Woodway 4Front Service Manual Download

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Motorized Performance & Fitness

Treadmills

Includes servicing

information on

the models:

4Front

Desmo

ELG

Mercury

Path

Pro

Pro XL

Desmo, Mercury, and

Path models built after

Jan. 2003 and contain-

ing a Brushless Motor

System

Service Manual

05/2016 SM-MT-EN-02

Summary of Contents for 4Front

Page 1: ...ss Treadmills Includes servicing information on the models 4Front Desmo ELG Mercury Path Pro Pro XL Desmo Mercury and Path models built after Jan 2003 and contain ing a Brushless Motor System Service...

Page 2: ...20 79576 Weil am Rhein Germany WOODWAY USA Inc W229 N591 Foster Ct Waukesha WI 53186 USA Tel 49 0 7621 940 999 0 Fax 49 0 7621 940 999 40 E mail info WOODWAY de Web www WOODWAY de Tel 1 262 548 6235...

Page 3: ...ons 17 3 1 Turning the Treadmill ON OFF 17 3 2 Name Plate 17 3 3 Electrical Specifications 18 3 3 1 North America 18 3 3 2 UK 19 3 3 3 Germany 19 4 Parts Description 20 4 1 Interface Board 20 4 1 1 Ci...

Page 4: ...eart Rate Replacement 55 6 11 Handrail Replacement 57 6 12 Drive Shaft Replacement 59 6 13 Idler Shaft Replacement 61 6 14 Brushless Motor Replacement 64 6 15 Running Belt Replacement 67 7 Calibration...

Page 5: ...05 2016 SM MT EN 02 5 9 2 4 Incline System 80 10 Warranty Information 81 11 Maintenance Report 82 12 Disposal Notice 83 13 Table of Figures 84 14 Appendix 85...

Page 6: ...ay the feel of running on a soft pine needle covered path in the forest In 1983 a manufacturing license was awarded to Sakai Medical for the use of WOODWAY technology in the Japa nese marketplace In 1...

Page 7: ...y adapters especially those without grounding provisions Doing so could potentially result in electrical shock Do not operate motorized treadmills in damp or wet locations Do not operate the heart rat...

Page 8: ...emergency stop procedures Always use the emergency safety pull cord supplied with the treadmill It can be clipped to an article of clothing while training This is for the user s safety in case of an e...

Page 9: ...e of Danger Description of the consequences of ignoring the danger Measures instructions and forbidden actions to avoid the hazard Further measures Classification NOTE NOTE or ATTENTION no danger symb...

Page 10: ...Magnet Information sign on attaching the safety cord to the user as well as for storing the emergency off magnet with the safety cord and clip out of the reach of children when not in use Notice on Di...

Page 11: ...he risk of injury from moving parts unplug the treadmill before servic ing Use time delay fuses if applicable 1 3 2 Desmo ELG Mercury Path Pro Pro XL Protective Ground Wire Connection Motorized treadm...

Page 12: ...cover Notice on Desmo Bottle Holder To prevent injury stand on the side panels prior to starting the device Read the op erating instructions prior to use Warning to Not Tension Belt To prevent incorr...

Page 13: ...erating or servicing instruc tions In addition local accident prevention regulations and general safety conditions for intended use of the treadmill apply The manufacturer reserves the right to make t...

Page 14: ...ent parts Original replacement parts have particular qualities and ensure reliable and safe operation Developed for specific use with the device Manufactured for high quality and excellence Ensure the...

Page 15: ...cumstances Customer number if available What action has already been taken The address of your local service center can be obtained from the manufacturer After repair or re installation the actions li...

Page 16: ...16 05 2016 SM MT EN 02 2 6 EC Declaration of Conformity Fig 1 EC Declaration of Conformity...

Page 17: ...el it has an alphanumeric code with 7 8 characters or a numeric code with 9 digits The serial number can be found on the name plate which is mount ed on the rear of the display or on the left front of...

Page 18: ...115 VAC 208 230 VAC 208 230 VAC Voltage Requires at least 115 V from wall outlet Requires at least 208 230 V from wall outlet Requires at least 208 230 V from wall outlet Frequency 50 60 Hz 50 60 Hz...

Page 19: ...rements Outlet Compatibility G BS 1363 plug If voltage falls 10 below 230 V treadmill will shut off and reset 3 3 3 Germany Description Parameters 230 VAC Voltage Requires at least 230 V from wall out...

Page 20: ...20 05 2016 SM MT EN 02 4 Parts Description 4 1 Interface Board Fig 3 Interface board C1216...

