Dyaco FT98A-YT41 Service Manual Download

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FT98A-YT41

Treadmill

Service Manual

Summary of Contents for FT98A-YT41

Page 1: ...FT98A YT41 Treadmill Service Manual ...

Page 2: ...r Board LED Indicator Locations 6 6 Controller Indicator LED Debugging 6 7 Driver Board Function 6 8 Main connector of the console 7 Product Safety Instructions 7 1 Important Safety Instructions 7 2 Important Electrical Instructions 7 3 Important Grounding Instructions 8 Error Messages Troubleshooting for Electronic Issues 8 1 Error Message LS1 LOW SPEED 8 2 Error Message E1 8 3 Circuit Diagram 8 ...

Page 3: ...rts 12 1 Lower Controller Replacement 12 2 Console Replacement 12 3 Motor Replacement 12 4 Breaker Replacement 12 5 AC Power Switch Replacement 12 6 Front Rear Roller Replacement 12 7 Running Deck Belt Cushion Replacement 12 8 Speed Sensor Replacement 12 9 Incline Motor Replacement ...

Page 4: ...S Se er rv vi ic ce e M Ma an nu ua al l 3 ...

Page 5: ...S Se er rv vi ic ce e M Ma an nu ua al l 4 1 FT98A Treadmill Outlines ...

Page 6: ...S Se er rv vi ic ce e M Ma an nu ua al l 5 Console Incline adjustment button Speed adjustment button Hand Pulse Sensor ...

Page 7: ...S Se er rv vi ic ce e M Ma an nu ua al l 6 Lower Controller Incline Motor Driving Motor ...

Page 8: ...S Se er rv vi ic ce e M Ma an nu ua al l 7 ...

Page 9: ...S Se er rv vi ic ce e M Ma an nu ua al l 8 2 Electronic Parts ...

Page 10: ...S Se er rv vi ic ce e M Ma an nu ua al l 9 2 1 Upper Controllers DISPLAY Hand Pulse Heart Sensors Hand Pulse Heart Sensors ...

Page 11: ...S Se er rv vi ic ce e M Ma an nu ua al l 10 2 2 Lower Controller and Driver DC MOTOR Motor Controller INCLINE MOTOR ...

Page 12: ...S Se er rv vi ic ce e M Ma an nu ua al l 11 3 Electrical Configurations ...

Page 13: ...for console incline driver and DC motor driver link the console to output appropriate voltages for motor that control the treadmill functions TREADMILL MOTOR This is a variable speed for DC motor To control the 0 180 230VAC or 0 90 120VAC voltages on the main controller it can to increase or decrease speed of running belt GENERAL INFORMATION CONSOLE Contains Key controls and LCD Display Main contr...

Page 14: ...se The higher the voltage the faster the motor turns The green wire is ground NOTICE BEFORE OPERATION The treadmill will increase or decrease speed slowly It means that it will take you a little time to reach the speed you adjusted When you work on the treadmill you must check the emergency switches both on left and right side are turned on and turn around the switch to check it is off Also check ...

Page 15: ...S Se er rv vi ic ce e M Ma an nu ua al l 14 4 FT98A Treadmill Product Operation ...

Page 16: ...S Se er rv vi ic ce e M Ma an nu ua al l 15 Display Windows LCD Function display locations LCD Display ...

Page 17: ... enter OFF Mode Function SPEED Display the current speed in Kilometer or Mile per hour DISPLAY range is 0 00 to 99 9 km h WORK range is 1 0 to 16 0 km h 0 6 10MPH Press FAST or SLOW to adjust speed each increment and decrement is 0 1 km h mph TIME TIME is either COUNT UP or COUNT DOWN DISPLAY range is 0 00 to 99 99 WORK range is 0 00 to 99 59 COUNT DOWN setup range is 10 00 to 99 00 In RUN Mode pr...

Page 18: ...ays the heart rate beat by using hand pulse or receiver When use receiver a chest belt must be worn DISPLAY range is 0 to 999 WORK range is 30 to 210 In RUN Mode if the treadmill doesn t have a signal for 8 seconds then display value will become no display ...

Page 19: ... 2 3 4 5 6 7 8 9 10 FAST Slow Key Adjustment Speed Enter Key Set data function STOP Key End workout Safety Key Emergency function Incline quick keys 1 2 3 4 5 6 7 8 9 10 PROGRAM Key Choose Program Up down Key Adjustment incline START Key To workout Select Key Switch Speed or Grace profile ...

