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Sears 30727, Service Manual

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Sears 30727 Service Manual Download Page 38

8 

 |  008 Sears CA Treadmill Service Manual [rev 1.0]

Section Three | 

Troubleshooting

Treadmill Troubleshooting

 

>>

 Elevation | Model 30727 Only

It’s recommended to send console cables for elevation repairs on all models using 
sectional console cables.

Symptom

Possible Cause

Test Procedure

Repair

Elevation motor starts 
running as soon as the power 
is turned on. Constant down 
or up..

Failed lower board.

-Turn on power. Do not press 
start. Wait 30-60 seconds and 
see if motor is hot. Use 
caution. Motor can get very 
hot.

Replace lower board.

Elevation motor bobs up and 
down with out command.

Failed elevation motor.

Replace elevation motor.

Elevation motor does not 
reach minimum or maximum 
settings.

-Failed elevation motor.
-Failed console cable (CC).
-Improperly calibrated 
 elevation motor.

-Verify there are no pinches 
or cuts on the elevation 
wires. Reference CC 
continuity p22.
-Verify the connections of 
above wires.

-Recalibrate elevation motor 
by hand. Reference Resetting 
the Incline Motor p18.
-Replace elevation motor.

Elevation is stuck down and 
does not function.  Console 
is responsive to the buttons 
being pressed.

Failed console cable (CC).

-Verify console cable 
connections. Verify there 
are no pinches or cuts in the 
cable. Reference CC 
continuity p22.

Replace console cable.

Failed elevation motor.

-Put machine in hardware 
test (Eng1) and press start.  
Elevation doesn’t respond 
when buttons are pressed. 
(You may see a value for 
elevation that reads 255 or 
1023.  That value will not 
change when the buttons are 
pressed). 
Reference Eng. Mode p26.

Replace elevation motor.

Failed upper board.

-Put machine in hardware 
test (Eng1) and press start.  
Incline will work in hardware 
test only.
Reference Eng. Mode p26.

Replace upper board.

Elevation is stuck at the 
highest position and will 
not come down.  Console is 
responsive to the buttons be-
ing pressed.

Failed upper board, lower 
board, console cable, and 
elevation motor.

-Verify all wire connections.

Replace upper board, console 
cable, and elevation motor.

The incline will go up, but 
not down. (very rare)

Failed lower board.

-The incline will act normally 
when going up, bet when the 
down incline is pressed there 
is no movement.

Replace lower board.

Summary of Contents for 30727

Page 1: ...Sears Canada Service Manual Treadmills Models 30750 30727 ...

Page 2: ...s 5 Step Diagnostic Process 13 Recommended Tools 5 Wiring Diagrams and Schematics 15 Parts Diagrams Resetting the Incline Motor 18 30750 6 Voltage Checks 19 30727 7 Engineering Mode 26 Maintenance Section Three Preventative 8 Troubleshooting 28 Lubrication 9 Exploded Drawings Tensioning Alignment 10 30750 43 Proper Heart Rate Usage 11 30727 44 ...

Page 3: ...UDE Read the owner s manual and follow all operation instructions Operate the treadmill on a solid level surface Locate the rear of the treadmill at least four feet from walls or furniture Keep the area behind the treadmill clear Visually check the treadmill before beginning service or maintenance operations If it is not completely assembled or is damaged in any way exercise extreme caution while ...

Page 4: ...r physician before continuing Do not wear clothes that might catch on any part of the treadmill Keep power cord away from heated surfaces Keep children off of treadmill at all times Do not use treadmill outdoors Unplug treadmill before moving it Do not remove the treadmill motor cover or roller covers Treadmill should be plugged into a dedicated 20 amp circuit for optimal performance WARNING Impro...

Page 5: ...strap when handling electronic parts Flat head screwdrivers Digital multi meter Drive belt tension gauge Allen wrench set Metric Open end wrenches of assorted sizes Metric Clamp on amp meter 1 2 drive ratchet and sockets of assorted sizes Blue Thread Lock Cable ties Motor commutator stone Needle nose pliers Damp cloth Rubber mallet Hammer Drop cloth Ruler Snap ring pliers Wire cutters Available th...

Page 6: ...T RUNNING DECK SIDE RAIL ROLLER END CAP REAR ROLLER ADJUSTMENT BOLTS CONSOLE ON OFF SWITCH CIRCUIT BREAKER POWER CORD TRANSPORT WHEEL WATER BOTTLE POCKET Water Bottle Pocket Control Panel Safety Key Placement Console Mast Motor Cover Running Belt Running Deck Side Rail Roller End Cap Rear Roller Adjustment Bolts On Off Switch Circuit Breaker Power Cord Transport Wheel Console ...

