CIRCLE FITNESS M8 LED Service Manual Download

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Summary of Contents for M8 LED

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Page 2: ...Start Stop Accelerate Slow down 19 4 3 Use external Key Pad to to Control Incline 20 5 MAINTENANCE 21 5 1 General Maintenance 21 5 2 Running belt and running deck lubrication 21 5 3 How to spray silicone on deck 22 5 4 Preventive Maintenance Schedule 23 5 5 Running Belt Deck Maintenance Schedule 24 5 6 Troubleshooting the Treadmill 25 6 PART REPLACEMENT GUIDE 27 6 1 Toolkits Components Required 27...

Page 3: ...Manual Description Treadmill Model M8 LED Page 3 of 66 Release Date 2017 12 3 6 10 Hand Pulse Plate Replacement 56 6 11 Inverter Replacement 57 6 12 Incline Motor Replacement 59 6 13 Membrane and Overlay Replacement 63 ...

Page 4: ... FITNESS provides this manual primarily to assist qualified service technicians in the service of the appliance Should the reader have any questions or concerns which have not been satisfactorily addressed please call send an e mail message or write to the CIRCLE FITNESS Technical Support Department for assistance Tel 886 4 2359 1000 259 Fax 886 4 3505 5801 Email chris chang pandfbrother com CIRCL...

Page 5: ...Document Service Manual Description Treadmill Model M8 LED Page 5 of 66 Release Date 2017 12 5 1 INFORMATION FOR COMPONENTS SYSTEM 1 1 System wiring diagram ...

Page 6: ...on I O AC input TB1 P10ML 03 TKP 3 L AC input I 2 N 1 GRD Grounding 1 2 2 Definition of EMI Filter CN4 Terminal name Terminal type Terminal remark Terminal description I O EMI Filter connector XH 7P 2 5mm 180 M J2 1 FDC V O 2 FDC V O 3 RS485 Communications transmission terminal I O 4 RRS485 Communications transmission terminal I O 5 IP5V 5V power O 6 SAFE KEY Emergency stop input terminal I 7 WAKE...

Page 7: ...Incline motor connector J8 Terminal name Terminal type Terminal remark Terminal description I O Incline motor connector PCH250 Terminal J8 1 Incline motor COM terminal O 2 X X 3 Incline motor UP terminal O 4 X X 5 Incline motor DOWN terminal O 1 2 5 Definition of Incline motor position feedback J4 Terminal name Terminal type Terminal remark Terminal description I O Incline motor position feedback ...

Page 8: ... 2 Definition of J8 Heart rate Hand Pulse Connector PIN 1 2 3 4 5 Define Hand contact info Separate output Standard pulse input VCC GND 1 3 3 Definition of J1 Safety Key Connector PIN 1 2 3 Define 12V X ESP 1 3 4 Definition of J17 Fan Connector PIN 1 2 Define 12V GND 1 3 5 Definition of J3 Quick Shaft Speed Connector PIN 1 2 3 Define Fast COM 5V SLOW 1 3 6 Definition of J7 Quick Shaft Incline Conn...

Page 9: ... Description Treadmill Model M8 LED Page 9 of 66 Release Date 2017 12 9 1 3 7 Definition of J4 Bluetooth Connector PIN 1 2 3 4 Define 5V GND RS 232 Rx RS 232 Tx 1 3 8 Definition of J2 Bluetooth Connector PIN 1 2 Define 5V GND ...

Page 10: ...add lubrication non self lubricating system check the input current status Motor current output current should be the value as below user weight is lower than 100 kilogram and under 8km h New Machine Slight wear Moderate wear Need exchange Output current 5 6 7 5 7 5 2 Inverter is damaged Detecting current component of inverter is damaged if operate normally and motor current output current is in r...

Page 11: ... current output current should be at the value as below user weight is lower than 100 kilogram and under 8km h New Machine Slight wear Moderate wear Need exchange Output current 5 6 7 5 7 5 8 CALORIES TIME E10 0L The motor current is operating higher than rated 110 in a certain time which means the loading is too high should replace the running belt deck Analysis and Solution Running belt deck is ...

Page 12: ...8km h New Machine Slight wear Moderate wear Need exchange Output current 5 6 7 5 7 5 10 CALORIES TIME E02 ntcF Temperature sensor is abnormal replace the inverter 11 CALORIES TIME E13 LF Motor cable is not connected check the connection 12 CALORIES TIME E14 dbuP The brake system of inverter is damaged replace the inverter 13 INCLINE Err Incline motor won t reach the selected position Analysis and ...

