illustrations are service views that complement the procedures. Throughout the manual, all messages viewed on the consoles are shown in uppercase letters and quotation marks. Any keys depressed on the console will appear in uppercase letters. Descriptions using the words “left” and “right” refer to the orientation of a user standing on the treadmill’s striding belt, facing the console. “Front” is the area of unit with the console, the “rear” of the treadmill is behind the user. This manual is comprised of these sections:

Table of contents Introduction Troubleshooting “How to…” service and repair guides Electronics Index

When an operating problem occurs, attempt to isolate the cause by referring to the troubleshooting guides and diagnostic tests. Symptoms are listed in these guides with tests and probable causes. Once the source of the problem has been identified, refer to the “How To…” guides for repair procedures. The “How To…” guides are organized by replaceable part or assembly name. For convenience, each guide lists the tools and estimated time required to complete the repair. Before installing a part, read the entire "How To..." section and follow the step-by-step procedures. This will ensure a safe and efficient installation.

These symbols are occasionally used to highlight information:

Information that will be helpful while performing a procedure.

Information that will prevent damage to the treadmill.

Information that will prevent personal injury or damage to the treadmill.

95T-DOMLX-01, 95TDOMHX-01, and 95T-INTHX-01 Treadmills

Introduction

6


Introduction

7

CONTACTING CUSTOMER SUPPORT

Life Fitness Customer Support Services can be contacted Monday through Friday from 8:00 am to 5:00 pm (Central Time).

Life Fitness Customer Support Services 5100 River Road, Schiller Park, IL 60176 (USA) Telephone: toll-free (800) 351-3737, local (847) 451-0036 Fax: toll-free (800) 216-8893, local (847) 288-3702 www.lifefitness.com [email protected]

Please be prepared to provide this information:

• Serial number • Model number • Part name and number • Problem or symptom

Model and serialnumber locations


Introduction

8


Introduction

9

THEORY OF OPERATION The treadmill is an electromechanical fitness device that operates on alternating current. The main components of the treadmill are:

Frame Striding belt and deck Display console Drive motor DSP Motor controller Lift (incline) motor Electronics Activity Zone

AC power enters the unit through the line cord. This is converted to DC power, which is necessary to operate the motor controller and various other electrical and mechanical components. The operator controls all of the treadmill’s electromechanical components and makes adjustments to the unit’s speed and incline through the display console. Custom workout programs are selected through the console as well.

The frame is critical, not only for supporting the user’s weight, but also for providing a stable base for the moving components. The striding belt and deck are designed to endure constant mechanical stress loads. The main motor has a pulley on the end of its shaft, which is connected by a Poly-V drive belt to the front roller pulley. The striding belt tension is adjustable by means of tensioning bolts, which are located at the ends of the rear roller. When turned, these bolts also help center the striding belt. The striding belt is pre-lubricated which helps minimize wear. The deck is flexible which provides lower impact to the user. LifeSprings under the deck absorb impact while providing support and stability to the user.

The display console is the control center of the treadmill, where all programming operations and diagnostic functions are controlled. Selections are made with touch keys. The console allows the user to choose operational settings; specify workout routines; and input information such as weight, age, display, language, etc.


Introduction

10


Introduction

11

SERVICE TOOLS Unless otherwise specified, these tools are required to perform the service procedures in this manual:

Screwdrivers (Phillips and flat blade) Pliers (regular and needle nose) Rubber mallet Snap ring pliers (internal and external) Socket wrenches (English and metric) Combination, open-end, or box wrenches (English and metric) Allen wrenches (English and metric) Mini flashlight Removable thread locking compound Cord or twine 2 blocks (e.g., scrap 4 X 4 wood) Loctite 242 Multimeter

Specialized tools may be required to complete some service procedures safely. Using tools improperly can result in damage to equipment or personal injury.


Introduction

12


Introduction

13

GLOSSARY

Term Definition

Activity Zone The remote keypad located on the Ergo bar which allows quick and easy access to the functions provided on the main console

Anti-slip pad A rubber strip located on the surface of each side of the frame used to avoid slipping while mounting or dismounting the treadmill

Bucket A software memory area Connector A device used to join wiring to complete an electrical circuit Cable tie A plastic strap used to secure wiring

Console The electronic component used for making direct input settings and monitoring the output messages displayed in the digital readout display (also “display console board”)

Deck A fibrous particleboard used for the running surface DSP Digital Signal Processor

EEPROM Electrically Erasable Programmable Read Only Memory, a rewriteable memory chip that holds its content without power

Electromechanical Relating to a mechanical device or system that is controlled or actuated by electricity

EPROM Erasable Programmable Read Only Memory, a special type of memory that retains its contents until exposed to ultraviolet light

Ergo bar The crossbar containing the Lifepulse sensors (from “ergonomic”)

ESD

Electrostatic Discharge, the sudden and momentary electric current that flows when an excess of electric charge, stored on an electrically insulated object, finds a path to an object at a different electrical potential (such as ground)

Flash memory A form of non-volatile computer memory that can be electrically erased and reprogrammed

Front roller The motor-driven roller that moves the striding belt

Heat sink An object, usually metal, which lowers the temperature of a heat-generating component through thermal mass and heat dissipation

Home switch The component that senses the treadmill’s zero-incline position

IEC The common name for a C13 plug/C14 socket combination; from International Electromechanical Commission, a standards and conformity assessment body

Integrated circuit A small electronic device made of a semiconductor material (also known as a “chip”)

Jumper An electrical connector used to short circuit two electrical points km/h Kilometers per hour table continued…


Introduction

14

GLOSSARY – CONTINUED

Term Definition

LED Light Emitting Diode

Leveler One of two adjustable supports under the rear of the treadmill, which level and stabilize the unit by raising or lowering the rear corners

Lifepulse The component that measures heart rate through hand sensors LifeSpring Elastic devices used for deck suspension

Lift motor The component that raises and lowers the unit for incline and decline operations

Loopback test A diagnostic procedure in which a signal is transmitted and returned to the sending device after passing through a network or circuit

Drive belt The component which transmits power from the drive motor to the front roller

Main wire harness The device which connects circuit boards

MET Metabolic Equivalent, the ratio of the metabolic rate of the average person while seated and resting to the metabolic rate of a particular person while performing a task

Motor controller Electronic device which regulates the speed of the striding belt mph Miles per hour

Polar® receiver A radio frequency device which monitors a heart rate through signals received from a chest strap transmitter

PWM Pulse Width Modulation

Rear roller The free-spinning, adjustable component used to tension and center the striding belt

Rear roller guards Protective components located on each end of the rear roller rpm Revolutions per minute Single-phase AC Producing, carrying, or powered by one alternating voltage Static current Steady flow of electricity Stop switch The electrical component used to terminate a workout routine Stride sensor The component which detects a user’s impact on the deck Striding belt The moving part of the unit on which a user walks or runs

Telemetry receiver A device which reads a heart rate signal from a chest strap transmitter

Three-phase AC Producing, carrying, or powered by three equal, alternating voltages

Velcro® a brand name of fabric hook-and-loop fasteners used for connecting objects

Wax/lift board A circuit board located under the motor shroud used to communicate input/output signals from the console to the lift and drive motors


TROUBLESHOOTING

95T-DOMLX-01, 95T-DOMHX-01 and 95T-INTHX-01 Treadmills

Troubleshooting

17

TROUBLESHOOTING Tool required: multimeter

Symptom Probable Cause Corrective Action

Insufficient line voltage at outlet

Unplug the treadmill from the wall outlet and measure the line voltage with a multimeter at the outlet. Switch the treadmill to an outlet with sufficient line voltage if necessary.

