Trackmaster FVX325 Field Service Manual Download

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TRACKMASTER

August, 2006

FVX, TMX Series Service Manual

vii

Chapter 14 Flowcharts & Instructions for Trouble Shooting . . . . . 1 4 -1

Instruction for Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 -14

Power Distribution Fault Isolation (1)120 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 -14

Power Distribution Fault Isolation (2) 208-240 VAC . . . . . . . . . . . . . . . . . . . . . . 1 4 -14

Power Distribution Fault Isolation (3)120 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 -14

Power Distribution Fault Isolation (4) 208-240 VAC . . . . . . . . . . . . . . . . . . . . . . 1 4 -14

FG 309 Elevation and Power Supply A/C Voltage Distribution

Fault Isolation Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 -15

FG 302 Elevation and Power Supply A/C Voltage Distribution

Fault Isolation Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 -16

ESB Circuit Fault Isolation Instruction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 -17

Speed Sensor Fault Isolation FVX, TMX No Control Series . . . . . . . . . . . . . . . . 1 4 -18

Interior Interface Cable Fault Isolation FVX, TMX No Control Series . . . . . . . 1 4 -18

Perform Incorrect Belt Speed Fault Isolation FVX, TMX No Control Series . 1 4 -18

Speed Sensor Fault Isolation FVX, TMX Control Series . . . . . . . . . . . . . . . . . . . 1 4 -18

Speed V-Guide 10.92’ (3.33m). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 -19

Speed V-Guide 8.45’ (2.56m). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 -19

Perform FVX, TMX Manual Control Series Incorrect

Belt Speed Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 -20

Perform FVX, TMX Programmable Control Series Incorrect

Belt Speed Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 -20

Test Plug Procedure (FVX, TMX No Control Series Units Only) . . . . . . . . . . . 1 4 -21

Elevation Sensor FVX, TMX No Control Series Fault Isolation Procedure . . . 1 4 -21

Elevation Sensor FVX, TMX Control Series Fault Isolation Procedure . . . . . . 1 4 -21

Chapter 15 Treadmill Report/Service Log . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 -1

TMX425 Series Maintenance Inspection Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 -1

FVX325 Series Maintenance Inspection Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 -3

Emergency Stop Button (ESB) Location Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 -5

FVX325 Series Treadmill Field Service Manual Log Sheet. . . . . . . . . . . . . . . . . . . . . 1 5 -6

TMX425 Series Treadmill Field Service Manual Log Sheet . . . . . . . . . . . . . . . . . . . . 1 5 -7

Summary of Contents for FVX325

Page 1: ...commitments as required by the FDA under 21 CFR 1020 30 and any amendments to it and other local regulatory requirements Use of this document by unauthorized persons is strictly prohibited This docume...

Page 2: ...Programmable Control TMX No Control TMX__C Manual Control TMX__CP Programmable Control Revision Level 5 August 2006 Refer equipment servicing to Full Vision Inc authorized service personnel only Any...

Page 3: ......

Page 4: ...ss Full Vision Inc 3017 Full Vision Drive Newton Ks 67114 PARTS DEPARTMENT Models FVX325 FVX325C FVX325CP TMX435 TMX425C TMX425CP Service Line 316 283 8110 Address Full Vision Inc 3017 Full Vision Dri...

Page 5: ...X325 Series Treadmill Field Service Manual Part 317 07189 317 07191 Note Due to continuing product innovation specifications in this manual are subject to change without notice Printed in USA TRACKMAS...

Page 6: ...ignment 4 6 Belt Tension Adjustment 4 7 Drive Belt Tension Adjustment 4 8 Connector and Switch Locations 4 9 Power Requirements 4 10 Operating and Storage Condition Recommendations 4 11 Installation A...

Page 7: ...7 5 Input from FG309 to Control Console 7 6 Elevation Sensor 7 6 Speed Sensor 7 6 Chapter 8 Removal and Replacement of Components 8 1 Hood Removal Procedure FVX Series 8 1 Hood Removal Procedure TMX...

Page 8: ...tputs 9 7 Electrical Connections 9 8 Physical Requirements Restrictions 9 8 Chapter 10 Production Qualification Description FG302 Smart Power Supply 10 1 Test Fixture 1 0 1 Test Fixture Connections 1...

Page 9: ...or Pan Assembly 1 3 20 TMX425 Series 115V Motor Pan Assembly w CE Components 1 3 22 TMX425 Series 220V Motor Pan Assembly 1 3 24 TMX425 Series 220V Motor Pan Assembly w CE Components 1 3 26 TMX Series...

Page 10: ...Control Series 1 4 18 Perform Incorrect Belt Speed Fault Isolation FVX TMX No Control Series 1 4 18 Speed Sensor Fault Isolation FVX TMX Control Series 1 4 18 Speed V Guide 10 92 3 33m 1 4 19 Speed V...

Page 11: ...TRACKMASTER viii FVX TMX Series Service Manual August 2006...

Page 12: ...equired An amp probe capable of reading up to 20 amps is recommended Specific hand tools required are listed at the beginning of all removal and replacement procedures A complete list of all tools req...

Page 13: ...treadmill while it is plugged into a power outlet Line voltage will cause severe injury or death Drawings Chapter 13 assembly drawings Directional Orientation References to left right front and rear...

Page 14: ...this equipment It calls notice to the things to which you must pay special attention during operation and when the equipment is operated in conjunction with other equipment Protective earth ground Al...

Page 15: ...TRACKMASTER 1 4 FVX TMX Series Service Manual August 2006...

Page 16: ...ar Maintenance regardless of usage is essential to ensure that the treadmill will always be functional when required Equipment identification Below is a list of treadmills that are available for purch...

Page 17: ...on and Identification The serial plate is located on the right side rail of the treadmill Explanation of Serial Decal Information Item Name Description A Manufacture Full Vision Inc B Model Number Ide...

Page 18: ...0lb flywheel attached to the motor s drive shaft keeps footfall variance to a minimum An adjustment plate between the motor and the treadmill motor pan allows for belt tension adjustment using adjustm...