Page 20: ... to change each function MANUAL can set using time Pre set PROGRAM can set using time and speed FAST button If user doesn t enter a setting then this button is non functional SLOW button If user doesn t enter a setting then this button is non functional PROGRAM button While program setting pressing this button changes the PROGRAM with the sequence as below P0 P1 P2 P3 P4 P5 USER1 USER2 HRC1 HRC2 _...

Page 21: ...e FAST button Press the button to increase your speed and each increase is 0 1kph If button is pressed continuously then speed increases to MAX SPEED quickly SLOW button Press the button to decrease your speed and each decrease is 0 1kph If button is pressed continuously then speed decreases to MIN SPEED quickly SPEED RAPID button Speed will set to 1kph MPH 2kph MPH 3kph MPH 4kph MPH 5kph MPH 6kph...

Page 22: ...S Se er rv vi ic ce e M Ma an nu ua al l 21 5 FT98A Treadmill Unit Block Diagrams ...

Page 23: ...S Se er rv vi ic ce e M Ma an nu ua al l 22 Treadmill Configuration ...

Page 24: ...S Se er rv vi ic ce e M Ma an nu ua al l 23 6 FT98A Treadmill Basic Connections and Wiring ...

Page 25: ...S Se er rv vi ic ce e M Ma an nu ua al l 24 6 1 Display Board wire Connections ...

Page 26: ...S Se er rv vi ic ce e M Ma an nu ua al l 25 6 2 Display Board PCB Component Locations PCB Board Top ...

Page 27: ...S Se er rv vi ic ce e M Ma an nu ua al l 26 PCB Board Bottom ...

Page 28: ...S Se er rv vi ic ce e M Ma an nu ua al l 27 6 3 Driver Board Wire Connections ...

Page 29: ...S Se er rv vi ic ce e M Ma an nu ua al l 28 6 4 Driver Board PCB Component Locations ...

Page 30: ...LIMIT THE CURRENT OF DC MOTOR NO LIT NORMAL LIT OVER CURRENT CONTROLLER SHUT DOWN NO LIT NORMAL LIT SHUT DOWN MOTOR DRIVER LED LIT POWER ON NOT LIT NORMAL POWER DICATOR LIT VCC POWER CIRCUIT ON PWM SIGNAL INDICATOR FLASHED LIT WHEN MOTOR IS DRIVE SPEED Indicator Incline UP Incline DOWN ...

Page 31: ...S Se er rv vi ic ce e M Ma an nu ua al l 30 6 6 Controller Indicator LED debugging ...

Page 32: ... 31 6 7 Driver Board function M 0 180Vdc TO MOTOR RED WIRE M 0 180Vdc TO MOTOR BLACK WIRE TORQUE SPEED SENSOR CONNECTION TO CONSOLE Transformer ACL 110VAC IN ACN 110VAC IN NCLINE VR INCLINE POWER WHITE INCLINE POWER BLACK INCLINE POWER BLACK ...

Page 33: ...S Se er rv vi ic ce e M Ma an nu ua al l 32 6 8 Main connector of the console DRIVER CABLE ...

Page 34: ...S Se er rv vi ic ce e M Ma an nu ua al l 33 7 Product Safety Instructions ...

Page 35: ... control This part is available through most electrical supply stores Examples Grainger part 1D237 or available online at www squared com part QO120HM 7 3 Important Grounding Instructions This product must be grounded If the treadmill should malfunction or breakdown grounding provides a path of least resistance for electric current reducing the risk of electric shock This product is equipped with ...

Page 36: ...S Se er rv vi ic ce e M Ma an nu ua al l 35 8 FT98ATreadmill Error Messages Troubleshooting for Electronic Issues ...

Page 37: ... l 36 Error code items Error Message Explain LS1 Display board CPU did not receive the RPM signal Err The console board is not detecting the VR voltage value or the voltage value has exceeded the range Prepare Picture Tool name Multi meter ...

Page 38: ...S Se er rv vi ic ce e M Ma an nu ua al l 37 8 1 Error Message LS1 LOW SPEED Definition Display board CPU did not receive the RPM signal Configuration ...

Page 39: ...l l 38 Cause of LS1 LOW SPEED The motor doesn t turn LS1 LOW SPEED appears Explanation The drive board did not sent voltage to the motor so the motor didn t operate And the display board didn t receiver the RPM sensor signal Configuration ...