Defective Line Cord

Inspect line cord for proper seating in wall outlet and treadmill. Reseat if necessary. Inspect line cord for damage. Replace line cord if necessary.

Defective line filter Using a multimeter, check for line voltage at TP2. If no line voltage is present, replace the line filter.

No power to treadmill

Defective power switch

Remove the motor cover and turn the power switch on. Using a multimeter, check for line voltage at TP1. If no line voltage is present, replace the power switch.


Unplug the treadmill from the wall outlet and measure the line voltage at the outlet with a multimeter. Switch the treadmill to an outlet with sufficient line voltage if necessary.

Defective Line Cord

Inspect line cord for proper seating in wall outlet and treadmill. Reseat if necessary. Inspect line cord for damage. Replace line cord if necessary.

Defective line filter Using a multimeter, check for line voltage at TP2. If no line voltage is present, replace the line filter.

Defective power switch

Remove the motor cover and turn the power switch on. Using a multimeter, check for line voltage at TP1. If no line voltage is present replace the power switch.

Defective DSP controller If the LEDs on the motor controller are not illuminated, replace the motor controller.

No power to console

Defective main cable harness

Ensure solid connections at both ends of the main cable harness. Using a multimeter, test for point-to-point continuity on the cable. Replace the main cable harness if necessary.

95T-DOMLX-01, 95TDOMHX-01 and 95T-INTHX-01 Treadmills

Troubleshooting

18

TROUBLESHOOTING – CONTINUED


Treadmill not on a dedicated line

Connect the treadmill to a dedicated line. See operation manual for power requirements.

Improperly seated power cord at outlet

Properly seat the power cord in the outlet.

Damaged or missing ground prong on power cord

Replace the power cord.

Stop switch is false triggering Replace the stop switch.

Loose connections on display console

Inspect all cable connections at the console. Tighten as necessary.

Treadmill pauses or resets randomly

Damaged or shorted main cable harness

Ensure solid connections at both ends of the main cable harness. Using a multimeter, test for point-to-point continuity and point-to-ground continuity on the main cable harness. Replace the main cable harness if necessary.

Stop switch is false triggering Replace the stop switch.

Workout summary appears in the middle of a workout Loose main cable

connections at console Verify that all cable connections at the console are secure.


Unplug the treadmill from the wall outlet. Using a multimeter, measure the line voltage at the outlet. Switch the treadmill to an outlet with sufficient line voltage if necessary.

Worn deck and/or striding belt

Perform the belt/deck test (see the console service manual). Replace the belt and flip the deck if necessary (see page 66).

Main motor binding Check the drive motor shaft for binding or roughness. Replace the motor if necessary.

Reduced maximum speed

Front or rear roller binding Inspect rollers for binding or roughness. Replace the front and/or rear roller if necessary.


Troubleshooting

19



Treadmill not level Level the treadmill according to the instructions in the operation manual.

Faulty front or rear roller bearings

Inspect rollers for binding or roughness. Replace rollers as necessary.

Knocking noise

LifeSprings incorrectly positioned and/or have loose mounting hardware

Reposition or tighten the LifeSprings and mounting hardware.

Foreign objects under treadmill

Remove any debris or foreign objects causing interference.

Rubbing sound from under the treadmill Striding belt not positioned

properly

Reposition the striding belt so that it is between the belt guides on both sides of the treadmill and not resting on any LifeSpring brackets.

Worn or damaged main drive belt

Inspect the main drive belt for damage or wear. Replace the main drive belt if necessary. Squeaking noise when belt

moves Drive motor pulley and front roller pulley misaligned

Align the pulleys as described in the procedure on page 53.

Obstruction in lift mechanism

Remove anything interfering with the operation of the lift mechanism.

Grinding noise during incline

Defective lift motor Replace the lift motor.

Grinding noise on footfall Excessive friction between deck and striding belt

Perform the belt/deck test (see console service manual) Replace the belt and flip the deck if necessary (see page 66).

Striding belt slips Incorrect striding belt tension

Adjust the striding belt tension as described on page 70.


Troubleshooting

20



Treadmill not level Level the treadmill according to the instructions in the Operation manual.

Striding belt not within belt barriers

Position the striding belt inside the belt barriers on both sides of the frame.

Striding belt not tracking properly

Adjust the tracking of the striding belt as described on page 71.

Striding belt not centered or traveling beyond its tracking limits

Worn striding belt

Perform the belt/deck test (see console service manual) Replace the belt and flip the deck if necessary (see page 66). The striding belt and deck should always have new surface to new surface when a striding belt is being replaced.

Lift motor will only incline

DSP controller not receiving proper incline positioning information

Check cable connections between the lift motor and the DSP controller. Replace components as necessary.

Abnormally high Lifepulse readings

Electromagnetic interference from devices such as cell phones, televisions, or computers in close proximity to the treadmill

Identify the interfering source and turn it off or increase the distance between it and the treadmill.

Dirty Lifepulse sensors

Wipe the sensors with a clean, damp cloth. Verify proper operation using the Lifepulse test (see Apollo or Gemini service manual.

Pace over 4.5 mph (7.5 km/h) while attempting to read heart rate

Slow the pace to less than 4.5 mph (7.5 km/h).

User has an unusual heart condition or signal

Have another user grasp the sensors to compare and verify any unusual signal.

Loose connection between sensors and console

Verify that the Lifepulse cable connections at both the hand sensors and console are secure.

Faulty Lifepulse sensors Replace the Lifepulse sensors.

Lifepulse system does not respond or displays incorrect reading

Faulty console board Conduct the Lifepulse test (see console service manual). Replace the console board if necessary.


Troubleshooting

21



Pinched wire harness Inspect the wire harness for damage. Replace as necessary.

Interference from electronic devices such as cell phones, televisions, or computers in close proximity to the treadmill.

Console displays a heart rate reading without a signal present

Electromagnetic interference from another telemetry device

Identify the interfering source and turn it off or increase the distance between it and the treadmill.

Telemetry feature turned off

Enable the telemetry feature (see console service manual).

Transmitter sensors not making good contact with user’s body

Refer to Operation manual for the correct placement of the transmitter on the user’s body. Tighten the chest strap and moisten the sensors to make better contact between the transmitter and the user’s skin.

Transmitter exceeding usable monitoring range

Stay within 3 feet (1 meter) of the receiver.