Page 19: ...TRACKMASTER 3 2 FVX TMX Series Service Manual August 2006 Power Supply Relay Board Detail...

Page 20: ...the bed assembly to a comfortable height keeping knees bent and backs straight as you lift Rotate the treadmill in the direction you want to go the treadmill will pivot on its wheels and push forward...

Page 21: ...en wrench 1 Rotate handrail to up right position 2 Start 2 3 8 16 Socket head cap screw into lower legs 3 Start 2 3 8 16 Socket head cap screw into upper handrail 4 At this point tighten all 8 3 8 16...

Page 22: ...re should be left loose to aid easy assembly 7 Install the outer rails by first routing wire through hole provided your application has a wire in the rail 8 Slide the outer rail over the bracket and s...

Page 23: ...August 2006 Check unit for proper operation If unit has no power check ESB Emergency Stop Button to assure the button is not pressed and wires are connected at board To check unit for proper operatio...

Page 24: ...treadmill reaches 20 elevation the next push of the button will start the treadmill running belt 6 With each push of the button the treadmill will increase speed by 2 5 miles per hour 7 Once the trea...

Page 25: ...normal during use Do not allow the running belt to travel all the way to either side To adjust the belt tracking do the following 1 Turn the treadmill s power switch to ON CAUTION Do not stand on the...

Page 26: ...is looseness is noticeable when the belt tends to hesitate or stick If the belt is loose and slipping see illustration below 1 Turn the treadmill s power switch to ON 2 Start treadmill and increase to...

Page 27: ...of force 3 The drive belt should deflect approximately to 3 8 4 If deflection is more that 3 8 see Motor Pan Assembly Chapter 13 for detail drawing 5 Loosen 4 Motor mounting nuts on underside of tread...

Page 28: ...TRACKMASTER August 2006 FVX TMX Series Service Manual 4 9 Connector and switch locations The illustration below shows the various connectors and switches located on the base of the treadmill...

Page 29: ...edicated circuit A dedicated circuit is a power outlet reserved for the exclusive use of your treadmill This requires a power line to be routed from the main breaker box or sub panel to the power outl...

Page 30: ...o plugging in treadmill Failure to do so will cause inverter drive to FAIL If input power has not been applied to the drive for a period of time exceeding three years due to storage etc the electrolyt...

Page 31: ...TRACKMASTER 4 12 FVX TMX Series Service Manual August 2006...

Page 32: ...echnician electrician or technically qualified personnel can find instructions on performing these tests in the maintenance section later in this manual Operating Controls The treadmill has two operat...

Page 33: ...careful supervision Keep hands feet and clothing away from any moving parts Never drop or insert objects into any opening Avoid draping towels over the safety side rails or dropping objects on the be...

Page 34: ...l should be serviced by authorized technicians only Power cord should be routed through clamp and kept clear of elevation mechanism Personnel present when treadmill is in use need to be aware of the d...

Page 35: ...increase in increments of 0 5 Incline Down Decrease elevation grade in percentage decrease in increments of 0 5 Speed Up Select speed increase speed adjustable in increments of 0 1 mph Speed Down Sel...

Page 36: ...er 8 passes from left to right from Incline to Speed to Time Distance Display The six indicator lights located to the right and left of the Time Distance window along with the Heart Rate indicator lig...

Page 37: ...s displayed in Time Distance window Run belt is moving 50 is displayed in the Incline window the value in the Speed window is the output of the Speed Sensor as read by the Control Console 50 is the PW...

Page 38: ...layed in Speed window to verify successful test EE TIME DISTANCE PACE CALORIES CAL MINUTE METS SPEED PAS Advance to next test by pressing select DOG TIME DISTANCE PACE CALORIES CAL MINUTE METS Watchdo...

Page 39: ...de the user from inadvertently accessing the programming mode 4 Click on GP32DLG Serial Download icon on laptop or desktop computer ICON 5 Click on Load S FILE 6 Select software version provided for d...

Page 40: ...l control console 8 Press the SELECT and the INCLINE keys simultaneously turn on the main power release the SELECT and the INCLINE keys when you hear a continuous tone This may take numerous attempts...

Page 41: ...5 mph is minimum speed for 220v units 1 0 mph is minimum speed limit for 110v units 0 5 appears in the Speed Display 3 P 3 will appear in the Center Display with a default setting of 12 0 for MPH or...

Page 42: ...Observe P 8 Select Serial Heart rate or Polar Heart rate by using INCLINE arrow keys Select combined Polar contact heart rate or Polar only Select Polar H rate for chest strap only Hr appears in the I...

Page 43: ...ed Display Parameter is the fixed timer that limits the treadmill workout time Parameter is used to set the Cool Down Time Period Press START key Center Display Action required Changes Affect Paramete...

Page 44: ...TMX425 Series elevation charts Center Display Action Required Changes Affect Parameter Options Observe CALE Press and hold Enter key and Stop key simultaneously to enter Elevation Calibration Mode Ad...

Page 45: ...Version Phase SW Version Number Figure 1 3 Control Console Idle Phase Figure 1 4 Control Console Backside RS232 Port resets SCAN SELECT 1 4 1 bri SCAN SELECT 150 SCAN SELECT 0 0 0 5 Dim Grade Inches M...

Page 46: ...sed decreased during exercise Speed default is 0 5 mph 7Kmh speed may be adjusted at any time during exercise Time default is 30 minutes 1 Press START or ENTER switch 2 Use the number keypad to enter...

Page 47: ...12 Press one of the STOP switches to bring the treadmill running belt to a stop this will also reset the elevation 13 Press the COOL DOWN switch to begin a sixty second cool down phase 14 Completion...

Page 48: ...prior to belt start Speed Incline may be adjusted by pressing the plus or minus keys in the Speed Incline windows Press one of the STOP switches to bring the treadmill running belt to a stop this will...

Page 49: ...and fitness test score is displayed in the message center HRC AEROBIC Aerobic workout designed to maintain a target heart rate determined by user input POLAR chest strap is required to use this progr...