Page 13: ... the Emergency stop wire Press GO to start Shows EMERGENCY STOP Reconnect the RJ45 network cable or replace it Check if the Emergency Stop button is connected properly 14 Press GO then Message window shows EMERGENCY STOP Emergency protection of inverter EMERGENCY STOP NO YES Remove the console back cover ...

Page 14: ... and TIME window shows total used distance 0 9999 km mi When total used distance is reached to 9999 it will reset to zero and DISTANCE window shows 1 Press SPEED INCLINE button to next setting Average Used Speed Depend on the unit is Metric Imperial MESSAGE window shows AVERAGE SPEED and TIME window shows the value Press SPEED INCLINE button to next setting Average Used Speed Total Used Distance T...

Page 15: ... Settings In idle mode press Clear button and press 0001 on numeric keypad then press Enter button MESSAGE window shows FACTORY SETTINGS once then provided the information below NOTE If Clear button is pressed but the number is wrong or no actions within 10 seconds it can t be login Please repeat the login process again ...

Page 16: ...setting SPEED window shows the current value MESSAGE window shows MIN SPEED press Fast Slow Up Down to change the minimum speed Press Enter to confirm and go to next setting Maximum incline setting INCLINE window shows the current value MESSAGE window shows MAX INCLINE press Fast Slow Up Down to change maximum incline setting Press Enter to confirm and go to next setting HRC Control setting Defaul...

Page 17: ...nnot be used when next powering on Setting Procedure In idle mode press Clear button and press 0400 on numeric keypad then press Enter button MESSAGE window shows LOCK TIME and TIME window shows 0 NOTE If Clear button is pressed but the number is wrong or no actions within 10 seconds it can t be login Please repeat the login process again Use numeric keypads to set password and press button to ret...

Page 18: ...4 1 External Keypad Connection and Moniter Mode 1 Connect the External Keypad KP 208 to the inverter as showing below 2 Monitor Mode Operation External Keypad Present output frequency Not available Not available Status of incline motor Not available Not available Not available Output System DC BUS Output frequency setting Output voltage ...

Page 19: ...7 12 19 4 2 Use External Key Pad to Control Start Stop Accelerate Slow down You can press PROG to login parameter page in any mode then press to select F_001 Press FUN DATA to login F_001 initial setting is 0 Press to set it 1 Press FUN DATA to save and leave Accelerate Start Stop Slow down ...

Page 20: ... Manual Description Treadmill Model M8 LED Page 20 of 66 Release Date 2017 12 20 4 3 Use external Key Pad to to Control Incline Incline present parameter Incline parameter set point Incline up Incline down Monitor mode ...

Page 21: ...the pad of the finger to press the selection buttons on the console Use a 100 cotton cloth lightly moistened with water and a mild liquid cleaning product to clean Other fabrics including paper towels may scratch the surface Do NOT use ammonia or acid based cleaners Brush away any wax deposits from the deck and belt area 5 2 Running belt and running deck lubrication Regular maintenance is necessar...

Page 22: ...ure to do so could cause injury such as cutting your hand on the edge of the belt and crushing your fingers between the rear roller and the belt Do NOT spray too much silicone on the deck It can cause the running belt to slip when in use if there is too much lubrication WARNING The running belt should be centered and adjusted within the area which has been indicated by the arrows on right roller c...

Page 23: ...y Weekly Monthly Season 6 Months 1 Console Screws Visual Inspection 2 Frame Wipe Visual Inspection 3 Surface of the Running area Clean dust Visual Inspection 4 Power Cord Visual Inspection 5 Overlay Wipe Visual Inspection 6 Handlebar Wipe Visual Inspection 7 Handlebar screws Visual Inspection 8 Front Roller Groove Wipe Visual Inspection 9 Rear Roller Visual Inspection 10 Safety Key Wipe 11 Drive B...

Page 24: ...0km 12month 15000km 15month M8 no silicone oil required no silicone oil required Detect motor current no silicone oil required no silicone oil required Motor Current List New Machine Slight wear Moderate wear Need exchange Output current 5 6 7 5 7 5 Running belt deck is worn It will cause the motor current input current to be too high it s probably in a long term of Moderate wear or Need exchange ...