Page 21: ...nning surface not currently in use Phoenix elevation motor and elevation capacitor Pos 1 and 2 not currently in use brake on Baldor motors Pos 3 white wire motor Pos 4 capacitor wire and red wire moto...

Page 22: ...goes out drive will not speed up display will turn on and elevation can change Goes on when 12 V supply properly signals to drive to increase speed Flashes with each pulse from encoder through drive...

Page 23: ...23 4 2 Drive Boards Fig 4 CAN drive board B3215 Fig 5 Quantum brushless drive board B3205 1 Wiring connections 2 Diagnostic lights 3 Encoder connector P1 4 Control connector P2 5 Calibration buttons...

Page 24: ...l Motor wires Either the motor wires have shorted or the drive board is defective and needs to be replaced Red LEDs blinking Fault Type Issue with Suggestions OT Belt Jammed for 10 Seconds Motor Check...

Page 25: ...ow white Common green 4 2 5 Calibration Buttons To change a setting hold down the appropriate calibration button for second The in terface board will not recognize quick pulses of the buttons To save...

Page 26: ...H but motor rotates Fault Display Mode Faults saved display S1 S3 S4 must be pressed before turning device ON to get into display mode Power ON Power ON while pressing buttons Short circuit fail Displ...

Page 27: ...ence Belt off fault Display if appli cable the num ber blinking is the number of occur rence Belt jammed fault Display if appli cable the num ber blinking is the number of occur rence End of fault dis...

Page 28: ...manent magnet Sinusoidal windings 2 5 HP continuous 6 HP max 3 550 lb 1 610 kg dynamic load ABEC bearings 8 pole construction smooth rotation Industrial 1000 line encoder with com mutation tracks seal...

Page 29: ...mbly Instructions 5 1 Preparation The treadmill can be delivered in various states of assembly Disassembly assembly may be required for moves or relocation into other rooms NOTE In WOODWAY performance...

Page 30: ...rench 1x Phillips head screwdriver 1 Fig 6 4Front assembly side panel Remove the covers on the left and right Fig 7 4Front assembly wiring Insert wire and protective cover into the guard rail tube to...

Page 31: ...ng tube into the mounts Note Do not damage the wires Be careful not to pinch yourself Fig 10 4Front assembly connection 1 Pull the wire and protective cover out of the railing tube Fig 11 4Front assem...

Page 32: ...and tighten both retaining screws Attach the protective conductor green to the contact tab on the housing Fig 13 4Front assembly fixing the railing Tighten railing mount bolts Fig 14 4Front assembly...

Page 33: ...assembly inserting tubes Insert the railing tube into the mounts on both sides Note Be careful not to pinch yourself Fig 16 Desmo assembly wiring Pull the display and protective conductor wires out o...

Page 34: ...ctronic cover plate on the right side of the treadmill frame using a Phillips screw driver Fig 19 Desmo assembly connection 1 Lay the wire through the hole in the console Fig 20 Desmo assembly connect...

Page 35: ...10 Fig 22 Desmo assembly connection 4 Connect the wires to the frame with the sup plied wire ties Remount the electronic cover plate Fig 23 Desmo assembly side covers Slide the side covers onto the l...

Page 36: ...n the rear left side 5 4 ELG Please contact your local representative for ELG assembly assistance 5 5 Mercury Path Tools required for assembly 1 x combination wrench or ratchet wrench 1 x Phillips hea...

Page 37: ...the guard rail tube to prevent damage during insertion Fig 28 Mercury Path assembly tube mount Prepare the mount for the tube Loosen bolts if necessary Fig 29 Mercury Path assembly insert tubes Inser...

Page 38: ...tective cover out of the railing tube hole in railing tube Fig 31 Mercury Path assembly connection 2 Lay the wire with protective cover through the hole in the console Fig 32 Mercury Path assembly con...

Page 39: ...to the circuit board Note Do not connect to the position marked with the red X in Fig 31 Fig 34 Mercury Path assembly fixing the railing Tighten railing mount bolts Fig 35 Mercury Path assembly elect...

Page 40: ...not tighten the screws yet Fig 37 Mercury Path assembly cover plates Slide the cover plates over the tube on both sides and fix with screws Tighten large screws first then the rest Note Ensure distanc...

Page 41: ...XL assembly insert railing Insert both sides of the railing into the mounts First slide the cover plates over the railing Note Do not damage the wires Be careful not to pinch yourself Fig 39 Pro ProXL...

