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Core Fitness Systems

2003-2004 Treadmill

Service Manual

RT1

CFS Series

If you have any questions, please call the Sears Parts and Repair Center at

1-800-488-1222

Содержание RT1

Страница 1: ...Core Fitness Systems 2003 2004 Treadmill Service Manual RT1 CFS Series If you have any questions please call the Sears Parts and Repair Center at 1 800 488 1222 ...

Страница 2: ...ating Procedures 12 CFS 5 Step Diagnostic Process 14 Upper Board Troubleshooting 19 Console Cable Voltage Chart 20 Auto Calibration Instructions 21 Lower board troubleshooting 32 Wiring Diagrams 36 Lower Control Board Diagnostic LED Chart 38 Manual Speed Calibration 41 Incline Motor Troubleshooting 42 Drive Motor and Roller Troubleshooting 46 Parts Replacement 50 ...

Страница 3: ...3 ...

Страница 4: ...high voltage components When you perform maintenance procedures with the hood removed remove jewelry especially from ears and neck tie up long hair remove neck ties and do not wear loose clothing When the treadmill is operating the capacitor will hold a lethal amount of charge Do not touch the capacitor as serious injury or death might result When the treadmill is turned off and the power cord is ...

Страница 5: ... is moving Before starting the running belt straddle the belt by placing your feet firmly on the sides of the treadmill You should also step off the belt and onto the sides of the treadmill after turning off the running belt Do not rock the unit Do not stand or climb on the handrails electronic console or hood Do not set anything on the handrails electronic console or hood Never place liquids on a...

Страница 6: ...cian of serviceman if you are in doubt as to whether the product is properly grounded Do not modify the plug provided with the product if it will not fit in the outlet have a proper outlet installed by a qualified electrician SAFETY TIPS Never use the treadmill before securing the safety tether clip to your clothing If you experience chest pains nausea dizziness or shortness of breath stop exercis...

Страница 7: ...trap when handling electronic parts flat head screwdrivers digital multi meter drive belt tension gauge Allen wrench set Metric open end wrenches of assorted sizes Metric clamp on AC amp meter drive ratchet and sockets of assorted sizes blue loc tite cable ties Motor commutator stone needle nose pliers damp cloth rubber mallet drop cloth ruler snap ring pliers wire cutters ...

Страница 8: ... can become pinched or cut Check the tension and alignment of the running belt Make sure that the treadmill belt will not damage any other components on the treadmill by being misaligned Every Week Clean underneath the treadmill following these steps Turn off the treadmill with the on off switch then unplug the power cord at the wall outlet Fold the treadmill into the upright position making sure ...

Страница 9: ...p This is a normal and common adjustment To eliminate this slipping tension both the rear roller bolts with the appropriate sized Allen wrench turning both the left and right bolt 1 4 TURN as shown below 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 NOTE The belt tension is set properly when the running belt is of an ...

Страница 10: ... to the other and that the belt is centered between the side rails If the running belt is not tracking properly follow the following procedures If the running belt tracks to the left turn the left roller bolt clockwise of a turn keeping the belt tension in mind Over tightening the running belt may cause damage to the running belt and roller bearings If the running belt tracks to the right turn the...

Страница 11: ...d of the treadmill 5 With a 13mm wrench loosen the attachment nuts M08 and washers M09 holding the motor to the frame 6 With a 6mm Allen wrench loosen the two motor bracket attachment bolts M45 M46 and adjust to proper position 7 Tighten the two motor attach bolts M45 M46 with a 6mm Allen wrench 8 Verify the proper tension on the drive belt Using a timing belt tension gauge the proper tension shou...

Страница 12: ...ubrication is ever added to a CFS treadmill Please contact the Sears service department to obtain the proper lubrication for reapplication Do not apply other manufacture s lubrication to a CFS treadmill PROCEDURES 1 For optimal results the running deck and belt should be warm before reapplication of lubrication It is recommended to run the treadmill at 5mph for 10 15 minutes before proceeding 2 Wi...

