Vision Fitness Vision Series Page 65 Service Manual Download

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MOTOR BEARINGS & CARBON BRUSH REPLACEMENT

Tools required:

Nutdriver (10mm, 11mm)

Bearing puller

Wooden-hammer

Procedure:

Remove the bearings at both sides of the shaft by using bearing puller.

Install the new bearings to the shaft by using wooden-hammer.

Install the two end caps and use the nutdriver (10mm, 11mm) to lock the caps to
the main enclosure.

Install the carbon brush and the carbon brush cover.

(The end of the procedure.)

10.

Replace the carbon brush with a new one.

11.

Install the carbon brush and the carbon brush cover.

12.

Turn the power on, let the treadmill run for about 1 hours at 3.0 kph.

7-15 Revision: 1.0 Date: 2001-06-01

Summary of Contents for Vision Series

Page 1: ......

Page 2: ... 3 WIRING DIAGRAM o WIRING DIAGRAM TERMINAL END T7200 7400 3 1 o WIRING DIAGRAM MCB T7200 7400 3 2 o WIRING DIAGRAM TERMINAL END T8200 8400 8500 3 3 o WIRING DIAGRAM MCB 110v T8200 8400 8500 3 4 o WIRING DIAGRAM MCB 220v T8200 8400 8500 3 5 o WIRING DIAGRAM MCB T8600 3 6 n SECTION 4 CONSOLE ENGINEERING MODE GUIDE o HRC CONSOLE ENGINEERING MODE GUIDE 4 1 o NON HRC CONSOLE ENGINEERING MODE GUIDE 4 2...

Page 3: ...T7400 8400 8500 8600 7 1 o MCB T7200 8200 7 2 o CONSOLE CONTROL BOARD T7400 8400 8500 8600 7 3 o CONSOLE CONTROL BOARD T7200 8200 7 4 o KEY PAD T7400 8400 8500 8600 7 5 o KEY PAD T7200 8200 7 6 o RUNNING BELT DECK ROLLER T7200 8200 7 7 o RUNNING BELT DECK ROLLER T7400 8400 8500 8600 7 8 o MOTOR T7200 8200 7 9 o MOTOR T7400 8400 8500 8600 7 10 o INCLINE MOTOR T7200 8200 7 11 o INCLINE MOTOR T7400 8...

Page 4: ...SECTION 1 MAINTENANCE PROCEDURE ...

Page 5: ...ct 3 Carbon Brush Inspect Replace Power Cord Inspect Display Console Clean Inspect Handlebar Clean Inspect Handrail Handlebar Inspect Front Roller Clean Inspect Rear Roller Inspect Emergency Button Test Tension Wheel Inspect V Belt Clean Inspect Deck Re waxing Inspect Re waxing Running Belt Inspect Control Box Clean Vacuum Motor Clean Air Shock Lubricate 1 1 Revision 1 0 Date 2001 06 01 ...

Page 6: ...th the rear rollers Allen bolts 1 4 TURN as shown above Try the treadmill again to check for slipping Repeat if necessary but NEVER TURN the roller bolts more than 1 4 turn at a time Drive Belt If you have tensioned the running belt and are still experiencing a slipping adjust the tension screw Then try the treadmill again to check for slipping P Pe er rf fe ec ct t T Te en ns si io on n o o f f R...

Page 7: ...ight hand The volume of silicon applied is about 25CC 3 Tighten the tension bolts 4 Start the treadmill Step on the treadmill belt to walk the silicon in Adjust the belt tension if necessary 5 With the clamp on meter measure the current draw of the motor Clamp on either the red or the black wire The current should be less than 15Amps for 110V model less than 7 5Amps for 220V model 1 3 Revision 1 0...

Page 8: ...rooves in belt for dirt or dust and clean it 2 Check the grooves in motor pulley for dirt or dust and clean it 3 Check the grooves in roller pulley for dirt or dust and clean it If dirty grooves in the drive belt motor and roller pulley there will be noises while running 1 4 Revision 1 0 Date 2001 06 01 ...

Page 9: ...Fold up and engage the frame to the left support by using the deck locking knob 2 Add the lubricating oil on the shaft of the air shock 3 Lift the frame up and down repeating this several times to allow the lubricating oil blend into air shock 1 5 Revision 1 0 Date 2001 06 01 ...