Faulty connection at receiver

Check the receiver cable to ensure proper connection. Replace the receiver as necessary.

Faulty transmitter Replace the transmitter.

No heart rate transmitter detected

Faulty receiver Replace the receiver.


Troubleshooting

22


HOW TO…


“How To…”

25

HOW TO... REPLACE THE CUP HOLDERS Tool required: No tools required Estimated time required: 15 minutes

1. Reach under the bridge and disengage the clip locking the cup holder to the bridge cover.

2. Lift out the cup holder.

3. Slide the new cup holder down until it locks into place.


“How To…”

26

Line Cord

Retaining Bracket

HOW TO... REPLACE THE LINE CORD Tool required: stubby Phillips screwdriver Estimated time required: 20 minutes

1. Turn the treadmill power switch off.

2. Unplug the line cord from the wall outlet.

3. Lift the front end of the treadmill approximately 4 inches off the floor and place a block of wood underneath both sides to support it.

4. Remove and save the two screws that secure the line cord retaining bracket to the motor pan.

5. Unplug the defective line cord.

6. Install the new line cord, using the screws removed and saved in step 4, in reverse order.


“How To…”

27

Rear ConsoleCover Screws (2)

Rear Console Cover

HOW TO… REPLACE THE REAR CONSOLE COVER Tool required: 4mm Allen wrench Estimated time required: 15 minutes

1. Remove and save the two Allen bolts that secure the rear console cover to the console mounting bracket.

2. Remove the rear console cover.

3. Install the new rear console cover using the bolts removed and saved in step 1.


“How To…”

28

Rear ConsoleCover Screws (2)

Rear Console Cover

Console MountingScrews (4)

Console Bracket

Console

HOW TO… REPLACE THE CONSOLE ASSEMBLY Tools required: Phillips screwdriver, 4mm Allen wrench Estimated time required: 30 minutes



3. Remove the rear console cover. See the “How To…” on the previous page.

4. Remove and save the four Phillips screws that secure the console assembly to the console mounting bracket.

5. Disconnect all cables to the console assembly.

6. Remove the console assembly.

7. Install the new console assembly in reverse order using the screws removed and saved in step 4.

The replaced console and all associated paperwork must be returned to Life Fitness.


“How To…”

29

Neck SpacerScrews (2)

Console Bracket

ConsoleNeck

Spacer

HOW TO… REPLACE THE CONSOLE NECK SPACER Tools required: Phillips screwdriver, 4mm Allen wrench Estimated time required: 20 minutes



3. Remove the rear console cover. See the “How To….” on page 27.

4. Remove the console assembly. See the “How To…” on page 28.

5. Remove and save the two Allen bolts that secure the console neck spacer to the console mounting bracket.

6. Remove the console neck spacer.

7. Install the new console neck spacer in reverse order using the bolts removed and saved in step 5.


“How To…”

30

Bezel Access Door

Screws

Activity Zone assembly

(as seen from below)

HOW TO… REPLACE THE ACTIVITY ZONE ASSEMBLY Tools required: 4mm Allen wrench, mini flashlight Estimated time required: 20 minutes



3. Remove the bezel access door located on the bottom of the lower bridge cover.

4. Remove and save the two bolts that secure the Activity Zone assembly to the bridge weldment. (Use the flashlight to locate the bolts.)

5. Disconnect cable connections to the Activity Zone.

6. Remove the Activity Zone assembly.

7. Install the new Activity Zone assembly in reverse order, using the bolts removed and saved in step 4.


“How To…”

31

Plug (5)

Allen Screw (5)

HOW TO… REPLACE THE INSIDE HANDRAIL COVERS Tool required: 4mm Allen wrench Estimated time required: 20 minutes

1. Remove and save the five plugs in the inside handrail covers that conceal the mounting bolts.

2. Remove and save the five Allen bolts that secure the inside handrail cover to the handrail.

3. Remove the cover by tilting it toward the inside of the unit and then pulling down.

4. Install the new Inside Handrail Cover in reverse order, using the bolts removed and saved in step 2.


“How To…”

32

Lower Bridge CoverAllen Screws (10)

Bridge Weldment

Upright Bolt Heads (2 on each side)

HOW TO… REPLACE THE LOWER BRIDGE COVER Tools required: 4mm Allen wrench, mini flashlight Estimated time required: 30 minutes



3. Remove the cup holders. See the “How To…” on page 25.

4. Remove the Activity Zone assembly. See the “How To…” on page 30.

5. Remove and save the two Allen bolts that secure the lower bridge cover to the bridge weldment.

6. Remove and save the ten Allen bolts that secure the lower bridge cover to the upper bridge cover.

7. Tilt the lower bridge cover to either side of the unit to enable the lower bridge cover to clear the upright bolt heads

8. Remove the lower bridge cover.

9. Install the new lower bridge cover in the reverse order using the bolts removed and saved in steps 5 and 6.


“How To…”

33

Handrail

Outer Handrail Cover

HOW TO… REPLACE THE OUTSIDE HANDRAIL COVERS Tools required: 4mm Allen wrench, mini flashlight Estimated time required: 45 minutes




4. Remove the inside handrail cover. See the “How To…” on page 33.


6. Remove the lower bridge cover. See the “How To…” on page 32.

7. Remove and save the six Allen bolts that secure the outer handrail cover to the handrail.

8. Remove the outer handrail cover.

9. Install the new outer handrail cover using bolts removed and saved in step 7.


“How To…”

34

HOW TO... REPLACE THE UPPER BRIDGE COVER

Tools required: 4mm Allen wrench, mini flashlight Estimated time required: 30 minutes




4. Remove the console assembly. See “How To…” on page 28.

5. Remove the console neck spacer. See “How To…” on page 29.

6. Remove the inside handrail covers. See the “How To…” on page 31.



9. Remove the outer handrail covers. See the “How To…” on page 33.

10. Remove and save the six bolts that secure the upper bridge cover to the bridge frame.

11. Remove the upper bridge cover.

12. Install new upper bridge cover in reverse order using the bolts removed and saved in step 8.


“How To…”

35

Handrail

Ergo Bar

Screw (2)

Allen Bolt (2)

HOW TO... REPLACE THE HANDRAIL Tools required: 4mm Allen wrench, 8mm Allen wrench, mini flashlight Estimated time required: 45 minutes








8. Remove and save the two bolts that secure the handrail to the Ergo bar.

9. Remove and save the two Allen bolts that secure the handrail to the upright.

10. Remove the handrail.

11. Install the new handrail in the reverse order using the bolts removed and saved in steps 8 and 9.


“How To…”

36

Heart Rate Hand Sensor(right hand assembly shown)

Upper Gasket

Lower Gasket

Heart Rate Sensor Connectors (2)

Upper HeartRate Assembly

Lower HeartRate Assembly

Ergo Bar

Phillips Screw (2)

HOW TO... REPLACE THE HEART RATE HAND SENSORS Tool required: Phillips screwdriver Estimated time required: 15 minutes