Page 42: ...tube and lay it along the railing mount to the circuit board Fig 42 Pro ProXL assembly connection 2 Attach the protective conductor green to the contact tab on the housing Fig 43 Pro ProXL assembly c...

Page 43: ...he right side Fig 45 Pro ProXL assembly fixing the railing 2 Tighten railing mount bolts on the left side Fig 46 Pro ProXL assembly side covers Slide the side covers on both sides and fix with screws...

Page 44: ...servicing equipment must not be con nected to power Ensure the device cannot be switched back on 6 1 Ordering Parts Original WOODWAY parts can only be ordered through WOODWAY Customer Service Before...

Page 45: ...ed back on 2 Remove the cup holders by sliding them up and off the posts No screw removal is required Pos 1 3 Using a Phillips screwdriver remove 4 screws located on back of display Pos 3 4 Carefully...

Page 46: ...g up the T on the display with the slot on the cup holder 6 2 2 Mercury Path Fig 48 Display replacement Mercury Path 1 Display housing mounting screws 2 Display board mounting screws 3 Display housing...

Page 47: ...ve the trim plate screws using either standard Phillips head screwdriver 6 Using the Phillips head screwdriver remove the 2 silver screws located on both ends of the side cover 7 Once the side cover h...

Page 48: ...ocat ed on both ends of the side cover Pos 2 3 Remove the side cover Pos 1 Perform the following steps in order to properly reinstall the side cover 1 Place the side covers back on the frame Make sure...

Page 49: ...ement Fig 50 Motor controller replacement 1 Boot screws 2 Boot 3 Side cover screws 4 Side cover 5 Electrical cover 6 Electrical cover screws 7 Motor control board screws 8 Motor control board 9 Motor...

Page 50: ...y disconnect the wires connected to the motor control board P1 P2 and motor power wires Pos 9 10 11 8 Remove the 4 screws holding the motor control board to the frame and remove the motor control boar...

Page 51: ...eadmill with the AC power cord coming out of it right side running direction 3 Remove the trim plate boot screws 4 Slide the trim plate boot up the handrail and out of the way 5 Remove the 2 screws ho...

Page 52: ...nt parts Fig 52 Speed incline control replacement 1 Switch 2 Switch nut Standard screwdriver small Nut driver Perform the following steps in order to properly remove the speed incline control 1 Unplug...

Page 53: ...prying up the corner of the overlay Once a corner is lifted the overlay should peel off easily 3 Remove the three 8 32 x Phillips flat head machine screws that hold the side switch PCB down Pos 2 4 4...

Page 54: ...he PCB Make sure the overlay is centered and no edges are sticking up Pos 1 6 9 Foot Assembly Replacement Save all removed hardware for installation of replacement parts Fig 54 Foot assembly replaceme...

Page 55: ...ve the foot Pos 1 1 Using the 12 combination square adjust to the distance between the bottom of the frame and the bottom of the elevation block foot Pos 3 2 Place the combination square on the frame...

Page 56: ...n the inside of the grip 2 Install the new plastic grips using the new hardware included The grips only fit together in one orientation If it does not look like a proper fit turn one of them around an...

Page 57: ...05 2016 SM MT EN 02 57 6 11 Handrail Replacement Fig 56 Handrail replacement 1 Handrail assembly 2 Clamp nut 3 Clamp 4 Electrical cover 5 Electrical screw...

Page 58: ...hold in the handrail to prevent damage during the handrail removal 6 Using the 9 16 or wrench loosen the nuts on the clamps that hold the handrail in place Pos 2 3 They do not need to come completely...

Page 59: ...2 Drive shaft bearing nuts 3 Drive belt 4 Motor mounting bolts 5 Motor 6 Zerk fittings Box wrench and 9 16 Deep well socket and 9 16 Ruler 12 Torque wrench Standard screwdriver large Loctite red Grea...

Page 60: ...and push it as far forward as it will go Make sure the Zerk fittings on the bearings are pointed out and accessible Pos 1 6 2 Tighten the drive shaft bearing nuts and loosen the set screws on both bea...

Page 61: ...05 2016 SM MT EN 02 61 6 13 Idler Shaft Replacement...

Page 62: ...w 4 Idler shaft bearing nut 5 Idler shaft tensioning bracket 6 Idler shaft tensioning bracket nut 7 Idler shaft assembly 8 Tensioning bolt jam nut 9 Tension measurement 10 Centerline of treadmill Box...

Page 63: ...s and set screws so they are not fully tightened Pos 2 3 4 4 Put the idler shaft tensioning bracket on the shaft on the front left side of the treadmill Do not fully tighten the set screws Pos 5 7 5 A...