Page 10: ...SECTION 2 IMPORTANT SAFETY INSTRUCTIONS ...

Page 11: ...lectrical shock This product is equipped with a cord having an equipment grounding conductor and a grounding plug The plug must be plugged into an appropriate outlet that is properly installed and grounded in accordance with local codes and ordinances DANGER Improper connection of the equipment grounding conductor can result in a risk of electric shock Check with a qualified electrician of service...

Page 12: ...SECTION 3 WIRING DIAGRAM INSTRUCTION ...

Page 13: ... H1 G1 AC1 of MCB Ø B2 Ground G3 AC2 of MCB Ø B3 G2 G4 H2 WIRING DIAGRAM TERMINAL END CE T7200 7400 INPUT POWER ON OFF SWITCH BREAKER Ø A1 I1 Ø A2 Ground Ø A 3 G2 Ø G1 B3 Ø G3 B4 ØG4 I2 ØB1 O1 ØB2 AC1 of MCB ØB5 Ground ØO2 AC2 of MCB CHOCK FILTER 3 1 Revision 1 0 Date 2001 06 01 ...

Page 14: ...ire red Ø T2 Motor wire black Ø T3 G1 of on off switch CE B2 of Filter Ø T4 G3 of on off switch CE O2 of Chock Ø T5 Elevation cable Ø T6 8 pin console cable Ø T7 6 pin console cable Ø T8 speed sensor cable Fuse 3 2 Revision 1 0 Date 2001 06 01 ...

Page 15: ... Ø A1 D2 M1 N1 Ø A2 Ground M2 F1 Ø A3 Q1 M5 Ground Ø Q2 D4 F2 N2 Ø D1 M3 N3 AC1 of MCB Ø D3 M4 N4 AC2 of MCB WIRING DIAGRAM TERMINAL END Ø A1 D2 D4 Q2 Ø A2 Ground D1 AC1 of MCB Ø A3 Q1 D3 AC2 of MCB 3 3 Revision 1 0 Date 2001 06 01 ...

Page 16: ...B 110V T8500 8400 8200 Ø T1 Motor wire black Ø T2 Motor wire red Ø T3 D1 of on off switch Ø T4 D3 of on off switch Ø T5 8 pin console cable Ø T6 Elevation cable Ø T7 6 pin console cable 3 4 Revision 1 0 Date 2001 06 01 ...

Page 17: ...1 Motor wire black Ø T2 Motor wire red Ø T3 CE N3 of Capacitor Non CE D1 of on off switch Ø T4 CE N4 of Capacitor Non CE D3 of on off switch Ø T5 8 pin console cable Ø T6 Elevation cable Ø T7 6 pin console cable 3 5 Revision 1 0 Date 2001 06 01 ...

Page 18: ... wire black Ø T2 Motor wire red Ø T3 CE N3 of Capacitor Non CE D1 of on off switch Ø T4 CE N4 of Capacitor Non CE D3 of on off switch Ø T5 8 pin console cable Ø T6 Elevation cable Ø T7 6 pin console cable 3 6 Revision 1 0 Date 2001 06 01 ...

Page 19: ...SECTION 4 CONSOLE ENGINEERING MODE GUIDE ...

Page 20: ...r T 8500 T 8400 T 8200 is 5 0ml 7 5kl For T 8600 is 6 0ml 9 0kl u Press ENTER SELECT key to store P4 min elevation u Press ENTER SELECT key to store P5 max elevation uPress ENTER SELECT key to store P7 max time 99 u Press ENTER SELECT key to store P8 user weight 80 kg or 150 lb uPress ENTER SELECT key to store Press UP or DOWN key to reach P0 P8 address Press SLOW or FAST key to choose unit Press ...

Page 21: ... The display should read 1 Turn power on then remove the safety key from the console 2 Press and hold down the UP and SLOW key 3 Place the safety key back on the console 4 The display should read 1 Turn power on then place the safety key on the console 2 Press and hold down the UP and SLOW keys about 7 seconds 3 The display should read OR 1st revision 2nd revision 3st revision 4 2 Revision 1 0 Dat...