Page 50: ...get heart rate elevation will decrease If elevation equals 0 and actual heat rate exceeds target heart rate the belt will slow down until target heart rate is achieved 13 Press either STOP switch to b...

Page 51: ...ve completed your desired number of segments press the START switch ENTER WEIGHT will appear 9 Use the number keypad to enter weight 10 Press ENTER switch 11 Press START switch to begin workout 12 A t...

Page 52: ...8 Press START switch to begin workout To overwrite an existing program 1 Press the PROGRAM SELECT 10 times USER PROGRAM will be displayed 2 Press ENTER PRESS ENTER TO USE A EXISTING PROGRAM OR CLEAR...

Page 53: ...Incline and until message center reads TEST MODE Observe Message Center Display Message Center Press any switch to begin Self Test Observe each leg of all readouts is sequentially lit Message Center...

Page 54: ...to next test by pressing any switch Readout Test Observe time Distance Incline Speed windows Each leg of each readout is lit sequentially Advance to next test by pressing any switch Time Distance Incl...

Page 55: ...continue until ended by pressing any switch Advance to next test by pressing any switch All Lamps Test Observe all LED s all readouts all dots of Dot Matrix lit Advance to next test by pressing any s...

Page 56: ...ase WARNING Prior to starting the Belt Motor Test remove all items from the running belt and stand clear of the running belt during test Advance to next test by pressing STOP Motor Test Observe Messag...

Page 57: ...e as selected in the programming parameters The distance window displays HR using the Contact Grips The Time window displays HR using a POLAR Chest Strap or heart rate generator The heart symbol displ...

Page 58: ...essing the programming mode 4 Click on GP32DLG Serial Download icon on laptop or desktop computer ICON 5 Click on Load S FILE 6 Select software version provided for download software version XX 7 Conn...

Page 59: ...key if a change is needed use the numeric keypad to make change and press ENTER key Controller Display Action Required Changes Affect Parameter Options Observe Time Limit Enter time limit desired usin...

Page 60: ...ic keypad Maximum Elevation Grade 25 for 25 elevation medical units Maximum Correction Factor appears in Message Center 7 Maximum Correction Factor will appear in the Message Center with a default set...

Page 61: ...ER key Controller Display Action Required Changes Affect Parameter Options Observe Medgraph SCO Select Medgraph SCO or Normal SCO by using incline arrow keys Selection of Medgraph SCO allows serial co...

Page 62: ...djusts speed accuracy at all speed ranges low medium and high speeds N A Press Stop Enter for GRD CAL appears in Message Center 17 Press Stop Enter for GRD CAL will appear in the Message Center This f...

Page 63: ...gure 1 2 SW Version Phase SW Version Number Figure 1 3 Control Console Idle Phase Figure 1 4 Control Console Backside RS232 Port 0 00 0 00 0 0 0 5 0 0311 bri 0 0 53 bri Dim Grade Inches MM A 0 3 04 77...

Page 64: ...or fraying or other damage Perform safety tests on any repaired line cords Inspect the following for excessive wear or damage Walking Belt Drive Belt Handrail and Hardware Test the stop switch assembl...

Page 65: ...ior of motor pan by gently vacuuming with hose attachment any foreign objects or debris 8 Replace the hood and its bolts and slide the hood grommets back into place CAUTION AVOID USING LIQUID CLEANERS...

Page 66: ...displayed 9 Change Max PWM correct factor to 4 10 Stand clear of running belt and clear the belt 11 Press calibrate Belt 12 Observe Running belt starts and increases to approximately 12 m p h 13 Belt...

Page 67: ...times plus or minus 32 this is within the advertised 2 accuracy 9 This should verify the treadmill is within required tolerance of speed TMX SERIES VERIFYING BELT SPEED CALIBRATION IN THE FIELD Tools...

Page 68: ...to 101 8 Determine actuator motor ratio Fine thread Ratio 153 1 Course thread Ratio 115 1 after ratio is determined click on the box indicating Course or Fine 9 Adjust incline to 5 grade 10 Remove fro...

Page 69: ...treadmill to stop at 25 to complete the grade calibration If the cam was turned to adjust the lower switch the upper cam will need to be reset to zero to allow the treadmill to park in the correct po...

Page 70: ...vice Manual 6 7 TMX425 Series Elevation Chart FVX325 TMX425 Series Elevation Actuator Adjustment Dim Grade Inches MM A 0 3 04 77 3mm B 5 3 36 85 2mm C 5 6 59 167 3mm D 10 10 72 272 2mm E 15 14 85 377...

Page 71: ...o return to 4 then press the Select key 9 P7 in the Incline window 3175 in the Center window Do not Adjust Use UP or DOWN Speed key to return to 3175 then press the Select key 10 P8 in the Center wind...

Page 72: ...on below Press start to go to next grade Repeat process for all grades Pressing Select after CALS and CALE appear will take you out of Setup Check and back to normal operation Replace end cap and bolt...

Page 73: ...or or other measuring device to determine the degree of elevation or use the procedure provided to measure the distance from the floor to the bottom of the side rail 7 Press the up incline button unti...

Page 74: ...levation Chart Dim Grade Inches MM A 0 3 04 77 3mm B 5 3 32 84 3mm C 5 5 62 142 8mm D 10 8 42 223 8mm E 15 11 20 284 5mm F 20 13 48 342 4mm G 25 15 84 402 4mm Dim Grade Inches MM A 0 3 04 77 3mm B 5 3...

Page 75: ...clean and lubricate it once every 6 months 1 Raise the treadmill to its maximum elevation 2 Turn the main power switch to the OFF position and unplug the treadmill from its outlet 3 Using a lint free...

Page 76: ...ure Main Breaker throws when powering up treadmill Treadmill is not on a dedicated circuit Improper circuit breaker is installed Outlet is wired incorrectly Power cord is damaged shorted Inverter is d...

Page 77: ...evate treadmill up and down and increase treadmill running belt speed It also routes speed and elevation sensor information to control console Trouble shooting the treadmill begins with understanding...