Page 64: ...following figures the running belt and handrails have been removed only to im prove the view DO NOT REMOVE the running belt or handrails they should remain in stalled during the replacement process S...

Page 65: ...Electrical cover screws 7 Motor 8 Motor control board 9 Motor access opening 10 Motor power terminals R S T 11 Motor control connector P1 12 Motor mounting hardware 13 Drive belt 14 Motor pulley Stand...

Page 66: ...os 13 14 11 Move to the opposite right side of the treadmill and remove the motor from the device via the opening in the frame Pos 9 1 Slide the motor into the treadmill opening between the drive shaf...

Page 67: ...place the belt on the treadmill right side up i e not upside down or backwards the runner should be able to see and read the WOODWAY name on the belt 1 Using 2 people lower the running belt over the...

Page 68: ...slat screws clips Visual inspection to ensure slat screws are not damaging or making contact with the teeth on the drive shaft assembly If any slat screws clips are not tight and or in good condition...

Page 69: ...ausing noise or that do not spin freely Required tools 2 ft level wrench When the treadmill wobbles or seems unstable the support feet must be checked Check both ends of the treadmill with a level Loo...

Page 70: ...016 SM MT EN 02 Standard LED Mercury Path Desmo 00 04 Group Training 4Front Pro Pro XL Personal Trainer LCD 4Front Pro Pro XL Personal Trainer LCD Desmo 2005 ELG Personal Trainer LCD Mercury Path Desm...

Page 71: ...together 8 Press the OFF button on the display twice to save the changes and exit Diagnostic Mode To adjust elevation incline through the treadmill s LED display perform the following 1 Turn OFF the...

Page 72: ...admill is set to 0 MPH the belt may move slightly due to electrical vari ance It is possible to adjust this movement through the treadmill s display board If the belt movement does not stop after perf...

Page 73: ...dmill please consider the answers to the following questions before calling WOODWAY Customer Service What are the make model and serial number What happened before the problem occurred Did the problem...

Page 74: ...d may cause the treadmill to reset The power supply for the display on the interface card may be defective Contact WOODWAY Customer Service for assistance 8 3 Running Surface Belt Problems If the runn...

Page 75: ...he connection between the display and interface If the connection is good the display or the interface is bad try replacing display first then try re placing the interface board Contact WOODWAY Custom...

Page 76: ...bolts Ensure the drive belt tension has approx deflection between the motor pulley and drive roller Once you start adjusting the tension you will hear and see the difference in the vi bration of the...

Page 77: ...4 pin connector is plugged in on the back of the display board See if LED 6 on the interface board is red If LED 6 stays on both while the magnet is in place and when removed the is sue is with the i...

Page 78: ...lean and examine the machine regularly for damage and or wear paying special attention to areas susceptible to wear In case of doubt or questions always contact WOODWAY Customer Service or your dealer...

Page 79: ...ry to minimize noise The teeth do not need to be lubricated When the running surface belt rubs on the side of the guide rollers the use of a small amount of lubricant Molykote or similar product on th...

Page 80: ...4 Incline System The incline systems on WOODWAY treadmills are lubricated by the manufacturer The system must be checked when used over several hours or in a very dusty environment If required apply a...

Page 81: ...shall not apply if there is any modification to the products or accessories or if there is a failure to provide maintenance as outlined in the Owner s Manual WOODWAY GIVES NO OTHER WARRANTIES EITHER E...

Page 82: ...82 05 2016 SM MT EN 02 11 Maintenance Report DATE MAINTENANCE MEASURES FROM REMARKS...

Page 83: ...ing is disposed of through resource recycling The metal parts of the machine go to scrap metal disposal Plastic parts are given to plastic recycling Rubber parts are disposed of as hazardous waste The...

Page 84: ...bly side covers 36 Fig 26 Mercury Path assembly electronic cover plate 36 Fig 27 Mercury Path assembly wiring 37 Fig 28 Mercury Path assembly tube mount 37 Fig 29 Mercury Path assembly insert tubes 37...

Page 85: ...Idler shaft replacement 62 Fig 59 Brushless motor replacement 65 Fig 60 Lubrication axle bearing 79 Fig 61 Lubrication drive axle 79 Fig 62 Lubrication toothed belts 80 Fig 63 Lubrication incline sys...

Page 86: ...86 05 2016 SM MT EN 02 1...

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Page 88: ...88 05 2016 SM MT EN 02 3...

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Page 90: ...90 05 2016 SM MT EN 02 5...

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Page 96: ...96 05 2016 SM MT EN 02 11...

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