Page 22: ...s the UP key to reach the P1 address 4 Pressing the FASTor SLOWkey and using a tachometer to adjust the speed of the treadmill to 10 0mph 15 0 kph 12 0mph 18 0 kph for T8600P Press the SELECT key to store Press the START key to calibrate IV To set elevation values 1 Press the UP key to reach the P4 address 2 Press and hold down the SLOWkey until the deck goes to the minimum incline Press FAST key ...

Page 23: ...SECTION 5 MCB LED INSTRUCTIONS ...

Page 24: ...T7200 7400 MCB LED Layout T8200 8400 8500 MCB LED Layout T8600 MCB LED Layout 220V 110V 220V 110V 220V 110V 5 1 Revision 1 0 Date 2001 06 01 ...

Page 25: ...direct current supply necessary for the operation of the MCB circuitry If dim the supply voltage may be marginal and if out not present or inadequate If this light is not lit the MCB will not operate even if the PCB is operating properly If the AC light is lit and the 11V and 18V light are not check fuse F1 If the 11V light is lit and the 18V light is not lit return the board to JMI Light When lit...

Page 26: ...ear or damaged components which might have lead to the extended current limit condition If this problem persists return the board to JMI Light When lit indicates the current to the motor has reached the peak current trip point of 26 Amps The MCB will limit the current when the current limit point has been reached If the current limit continues for roughly 5 seconds the MCB shuts down and the I Lim...

Page 27: ...e is not moving check and verify incline motor and its connection to the board check fuse F2 If this problem persists replace MCB Light Indicates the PCB is commanding the incline motor to move down If the User is commanding the incline to decrease and this light is not lit check cabling verify proper PCB operation and replace it if either is defective If the problem persists replace the MCB If th...

Page 28: ...ON OFF ON OFF OFF OFF OFF OFF 5 ON ON ON OFF OFF OFF OR BLINKING N A N A 6 ON ON ON DIM OFF ON BLINKING N A N A 7 ON ON ON ON ON BLINKING N A N A 8 ON ON ON ON OFF COMES ON BRIEFLY THEN SHUTS OFF N A N A 9 ON ON ON ON OFF N A ON OFF 10 ON ON ON ON OFF N A ON OFF 11 ON ON ON ON OFF N A OFF ON 12 ON ON ON ON OFF N A OFF ON 5 3 Revision 1 0 Date 2001 06 01 ...

Page 29: ... VCD to the motor leads and spinning the tread and observing a voltage If no voltage Bad motor 6 Will not operate the motor A 5 second current limit time out has occurred Resets console or cycle power to correct Check treadmill for excessive wear or mechanical defects If problem persists return MCB 7 MCB in current limit mode The MCB is experiencing a discontinuous over current events Check for me...

Page 30: ...SECTION 6 TROUBLESHOOTINGS ...

Page 31: ...ircuit breaker to see if it has tripped off If it is tripped off like diagram B reset the breaker And check which part is short circuited Then replace the short circuited part 2 The switch is turned to the ON position If the switch light isn t lit replace the switch u Verify wire connection AC1 AC2 on the MCB refer to wiring diagram u Verify the ON OFF switch breaker socket wires are connected 3 V...

Page 32: ...r to see if it is within 120V 15 or 230V 15 u If the power voltage isn t within the range look for a qualified electrician for help 2 Open the motor cover if the belt has stretched and is slipping across the rollers when running u Adjust the belt tension 3 Remove the motor cover and run the machine at low speed then adjust the IR COMP of MCB u If it hasn t been improved replace new MCB 4 Replace n...

Page 33: ...ole cable with a new one 2 Replace the PCB 3 Replace the MCB All or some of the keys on console do not work Possible causes 1 Keypad connecting plug is not fit in properly 2 Keypad is damaged 3 PCB is damaged Fix 1 Disconnect the keypad and replace the keypad and check again 2 Replace the keypad 3 Replace the PCB 6 3 Revision 1 0 Date 2001 06 01 ...

Page 34: ...ill run without using it for at least 5 days because sometimes the bearing will settle and become quiet then check if the noise has disappeared 2 Replace the front roller with a new one to see if the noise disappear 3 Remove drive belt and check the grooves in belt for dirt or dust and clean if necessary Clean also the motor pulley and the roller pulley grooves and check if the noise has disappear...