Page 78: ...TRACKMASTER August 2006 FVX TMX Series Service Manual 7 3 Drive Circuit Board Manual Control FG309 Drive Circuit Board Programmable Control FG309...

Page 79: ...available at J3 Pin 5 black The Input to the three voltage regulators on the Power Supply is the same unregulated 12 volts seen at the output of diode D5 Voltage regulator input is Pin 1 DC Ground is...

Page 80: ...scale 7 58 volts U1 Pin 4 output to inverter to DC Ground D C scale 7 58 volts J3 Pin 4 gray to J3 Pin 5 black output to inverter FG309 Elevate Up Elevate Up elevup received from control console at J4...

Page 81: ...to control console Elevation Sensor Elevation sensor elevin received from Elevation Reed Switch J1 Pin 1 Verify sensor will change states Elevation Sensor Off D13 unlit D C scale 0 0 volts J1 Pin 1 o...

Page 82: ...quired 1 4 Hex Socket or Flat Blade Screw Driver 1 Turn the treadmill main power switch to the off position 2 Unplug the Treadmill from the wall receptacle 3 Allow treadmill to discharge for 3 minutes...

Page 83: ...o the off position 2 Unplug the Treadmill from the wall receptacle 3 Allow treadmill to discharge for 3 minutes 4 Slide the hood grommets up the center handrail approximately 2 5 Remove the three hood...

Page 84: ...location they hook at the inverter 9 Unplug Speed sensor from the power supply relay board 10 Remove 4 Motor mounting nuts on underside of treadmill 11 Remove 2 Motor tension adjustment nuts outside...

Page 85: ...ts on the underside of the motor pan but leave loose until the belt is properly tensioned and tracked according to the drive belt tension and adjustment section in this manual 27 Attach motor wires th...

Page 86: ...g bolts on the lower front end of treadmill 7 Slide hood up treadmill center rail and force past the grommets allow hood to hang from grommets 8 Remove the ground wire at the inverter using the Philli...

Page 87: ...ght 27 IMPORTANT Once bolts are tight use a dial indicator on the flywheels face Check for a maximum of 004 TIR correct for error by tightening bolts at high spots Note Excessive vibration when treadm...

Page 88: ...the small flat blade electrical screwdriver Note T 1 T 2 T 3 designation on the wires and the designation where they hook at the inverter 41 Plug the speed sensor back in to the power supply relay boa...

Page 89: ...ension on the bolts to avoid stripping the threads on the tension bolt or roller 10 Push rear roller forward as far as it will go 11 Use a 1 4 inch Allen wrench or socket to remove bolt securing the f...

Page 90: ...TRACKMASTER August 2006 FVX TMX Series Service Manual 8 9 FVX Series TMX Series...

Page 91: ...on the bolts to avoid stripping the threads on the tension bolt or roller 10 Push rear roller forward as far as it will go 11 Use a 1 4 inch Allen wrench or socket to remove bolt securing the front ro...

Page 92: ...TRACKMASTER August 2006 FVX TMX Series Service Manual 8 11 FVX Series TMX Series...

Page 93: ...socket and remove the four flat head Allen screws which secure the running deck cross braces There are four screws total two on the left side and two on the right side 13 Push the deck to one side of...

Page 94: ...for the belt deck and rollers is to the left during installation Verify the timing belt goes around the front roller sprocket and that it is not pinched Replace the securing bolt and tighten 22 Lift...

Page 95: ...3 Lift the edge of the running belt up use 3 16 Allen wrench or socket and remove the six flat head Allen screws which secure the running deck cross braces There are six screws total three on the left...

Page 96: ...for the belt deck and rollers is to the left during installation Verify the timing belt goes around the front roller sprocket and that it is not pinched Replace the securing bolt and tighten 23 Lift...

Page 97: ...rear roller When removing the tension bolts maintain equal tension on the bolts to avoid stripping the threads on the tension bolt or roller 12 Push rear roller forward as far as it will go 13 Lift th...

Page 98: ...socket to completely remove left and right tension bolts from rear roller When removing the tension bolts maintain equal tension on the bolts to avoid stripping the threads on the tension bolt or rol...

Page 99: ...nning deck cross brace with the damaged deck cushions 13 Use a 1 2 inch wrench or socket with extension to remove the two bolts securing the deck cross brace to the treadmill side channels Remove the...

Page 100: ...cket and remove the two flat head Allen screws which secure the running deck cross brace with the damaged deck cushions 14 Use a 1 2 inch wrench or socket with extension to remove the two bolts securi...

Page 101: ...wer front end of treadmill 5 Set hood to the side of treadmill 6 Loosen 4 Motor mounting nuts on underside of treadmill 7 Loosen 2 Motor tension adjustment nuts inside motor pan of treadmill allowing...

Page 102: ...TRACKMASTER August 2006 FVX TMX Series Service Manual 8 21 FVX Series...

Page 103: ...grommets allow hood to hang from grommets 7 Remove two hex socket head cap screws retaining Right hand side rail bracket 8 Remove Two Hex head bolts retaining Right hand side rail bracket and remove...

Page 104: ...TRACKMASTER August 2006 FVX TMX Series Service Manual 8 23 TMX Series...

Page 105: ...ip tie that holds the wire to the motor pan gusset 10 Remove the top bolt and nut from the actuator watch out for nylon washers on each side of the actuator 11 With blanket in suitable spot place a fo...

Page 106: ...TRACKMASTER August 2006 FVX TMX Series Service Manual 8 25 FVX TMX Series...

Page 107: ...ductor plug with rd gry blk wh prpl wires on it 8 Unplug the 4 conductor and 3 conductor plugs from the power supply relay board 9 Unplug the two single conductor spades from the power supply relay bo...

Page 108: ...TRACKMASTER August 2006 FVX TMX Series Service Manual 8 27 FVX Series...

Page 109: ...inverter signal harness from the power supply relay board this is a 5 conductor plug with rd gry blk wh prpl wires on it 9 Unplug the 4 conductor and 3 conductor plugs from the power supply relay boa...