1. Remove and save the two Phillips screws that secure each set of heart rate electrodes to the Ergo bar.

2. Note which wires go to the top electrode and which go to the bottom electrode.

3. Disconnect the wires from both electrodes.

4. Plug the wires into the new electrodes.

5. Position the electrode gaskets between the electrodes and the Ergo bar.

6. Install the new electrodes in the Ergo bar, using the screws removed and saved in step 1.

7. Test the unit to verify that the new electrodes are working properly.


“How To…”

37

Screws tobridge frame (3)

Washers (3)

Washers (2on each side)

Screws tohandrails (2on each side)

HOW TO... REPLACE THE ERGO BAR ASSEMBLY Tools required: 4mm Allen wrench, mini flashlight Estimated time required: 45 minutes








8. Remove and save the four bolts that secure the Ergo bar to the handrails.

9. Remove and save the three bolts that secure the Ergo bar to the bridge frame.

10. Disconnect the heart rate cable from the Ergo bar to the console.

11. Install the new Ergo bar assembly in reverse order using the hardware removed and saved in steps 8 and 9.

When reattaching the Ergo bar to the handrails, it is critical to maintain the proper bolt angle to prevent stripping the threads.


“How To…”

38

HOW TO... REPLACE THE TOP MOTOR SHROUD COVER Tool required: Phillips screwdriver Estimated time required: 15 minutes

1. Remove and save the six Phillips screws that secure the top motor shroud cover to the motor cover mounting brackets and frame.

2. Install the new top motor shroud cover using the Phillips screws removed and saved in step 1.


“How To…”

39

Right Upright CoverScrew (2)

HOW TO... REPLACE THE UPRIGHT COVERS Tools required: Phillips screwdriver Estimated time required: 30 minutes

1. Remove the top motor shroud cover. See the “How To…on page 38.

2. Remove and save the two Phillips screws that secure the upright cover to the upright.

3. Loosen the screw securing the upright cover to the main frame (in front of the upright).

4. Remove the upright cover.

5. Install the new upright cover in reverse order, using the screws removed and saved in step 2.


“How To…”

40

Bridge

Left Upright

Allen Bolt (3 for each upright)

Right Upright

HOW TO... REPLACE THE UPRIGHTS Tools required: Phillips screwdriver, 4mm Allen wrench, 8mm Allen wrench Estimated time required: 45 minutes



3. Remove the top motor cover. See the “How To…” on page 38.

4. Remove either the right or left upright shroud depending on which upright is being replaced. See the “How To…” on page 40.





9. Remove and save the six upper bolts (three per upright) that secure the bridge to the uprights.


“How To…”

41

HOW TO... REPLACE THE UPRIGHTS - CONTINUED

10. Cables run through both of the uprights. Depending on which upright is being replaced, the appropriate cable must be disconnected. If replacing the left upright, this will require disconnecting the power cables to the attachable TV and rerouting them through the new upright. The transformer cable also must be removed and rerouted if the left upright is being replaced.

11. Carefully lift the bridge frame assembly up and out of the uprights and set it to the side.

12. Remove and save the three lower bolts that secure the upright to the base frame.

13. Install the new upright in reverse order using the hardware removed and saved in the previous steps.


“How To…”

42

MotorController

Main Cable

Main Cable Connector

HOW TO... REPLACE THE MAIN CABLE Tools required: Phillips screwdriver, 4mm Allen wrench Estimated time required: 30 minutes






6. Disconnect one end of the main cable from the motor controller.

7. Disconnect the cable between the top of the left upright and the console.

8. Pull the main cable out of the left upright.

9. Install the new main cable in reverse order.


“How To…”

43

Upper Motor Shroud

Lower Motor Shroud

Lower MotorShroud Screws(2 of 4 shown)

HOW TO... REPLACE THE BOTTOM MOTOR SHROUD COVER Tools required: Phillips screwdriver Estimated time required: 30 minutes

1. Remove the top motor shroud cover. See the “How To…” on page 38.

2. Remove and save the four Phillips screws that secure the bottom motor shroud cover to the motor cover mounting brackets.

3. Install the new bottom motor shroud cover in reverse order using the screws removed and saved in step 2.


“How To…”

44

HOW TO... REPLACE THE REAR END CAPS Tools required: Phillips screwdriver Estimated time required: 15 minutes

1. Remove and save the two Phillips screws that secure the right or left rear end cap to the frame.

2. Install the new rear end cap using the screws removed and saved in step 1.


“How To…”

45

Upper Extrusion

RearEndCap

Lower ExtrusionFoam Strip

Lower Extrusion

Velcro Strip (one of four)

Cross-section

Upper Extrusion

Foam Strip

Lower Extrusion

HOW TO... REPLACE THE LOWER EXTRUSIONS Tools required: Phillips screwdriver, 4mm Allen wrench Estimated time required: 30 minutes

1. Remove the corresponding right or left rear end cap. See the “How To…” on page 44.

2. The lower frame extrusion is attached to the frame by a series of Velcro strips mounted along the length of the frame. Separate the Velcro strips and pull the lower frame extrusion out and away from the side of the treadmill.

3. Save the foam strip that is positioned between the upper and lower extrusions.

4. Install the new lower frame extrusion in reverse order.

5. Install the foam strip by pressing it into the space between the lower and upper frame extrusions.


“How To…”

46

Anti-slip Pad

Upper Extrusion

UprightCover

HOW TO... REPLACE THE UPPER EXTRUSION/ANTI-SLIP PAD ASSEMBLIES Tools required: Phillips screwdriver, small flat blade screwdriver Estimated time required: 30 minutes


2. Remove the upright shroud. See the “How To…” on page 39.

3. Remove the Phillips screws that secure the motor cover mounting bracket to the upper extrusion.

4. Note the location of the anti-slip pad.

5. Using a small flat blade screwdriver, carefully pry up one end of the anti-slip pad.

6. Continue to peel the anti-slip pad until it is completely removed from extrusion.

7. Remove the lower extrusion. See the “How To…” on page 45.

8. Remove and save the nine screws that secure the upper extrusion to the frame.


“How To…”

47

rectangular holesfor anti-slip pad locating tabs

HOW TO... REPLACE THE UPPER EXTRUSION/ANTI-SLIP PAD ASSEMBLIES - CONTINUED

9. Install the new upper extrusion to the frame using the screws removed in step 8.

10. Peel the backing off the anti-slip pad.

11. Position the pad on the upper extrusion, using the locating tabs on the back of the anti-slip pad.

12. Press down firmly on anti-slip pad to adhere it securely to the extrusion.


“How To…”

48

Idler Arm

Allen Wrench

Idler Arm Access Hole

Frame

HOW TO… REPLACE THE FRONT ROLLER ASSEMBLY Tools required: Phillips screwdriver, flat blade screwdriver, 5/32” Allen wrench, 5/16” Allen wrench, 9/16” socket, 3/8”

ratchet, 5” long (12.7cm) 5.5mm Allen wrench Estimated time required: 45 minutes



3. Loosen the rear roller tensioning bolts to relieve tension on the striding belt. Count the number of rotations. This will simplify re-tensioning the striding belt later.