Page 35: ... connection MTR1 and MTR2 on the MCB then plug in the power cord and turn on the power switch Then press START button 1 Verify the LED indicator of MTR is lit If that LED MTR is not lit replace MCB 2 Verify if LED PWM is lit if it is not lit replace 8 pin console cable 3 If LED PWM is still not lit replace PCB 4 Replace Motor 6 5 Revision 1 0 Date 2001 06 01 ...

Page 36: ...new 8 pin console cable to connect PCB and MCB Then press FAST and SLOW key to see if the incline motor will be activated 2 OR Replace the incline motor 3 OR Replace PCB 4 OR Replace MCB u In the P5 of Engineering Mode Then press FAST and SLOW key to verify if the number in the left window varies as the elevation changes u OR Ø Replace 8 pin cable and check Ø Replace incline motor and check Ø Repl...

Page 37: ... Problem Result E1 EEPROM error total checksum E2 EEPROM error individual checksum E3 speed position is outside the range E4 elevation range is too short E5 incline stall condition E6 signal of elevation is lost 6 7 Revision 1 0 Date 2001 06 01 ...

Page 38: ...Fix 1 Re calibrate the parameters from P0 to P6 then check again 2 Replace PCB Error Message E3 on the Console Possible cause 1 Speed is out of range 2 PCB is damaged Fix 1 Enter the engineering mode to re calibrate the speed 2 Replace PCB 6 7 Revision 1 0 Date 2001 06 01 ...

Page 39: ...e calibrate the elevation 2 Replace PCB Error Message E5 on the Console Possible cause 1 Range of elevation is not proper 2 PCB is damaged Fix 1 Enter the P4 P5 of Engineering Mode1 to recalibrate the incline u If the elevation is stuck at either end release the pipe before the calibration 2 Replace PCB 6 7 Revision 1 0 Date 2001 06 01 ...

Page 40: ...pin cable has not been connected well 3 damaged PCB 4 damaged MCB 5 damaged elevation motor Fix 1 Replace the 8 pin cable 2 Verify the connections of the 6 pin AMP plug of the elevation motor and the 8 pin console cable 3 Replace the PCB 4 Replace the MCB 5 Replace the elevation motor 6 7 Revision 1 0 Date 2001 06 01 ...

Page 41: ...st very well 2 Transmitter Polar belt is at low battery status 3 Transmitter Polar belt is damaged 4 Heart rate control board is damaged 5 PCB is damaged Fix 1 Center the transmitter on your chest below the pectoral muscle breast as shown then check again 2 Remove the battery cover of the transmitter Replace a new battery and check again u Actually as moisture may activate the transmitter please d...

Page 42: ...SECTION 7 PARTS REPLACEMENT PROCEDURE ...

Page 43: ...es and wires connecting to the MCB 3 With the screwdriver remove the MCB 4 Replace the MCB and tighten the screws holding the MCB to the frame 5 Reconnect all the cables and wires to the MCB by referring to the wiring diagram 6 Enter the engineering mode recalibrate the speed of the treadmill 7 Install the motor cover 7 1 Revision 1 0 Date 2001 06 01 ...

Page 44: ...d up and engage the frame to the left side support by using deck locking knob 3 Remove the motor cover 4 Disconnect the cables from connected the MCB 5 With the screwdriver loosen MCB and remove it 6 Replace the MCB with a new one and tighten the screws holding the MCB to the frame 7 Reverse step 1 4 to install all parts 7 2 Revision 1 0 Date 2001 06 01 ...

Page 45: ...crews of the handle bar Then remove the handle bar 2 Loose the screws of the console upper cover Then Knock the console upper cover carefully and remove it 3 Unplug the cables connecting to the PCB 4 With the screwdriver remove the PCB 5 Replace the PCB with a new one 6 Reverse step 1 4 to install all parts 7 3 Revision 1 0 Date 2001 06 01 ...

Page 46: ...dure 1 With the screwdriver loose the screws of the console bottom pate Then remove it 2 Unplug the cables connecting to the PCB 3 With the screwdriver remove the PCB 4 Replace the PCB with a new one 5 Reverse step 1 3 to install all parts 7 4 Revision 1 0 Date 2001 06 01 ...