Page 110: ...TRACKMASTER August 2006 FVX TMX Series Service Manual 8 29 TMX Series...

Page 111: ...wires to feed through the hole 7 Unplug the two wires off the circuit breaker to replace when replacing more than one perform the replacement one at a time to keep the wires on the correct value of ci...

Page 112: ...onductor plug with red gray black white purple wires on it 7 Unplug the brown black power input wires on the inverter 8 With a screw driver remove nylone rivet and slide inverter support top out of in...

Page 113: ...TRACKMASTER 8 32 FVX TMX Series Service Manual August 2006 FVX Series...

Page 114: ...y relay board this is a 5 conductor plug with red gray black white purple wires on it 9 Unplug the brown black power input wires on the inverter 10 Remove the ground wire using the Phillips screwdrive...

Page 115: ...TRACKMASTER 8 34 FVX TMX Series Service Manual August 2006 TMX Series...

Page 116: ...of an RS 232 serial port the unit accepts commands to modify the belt state the belt speed and the deck elevation The current state of the control may also be queried through the use of this serial po...

Page 117: ...current target speed If the measured speed is within range it is used to make minor adjustments to the speed output if it is determined that the actual speed and measured speed differ by more than 0 0...

Page 118: ...the next 2 bytes of ASCII data Note 5 A7 167 Set Stage to the next 2 bytes of ASCII data Note 5 A8 168 Reset Distance Total Time and Energy to 0 Note 5 A9 169 Set Weight to the next 4 bytes of ASCII...

Page 119: ...ect Stop Enabled 33h Belt Started Comm Disconnect Stop Disabled D1 209 Current Belt Speed follows as 4 bytes of ASCII data Note 3 D2 210 Current Elevation follows as 4 bytes of ASCII data Note 4 D3 21...

Page 120: ...e transmit acknowledge command the output response will always be followed by the input string received from the host Sending this command when the flag is set will result in it being cleared again No...

Page 121: ...be removed at any point to stop the staging process The following table shows the sequence of self test stages Stage Incline Speed mph 1 5 0 0 2 10 0 0 3 15 0 0 4 20 0 0 5 20 1 0 6 20 2 5 7 20 5 0 8 2...

Page 122: ...put voltage selection switch allows the unit to be used at 115VAC or 230VAC G Emergency Stop Switch A normally closed switch input used to switch power to the SPS control must be rated at 24 Volts and...

Page 123: ...interfacing with the host controller F Emergency Stop Switch Two 0 187 quick connect blade terminals are provided for an emergency stop switch input PHYSICAL REQUIREMENTS AND RESTRICTIONS A The printe...

Page 124: ...ll switch connection on the dut ref J4 J5 on FG0302 A single relay is included on the test fixture to switch AC Hot to the dut JP4 pins 3 and 4 The test fixture provides AC Common to pins 1 and 2 of J...

Page 125: ...s from the relays are tested for mutual exclusion to check for circuit shorts Test Belt The PC applies an output to J2 pin 2 of the dut and after directing a command to the dut to start the belt measu...

Page 126: ...TRACKMASTER August 2006 FVX TMX Series Service Manual 10 3 Power Supply Board FG302...

Page 127: ...TRACKMASTER 10 4 FVX TMX Series Service Manual August 2006...

Page 128: ...umper pins 1 and 11 white and violet wires The treadmill belt starts pressing the up button will increase the speed of the running belt pressing the down arrow will decrease the speed of the running b...

Page 129: ...nditions Measure between Pins 1 Violet and 2 black Treadmill on motor off Motor on at minimum speed Table 2 2 Inspect Fault History Press the inverter Mode button 3 times the inverter readout displays...

Page 130: ...OUTPUT TB 15 OUTPUT NONE 01 RUN 02 FAULT 03 INVERSE FAULT 04 FAULT LOCKOUT 05 AT SET SPEED 06 ABOVE PRESET 3 07 CURRENT LIMIT 08 AUTO SPEED 09 REVERSE 10 NONE 01 NONE 01 08 TB 30 OUTPUT NONE 01 0 10 V...

Page 131: ...ATION TIME 0 1 3600 0 SEC 10 0 SEC 21 DC BRAKE TIME 0 0 3600 0 SEC 0 0 SEC 22 DC BRAKE VOLTAGE 0 0 30 0 0 0 23 MINIMUM FREQUENCY 0 0 MAXIMUM FREQUENCY 3 0 Hz 24 MAXIMUM FREQUENCY MINIMUM FREQ 240 0 Hz...

Page 132: ...tory NOTE 3 If LINE VOLTAGE is set to LOW Maximum setting is 150 NOTE 4 Maximum setting is 1300 0 Hz factory default is 999 9 on drives with High Output Frequency option NOTE 5 After the burn in chang...

Page 133: ...RRENT LIMIT 08 AUTO SPEED 09 REVERSE 10 NONE 01 10 TB 13A FUNCTION SELECT NONE 01 0 10 VDC 02 4 20 mA 03 PRESET SPEED 1 04 RUN REVERSE 05 START REVERSE 06 EXTERNAL FAULT 07 REMOTE KEYPAD 08 DB FAULT 0...

Page 134: ...MPLETION 0 0 5 0 0 0 31 37 PRESET SPEEDS 0 0 MAXIMUM FREQUENCY 0 0 Hz 38 SKIP BANDWIDTH 0 0 10 Hz 0 0 Hz 39 SPEED SCALING 0 0 6500 0 0 0 42 ACCEL DECEL 2 0 1 3600 0 SEC 20 0 SEC 44 PASSWORD 000 999 13...

Page 135: ...SET SPEED 06 ABOVE PRESET 3 07 CURRENT LIMIT 08 AUTO SPEED 09 REVERSE 10 NONE 01 10 TB 13A FUNCTION SELECT NONE 01 0 10 VDC 02 4 20 mA 03 PRESET SPEED 1 04 RUN REVERSE 05 START REVERSE 06 EXTERNAL FA...