Page 7: ... ROLLER END CAP CONSOLE MAST REAR ROLLER ADJUSTMENT BOLTS FOOT LOCK LATCH SUPPORT BAR AUDIO IN JACK MP3 POCKET CONSOLE FAN Console Mast Speakers Water Bottle Pocket Reading Rack Grip Pulse Handrails Running Belt Running Deck Side Rail Roller End Cap Rear Roller Adjustment Bolts Motor Cover Foot Lock Latch Power Cord Transport Wheel Handlebar Console Mast Cover Support Bar On Off Switch Circuit Bre...

Page 8: ...e treadmill by being misaligned EVERY WEEK Clean underneath the treadmill following these steps Turn off the treadmill with the on off switch then unplug the power cord at the wall outlet Fold the treadmill into the upright position making sure that the lock latch is secure Move the treadmill to a remote location Wipe or vacuum any dust particles or other objects that may have accumulated undernea...

Page 9: ...ord at the wall outlet Loosen both the rear roller bolts For best results place two removable marks on both sides of the frame and note roller position Once the belt is loosened take the bottle of lubricant and apply it to the entire top surface of the running deck Tighten both rear roller bolts matching up the marks for proper position to original position After you have applied lubricant plug in...

Page 10: ...he treadmill speed between 3 4mph stand behind the treadmill and watch the movement of the running belt DO NOT STAND ON THE TREADMILL AND DO NOT TOUCH THE TREADMILL WHILE PERFORMING THIS PROCEDURE As you watch the running belt make sure that the belt runs without moving from one side to the other and that the belt is centered between the side rails 2 If the running belt is not tracking properly fo...

Page 11: ...interference such as fluorescent lights computers underground fencing home security systems or appliances containing large motors These items may cause erratic heart rate readouts You may experience an erratic readout under the following conditions Gripping the heart rate handlebars too tight Try to maintain moderate pressure while holding onto the heart rate handlebars Constant movement and vibra...

Page 12: ... 13 Wiring Diagrams and Schematics Digital Drive 30727 15 Wiring Diagram 30750 16 Power Source 17 Resetting the Incline Motor 18 Voltage Checks No Motor Movement 19 Motor AC Wire 21 Console Cable 22 Speaker Amp Board 22 9 Wire Console Cable 30750 23 12 Wire Console Cable 30727 24 Incline Wire 25 Engineering Mode 30727 26 ...

Page 13: ...ge is present at the wall outlet Nominal 120 volts AC may vary between approximately 105 volts AC and 135 volts AC If the AC voltage is missing or incorrect check the AC service or consult an electrician The following steps are provided as routine checkpoints when diagnosing problems on a Horizon Fitness treadmill If followed correctly these checkpoints should help diagnos the majority of problems...

Page 14: ...ushes and the motor commutator for any uneven wear If the surface of the motor brush is pitted rough has burn marks or the commutator has a black residue on it replace the motor Step 4 Proper Speed Calibration To ensure proper belt speed and proper calibration use engineering mode to verify that machine is running in MPH not KM Auto calibrate the machine from engineering mode if the belt speed is ...

Page 15: ... 4 1 1 3 AUDIO OUT 070674 076820 072156 078687 078691 073303 078687 078690 Speaker R Speaker L D3 D4 D1 D2 COM1 COM2 NULL 插至PCB A座 感應器握管 059940 A 3 1 AUDIO IN 067517 00 073705 077117 076819 GND SIGN 2 1 safekey 074949 071206 074973 002671 A PCB SXT7 7 Upper Control Board 071206 075922 KEYPAD 075204 MCB WHITE BLACK BLACK RED WHITE BLACK WHITE GREEN Power Cord 110 120 VAC GREEN 2 5vdc EL Vcc 2 5v EL...

Page 16: ...readmill Service Manual rev 1 0 Section Two Wiring Diagrams and Schematics Wiring Diagram 30750 Finger Pulse Receiver Console Cable Switch Key NG Safe Key 30750 Console Cable Finger Pulse Receiver Switch Key NG Safe Key ...

Page 17: ...ermine connection point B Ground C Socket wire to breaker or on off switch Wire Length will determine connection point D On Off switch to motor control board E On Off switch to motor control board F On Off switch to breaker Note Wires A C are interchangeable Power Source Wiring Diagram A B C A F D E C F To Motor Control Board Breaker On Off Switch Socket ...

Page 18: ...the Motor Control Board 3 Fold treadmill into locked position 4 Undo bolt that attaches the elevation tube to the bottom of the machine F1 F1 F2 5 Power up the machine and let the incline spin freely in the tube until it reaches its zero position and then turn power off 6 Spin shaft manually until it is almost flush with the incline motor casing and only about 1 thread is visible F2 7 Reinsert bol...