Страница 13: ...ld the treadmill to the upright position making sure the treadmill is locked securely 2 Add 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 ...

Страница 14: ...ds a 20 amp dedicated circuit but a 15 amp dedicated circuit may be sufficient Make sure that proper voltage is being supplied from the wall outlet Warning Hazardous voltages will be tested in the following procedure Exercise extreme caution when performing these procedures Do not connect or disconnect any wiring connectors or other components with the power applied to the treadmill Disconnect the...

Страница 15: ...e rpm sensor wire is positioned as close to the front roller pulley as possible The factory standard is a distance or 2 4 mm between the sensor wire and the front roller pulley Loosen the sensor bracket attachment screws and position sensor bracket closer to front roller pulley if the distance is greater than 2 4 mm Verify that the sensor wire is attached to the sensor bracket properly The proper ...

Страница 16: ...speed keys for about 5 seconds to enter the Engineering Mode Menu The console should beep three times and Auto Set should be displayed once in the Engineering Mode Menu While in the Engineering Mode Menu press the Select button until Hardware Test appears in the display Press the Start button to select Press Start to begin At this time the running belt should begin moving The readout in the speed ...

Страница 17: ...10 quick speed keys for about 5 seconds to enter the Engineering Mode Menu The console should beep three times and Auto Set should be displayed once in the Engineering Mode Menu While in the Engineering Mode Menu press the Select button until Hardware Test appears in the display Press the Start button to select Press Start to begin At this time the running belt should begin moving The readout in t...

Страница 18: ...ic LED can be found by referencing the lower control board Diagnostic LED chart in the table of contents Verify that proper voltage is being transferred through the console cable reference console cable voltage chart in the table of contents If the techniques described in the five step diagnostic process did not resolve the problem reference the symptoms in the table of contents and review other p...

Страница 19: ...ration procedures 21 No display on console 23 All or some of the keys on console will not work 25 Error message E1 or E2 on console 26 Diagnostics Mode 28 Heart rate control function does not work 29 Static shocks from upper board heart rate grips 30 Console exploded diagram 31 ...

Страница 20: ...volts B9 Light Green 0 volts B10 Black 5 volts B11 Grey action 5 volts Normal 0 volts B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 Elevation Down Elevation Up B6 Purple 5 volts B12 White action 5 volts Normal 0 volts To check the voltage of a specific function i e e levation motor control etc place the negative lead of your multi meter on pin B4 or B5 and place the positive lead on the desired pin Follo...

Страница 21: ... for about 5 seconds to enter the Auto Set Menu The console should beep three times and Auto Set should be displayed once in the Auto Set menu Press Select button until Hardware Test appears in the display Press the Start button to select Press Start to begin At this time the running belt should begin moving The readout in the speed window will indicate the start speed of the treadmill which shoul...

Страница 22: ...n the auto calibration sequence to properly set and store the speed values Note This may take between 2 to 3 minutes to complete the auto calibration sequence Upon successful calibration there will be four beeps and it will automatically exit Engineering Mode and will return you to the original screen Troubleshooting If the Auto Calibration was unsuccessful Repeat Step 1 to confirm that the Speed ...

Страница 23: ...sible causes Check voltage of wall outlet Warning Hazardous voltages will be tested in the following procedure Exercise extreme caution when performing these procedures Do not connect or disconnect any wiring connectors or other components with the power applied to the treadmill Disconnect the treadmill power cord from the wall outlet Using an AC voltmeter verify that the proper AC voltage is pres...

Страница 24: ...s lit If the switch is not lit check the power cord connection and function Improper wiring Check all wiring coming in from the power switch to the lower board to the upper board Refer to wiring diagrams Inspect diagnostic LED s on lower board Determine defective part according to chart Check voltage of console cable Determine defective part by using console cable chart Refer to console cable volt...

Страница 25: ... Keys on Console Will not Work Possible causes Keypad electrodes N74 are not coming into proper contact with upper control board N17 Remove keypad and reposition The upper control board N17 is defect Replace entire console ...