Page 136: ...ACCEL BOOST 0 0 20 0 0 0 30 SLIP COMPLETION 0 0 5 0 0 0 31 37 PRESET SPEEDS 0 0 MAXIMUM FREQUENCY 0 0 Hz 38 SKIP BANDWIDTH 0 0 10 Hz 0 0 Hz 39 SPEED SCALING 0 0 6500 0 0 0 42 ACCEL DECEL 2 0 1 3600 0...

Page 137: ...EED 06 ABOVE PRESET 3 07 CURRENT LIMIT 08 AUTO SPEED 09 REVERSE 10 NONE 01 10 TB 13A FUNCTION SELECT NONE 01 0 10 VDC 02 4 20 mA 03 PRESET SPEED 1 04 RUN REVERSE 05 START REVERSE 06 EXTERNAL FAULT 07...

Page 138: ...COMPLETION 0 0 5 0 0 0 31 37 PRESET SPEEDS 0 0 MAXIMUM FREQUENCY 0 0 Hz 38 SKIP BANDWIDTH 0 0 10 Hz 0 0 Hz 39 SPEED SCALING 0 0 6500 0 0 0 42 ACCEL DECEL 2 0 1 3600 0 SEC 20 0 SEC 44 PASSWORD 000 999...

Page 139: ...TRACKMASTER 11 12 FVX TMX Series Service Manual August 2006...

Page 140: ...th ESB 75 hrs TMX Series Handrail replacement center with or without ESB 1 5 hrs TMX Series Handrail replacement center 425C CP 1 75 hrs FVX Series handrail take off and reinstall for moving 75 hrs Ha...

Page 141: ...eries Recalibrate belt speed on FVX__C CP or TMX__C CP 25 hrs FVX TMX Series Recalibrate Elevation includes time to download program 75 hrs FVX TMX Series Recalibrate Elevation on FVX__C CP or TMX__C...

Page 142: ...Part Numbers FVX Series Inverter Assembly 220V Software Version 402 403 404 13 Item Description Part Number Qty 1 Inverter Lesson 317 160 104 1 2 Inverter Signal Harness 317 160 036 1 3 Power Input H...

Page 143: ...Version 301 Item Description Part Number Qty 1 Inverter Leeson 317 160 008 1 2 Inverter Signal Harness 317 160 036 1 3 Power Input Harness 317 160 069 1 4 Capacitor 317 160 035 1 5 HN 8 32 Nylon 001...

Page 144: ...Version 301 Item Description Part Number Qty 1 Inverter Leeson 317 160 008 1 2 Inverter Signal Harness 317 160 036 1 3 Power Input Harness 317 160 069 1 4 Capacitor 317 160 035 1 5 HN 8 32 Nylon 001...

Page 145: ...220V Software Version 402 403 404 Item Description Part Number Qty 1 Inverter Leeson 317 160 104 1 2 Inverter Signal Harness 317 160 036 1 3 Power Input Harness 317 160 069 1 4 Capacitor 317 160 035...

Page 146: ...110V Software Version 402 403 404 Item Description Part Number Qty 1 Inverter Leeson 317 160 105 1 2 Inverter Signal Harness 317 160 036 1 3 Power Input Harness 317 160 069 1 4 Capacitor 317 160 035...

Page 147: ...1 4 SSS 20 SUPPLIED WITH 317 160 032 1 5 MOTOR GROUND WIRE 317 160 072 1 6 DECAL CAUTION ELECTRIC 317 160 103 1 7 COLLAR ASSEMBLY 317 178 001 1 8 MOTOR LEESON 317 160 007 1 9 HNS 5 18 18 FLANGE 001 1...

Page 148: ...H MAGNET 317 160 101 1 3 MOTOR BASE WELDMENT 317 378 001 1 4 BUSHING W SHOULDER 317 160 052 4 5 MOTOR GROUND WIRE 317 160 108 1 6 DECAL CAUTION ELECTRIC 317 160 103 1 7 WASHER DELRIN 317 160 051 4 8 M...

Page 149: ...OP 317 180 005 1 4 HARNESS ESB SIDE 317 399 006 1 5 RIVET POP 125 DIA X 430 SS 001 239 007 2 6 ESB BOX DRILLED 317 399 004 1 7 MOUNT ESB 317 400 001 1 8 HWHTS 8 32 X 3 8 LG 001 1284 4 9 BOLT WITH NUT...

Page 150: ...180 004 1 5 LABEL PLATE 317 180 006 1 6 SWITCH EMERGENCY STOP 317 180 005 1 7 HARNESS ESB SIDE 317 399 006 1 8 ESB BOX DRILLED 317 399 004 1 9 MOUNT ESB 317 400 001 1 10 HWHTS 8 32 X 3 8 LG 001 1284...

Page 151: ...X Series Elevation Assembly Item Description Part Number Qty 1 FVX ELEVATION WELDMENT TMX ELEVATION WELDMENT 317 617 001 317 373 001 1 2 HHCS 3 8 16 X 3 25 LG GR5 001 1519 2 3 SPANNER WHEEL 317 160 05...

Page 152: ...06 FVX TMX Series Service Manual 13 11 FVX TMX Line Reactor Assembly Item Description Part Number Qty 1 LINE REACTOR 2 COIL MTE 317 160 126 1 2 HARNESS INVERTOR POWER 317 160 069 1 3 HARNESS HARMONICS...

Page 153: ...396 002 1 20 DIE SPRING 317 160 140 2 21 NYLONE WASHER 317 160 086 2 22 HNS 3 8 16 FLANGE NUT 001 1399 2 23 HN STOVER LOCK 3 8 16 FLANGE NUT 001 1820 4 24 INVERTER ASSEMBLY 230VAC 317 621 001 1 25 IN...

Page 154: ...tor Pan Assembly Item Description Part Number Qty 47 BREAKER 1 4AMP 317 160 024 2 48 HHWHTS 8 32 X 375 001 1744 2 49 MAIN WIRE HARNESS 317 160 113 1 50 SURGE PROTECTOR 317 160 129 1 51 LW 10 EXT TOOTH...