Page 40: ...S Se er rv vi ic ce e M Ma an nu ua al l 39 LCD display show LS1 ...

Page 41: ...S Se er rv vi ic ce e M Ma an nu ua al l 40 LS1 LOW SPEED solution follow chart ...

Page 42: ...S Se er rv vi ic ce e M Ma an nu ua al l 41 Terminals for motor cable Red for M Black for M PWM LED POWER LED ...

Page 43: ...S Se er rv vi ic ce e M Ma an nu ua al l 42 LS1 LOW SPEED solution follow chart check RPM sensor device procedure ...

Page 44: ...otor The speed sensor is small and black with a wire connected to it 3 Make sure the sensor is as close as possible to the pulley without touching it You will see a magnet on the face of the pulley make sure the sensor is aligned with the magnet There is a screw that holds the sensor in place that needs to be loosened to adjust the sensor Re tighten the screw when finished Reed switch RPM Speed se...

Page 45: ...nnection for cables The speed sensor didn t detect signal completely Check the gap between speed sensor and magnet To keep the gap distance less than 3 mm Defective sensor or bad cable connection Check if the sensor and cables are circuit short damaged Change the sensor or cables The motor can not move The motor can not work Check if the motor wire is plug well and the controller is normal power s...

Page 46: ...rv vi ic ce e M Ma an nu ua al l 45 8 2 Error Message Err Definition The console board is not detecting the VR voltage value or the voltage value has exceeded the range Err appears on the display Configuration ...

Page 47: ...e VR value exceeds the range Err appears on the display Incline motor isn t operation up or down making the VR value exceed the range After turning on the unit the display board detects that the incline VR voltage exceeds the range so Err appears Action Flow Chart ...

Page 48: ...S Se er rv vi ic ce e M Ma an nu ua al l 47 ...

Page 49: ...es are broken or disconnected Display board 1 Inspect the incline wire and 12 pin cable connections 2 Test whether the VR voltage varies at the incline wire terminal 12 pin cable 1 Inspect the wire connections 2 Inspect whether wires are broken or crimped 3 Replace the wires and test again Driver board Inspect the display board 12 pin connections ...

Page 50: ...sole to driver board connector pin define function The console to driver board connector pin define function 1 Controller S W 2 Incline down output 3 Incline up output 4 Vin 5 Speed up output 6 Speed down output 7 GND 8 GND 9 Speed sensor input 10 VCC 11 ADC input 12 GND ...

Page 51: ... DOWN White NEUTRAL The position sensor wires Red Ground White Position signal Black 5vdc 0 5v depending on incline position DOWN LED 12 11 10 9 8 7 6 5 4 3 2 1 1 Controller S W 2 Incline down output 3 Incline up output 4 Vin 5 Speed up output 6 Speed down output 7 GND 8 GND 9 Speed sensor input 10 VCC 11 ADC input 12 GND UP LED ...

Page 52: ...e loose If everything is tight then the potentiometer could be bad If there is no count then check the voltage at the potentiometer There should be 5vdc between the black and red wire and there should be a voltage between the red and white wire This voltage will be about 4 5 4 7 Vdc when the motor is at the lowest position the number isn t too critical as long as it s somewhere in this neighborhoo...

Page 53: ...S Se er rv vi ic ce e M Ma an nu ua al l 52 Error Message Err Definition During incline action the display board CPU cannot read the VR value so Err appears Configuration ...

Page 54: ...lay Explanation Press the incline UP and DOWN key The driver board UP or DOWN indicator lights The incline operates moving the VR which changes the VR value The display board CPU reads the incline VR value If there is no VR value change to the CPU the incline is not operating when it should be Err appears on the display Action Flow Chart ...

Page 55: ...S Se er rv vi ic ce e M Ma an nu ua al l 54 ...

Page 56: ... whether the 12 PIN cable is connected well 2 Test by replacing the cable with a good one Driver board Inspect whether the driver board UP DOWN LED is lit 1 Press incline UP or DOWN key again making the incline motor return to its position 2 If ERR still appear re calibrate the incline set Incline motor 1 Inspect whether the incline motor is stuck 2 Inspect whether the incline gears are cracked 3 ...

Page 57: ...S Se er rv vi ic ce e M Ma an nu ua al l 56 8 3 Circuit diagram ...