Страница 26: ...in table of contents Verify the signal of the RPM sensor by entering Diagnostics Mode If there is no signal present check the continuity of the RPM sensor wire If there is no continuity replace the sensor wire If the problem persists replace the entire console If there is no belt movement upon start up of the treadmill and an E 1 message occurs follow the possible causes below Possible cause Verif...

Страница 27: ...disconnect any wiring connectors or other components with the power applied to the treadmill Disconnect the treadmill power cord from the wall outlet Using an AC voltmeter verify that the proper AC voltage is present at the wall outlet Nominal 120 Vac may vary between approximately 105 Vac and 135 Vac If the AC voltage is missing or incorrect check the AC service or consult an electrician Follow t...

Страница 28: ...e display should change Press Start to light entire display Press and hold the Stop button for three seconds to return to the Engineering Mode Menu Eng1 Hardware Test Use to check running belt speed and deck elevation While in the Engineering Mode Menu press Select button until Hardware Test appears in the display Press the Start button for three to select Press Start to begin At this time the run...

Страница 29: ...ntire console Defective upper board Replace entire console When holding the heart rate handlebars the display in the Pulse display window should register HR If this registers but the actual heart rate reading does not register or is erratic follow the possible causes below Possible causes Try standing off to the side of the treadmill and use a loose cupping grip while pressing your palms against t...

Страница 30: ...ontact Sears for lubrication application Defective grounding fibers in running belt Replace running belt Note Improper grounding of the upper board or running belt may also cause other symptoms like erratic speed scrambled reading of the upper board resetting of the treadmill or erratic or non responsive heart rate function ...

Страница 31: ...31 Console Exploded Diagram ...

Страница 32: ...32 LOWER BOARD TROUBLESHOOTING CONTENTS Treadmill will not start 33 Treadmill will reset 34 Running speed is not stable 35 Wiring diagram 36 Lower board LED diagnosis 38 Speed Calibration 40 ...

Страница 33: ...ts Verify the diagnostic LED s on the lower board Reference diagnostic LED chart for possible causes Measure voltage from motor reference voltage checkpoints in table contents If no voltage is present unplug the treadmill and visually inspect the motor brushes and springs to make sure they are installed properly Repeat voltage reading if necessary If problem persists replace the lower board ...

Страница 34: ...wer cord from the wall outlet Using an AC voltmeter verify that the proper AC voltage is present at the wall outlet Nominal 120 Vac may vary between approximately 105 Vac and 135 Vac If the AC voltage is missing or incorrect check the AC service or consult an electrician Make sure that the treadmill is connected to a dedicated 20amp circuit with out the use of an extension cord Verify all wire con...

Страница 35: ...r cord from the wall outlet Using an AC voltmeter verify that the proper AC voltage is present at the wall outlet Nominal 120 Vac may vary between approximately 105 Vac and 135 Vac If the AC voltage is missing or incorrect check the AC service or consult an electrician Make sure that the treadmill is connected to a dedicated 20amp circuit with out the use of an extension cord Verify that there are...

Страница 36: ...agram Motor Red RPM sensor wire Transformer green Console cable Elevation motor Elevation motor black Elevation motor red Elevation motor white Transformer red Transformer red Motor black AC1 from on off switch AC2 from on off switch ...

Страница 37: ...37 Wiring Diagram A SOCKET WIRE TO ON OFF SWITCH E ON OFF SWITCH TO LOWER BOARD AC1 B GROUND F ON OFF SWITCH TO BREAKER C SOCKET WIRE TO BREAKER D ON OFF SWITCH TO LOWER BOARD AC2 ...

Страница 38: ...38 Lower Board LED Diagnosis Top layer of lower control board Bottom layer of lower control board LED 1 LED 2 LED 3 LED 5 6 LED 4 LED 7 LED 8 ...

Страница 39: ...persists check the AC service from the wall outlet LED 5 6 Incline Motor Indicator When the upper board is commanding the incline motor to move UP or DOWN the LEDs go on LED 5 is for the UP function and LED 6 is for the DOWN function If the user is commanding the incline motor to increase decrease and the LED 5 LED 6 is not lit verify that all wire connections have been properly attached If the pr...