5. Remove the bottom motor shroud cover. See the “How To…” on page 43.

6. Insert a flat blade screwdriver into the slotted end of the idler bracket.

7. Raise the idler bracket just enough to insert the 5” (12.7cm) long 5.5mm Allen wrench into the access hole of the idler bracket. This will keep it in a raised position.


“How To…”

49

Drive Pulley Bolts (4)

HOW TO… REPLACE THE FRONT ROLLER ASSEMBLY – CONTINUED

8. Walk the drive belt off the drive motor sheave and front roller pulley.

9. Remove and save the 9/16” bolt that secures the left side of the front roller to the frame.

10. Slide the left end of the front roller as far as possible toward the left side of the frame.

11. The right side of the front roller will now clear the access hole in the right side of the frame.

12. Remove the front roller from under the striding belt.

13. Remove and save the four bolts and washers that secure the drive pulley to the front roller.

14. Install the removed drive pulley onto the new front roller using the hardware removed and saved in step 13.

15. Install the new front roller assembly.

16. Install the drive belt onto the front roller pulley and drive motor sheave.

17. Remove the 5” (12.7cm) long 5.5mm Allen wrench from the idler bracket.

18. Lower the idler bracket and remove the flat screwdriver from the idler bracket slot.

19. Tension the striding belt. See the “How To…” on page 70.


“How To…”

50

Rear Roller Tensioning Bolts

Idler ArmAllenWrench

Idler Arm Access Hole

Frame

HOW TO... REPLACE THE DRIVE BELT Tools required: Phillips screwdriver, flat blade screwdriver, 5” (12.7cm) long 5.5mm Allen wrench, socket wrenches Estimated time required: 20 minutes



3. Loosen the rear roller tensioning bolts to relieve tension on the striding belt. Count the number of rotations. This will simplify re-tensioning the striding belt later.


5. Remove the bottom motor shroud cover. See the “How To…” on page 43.

6. Insert a flat blade screwdriver into the slotted end of the idler bracket.

7. Raise idler bracket just enough to insert the 5” (12.7cm) long 5.5mm Allen wrench into the access hole of the idler bracket. This will keep it in a raised position.


“How To…”

51

FrontRoller

Bolt

HOW TO... REPLACE THE DRIVE BELT – CONTINUED

8. Walk the drive belt off the drive motor sheave.

9. Remove and save the 9/16” bolt that secures the left side of the front roller to the frame.

10. Slide the left end of the front roller as far as possible toward the left side of the frame.

11. The right side of the front roller will now clear the access hole in the right side of the frame.

12. Remove the old drive belt from the front roller pulley.

13. Install the new drive belt onto the front roller pulley and drive motor sheave locating the belt to the right side of the front roller pulley and centered on the drive motor pulley.

14. Re-install the front roller bolt.

15. Remove the Allen key from the idler bracket and lower the idler bracket.

16. Remove the flat blade screwdriver from the slot in the idler bracket.

17. Tension the striding belt. See the “How To…” on page 70.


“How To…”

52

IdlerBracket

ClevisPin

SupportBracket

IdlerSpring

HOW TO... REPLACE THE IDLER BRACKET ASSEMBLY Tools required: Phillips screwdriver, large flat blade screwdriver, 6mm Allen wrench, 13mm socket, 1/4” ratchet,

needle nose pliers, 5” (12.7cm) long 5.5mm Allen wrench Estimated time required: 45 minutes




4. Remove the seven bolts that secure the support bracket to the motor pan.

5. Remove the support bracket and set aside.

6. Remove the drive belt. See the “How To…” on page 50.

7. Disconnect the idler spring with the needle nose pliers.

8. Remove and save the clevis pin that secures the idler bracket assembly to the motor pan frame.

9. Remove the idler bracket assembly by lifting it straight up and off the motor pan frame.

10. Install the new idler bracket assembly in reverse order, using the hardware removed and saved in the previous steps.


“How To…”

53

Drive Motor Bolt(2 on each side

of motor)

Insulating Pad

Motor Pan

HOW TO... REPLACE THE DRIVE MOTOR Tools required: Phillips screwdriver, flat blade screwdriver, 3mm Allen wrench, 6mm Allen wrench, 13mm socket,

14mm socket, 3/8” long extension, 3/8” ratchet, 13mm long 5.5mm Allen wrench Estimated time required: 1 hour




4. Remove and save the seven bolts that secure the support bracket to the motor pan. Do not remove the bar tie.

5. Disconnect the cables between the drive motor and the motor controller.

6. Remove the drive belt. See the “How To…” on page 50.

7. Remove the idler bracket assembly. See the “How To…” on page 52.

8. Scribe the location of the drive motor on the insulating pads.

9. Scribe the position of the insulating pads on the frame. This and the previous step will aid in positioning the new drive motor and re-tensioning the motor drive belt.)


“How To…”

54

Hex Nut (1of 4 shown)

Hex Nut (1of 4 shown)

InsulatingPads (2)

Drive

Drive Belt

Drive Motor

Sheave

Bolt

Flywheel/Fan Assembly

HOW TO... REPLACE THE DRIVE MOTOR – CONTINUED

10. Remove and save the four hex nuts and washers that secure the drive motor to the motor mounting studs in the frame.

11. Lift the drive motor assembly up and off the studs and out of the motor pan.

12. Loosen the setscrews on the drive motor sheave.

13. Remove the sheave from the drive motor.

14. Loosen the setscrews that secure the flywheel/fan assembly to the drive motor.

15. Remove the flywheel/fan assembly and set aside.


“How To…”

55

Drive SheaveSetscrews (2)

Key

Drive Sheave


16. Install the previously removed flywheel/fan assembly and drive sheave onto the new drive motor. Use Loctite 242 on the flywheel setscrews. (Do not tighten the drive sheave setscrews until the alignment procedure is complete (see step 19).

17. Install the new drive motor in reverse order, using the locations scribed in steps 8 and 9 as mounting references. Reuse any hardware removed and saved in previous steps.

18. Slide the drive motor sheave onto the motor shaft.


“How To…”

56

Drive MotorSheave

Straightedge

Front RollerPulley


19. To align the drive motor sheave with the front roller pulley:

a. Using a straightedge, align the outer face of the drive motor sheave with the outer face of the front roller pulley.

b. If necessary, slide the drive motor sheave in or out on the shaft.

c. Tighten one of the two setscrews on the drive motor sheave.

d. Remove the other setscrew and apply Loctite 242 to its threads.

e. Insert and tighten that setscrew in the sheave.

f. Remove the first setscrew.

g. Apply Loctite 242 to its threads.

h. Insert and tight the first setscrew.

i. Repeat this procedure with the front roller pulley’s setscrews.