Page 58: ... within the range of 16 0 10 0 20 0 13 0 km mile 6 Press ENTER button after the max speed has been set and enter the next step for LEVEL setting The window will show MAX ELEV 15 Press UP DOWN button to adjust for proper value within the range of 10 15 7 Press ENTER button after the ELEV value has been set and the window will show PRESS START Pressing START button the LCD dot matrix will show CAL a...

Page 59: ...eans when the safety key is pulled off PLEASE INSTALL SAFE KEY TO START will be displayed SAFE MODE OFF means that there isn t any displayed when the safety key is pulled off 5 Press ENTER button after SAFE MODE has been set the window displays the total hour 6 Press ENTER button the window displays the total mileage 7 Press ENTER button the window displays the software version 8 Press STOP button...

Page 60: ...S Se er rv vi ic ce e M Ma an nu ua al l 59 8 5 Fuse replacement FUSE For AC 110V is 15A For AC 220V is 10A ...

Page 61: ... power or will not start check the fuse located on the motor controller DANGER Turn the power switch off and unplug the treadmill to reduce the risk of an electric shock Remove the motor cover Remove and replace the fuse on the motor controller Replace the motor cover ...

Page 62: ...faulty 1 Switch the AC switch 2 Insert the safe key on right position 3 Please check the wire and connect again 4 Replace 12 PIN computer cable 5 Replace fuse or controller 6 Replace varistor or controller 7 Replace safety key device 8 Replace console With no safe key but treadmill could display or operate 1 Safety device is broken short 1 Replace the safety key device or console When press START ...

Page 63: ...nitor After pressing START button the treadmill stops immediately 1 Controller is broken 1 Turn off the AC switch and turn on power again 2 Replace controller and calibrate it Erratic pulse display 1 Another chest belt in use around treadmill 2 Other magnetic field disturbance 3 Receiver is broken 1 Check for other chest belt use around treadmill 2 Change the position or direction of treadmill 3 R...

Page 64: ...nd pulse 2 Connect the cable again 3 Replace with new cable 4 Replace console or Hand pulse board Wireless lost its function No pulse displayed on monitor 1 Chest belt not worn properly 2 Distance is too far and exceeds range of receiver 3 Chest belt battery is weak or dead 1 Check chest belt has proper contact with skin and is oriented correctly 2 User chest belt in front of console within 3 feet...

Page 65: ...S Se er rv vi ic ce e M Ma an nu ua al l 64 9 Folding Unfolding and Transport ...

Page 66: ...r and slowly lower the running deck to the floor The deck will lower unassisted when it reaches about waist high As shown Figure 1 At the rear roller area to relieve pressure on the locking system Folding The Treadmill Make certain the treadmill is at minimum incline Lift the treadmill running deck until it is secured by the locking telescoping tube assembly in center back of base As shown Figure ...

Page 67: ...S Se er rv vi ic ce e M Ma an nu ua al l 66 10 General Maintenance ...

Page 68: ...lt Allow the belt to dry before using Belt Dust This occurs during normal break in or until the belt stabilizes Wiping excess off with a damp cloth will minimize buildup General Cleaning Dirt dust and pet hair can block air inlets and accumulate on the running belt On a monthly basis vacuum underneath your treadmill to prevent buildup Once a year you should remove the black motor hood and vacuum o...

Page 69: ...in use It is normal for some belts to drift near one side while the belt is running with no one on it After a few minutes of use the tread belt should have a tendency to center itself If during use the belt continues to move toward one side adjustments are necessary TO SET TREADBELT TRACKING A 10 mm Allen wrench is provided to adjust the rear roller Make tracking adjustments from the left side onl...

Page 70: ...of Lube and extra tubes can be ordered directly from or your authorized dealer You may also use a Lube n Walk kit that can be purchased through both aforementioned sellers Keeping the deck lubricated at the recommended intervals ensures the longest life possible for your treadmill If the lubricant dries out the friction between the belt and deck rises and places undue stress on the drive motor dri...

Page 71: ...reaker panel circuit breaker may be tripped 5 Treadmill defect Contact your dealer Tread belt does not stay centered The user may be walking while favoring or putting more weight on either the left or right foot If this walking pattern is natural track the belt slightly off center to the side opposite from the belt movement Treadmill belt hesitates when walked run on See General Maintenance sectio...