Page 155: ...TRACKMASTER 13 14 FVX TMX Series Service Manual August 2006 FVX325 Series 220V Motor Pan Assembly...

Page 156: ...y 1 FRAME 220V MOTOR PAN ASSEMBLY 317 600 001 1 1 2 ELEVATION ASSEMBLY 317 626 001 1 3 HSHSS 5 8 DIA X 1 LG 001 1730 2 4 ELEVATION DERLIN SPACER 317 160 060 4 5 FW DIA 001 1443 4 6 NLN 13 001 1676 2 7...

Page 157: ...DIA 001 1451 4 11 FW 5 16 DIA 001 1440 4 12 HNS 5 16 18 FLANGE 001 1398 4 13 DECK RUNNING BOARD 317 160 137 1 14 HSFCHCS 5 16 18 X 1 50 PLT 001 1739 4 15 BELT RUNNING WITH GUIDE 317 160 136 1 16 ROLL...

Page 158: ...TRACKMASTER August 2006 FVX TMX Series Service Manual 13 17 FVX325 Series Frame Assembly...

Page 159: ...Y 317 190 001 1 12 HOOD 317 160 135 1 13 VELCRO BACKING X 2 LG 317 160 057 2 14 HWHTCS 8 32 X 75LG TYPE F 001 1759 3 15 DECAL CAUTION 317 160 018 1 16 DECAL POWER SWITCH 317 160 019 1 17 POWER CORD AS...

Page 160: ...TRACKMASTER August 2006 FVX TMX Series Service Manual 13 19 FVX325 Series Final Assembly...

Page 161: ...2 X 3 8 001 1744 2 19 POWER CORD 115v 317 160 091 1 20 TAG CORD 317 160 077 1 21 TIE CABLE 10 X 4 00 317 160 075 1 22 DECAL RS232 317 160 081 1 23 SCREW HEX JACK 3 16 X 317 160 066 2 24 TIE CABLE 10 X...

Page 162: ...TRACKMASTER August 2006 FVX TMX Series Service Manual 13 21 TMX425 Series 115V Motor Pan Assembly...

Page 163: ...E CABLE 10 X 4 00 317 160 075 1 22 DECAL RS232 317 160 081 1 23 SCREW HEX JACK 3 16 X 317 160 066 2 24 TIE CABLE 10 X 4 00 317 160 075 2 25 MOUNT CIRCUIT BOARD 317 160 041 2 26 PHPHTS 8 32 X 001 1765...

Page 164: ...TRACKMASTER August 2006 FVX TMX Series Service Manual 13 23 TMX425 Series 115V Motor Pan Assembly w CE Components...

Page 165: ...2 X 3 8 001 1744 2 19 POWER CORD 220v 317 160 013 1 20 TAG CORD 317 160 077 1 21 TIE CABLE 10 X 4 00 317 160 075 1 22 DECAL RS232 317 160 081 1 23 SCREW HEX JACK 3 16 X 317 160 066 2 24 TIE CABLE 10 X...

Page 166: ...TRACKMASTER August 2006 FVX TMX Series Service Manual 13 25 TMX425 Series 220V Motor Pan Assembly...

Page 167: ...10 X 4 00 317 160 075 1 22 DECAL RS232 317 160 081 1 23 SCREW HEX JACK 3 16 X 317 160 066 2 24 TIE CABLE 10 X 4 00 317 160 075 2 25 MOUNT CIRCUIT BOARD 317 160 041 2 26 PHPHTS 8 32 X 001 1765 2 27 HH...

Page 168: ...TRACKMASTER August 2006 FVX TMX Series Service Manual 13 27 TMX425 Series 220V Motor Pan Assembly w CE Components...

Page 169: ...TRACKMASTER 13 28 FVX TMX Series Service Manual August 2006 TMX Series w CE Option 317 01784...

Page 170: ...16 HHCS 20 X GR5 001 1186 2 17 LW 1 4 001 1450 2 18 FW 1 4 001 1439 2 19 BELT DRIVE 317 160 026 1 20 HN 20 GR5 001 1386 6 21 LW 1 4 001 1450 6 22 HHCS 20 X GR5 001 1186 6 23 FW 1 4 001 1439 6 24 HHCS...

Page 171: ...TRACKMASTER 13 30 FVX TMX Series Service Manual August 2006 TMX425 Series Frame Assembly...

Page 172: ...1 2 1 8 DECK RUNNING BOARD 317 160 025 1 9 1 75 DECK ISOLATOR WITH STUD 317 345 003 6 10 FW 5 16 DIA 001 1440 6 11 LW 5 16 DIA 001 1451 6 12 HHCS 5 16 18 X 75 001 1167 6 13 HNS 5 16 18 FLANGE 001 139...

Page 173: ...TRACKMASTER 13 32 FVX TMX Series Service Manual August 2006 TMX425 Series Running Deck Assembly...

Page 174: ...ERNAL TOOTH 001 1736 4 11 HSBHCS 5 16 18 X 1 001 1735 4 12 HOOD ASSEMBLY 317 185 001 1 13 HWHTCS 8 32 X 75 TYPE F 001 1759 3 14 RUNNING DECK ASS Y 220v FULLY ASSEMBLED 317 200 1 3 1 15 DECAL SERIAL NU...

Page 175: ...TRACKMASTER 13 34 FVX TMX Series Service Manual August 2006 TMX425 Series Final Assembly...

Page 176: ...verify power cord connection to power on off switch and C E filter Turn treadmill power switch to the on 1 position Is the green power indicator lit 1E Turn treadmill power switch to the off position...

Page 177: ...e on position 1 Turn treadmill power switch to the off position 0 Refer to 208 240 VAC Power distribution drawing verify circuit continuity from brown and black input to power indicator to blades on t...

Page 178: ...Supply Driver Circuit PCB Perform FG 302 Elevation and Power Supply A C Voltage Distribution Fault Isolation Instructions 120 VAC present Yes No Perform Power Distribution Fault Isolation 3 Treadmill...