Страница 40: ...press and hold the 1 10 quick speed buttons for about 5 seconds to enter the Engineering Mode Menu The console should beep three times and Auto Set should be displayed once in the Engineering Mode Menu Hardware Test Use to check running belt speed and deck elevation While in the Engineering Mode Menu press the Select button until Hardware Test appears in the display Press the Start button to selec...

Страница 41: ...ill belt is running in a jerky or choppy motion To adjust the IR comp turn the dial clockwise to increase voltage to motor or counterclockwise to decrease voltage to motor To verify proper adjustment start the treadmill at 0 5 mph and ride the treadmill belt from the front to rear roller If the treadmill does not have any apparent jerky or choppy movement the IR comp is set properly IR Comp Adjust...

Страница 42: ...42 INCLINE MOTOR TROUBLESHOOTING CONTENTS Incline function does not work 43 Treadmill will incline up or down without command 44 Incline does not reach minimum or maximum settings 45 ...

Страница 43: ...ble causes Verify elevation motor shaft position The elevation motor shaft should be flush with the bottom of the motor housing If the position of the shaft is to close to the bottom motor housing the shaft may have become jammed To correct this remove the bottom bolt from the elevation motor and spin the shaft manually If the elevation shaft has become jammed and can not be spun free to the prope...

Страница 44: ... properly attached Inspect console cable for damage Check voltage of console cable Determine defective part by using console cable chart Verify diagnostic LED s on lower board Reference Diagnostic LED chart for possible causes Replace console cable If problem persists replace lower board and entire console ...

Страница 45: ... Verify elevation motor shaft position The elevation motor shaft should be flush with the bottom of the motor housing If the position of the shaft is to close to the bottom motor housing the shaft may have become jammed To correct this remove the bottom bolt from the elevation motor and spin the shaft manually ...

Страница 46: ...46 DRIVE MOTOR AND ROLLER TROUBLESHOOTING CONTENTS Thumping noises generating from under motor cover 47 Cleaning the motor 48 Thumping noises generating from rear of treadmill 49 ...

Страница 47: ...e brush covers on the drive motor and inspect the brushes and the motor commutator for any uneven wear Make sure the treadmill is turned off before doing this procedure If the surface of the motor brush is pitted rough or has burn marks replace the motor brush and stone the motor commutator Do not plug in the power cord and do not turn on the treadmill when the motor brushes are removed from the d...

Страница 48: ... drive motor With the brushes removed inspect the motor commutator for any unusual wear or burn marks If there is any abnormal marks or wear stone the motor commutator Make sure to blow any dust or particles from the motor commutator when finished After you replace a motor brush make sure the brush is seated securely and makes full contact with the commutator before you plug in the power cord and ...

Страница 49: ... the treadmill run for about 30 minutes without load to break the treadmill in Verify proper tension of the running belt Excessive noise may be created by an over tightened running belt Verify that there is proper clearance between the rear roller and the bottom deck cover and frame If problem persists replaced the rear roller ...

Страница 50: ...50 TREADMILL PARTS REPLACEMENT CONTENTS Running Belt Deck 51 Roller 53 Motor 54 Motor Brush 56 Lower Board 57 Console Cable 58 Incline Motor 60 Upper Board 61 Keypad Membrane Key 63 Air Shock 65 ...

Страница 51: ...e position of the rear roller before removing For best results place two removable marks on the left and right side of the deck and the running belt When reinstalling match up the marks for proper tension 3 With the Philips screwdriver remove the speed sensor 4 With a 6mm Allen wrench remove the front roller It is a good idea to note the position of the rear roller before removing 5 Loosen the bol...

Страница 52: ...completely Then assemble the rear roller and drive belt idler 7 Finish tightening the front roller 8 Start the treadmill and run it to ensure proper belt tension and side to side belt tracking If there is a problem with the belt tension or tracking adjust the rear roller position 9 Install the sensor side rails and all the covers ...