Page 47: ...ue on the console thoroughly 4 Replace the keypad and plug the new keypad with the PCB 5 Install the console upper cover and tighten the screws 6 Tear off about 2 cm wide of the protective paper on the backside of the overlay align the overlay to the top of the console press the overlay firmly on the portion with no paper on the backside then tear the remaining paper slowly Press the overlay down ...

Page 48: ...le thoroughly 4 Replace the keypad and plug the new keypad with the PCB 5 Install the console upper cover and tighten the screws 6 Tear off about 2 cm wide of the protective paper on the backside of the overlay align the overlay to the top of the console press the overlay firmly on the portion with no paper on the backside then tear the remaining paper slowly Press the overlay down to the console ...

Page 49: ...screws from the front top cover by using the screwdriver and remove it 2 Fold up and engage the frame to the left support by using the deck locking knob 3 Loosen the screws from the motor cover with the screwdriver Then lower down the frame 4 Loosen the screws from the rear top cover and remove it 7 7 Revision 1 0 Date 2001 06 01 ...

Page 50: ...the pulley of the front roller by using your right hand 7 Loosen the screws from the front and rear rollers remove the front roller and rear roller If replacing the roller go to step 13 8 Loosen the 8 screws holding the deck to the frame then remove the deck with the running belt If replacing the running deck go to step 11 9 Remove the fix plate with screwdriver 10 Replace the deck and tighten the...

Page 51: ... then assemble the front roller 16 Turn the flywheel clockwise with your left hand and place the drive belt onto grooves of the front roller pulley with your right hand 17 Install the front and rear rollers and adjust the belt tension screw such that you can only press with your thumb the belt down 1cm 1 5cm 18 Install the front rear rollers Adjust the running belt tension screw to center the runn...

Page 52: ...iver ü T handle key 6mm 5mm Procedure 1 Remove the screws from the front cover by using the screwdriver 2 Remove two rear plates from the end of the side rails 3 Pull out the two side rails 4 Elevate the machine to a proper height for removing the front roller 7 8 Revision 1 0 Date 2001 06 01 ...

Page 53: ... bolts from the front and rear rollers by using the T handle key 8mm 7 Remove the front roller drive belt and rear roller If replacing the roller go to step 12 8 Remove the 8 screws holding the deck to the frame then remove the deck with the running belt If replacing the running deck go to step 11 9 Remove the deck extension with screwdriver 10 Replace deck and tighten the deck extension then inst...

Page 54: ...emble the rear roller first then assemble the front roller 15 Place the drive belt on the transmission pulley by turning the flywheel clockwise by using left hand and place the drive belt on to grooves of the front roller pulley by using your right hand 16 Install the front rear rollers Adjust the running belt tension bolts to center the running belt at high speed 17 Try to step on the belt to che...

Page 55: ...er by using the screwdriver and remove it 2 Fold up and engage the frame to the left support by using the deck locking knob 3 With the screwdriver loosen the screws of the motor cover and remove it 4 Remove cables connecting to the upper and lower board remove also the ground wire by using screwdriver 7 9 Revision 1 0 Date 2001 06 01 ...

Page 56: ...e 7 Adjust belt tension adjusting screw located at bottom of the mounting bracket such that one can only push with one s thumb the drive belt down about 1 1 5cm then tighten the motor mount screws 8 Reconnect cables and the ground wire by referring to the wiring diagram and install all the covers 9 Turn the power on and enter the engineering mode to check if the extreme speeds are within the corre...

Page 57: ...ent can be made 6 Place the drive belt on the transmission pulley turn the flywheel clockwise by using your left hand and place the drive belt on to grooves of the front roller pulley 7 Adjust the belt tension adjusting screw until the tension is within 80 90lbs 8 Tighten the motor mount screws remark1 9 Reconnect cables and the ground wire 10 Turn on the power and enter the Engineering Mode to ch...

Page 58: ...r to open the cover 2 Fold up and engage the frame to the left support by using deck locking knob 3 Use screwdriver to loosen the screws from the motor cover and remove it 4 Use screwdriver to loosen the screws from the elevation assembly cover and remove it 5 Disconnect cables connecting to the incline motor and lower board 7 11 Revision 1 0 Date 2001 06 01 ...