Page 72: ...lers 2 If the noise is coming when the user is running on the treadmill with lowest level of incline it could be due to too much pressure with the incline cylinder only in case of the lowest incline level 3 If there is knocking noise during the workout check and make sure all bolts are tightened 4 When there is thumping noise while the belt is running This happens with a brand new treadmill or whe...

Page 73: ...S Se er rv vi ic ce e M Ma an nu ua al l 72 11 Installation of the Incline Motor ...

Page 74: ...S Se er rv vi ic ce e M Ma an nu ua al l 73 Incline Range must be adjusted to 210 mm minimum prior to installation ...

Page 75: ...S Se er rv vi ic ce e M Ma an nu ua al l 74 12 Disassembling and Assembling of Parts ...

Page 76: ...e M Ma an nu ua al l 75 12 1 Lower Controller Replacement 1 Remove motor cover 2 Disconnect all lower controller wirings 3 Use Phillips head Screwdriver to remove replace with new lower controller and reconnect all wirings ...

Page 77: ... M Ma an nu ua al l 76 12 2 Console Replacement 1 When replacing console use Phillips head screw driver to remove 4 Phillips Head Screws underneath the console 2 Use M5L Allen wrench to release six Button Head Socket Bolts ...

Page 78: ...S Se er rv vi ic ce e M Ma an nu ua al l 77 3 Disconnect console wirings and replace with new console ...

Page 79: ...c ce e M Ma an nu ua al l 78 12 3 Motor Replacement 1 Use Phillips head screwdriver to remove 4 Tapping screw securing the motor cover 2 Remove motor grounding wire greenish yellow motor wire red and motor wire black ...

Page 80: ...ble in reverse order of disassembly re hook belt readjust belt to be parallel with main frame after re hooking Do not tighten 4 securing screws yet 5 Use 14mm open end wrench to adjust belt tension using tension measuring device Adjust to white LBS area between 70 75LBS Use 14mm T shaped socket wrench to secure and tighten 4 securing screws 6 Connect grounding wires and motor wires red M black M ...

Page 81: ...Ma an nu ua al l 80 12 4 Breaker Replacement Remove Breaker connection wiring replace part and reconnect wiring 12 5 AC Power Switch Replacement Disconnect wiring to AC power switch replace AC power switch and reconnect wiring ...

Page 82: ... Phillips head screwdriver to loosen 2 screws on the rear adjustment base 2 Use M6 L Allen wrench to loosen 2 screws on the rear roller 3 Remove motor cover use 14mm T shaped socket wrench to loosen 4 screws Use 14mm open end wrench to loosen 1 belt tension screw and loosen drive belt ...

Page 83: ...ch to loosen front roller screws remove front and back rollers and replace with new Reassemble in reverse order of disassembly 5 When reassembled running belt tension needs to be adjusted and centered Belt tension also needs to be adjusted refer to 12 3 5 above ...

Page 84: ... to remove securing screws on cylinder and remove the cylinder 2 Perform step 12 6 and remove front and rear rollers 3 Use Philips screw driver to release two Philips head screws and take apart plastic covers at front of left and right rails Use Philips screw driver again to release four Philips head screws to release rail stoppers and take apart the rails following the direction of the arrow as i...

Page 85: ...the running board Remove the running board and replace running board or running belt If cushions need to be replaced remove 6 cushions and replace Reassemble in the reverse order as disassembly 5 When reassembled center and adjust running belt tension Belt tension also needs to be adjusted Refer to step 12 3 5 ...

Page 86: ...a al l 85 12 8 Speed Sensor Replacement including the wire 1 First remove motor top cover 2 Remove speed sensor wiring and proceed with parts replacement 3 After replacement a test to check if the sensor registers the magnet is required ...

Page 87: ...otor Replacement Zeroing the incline motor before take it apart from the machine or assemble it onto the frame The zeroing distance is 210mm 1 First remove the motor cover and adjust treadmill to folded position then proceed with old incline motor replacement ...

Page 88: ...S Se er rv vi ic ce e M Ma an nu ua al l 87 2 Use 14mm wrench to assemble new incline motor ...

Page 89: ...S Se er rv vi ic ce e M Ma an nu ua al l 88 3 Connect incline motor wiring with controller Red wire Connect to UP White wire Connect to COM Black wire Connect to DOWN ...

Page 90: ...S Se er rv vi ic ce e M Ma an nu ua al l 89 ...

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