Page 19: ... console cable connection If results vary from the upper board the console cable is the likely cause and a continuity check should be performed Desired Results The voltage charts contain typical desired results on a fully functional system A variance from the norm would indicate a defective component Checkpoint Voltage Before Start Volatge After Start Console Cable Grey to Yellow Gnd 0 0 vdc 0 3 v...

Page 20: ...ce from the norm would indicate a defective component Checkpoint Voltage Before Start Voltage After Start 0 5mph Voltage After Start 10 0mph Across Motor Out No Motor Attached 0 0 22 5 vdc 0 0 22 5 vdc 0 0 22 5 vdc Across Motor Out W Motor Attached 0 0 vdc 2 5 0 vdc 80 100 0 vdc Drive Motor Checkpoints Procedures Unplug the motor from the lower board Using a dc volt meter if non auto ranging set f...

Page 21: ...2008 Sears CA Treadmill Service Manual rev 1 0 21 Section Two Voltage Checks 1 20 V DC 8JSFT 7 Motor Voltage Check Spin motor flywheel to produce voltage AC Wire Voltage Check ...

Page 22: ... lead of your multi meter on pin B3 B4 or B5 and place the positive lead on the desired pin Follow the voltage charts on p23 9wire and p24 12wire Note 1 Wire colors are subject to change Console Cable Voltage Check Note 2 It may be necessary to remove the glue from the console cable to access the pins Speaker Amp Board Voltage 30727 Only JOHNSON A ce po w er CON2 D1 2 Voltage In Voltage Out 120v 1...

Page 23: ...fore started 0 0 vdc after started 1 4 vdc b f start 0 8 vdc after start 0 0 vdc b f start 1 4 vdc after start No belt movement 6 Blue Stop Constant 0 53 vdc 0 69 vdc 3 6 vdc when the safety key is removed Will remain at 3 6 vdc until Start is pressed 5 0 vdc safe off 1 3 vdc safe on 1 7 vdc running 1 9 vdc paused 16 6 vdc safe off 0 0 vdc safe on and running No physical symptoms were noticed when...

Page 24: ...vdc constant Range 15 to 17 vdc 0 0 vdc 17 vdc If one removed no issues If both removed UCB does not turn on At UCB green measures 0 46 vdc white 1 4 vdc all others 0 0 vdc 8 Purple 15 vdc constant Range 15 to 17 vdc 0 0 vdc 17 vdc 9 Grey Speed Command PWM 0 0 vdc before started 0 5 vdc at 0 5 mph 4 vdc at 10 mph Volt age changes as speed changes 0 0 vdc b f start 0 36vdc aft start increases as co...

Page 25: ...incline The voltage changes as the incline changes Large Quick Connects Wire Color Function Before Start After Start Not Inclining Or Declining While Inclining While Declining Physical Symptoms If Wire Cut ENG 1 Test Results Black w white as ground Incline Up 0 15 vac 0 15 vac 171 vac 120 vac Up incline works no down incline Up incline works down does not Value increases does not decrease Red w wh...

Page 26: ...ay will show 0 for miles or 1 for km The display will scroll MILES OR KM when Start is pressed to change The new setting is automatically saved when Start is pressed no other buttons need to be pressed to save Hardware Test Eng1 Eng0 appears in the time window HARDWARE TEST will scroll in the matrix or will be static in text box Press ENTER to select Press START to begin Speed s or t will change t...

Page 27: ...2008 Sears CA Treadmill Service Manual rev 1 0 27 Table of Contents Section Three Troubleshooting 28 Exploded Drawings 43 ...

Page 28: ...s Troubleshooting Failed Auto Calibration 29 Console Upper Board 30 Membrane Keypad Overlay 32 Safety Key Reed Switch 33 Heart Rate 34 Erratic Speed 30727 35 Erratic Speed 30750 37 Elevation 30727 38 Elevation 30750 39 No Motor Movement 40 Circuit Breaker 41 Noise 42 ...

Page 29: ...nsole cable Check voltage and continuity of console cable Reference p22 Replace console cable Failed Auto Calibration Belt never runs and E1 message on console See troubleshooting for no motor movement Reference p40 Failed Auto Calibration Board never sets speeds Belt will continue to run and not stop RPM sensor not aligned properly or has failed Verify positioning of sensor wire Wire coming from ...

Page 30: ...power cord Reference p13 Replace power cord No display on the con sole and power switch on machine is lit Breaker on machine has tripped or has failed Reset breaker Replace breaker if necessary Improper wiring or AC wires have failed Check all wiring coming in from the power switch to the motor control board and to the upper board Reference p17 Connect wires correctly or replace as needed Failed c...

Page 31: ...f plastic tab is broken replace console shell Slot style safety key only Inadequate power Check for dedicated circuit 20 amp is ideal and check wall outlet voltage 120 VAC Reference p13 Make sure machine is not on extension cord or surge protector If the AC voltage is missing or incorrect check the AC service or consult an electrician Damaged or improper wiring Verify there are no pinches or cuts ...