Page 179: ...Is 208 240 VAC present Perform Power Distribution Fault Isolation 4 Treadmill Model At FG302 Power Supply Driver Circuit PCB Perform elevation and power supply A C voltage distribution test At FG309...

Page 180: ...position No Twist ESB button to the unlocked up position Yes 1 E Verify Power Supply Voltage selector switch set for correct voltage FG302 SW1 FG309 SW1 No Set for correct voltage FG302 SW1 FG309 SW1...

Page 181: ...eadmill elevate when commanded at stress system Yes Is treadmill Power Indicator lamp lit What is the treadmill model number 1A Verify data cable is securely connected and stress system operating para...

Page 182: ...sor LED D7 No Yes Does D7 flash when the belt motor is operating 2A1 Yes No At FG309 P S PCB verify operation of Speed Sensor LED D12 No Yes Does D12 flash when the belt motor is operating Perform FVX...

Page 183: ...l running belt start Measure DC voltage from J3 pin 2 PWM to J3 pin 5 GND Yes No DC voltage Yes No Does treadmill belt respond to stress system Problem is isolated from treadmill refer to stress syste...

Page 184: ...r Inverter Drive Verify Leeson Speedmaster parameters Operate Belt motor locally at Leeson Speedmaster keyboard Perform Treadmill self test procedure Yes No Does treadmill run belt start 2A Yes No Doe...

Page 185: ...nverter Drive Verify Leeson Speedmaster parameters Operate Belt motor locally at Leeson Speedmaster keyboard Perform Treadmill self test procedure Yes No Does treadmill run belt start 2A Yes No Does t...

Page 186: ...move 3 screws retaining motor cover Lift and secure motor cover Yes No Does treadmill elevate when commanded at stress system Yes No Does Stress system register elevation Does the treadmill elevate to...

Page 187: ...lected Yes No When elevation selected is At FG302 P S PCB LED 3 Up lit Perform treadmill self test Yes No When elevation selected is At FG302 P S PCB LED 3 Up lit Replace FG302 P S PCB 3A Yes No Does...

Page 188: ...Yes No When elevation selected is At FG309 P S PCB LED 9 Up lit Select elevation using Control console Yes No When elevation selected is At FG309 P S PCB LED 9 Up lit Replace FG309 P S PCB 3A Yes No...

Page 189: ...ectors of power indicator to output of C E filter Repair break in wire or proceed to next step 2 Measure continuity through C E filter replace C E filter if defective or proceed to next step 3 Measure...

Page 190: ...ep 5 Turn treadmill power 0 position Unplug power cord from wall receptacle 6 Unplug output of C E filter use ohm meter to test continuity of cabling from C E filter to JP2 pins 3 and 1 If continuity...

Page 191: ...ep 5 Turn treadmill power 0 position Unplug power cord from wall receptacle 6 Unplug output of C E filter use ohm meter to test continuity of cabling from C E filter to JP4 pins 3 and 1 If continuity...

Page 192: ...4 J5 Emergency Stop ESB SW N C FVX TMX Manual Control FG 310 Controller PCB 1 Use Ohm Meter to test continuity from FG310 J9 to J10 with the switch in the up position 2 Isolate and repair any breaks f...

Page 193: ...speed to approximately 7 4 VDC at maximum speed 6 If voltage does not vary measure the voltage at FG 302 motor control output J3 pin 2 PWM and 5 DC GND Voltage should vary from 0 VDC at minimum speed...

Page 194: ...5 15 29 76 6 18 0 11 18 90 1 10 0 16 09 80 6 19 0 11 81 95 1 10 5 16 90 84 6 11 0 17 70 88 6 11 5 18 51 92 7 12 0 19 31 96 7 Speed V Guide 8 45 2 56m RPM S RPM S Speed Belt Length Speed Belt Length M...

Page 195: ...d or replace inverter cable as necessary 9 if voltage is not present at FG309 J3 replace FG 302 PCB Perform FVX__CP TMX__CP Incorrect Belt Speed Fault Isolation 1 Determine if the speed unit required...

Page 196: ...by 1 mile per hour 8 Once the treadmill reaches 9 5 mph each push of the button will bring the speed down 1mph 9 When minimum speed is reached the next press of the button will cause the treadmill run...

Page 197: ...TRACKMASTER 14 22 FVX TMX Series Service Manual August 2006...

Page 198: ...Tools 1 Multi meter 3 Service Manual 2 Standard Hand Tools Visual Inspection 1 Running Belt 3 Connectors 5 Handrail Hardware 2 Interface Cable 4 AC Power Cord 6 Drive Belt Cleaning 1 Handrails 2 Hood...

Page 199: ...ergency stop switch while unit is running at 3 m p h to verify operation 4 Monitor running belt tracking at 3 m p h Adjust if necessary using procedure in service manual 5 Verify speed calibration 1 m...

Page 200: ...meter 3 Service Manual 2 Standard Hand Tools Visual Inspection 1 Running Belt 3 Connectors 5 Handrail Hardware 2 Interface Cable 4 AC Power Cord 6 Drive Belt Cleaning 1 Handrails 2 Hood 3 Running Bel...

Page 201: ...rgency stop switch while unit is running at 3 m p h to verify operation 4 Monitor running belt tracking at 3 m p h Adjust if necessary using procedure in service manual 5 Verify speed calibration 1 m...

Page 202: ...TRACKMASTER August 2006 FVX TMX Series Service Manual 15 5 TMX Series Emergency Stop Button ESB Location Drawing...

Page 203: ...Sheet Please complete and return by fax to Full Vision Service Dept at 316 283 3350 Company Name Title Phone Number Fax Email Revision Sent Date Sent Address for Updates Signature of Recipient Electr...

Page 204: ...Sheet Please complete and return by fax to Full Vision Service Dept at 316 283 3350 Company Name Title Phone Number Fax Email Revision Sent Date Sent Address for Updates Signature of Recipient Electr...

Page 205: ...TRACKMASTER 15 8 FVX TMX Series Service Manual August 2006...

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