Страница 53: ...tch up the marks for proper tension 4 Reassemble the front roller and the drive belt Install the motor cover Rear roller 1 With a Philips head screwdriver remove the motor cover 2 With a 6mm Allen wrench loosen and remove the front roller It is a good idea to note the position of the front roller before removing For best results place two removable marks on the left and right side of the deck and ...

Страница 54: ...or cover 11 Unplug the motor wires from the lower board 12 Before continuing it is a good idea to weight down the treadmill deck to prevent the treadmill from springing up Removing the weight of the motor will significantly reduce the weight in the front end of the treadmill 13 With a 13mm wrench remove the attachment nuts M08 and washers M09 holding the motor to the frame 14 With a 6mm Allen wren...

Страница 55: ...ace the drive belt on the drive motor making sure that the motor pulley is aligned with the roller pulley 18 Tighten the two motor attach bolts M45 M46 with a 6mm Allen wrench 19 Verify the proper tension on the drive belt Using a timing belt tension gauge the proper tension should be between 65 to 75 lbs If a timing belt tension gauge is not available the drive belt should have approximately 3 8 ...

Страница 56: ... flat blade screwdriver 3 Check the surface of the motor brush If the surface of carbon brush is pitted rough or has burn marks replace the motor brush 4 Stone the surface of the motor commutator and blow out particles inside motor with an air compressor 5 Install the motor brush and the motor brush cover 6 Plug in the treadmill and let the treadmill run for about 1 hour at 5mph to allow the prope...

Страница 57: ...tely 1 minute until the light is out This is an indication that the stored power has left the board Failure to do so may result in injury 4 Unplug all the wires and cables from the lower board It is a good idea to note the position of all wiring before removing 5 With a Philips head screwdriver remove the lower board and replace it with a new one 6 Reconnect all the wires to the lower board Please...

Страница 58: ...nd unplug the power cord from the wall outlet 2 With a Philip head screwdriver remove the motor cover and disconnect the console cable from the lower control board 3 With a Philip head screwdriver remove the console AN1 from the console mast AN3 and unplug the console cable from the console 4 With a Philips screwdriver remove the back console assembly panels N57 ...

Страница 59: ...lug P30 from the console mast 8 Attach the new console cable to the existing cable and fish the new cable through the console mast 9 Once the new console cable is installed through the console mast connect the plugs to the lower board and upper boards 10 Attach the console assembly to the console masts with the 45 mm bolts and 13 mm nut and attach the console mast covers 11 Attach the back panel o...

Страница 60: ... bottom bolt attaching the motor shaft to the incline frame It may be helpful to tip the treadmill on its side to release pressure from the shaft bolt 5 Fold the treadmill down to the running position Remove the top bolt from the incline motor Remove the incline motor from the machine 6 When installing the new incline motor make sure the elevation shaft is flush with the motor casing See diagram b...

Страница 61: ...ase N01 to the bottom console case N02 5 Once all screws have been removed remove the side accent pieces N03 N04 and separate the top and bottom console cases 6 Unplug all the cables connecting to the upper board N17 7 With the screwdriver loosen screws N21 remove the upper board N17 and replace it with a new one 8 Reconnect the console cables 9 Attach the side accent pieces and top and bottom con...

Страница 62: ...62 Upper Board Replacement ...

Страница 63: ...s have been removed remove the side accent pieces N03 N04 and separate the top and bottom console cases 6 Unplug all the cables connecting to the upper board N17 7 With the screwdriver loosen screws N21 and remove the upper board N17 8 Once the upper board has been removed remove the keypad and replace with new one 9 Attach the upper board and secure with screws Reconnect the console cables 10 Att...

Страница 64: ...64 Keypad Replacement ...

Страница 65: ...en the nut that secures the top screws of the air shock to the frame 3 Unscrew the entire air shock counterclockwise to remove it from the bottom screw attachment screw 4 Remove air shock and replace it with a new one screwing the new air shock into the bottom screw and then securing the top of the air shock with the 13 mm nut ...

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