Page 25: ...ard and connector point insert PINs C Check fuse near on off switch is worked or not if worked push it back and restart again if work please maintenance the running belt and deck D Turn off power then open the motor cover turn on the power and check the console power pilot lamp LED2 where on the interface PCB it shall be light completely if not replace it Refer to Chapter 5 3 1 on next page Displa...

Page 26: ...Date 2017 12 26 5 7 Check if the Console power source is damaged Open the motor housing Measure the output voltage of inverter is 12V or not No Replace inverter Open the back cover Yes Measure the input power of console PCB Replace console PCB Yes Check RS 45 cable or replace it No ...

Page 27: ...Description Treadmill Model M8 LED Page 27 of 66 Release Date 2017 12 27 6 Part Replacement Guide 6 1 Toolkits Components Required Open End Wrench T type Wrench Allen Wrenches Belt Tension Gauge Screw Driver Combination Wrench ...

Page 28: ...12 28 6 2 Drive Belt Replacement STEP 1 Remove the Motor Covers by losing the screws STEP 2 Loosen 2 Tensioning screws on the rear roller via Allen wrench Caution Don t remove the Tensioning Screws from Treadmill STEP 3 Remove the Drive Belt from the front roller pulley and motor output shaft ...

Page 29: ...66 Release Date 2017 12 29 STEP 4 Remove 2 mounting screws on the front roller STEP 5 Loosen 3 motor mounting screws on motor plate STEP 6 Remove the drive belt and pull the front roller up to replace the new drive belt STEP 7 Install the new drive belt H041031 011 PJ 692 ...

Page 30: ... front roller pulley The V belt located the front roller pulley and the sheave Grooves has 1 grooves on each edge STEP 9 Push the motor to the front roller STEP 10 Place and install motor alignment fixture The rear end of the alignment fixture is fitted into the front roller and the front edge to be tightly attached to the motor surface Secure the motor fixture bolt Adjust the motor position The m...

Page 31: ... Pull up the belt to vibrate the belt and then use the tension gauge to measure the tension value for several times To average the measurement to compare with the factory default as well as STEP 12 Secure 3 motor mounting screws on motor plate STEP 13 Secure the front roller mounting screws on both sides ...

Page 32: ...of drive belt on motor pulley and front roller pulley to be at the second groove from left hand side of the treadmill STEP 15 Put the motor cover back and secure 2 screws on motor cover to assemble STEP 16 To properly tension a new running belt using M6 torque wrench 45 kgf cm and Allen wrench Rotating the tension bolts clockwise until heard the click of torque wrench Start the treadmill and run i...

Page 33: ...age 33 of 66 Release Date 2017 12 33 6 3 Drive Motor Replacement STEP 1 Remove the Motor Covers by losing the screws STEP 2 Remove 3 motor mounting screws on motor plate STEP 3 Remove the Drive Belt from motor output shaft Keep the Drive Belt on the front roller ...

Page 34: ...7 12 34 STEP 7 Remove the ribbon cable of motor on inverter metal sheet case STEP 8 Remove the motor from the frame Cleaning up all excessive belt shavings Install new M8 Motor into the motor location space STEP 9 Place and install motor alignment fixture with the lever shifted to the left ...

Page 35: ...P 10 Place and install spacer fixture located between the motor mounting back side and the edge of frame STEP 11 Make both front roller pulley and the motor pulley to be tightly attached to the motor alignment fixture STEP 12 Re install the new motor drive belt as M8 drive belt replacement instruction ...

Page 36: ... 14 Put the motor cover back and secure 2 screws on motor cover to assemble STEP 15 To properly tension a new running belt using M6 torque wrench 45 kef cm and Allen wrench Rotating the tension bolts clockwise until heard the click of torque wrench Start the treadmill and run it at 10 km hr Counting adjusting belt until the belt maintain centered and it does not move to one side or another within ...

Page 37: ...2 37 6 4 Running Belt Replacement STEP 1 Remove the Motor Covers by losing the screws STEP 2 Loosen 2 Tensioning screws on the rear roller via Allen wrench Caution Don t remove the Tensioning Screws from Treadmill STEP 3 Remove the Drive Belt from the front roller pulley and motor output shaft ...

Page 38: ...e 2017 12 38 STEP 4 Remove 2 mounting screws on the front roller STEP 5 Loosen 3 motor mounting screws on motor plate STEP 6 Remove the drive belt and pull the front roller up to take the drive belt out of the front roller STEP 7 Remove the 4 screws on rear roller cover to disassemble ...