Page 32: ...e Keys are pressed some of the buttons may function but there are no corresponding beeps Put in Eng0 to chech button function Reference p26 Replace membrane keypad Upper board defective Keys are pressed and there are corresponding beeps but console does not respond Sometimes the key will not beep until it is released Replace upper board Unit starts as soon as safety key is in place or console will...

Page 33: ...ove safety key and reapply Test magnet Replace safety key Failed reed switch or failed uper control board Short the switch connector on the upper board by using a flat blade screwdriver or by placing a jumper switch on the connector If the upper board still displays dashes then replace upper board Otherwise replace reedswitch Safety key will only register if moved outside of the proper position Im...

Page 34: ... rate continues to be erratic replace heart rate receiver Failed upper board Reference Proper Heart Rate Usage p11 Replace upper board No heart rate function Hand Grips Failed heart rate grips Reference Proper Heart Rate Usage p11 If there is absolutely no heart response replace heart rate grips Heart rate erratic User error Reference Proper Heart Rate Usage p23 Electromagnetic interference Check ...

Page 35: ...fails to auto calibrate refer to auto calibration troubleshooting Reference p29 Inadequate power Check for dedicated circuit 20 amp is ideal and check wall outlet voltage 120 VAC Reference p13 Make sure machine is not on extension cord surge protector or GFCI circuit If the AC voltage is missing or incorrect check the AC service or consult an electrician Failed or improper wiring Verify there are ...

Page 36: ...n on deck and running belt Place hand underneath running belt and feel for adequate silicone application Reference Maintenance p8 Apply silicone Failed motor control board MCB Replace MCB Erratic Speeds belt speed increases without command but shows change on display and beeps In a program Remove safety key then replace Start in P1 and see if reoccurs Stuck button Reference membrane keypad and ove...

Page 37: ...parts as needed Running belt feels choppy almost like it s stuttering when a cus tomer walks Torque adjustment on lower board is incorrect Running belt is loose Tighten running belt Do not overtighten belt if it still feels choppy Tech in the field only Adjust torque pod until belt runs smooth Replace lower board Running belt continues to move even after stop is pressed Torque Adjustment on lower ...

Page 38: ... Replace elevation motor Elevation is stuck down and does not function Console is responsive to the buttons being pressed Failed console cable CC Verify console cable connections Verify there are no pinches or cuts in the cable Reference CC continuity p22 Replace console cable Failed elevation motor Put machine in hardware test Eng1 and press start Elevation doesn t respond when buttons are presse...

Page 39: ...n unit back on CC is loose unattached or damaged Check CC at each connection point Unplug and reattach making sure the connection is secure Verify the CC is connected to the MCB Replace CC if damaged Improper use of the Two Touch membrane Keys Verify the customer is confirming each selection The incline increases as soon as power is applied without pressing start MCB is defective Replace MCB The i...

Page 40: ...rge protector or GFCI Reference p4 If the AC voltage is missing or incorrect check the AC service or consult an electrician Damaged or improper wiring Verify there are no pinches or cuts in the power cord power wires motor wires or console cable Verify console cable continuity Reference p24 Verify the connections of above wires and cords Replace parts as needed Failed motor control board MCB Verif...

Page 41: ...e AC voltage is missing or incorrect check the AC service or consult an electrician Inadequate lubrication on deck and running belt Place hand underneath running belt and feel for adequate silicone application Apply Silicon lubrication Reference Lubrication p9 Failed running belt Feel underside of running belt It should have a rough feel to it similar to denim Replace running belt Failed drive mot...

Page 42: ... verify alignment of drive belt Inspect for debris on drive motor pulley front roller pulley or on drive belt Align drive belt and or replace drive belt Optic disk is hitting the optic sensor guard Run unit and look for optic sensor disk missalignment Bend optic disk to straighten or replace optic disk Failed drive motor bearings Replace drive motor Motor brushes are not seated properly Inspect mo...

Page 43: ...2008 Sears CA Treadmill Service Manual rev 1 0 43 Section Three Exploded Drawings Exploded Drawing 30727 Note Drawings are updated periodicaly Contact Customer Tech Support for updated Drawing ...

Page 44: ...2008 Sears CA Treadmill Service Manual rev 1 0 Section Three Exploded Drawings Exploded Drawing 30750 Note Drawings are updated periodicaly Contact Customer Tech Support for updated Drawing Model 30750 V07 ...

Page 45: ...Horizon Fitness 1620 Landmark Drive Cottage Grove WI 53527 Phone 800 244 4192 Fax 608 839 1280 Version 1 0 JHP December 2007 ...

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