20. Re-install the Idler bracket and drive belt.


“How To…”

57

Lift Motor

Lift Frame

BoltNut

HOW TO... REPLACE THE LIFT MOTOR Tools required: Phillips screwdriver, 10mm socket, 13mm socket, 14mm socket, 1/4" extension, 3/8” extension, 1/4"

ratchet, 3/8” ratchet Estimated time required: 1 hour




4. Remove and save the nine bolts that secure the bar tie to the frame. Do not remove support bracket.

5. Disconnect the lift motor cable from the motor controller.

6. Disconnect the lift motor ground wire from the frame.

7. Carefully tilt the treadmill on its side.

8. Remove and save the nut and bolt that secure the lift motor to the lift frame.

9. Remove the clevis pin that secures the lift motor to the motor pan.

10. Remove lift motor from unit.

11. Install the new lift motor in reverse order using the hardware removed and saved in the previous steps.


“How To…”

58

Hex Nut (3)

Bolt (2)

Motor Controller

Motor Pan

Lift Motor Bracket(attached to bar tie)

HOW TO... REPLACE THE MOTOR CONTROLLER Tools required: Phillips screwdriver, 8mm socket, long 1/4” extension, 1/4” ratchet Estimated time required: 30 minutes




4. Record the cable connection locations.

5. Disconnect all cable connections to the motor controller.

6. Loosen the three hex nuts that secure the motor controller to the motor pan.

7. Remove and save the two bolts that secure the motor controller bracket to the lift motor bracket.

8. Remove the motor controller.

9. Install the new motor controller in reverse order using hardware removed and saved in the previous steps.


“How To…”

59

On/Off Switch

HOW TO... REPLACE THE ON/OFF SWITCH Tools required: Phillips screwdriver, 8mm socket, 1/4” ratchet, long 1/4” extension, needle nose pliers Estimated time required: 30 minutes




4. Record the location of wire connections to the on/off switch.

5. Disconnect the wires. Use needle nose pliers if necessary. (Some techs may need to remove the motor controller to allow more room to access the on/off switch.)

6. Squeeze the tabs on the top and bottom of the on/off switch and push out from inside the frame.

7. Install the new on/off switch in reverse order.


“How To…”

60

Line FilterPhillips Screw(1 of 2)

HOW TO... REPLACE THE LINE FILTER Tools required: Phillips screwdriver, 8mm socket, 1/4” extension, 1/4" ratchet Estimated time required: 45 minutes




4. Remove the motor controller. See the “How To…” on page 58.

5. Record the locations of the wires connected to the line filter.

6. Remove the wires.

7. Remove and save the two Phillips screws that secure the line filter to the motor pan assembly.

8. Remove the line filter.

9. Install the new line filter in reverse order, using the hardware removed in step 7.


“How To…”

61

Line Cord Retaining Bracket

HOW TO... REPLACE THE IEC RECEPTACLE Tools required: Stubby Phillips screwdriver, 8mm socket, 1/4” ratchet, a long 1/4” extension, 4 X 4 wood blocks Estimated time required: 30 minutes



3. Lift the end of the treadmill about four inches off the floor and place blocks of wood under both sides to support it.

4. Remove and save the two screws that secure the line cord retaining bracket to the motor pan. Set the retaining bracket aside.

5. Unplug the line cord from the unit and save.

6. Remove top motor shroud cover. See the “How To…” on page 38.



“How To…”

62

IEC ReceptacleScrew (2)

HOW TO... REPLACE THE IEC RECEPTACLE - CONTINUED

8. Record the location of the wires connected to the IEC connector

9. Disconnect the wires.

10. Remove and save the two screws that secure the IEC connector to the motor pan.

11. Remove the IEC connector.

12. Install the new IEC connector, using the hardware removed and saved in previous steps.


“How To…”

63

Home Switch

HOW TO... REPLACE THE HOME SWITCH

Tools required: Phillips screwdriver, 8mm socket, 1/4” ratchet, 1/4” extension Estimated time required: 45 minutes





5. Remove and save the hex nuts that secure the home switch to the studs on the frame. (The bar tie may have to be removed.)

6. Remove the home switch bracket assembly from the frame studs.

7. Disconnect the wires to the home switch.

8. Separate the home switch from the bracket. Save the bracket.

9. Install the new home switch on the bracket.

10. Install the new home switch with bracket in reverse order using the hardware removed and saved in the previous steps.


“How To…”

64

Rear Roller Guards

Phillips Screw (2)

HOW TO... REPLACE THE REAR ROLLER GUARDS Tools required: Phillips screwdriver Estimated time required: 20 minutes

1. Remove and save the two screws that secure the right or left rear end cap to the frame.

2. Remove and save the two screws that secure the rear roller guard to the frame.

3. Install the new rear roller guard in reverse order using the hardware removed in previous steps.


“How To…”

65

Rear Roller Tensioning Bolts

Striding Belt

Rear Roller

HOW TO... REPLACE THE REAR ROLLER ASSEMBLY Tools required: Phillips screwdriver, 5/16” Allen wrench Estimated time required: 45 minutes



3. Remove the rear end caps. See the “How To…” on page 44.

4. Remove the rear roller guards. See the “How To…” on page 64.

5. Remove and save the belt tensioning screws from the rear roller. Count the number of rotations. This will simplify re-tensioning the striding belt later.

6. Remove the rear roller from under the striding belt.

7. Install the new rear roller in reverse order, using the hardware removed and saved in previous steps.

8. Adjust the striding belt tracking. See the “How To…” on page 71.


“How To…”

66

Left Roller Guard

Right Roller Guard

Rear RollerAdjusting Screws

Washer (2)

Roller GuardScrew (2)

HOW TO... REPLACE THE STRIDING BELT AND DECK Tools required: Phillips screwdriver, 5/32” Allen wrench, 5/16” Allen wrench, 9/16” socket, 3/8” extension, 3/8”

ratchet, large flat blade screwdriver, 5” (12.7cm) long 5.5mm Allen wrench Estimated time required: 1 hour




4. Remove the roller guards. See the “How To…” on page 64.


6. Remove and save the tensioning screws from the rear roller. Count the number of rotations. This will simplify re-tensioning the striding belt later.


“How To…”

67

Rear RollerStriding Belt

Letter “R”

Rear Roller

Deck

DeckScrews (4)

StridingBelt

Front Roller Mounting Bolt

Lock Washer

Flat Washer

Front Roller

Rear Roller

Rear RollerAdjusting Screws (2)

Deck

DeckScrews (4)

StridingBelt

Front Roller Mounting Bolt

Lock Washer

Flat Washer

Front Roller

Belt Barrier

HOW TO... REPLACE THE STRIDING BELT AND DECK - CONTINUED

7. Remove the rear roller from under the striding belt just enough to mark the right end of the shaft with the letter “R” with a felt-tip marker so that it can be reinstalled in the same left-right orientation. This will maintain the same bearing wear pattern.