Page 39: ...ilips screwdriver STEP 10 Remove running deck from one side and replace new running belt Be aware of sharp edge of running deck wearing gloves at work is suggested To install new running belt place new belt with transverse direction and insert new deck through the running belt Install new running belt and deck locate on deck cushion and rubber cushion Lock and secure the deck with deck screws at 4...

Page 40: ...s Secure the front mounting screws via M6 wrench STEP 12 Place and install motor drive belt as M8 drive belt replacement instruction STEP 13 Put the rear roller cover back to position and secure screws on both sides via screwdriver STEP 14 Secure 2 tensioning screws on the rear roller STEP 15 Put the motor cover back and secure 2 screws on motor cover to assemble for complete The Rear Roller The F...

Page 41: ...otor cover to assemble STEP 17 To properly tension a new running belt using M6 torque wrench 45 kgf cm and Allen wrench Rotating the tension bolts clockwise until heard the click of torque wrench Start the treadmill and run it at 10 km hr Counting adjusting belt until the belt maintain centered and it does not move to one side or another within 5 minutes ...

Page 42: ...ate 2017 12 42 6 5 M8 Treadmill Side Rails Replacement STEP 1 Remove the Motor Covers by losing the screws STEP 2 Remove 4 screws on rear roller cover via screw driver STEP 3 Release the Side Rail Support bolts on right left sides Don t remove the Side Rail Support bolts on this step ...

Page 43: ... M8 LED Page 43 of 66 Release Date 2017 12 43 STEP 4 Remove the right left upper side rails from the treadmill STEP 5 Remove the Side Rail Support bolts via wrench and screw driver STEP 6 Remove the 2 screws on Velcro Support and remove it on both sides ...

Page 44: ...t side rails for replacement STEP 8 Place and install new side rails on both sides To make sure the Side Rail Support point on right position STEP 9 Install and secure 8 Side Rail Support bolts via wrench and screw driver NOTE Please leave gap to assemble the upper side rails Secure the 2 screws on Velcro Support to assemble ...

Page 45: ...mill NOTE The side rail support should be placed in the upper side rail groove STEP 11 Befor the upper side rails installed put rear roller cover back position Secure 4 screws on roller cover to assemble STEP 12 Pull the upper side rails back and close the roller cover to adjust the correct position Secure the Side Rail Support bolts on right left sides ...

Page 46: ...otor cover to assemble STEP 14 To properly tension a new running belt using M6 torque wrench 45 kgf cm and Allen wrench Rotating the tension bolts clockwise until heard the click of torque wrench Start the treadmill and run it at 10 km hr Counting adjusting belt until the belt maintain centered and it does not move to one side or another within 5 minutes ...

Page 47: ...ove and Replace the Quick Shift and Adjust the Tightness STEP 1 Remove the mounting screws on right left Handle Bars to disassemble Handle Bars STEP 2 Release screws to disassemble the Lower Console Base STEP 3 Remove the Mounting Screws and Washers on the quick shift assembly Mounting Screws and Washers ...

Page 48: ...STEP 5 The plastic white screw and the grub screw are used to control the tightness of the quick shift stick as figure above STEP 6 The white screw is to center the moving stick inside the quick stick assembly housing Tighten it until it meets but does not push the side surface of the moving stick If pushing too hard the moving stick will be stuck ...

Page 49: ...le on the moving stick It cannot be tightened too hard otherwise the movement of the moving stick will be improper STEP 8 In case the hinge screws are released please make sure the hinge screws are installed back with proper torque Otherwise the moving stick will be stuck as well You may try to tighten and feel the moving force and then decide to further tighten it or release the hinge screw ...

Page 50: ...Document Service Manual Description Treadmill Model M8 LED Page 50 of 66 Release Date 2017 12 50 NOTE If needed you may further dissemble the assembly as below ...

Page 51: ... 7 Align the Quick Shift to Central Position STEP 1 Measure whether the quick shift stick is in the center or not STEP 2 Unscrew the positioning screws for the quick shift assembly STEP 3 Move the quick shift assembly back or forth to center it Tighten the positioning screws to finish the adjustment ...

Page 52: ...2017 12 52 6 8 Panel of Console Replacement STEP 1 Remove seven screws on Lower Console Cover to disassemble STEP 2 Remove the cables and wires on Panel of Console STEP 3 Remove twelve screws on Panel of Console to disassemble Take the Panel out of Console Frame and replace the New Panel ...