Page 59: ...n the bolts from both ends of the incline motor by using wrench 17mm 7 Replace the incline motor 8 Reverse the step 6 5 9 Turn on the power and enter the Engineering Mode to check if the extreme speeds are within the correct range 11 Put on the covers and secure the screws 7 11 Revision 1 0 Date 2001 06 01 ...

Page 60: ...ling down heavily while removing the incline motor put a support with proper height under the front of frame 4 Remove the bolts and the nuts from the incline motor by using the wrenches 14 17 5 Replace the incline motor with a new one 6 Reconnect cables and the grounding wire to the connectors and the frame 7 Remove the support under the frame 8 Turn on the power and enter the Engineering Mode to ...

Page 61: ... the screwdriver and remove it 2 Fold up and engage the frame to the left support by using deck locking knob 3 With the screwdriver loosen the screws from the motor cover and remove it 4 With the screwdriver remove the console bottom plate then disconnect the console cable from the PCB and MCB Lower down the frame 7 13 Revision 1 0 Date 2001 06 01 ...

Page 62: ...il 6 Remove the snap bushing Tie the new console cable to the old one with a solid string at the rear end 7 Pull the old cable from the top end of the cable until the new cable treads all the way through the right support 8 Install the right hand rail and tighten the screws 9 Reconnect the console cable to PCB and MCB 10 Install all covers and secure the screws 7 13 Revision 1 0 Date 2001 06 01 ...

Page 63: ... the PCB and MCB 4 Remove screws of the left handle bar with the T handle key 5mm 5 Tie the old cable to the new one with a rigid string 6 Pull the old cable from the top end until the new cable threads all the way through the left support and the console 7 Connect the console cable to PCB and MCB 8 Install the console cover and handle bar middle left then tighten the screws 9 Install the front co...

Page 64: ...brush is smooth u If the surface of carbon brush is pitted rough or with burn marks replace the carbon brush If replacing the carbon brush go to step 10 3 Prior to disassembling the end caps you must make a mark on the end cap 4 Use the nutdriver 10mm 11mm to remove bolts from the end caps 5 Tap the shaft carefully with a wooden hammer to remove the end caps 7 15 Revision 1 0 Date 2001 06 01 ...

Page 65: ...gs to the shaft by using wooden hammer 8 Install the two end caps and use the nutdriver 10mm 11mm to lock the caps to the main enclosure 9 Install the carbon brush and the carbon brush cover The end of the procedure 10 Replace the carbon brush with a new one 11 Install the carbon brush and the carbon brush cover 12 Turn the power on let the treadmill run for about 1 hours at 3 0 kph 7 15 Revision ...

Page 66: ...king knob 2 Use wrench 13mm to loosen screws holding air shock to the frame and remove the air shock 3 Replace with a new air shock 4 Add some lubricating oil on the shaft of the air shock 5 Lift the frame up and down repeating this several times to allow the lubricating oil blend into air shock 7 16 Revision 1 0 Date 2001 06 01 ...

Page 67: ...SECTION 8 SERVICE FORM ...

Page 68: ...2 Light T8900 LED On LED On LED Off LED Off When you press the UP or DOWN key the LED status is Up Light Dn Light LED On LED On LED Off LED Off These LEDs are only for T 8900 MCB In order to fill out this Report properly please use the PWM MCB CHART and MCB LED aided troubleshooting which you can find in the Service Manual Please fill out this Report at the moment before repairing the problem Seri...

Page 69: ...uct Serial number Failure Symptom Pls refer to the service manual for the symptom of failure Cause of Failure Parts Replaced Suggestions to prevent Failure When parts needed please fill out a Parts Order Form as detailed as possible Date Place Prepared By Company Stamp 8 2 Revision 1 0 Date 2001 06 01 ...

Page 70: ...ddress FCA FOB Warranty Yes No Product Serial number Product Drawing Part Number Part Name Qty Remark Please refer to the spare part kit for all the information that are to be filled out above Date Place Signature Company Stamp 8 3 Revision 1 0 Date 2001 06 01 ...

Page 71: ...Warranty Claim Form Claim no Dealer Name Page of Pages MODEL SERIAL NUMBER DESCRIPTION OF DEFECT PARTS QTY AUTHORIZED BY 8 4 Revision 1 0 Date 2001 06 01 ...

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