8. Remove the four corner deck bolts that secure the deck to the frame.

9. Remove the deck from under the striding belt. Be careful not to hit the Stride Sensor assembly with the deck.

10. Insert a flat blade screwdriver into the slotted end of the idler arm. Raise the idler arm just enough to install the 5” (12.7cm) long 5.5mm Allen wrench into the access hole of the idler arm to keep the idler bracket in a raised position.

11. Walk the motor drive belt off the drive motor sheave and the front roller pulley.

12. Remove and save the bolt and washers that secure the left side of the front roller to the frame.

13. Slide the left end of the front roller shaft as far as possible toward the left side of the frame. The other end of the front roller will now clear the access hole in the right side of the frame.

14. Remove the motor drive belt from the front roller pulley.

15. Remove the front roller from under the striding belt.


“How To…”

68

Striding Belt(loosened)

Deck


16. Remove the striding belt.

17. Position the new striding belt inside the unit.

The arrow on the inside of the belt must point in the direction of belt rotation.

18. Position the front roller under the striding belt.

19. Place the right side of the front roller shaft in the access hole.

20. Secure the left side of the front roller with the mounting bolt and washers removed in step 12.

21. Reinstall the motor drive belt.

22. Install the new deck (or the existing deck, flipped) from the left side of the treadmill.

23. Secure the deck with the four mounting screws.

24. Remove any wax build-up on the rear roller using a plastic scraper or plastic putty knife.

25. Position the rear roller under the striding belt. Orient the roller so that the “R” identification mark at the end of the roller shaft is positioned on the right-hand side of the machine.


“How To…”

69


26. Secure the rear roller tensioning bolts by hand. Do not tighten these bolts. The belt should remain loose. foresee

27. Adjust the striding belt tension and tracking following the procedures on the following pages.

28. Reinstall the top motor cover.

29. Log the replacement of the striding belt and/or deck in the maintenance repair log in Diagnostics.


“How To…”

70

38½” ( 974 mm )

Tape

Tape

38 ” (984 mm)43

HOW TO...TENSION A STRIDING BELT Tools required: Allen wrenches Estimated time required: 15 minutes

1. Center the loose striding belt on the front and rear rollers.

2. Position the belt within the belt barriers.

3. Place two pieces of masking tape exactly 38 1/2” (977 mm) apart on the right and left edges of the striding belt as shown (four pieces total).

4. To tension the belt, tighten the tensioning bolts until the distance between the tapes (on both sides) is increased to 38 3/4” (984 mm) for a brand new striding belt and 38 3/8” (974mm) for an existing striding belt.

5. Adjust the striding belt tracking. See the “How To…” on page 71.


“How To…”

71

A

B B

HOW TO...ADJUST THE STRIDING BELT TRACKING Tools required: Allen wrenches Estimated time required: 15 minutes

1. Turn the treadmill power switch on.

2. Run the striding belt speed at 2.5 mph (4.0 km/h).

3. If the striding belt has moved to the right, turn the right tension bolt 1/8- turn clockwise and the left tension bolt 1/8-turn counterclockwise, (as shown in the illustration) to start moving the striding belt back to the center of the rear roller.

4. If the striding belt has moved to the left, turn the left tension bolt 1/8-turn clockwise and the right tension bolt1/8-turn counterclockwise (opposite the direction shown in the illustration) to start moving the striding belt back to the center of the rear roller.

5. Repeat this adjustment until the striding belt is centered. Allow the unit to operate for several minutes to see that the belt remains centered.


“How To…”

72

LifeSprings (4on each side)

Stride Sensor Assembly

LifeSpring

Tinnerman Clip

HOW TO... REPLACE THE LIFESPRINGS Tools required: 5/32” wrench, 5/16” wrench Estimated time required: 45 minutes



3. Loosen the rear roller tensioning bolts until the striding belt is slack enough to allow removal of the deck. Count the number of rotations. This will simplify re-tensioning the striding belt later.

4. Remove and save the four corner deck mounting bolts.

5. Carefully remove the deck. Be careful not to damage the Stride Sensor assembly with the deck.

6. Remove the screw that secures the LifeSpring to the frame.

7. Remove the LifeSpring from the treadmill frame. Do not save the Tinnerman clip on the LifeSpring.

8. Install the new LifeSpring in reverse order, using the screw removed in step 6. Orient the LifeSpring with the notch facing the inside of the treadmill. Use a new Tinnerman clip (not included with the new LifeSpring).

9. Tighten the LifeSpring mounting screws to 27-33 in-lbs (3.0-3.7 Nm).


“How To…”

73

LifeSprings (4on each side)


Phillips Screw

LifeSpring

Frame

HOW TO... REPLACE THE STRIDE SENSOR ASSEMBLY Tools required: Phillips screwdriver, 5/32” Allen wrench, 5/16” Allen wrench Estimated time required: 1 hour




4. Disconnect the Stride Sensor assembly cable from the motor controller.

5. Attach a heavy cord or twine about 3 feet (1 meter) long to the disconnected Stride Sensor assembly.

6. Loosen the rear roller tensioning screws until the striding belt is slack enough to allow removal of the deck. Count the number of rotations. This will simplify re-tensioning the striding belt later.

7. Remove and save the four corner bolts that secure the deck to the LifeSprings.

8. Carefully remove the deck from under the striding belt.

9. Remove and save the screw that secures the Stride Sensor assembly to the frame.


“How To…”

74


HOW TO... REPLACE THE STRIDE SENSOR ASSEMBLY – CONTINUED

10. Remove the Stride Sensor assembly by carefully pulling the cable out of the frame until the cord or twine tied to the end of the cable is exposed.

11. Attach the cord or twine to the new Stride Sensor assembly cable and feed it through the frame until the connector is exposed.

12. Install the Stride Sensor assembly to the frame using the screw removed and saved in step 9.

13. Install the remaining components in reverse order.


“How To…”

75

Rear Toe GuardAllen Bolts (2)

HOW TO... REPLACE THE REAR TOE GUARD Tools required: Phillips screwdriver, 6mm Allen wrench, 1/2” socket, 3/8” ratchet Estimated time required: 30 minutes


2. Remove and save the two Allen bolts and two hex nuts that secure the rear toe guard to the frame.

3. Remove the rear toe guard.

4. Install new rear toe guard using hardware removed and saved in step 2.


“How To…”

76


ELECTRONICS


Electronics

79

DSP CONTROLLER BOARD

Personnel must be trained and adequate precautions must be taken whenever working on this equipment. Considerable energy is stored in it for up to ninety seconds after it is removed from the circuit. Wait two full minutes after the unit is turned off before performing any procedures.