Page 53: ...Release Date 2017 12 53 STEP 4 Take the Panel out of Console Frame and replace the New Panel Secure twelve screws on the Panel of Console to assemble STEP 5 Plug the cables and wires back into the Panel Put the Lower Console Base back and secure the seven screws for complete ...

Page 54: ...er Cover via M2 wrench Remove the Emergency Stop Lower Cover STEP 2 Remove the 4 screws on Emergency Stop Base via screw driver Remove the Emergency Stop Base Service Package and Unplug the Emergency Stop Cable to disassemble STEP 3 Place and install the on Emergency Stop Base and plug the Emergency Stop Cable into the Base to assemble Secure the 4 screws part 2 via M2 wrench ...

Page 55: ...Document Service Manual Description Treadmill Model M8 LED Page 55 of 66 Release Date 2017 12 55 STEP 4 Place and install the on Emergency Stop Lower Cover and secure 4 screws part 1 for complete ...

Page 56: ...t Left Lower Hand Pulse Plate via screw driver to disassemble STEP 2 Unplug the Hand Pulse Transfer from Upper Lower Hand Pulse Plate STEP 3 Replace and install the Hand Pulse Plate Note Read the location indication inside the Hand Pulse Plate STEP 4 Plug the Hand Pulse Transfer into Upper Lower Hand Pulse Plate Secure 4 screws to assemble the Hand Pulse Plate ...

Page 57: ...eplacement STEP 1 Remove the Motor Covers by losing the screws STEP 2 Remove the 4 screws at 4 corners via the Philips screwdriver STEP 3 Unplug the Cable Wire Motor Core Wire Fan Wire Incline Motor Wire and EMI Filter Wire from the Inverter Replace and install the new Inverter and secure the 4 screws to assemble ...

Page 58: ... Service Manual Description Treadmill Model M8 LED Page 58 of 66 Release Date 2017 12 58 STEP 4 Plug the Cable Wire Motor Core Wire Fan Wire Incline Motor Wire and EMI Filter Wire into the Inverter for complete ...

Page 59: ...eplacement STEP 1 Turn on the power of the treadmill and adjust the incline level to maximum STEP 2 Place a sturdy objects under the treadmill and life the treadmill to keep balance Turn the power switch to OFF position STEP 3 Unscrew bottom bolt and screw on threaded rod of incline motor via M17 wrench and remove it ...

Page 60: ...age 60 of 66 Release Date 2017 12 60 STEP 4 Remove top bolt and screw on the top incline motor via 17 wrench STEP 5 Unplug the Black Red and White connector on inverter and Green wire on the frame STEP6 Remove the inlcine motor and replace the new inlcine motor ...

Page 61: ...utomatically if its not at the zero position VR on incline 0 STEP8 Install the incline motor and reattach to secure the top bolt screw and washers release 1 4 turn for better movement STEP9 The gap between Mainframe and the Cushion on incline motor will be 3mm to 5mm NOTE If this step is not done the incline motor might get jammed when it is powered on by the inverter and console You may refer the...

Page 62: ...f incline motor via M17 wrench to assemble Secure the Top bolt and screw should be fully tightened STEP11 Switch on the power and raise the incline level to remove the support sturdy objects Check no items on the treadmill and press STOP to restore the incline level Put the motor cover back and secure 2 screws on motor cover to assemble for complete ...

Page 63: ...iption Treadmill Model M8 LED Page 63 of 66 Release Date 2017 12 63 6 13 Membrane and Overlay Replacement STEP 1 Remove seven screws on Lower Console Cover to disassemble STEP 2 Release screws to disassemble the Lower Console Base ...

Page 64: ...e of membrane on the PCB of console STEP 4 Remove the faulty membrane and overlay on Console Clearing the Upper Console surface with alcohol to remove any left over adhesive STEP 5 Insert the flexible flat cable of membrane into the hole of the upper console Remove the protective film from the back of the membrane and paste it STEP 6 ...

Page 65: ... Model M8 LED Page 65 of 66 Release Date 2017 12 65 Plug the flexible flat cable of membrane back on the PCB of console and plug it in STEP 7 Remove the protective film from the back of the Upper Overlay and Lower Overlay and paste on the console ...

Page 66: ...on Treadmill Model M8 LED Page 66 of 66 Release Date 2017 12 66 STEP 8 Put the Lower Console Base back and secure the mounting screws to assemble Put the Lower Console Cover back and secure the mounting screws to assemble for complete ...

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CIRCLE FITNESS M8 LED, Service Manual

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