Description Location Function

LED1 12VDC indicator LED2 8VDC indicator LED3 Tx Communication indicator LED4 Lift (Up) direction LED5 Lift ON LED6 V bus indicator LED7 +VDC indicator LED8 3.3VDC indicator LED9 Incline 0 position indicator

Service LED

LED10 Incline Bottom position indicator

Connector Pin Functional Description

1 GND 2 Motor phase W 3 Motor phase V 4 Motor phase U 5 Not Used

P1 is a 6 Position female Mate-N-Lock connector for Motor

6 Not Used 1 Zero position switch

2 Zero position switch return (GND)

3 Bottom limit switch P4 is a 4 Position Mini-Fit Jr., for Home Switch

4 Bottom limit switch return (GND)


Electronics

80

DSP CONTROLLER BOARD - CONTINUED


1 RTN

2 RTN

3 8VDC

4 8VDC

5 Not used (LED) or 12V (LCD)

6 RXD (Receive Data)

7 TXD (Transmit Data)

8 Not used

9 12 VDC

P5 is a 10 Position Mate-N-Lock connector for Console power and signal

10 ESS (Emergency Stop Switch)

1 Down

2 Hot

3 Up

P6 is a 4 Position Mate-N-Lock connector for Lift Actuator

4 Not Used

1 Line

2 Neutral P7 is a 3 Position Mini-Fit Senior for AC Input Power input

3 Not Used

1 Therm1 = ESS Out P8 is a 2 Position Mini-Fit Jr. for Motor Thermal Switch 2 Therm2 = ESS In


Electronics

81

DSP CONTROLLER BOARD - CONTINUED


1 8VDC 2 6/8VDC 3 6VDC 4 12VDC

P9 is a 5 Position Mini-Fit Jr. for console voltage select

5 12V (ESS)

1 RTN

2 SSENSE

3 position C-grid connector for Stride Sensor interface 3 +12VDC P11 is a Faston connection for 200-240V only

1 Autotransformer return

P12 is a Faston connection for 200-240V only

1 Autotransformer out (120)

P13 is a Faston connection for 200-240V only

1 Autotransformer in (100-200-220/230-240VAC)

P16A is a Faston connection 1 Vbus (brake)

P16B is a Faston connection

1 Bus return (brake)


Electronics

82

POWER COMPONENTS SCHEMATIC

120V

POWER CABLE TO

DSP MOTOR

ON/OFFSWITCH

BLACK

WHITE

NEU

WHITE

HO

TG

ND

BLACK

GRN/YLW

LOAD

LINE

GRN/YLWMOV

POWER CABLE TO

DSP MOTOR

ON/OFFSWITCH

WHITEN

EU

HO

TG

ND

BLACK

GRN/YLW

LOAD

LINE

GRN/YLWMOV

200 - 240V


Electronics

83

BLOCK DIAGRAM


Electronics

84


INDEX


Index

87

A

Activity Zone, 9, 13 Activity Zone assembly,

replacing, 30 anti-slip pad, 13

B

belt squeaking noise, 20 block diagram, 83 blocks, 11 bottom motor shroud cover,

replacing, 43 bucket, 13

C

cable tie, 13 connector, 13 console, 13 console assembly,

replacing, 28 cord, 11 console displays a heart rate

reading but no signal, 22 console, no power, 17 console neck spacer,

replacing, 29 corrective action, 19 cup holders, replacing, 25 customer support,

contacting, 7

D

deck, 13 display console, 9 drive belt, 15 drive motor, 9 drive motor,

replacing, 54 DSP motor controller, 9, 13, 79

E

EEPROM, 13 electromechanical, 14 electronics, 9 EPROM, 13 Ergo bar, 13 Ergo bar assembly,

replacing, 37 ESD, 13

F

fax, 7 flash memory, 13 frame, 9 front roller, 13, 48

G

glossary, 14 grinding noise during

footfall, 20 grinding noise during

incline, 20

H

handrail, replacing, 35 heart rate hand sensors,

replacing, 36 heart rate reading on

display but no signal on console, 22

heart rate transmitter not detected, 22

heat sink, 13 home switch, 13 home switch,

replacing, 63

I

idler bracket assembly, replacing, 53

IEC, 13 IEC receptacle,

replacing, 61 inside handrail covers,

replacing, 31 integrated circuit, 13

INDEX


Index

88

J

jumper, 13

K

km/h, 13 knocking noise, 20

L

LED, 14 leveler, 14 Lifepulse, 14 Lifepulse,

incorrect reading, 21 Lifepulse,

non-responsive, 21 LifeSpring, 14 LifeSprings, replacing, 73 lift motor, 14 lift motor,

incline, 9,21 lift motor,

replacing, 57 line cord, replacing, 26 line filter, replacing, 60 Loctite, 11 loopback test, 14 lower bridge cover,

replacing, 32 lower extrusions,

replacing, 45

M

main cable, replacing, 42

main wire harness, 14 manual, how to use, 5 MET, 14 mini flashlight, 11 model number, 7 motor controller, 14 motor controller,

replacing, 58 motor drive belt,

replacing, 51 mph, 14 multimeter, 11

N

no power, console, 17 no power, treadmill, 17

O

on/off switch, replacing, 59

operation, theory of, 9 outside handrail covers,

replacing, 33

P

phone, 7 pliers, 11 Polar receiver, 14 power components

schematic, 82 power off, console, 17 power off, treadmill, 17 PWM, 14 R

rear console cover, replacing, 27

rear end caps, replacing, 44

rear roller, 14 rear roller assembly,

replacing, 65 rear roller guards, 14 rear roller guards,

replacing, 64 rear toe guard,

replacing, 76 reduced maximum

speed, 19 removable thread locking

compound, 11 rpm, 14 rubber mallet, 11 rubbing sound under the

treadmill, 20

S

screwdrivers, 11 serial number, 7 service tools, 11 single-phase AC, 14 snap ring pliers, 11 socket wrenches, 11

INDEX - CONTINUED


Index

89

S

(continued) static current, 14 stop switch, 14 Stride Sensor, 14 Stride Sensor assembly,

replacing, 74 striding belt, 14 striding belt, adjust

tracking, 72 striding belt and deck, 9 striding belt, existing belt

tension adjustment, 71 striding belt, new belt

tension adjustment, 70 striding belt,

not centered, 21 striding belt,

replacing, 66 striding belt slips, 20 striding belt,

tracking limits off, 21 symptoms, 19

T

table of contents, 2 telemetry receiver, 14 telephone, 7 tension a striding belt, 70 theory of operation, 9 three-phase AC, 14 tools required, 29 top motor shroud cover,

replacing, 38 treadmill, no power, 17 treadmill pauses or resets

randomly, 19 troubleshooting, 17 twine, 11

U

upper bridge cover, replacing, 34

upper extrusion/anti-slip pads, replacing, 46

upright covers, replacing, 39

uprights, replacing,40 using this manual, 5

W

wax/lift board, 14 workout summary,

in middle of a workout, 19

wrenches, 11

INDEX - CONTINUED


Index

90

©2007 Brunswick Corporation. All rights reserved. Life Fitness is a registered trademark of Brunswick Corporation. Zone Trainer and Heart Rate Zone Training are trademarks of Brunswick Corporation.

Any use of these trademarks, without the express written consent of Brunswick Corporation, is forbidden. M051-00K65-A003

JULY 2008