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AC7000M Service Manual

1. 21 Lower PCB Diagram 0 OO QAO wm M 12 Se oe on JP3 Elev Output Connector RL1 Elev Up Relay RL2 Elev Down Relay D1 Elev Up LED D2 Elev Down LED T P Ground T P 12 D7 12 LED J6 8 Pin Telco Connector JP2 Elev Pot Connector D6 Fwd LED J4 Belt Enable Connector J5 6 Pin Telco Connector T P Isolated Speed Reference C2 Cap J2 Speed Reference Output Connector T P Isolated Ground T1 Transformer J1 not printed on PCB Limit Switch Connector T P AC Hot Fused T P AC Com Fused F2 5A 250V fast acting fuse F3 5A 250V fast acting fuse T P AC Hot T P AC Com JP1 AC In Connector 22 F Block Diagrams AC7000 AF 300 4 Wire Block Diagram Wednesday December 03 2003 oe are A pe a m N ies y AF Starter j Wall Plug Cap Power Wires wis Down WS switch a Fa D GND Green ph Hot Com I Com 45 Elevation Brown Motor Blue A bw JP1 BOD S Up ai SAIS AKF UP lt JP3 Limit Switch
2. socket remove the 1 2 bolt that holds the potentiometer and mounting bracket Be careful with the cable as it is soldered to the potentiometer P1485 Bracket Sensor Elevation AC7000 P1479 Pinion Sensor Elevation AC7000 P1269 Pot Elevator AC7000 Install the new potentiometer P1269 onto the old bracket P1485 To do this step loosen the set screw on the pinion P1479 using a 1 16 Allen wrench and slide the pinion off the end of the potentiometer shaft Using a 72 wrench remove the nut that holds the potentiometer to the mounting bracket Pull the old potentiometer out of the bracket and insert the new one with the wires facing the top of the bracket Re install the 1 2 nut and tighten Slide the pinion back onto the potentiometer shaft and re tighten the set screw With the potentiometer gear facing you gently turn the gear counterclockwise until it stops You can damage the potentiometer if you turn it too far Then turn the gear clockwise 1 4 of a turn Mesh the potentiometer gear with the gear on the long shaft off the elevation motor Make sure they are properly aligned The teeth should be meshed together and the gears should line up with each other vertically 60 10 Reinstall and tighten the 7 bolt holding the potentiometer bracket 11 Reinstall the lower PCB mounting plate making sure not to pinch the potentiometer cable underneath it 12 Reconnect all eight 8 w
3. HI for high speed The elevation display shows the scale used by the software for 15 MPH the default is 240 Let the treadmill run until the numerical display on the IMO inverter stabilizes Press START The top display will show AUG for average speed The elevation display shows the scale used by the software for 6 MPH the default is 92 Let the treadmill run until the numerical display on the IMO inverter stabilizes Press START The top display will show SCAL and the elevation display will show PAS for pass for a few seconds Press START and the system will automatically reboot and resume normal operation 37 VI Adjustments and Parts Replacement A Running Belt Tracking and Tensioning 1 Checking Belt Tracking a b Observe the location of the belt P1246 on the deck P1425 or A2352 relative to the side rails Verify that the belt is centered between the side rails along the entire deck surface 2 Adjusting Belt Tracking a If the belt tracks to the left from front to rear Using a 5 16 Allen wrench turn the rear roller s left Allen bolt turn in the clockwise direction until the belt shifts to the right Repeat until the belt is centered If the belt tracks to the right from front to rear Turn the rear roller s right Allen bolt turn in the clockwise direction until the belt shifts to the left Repeat until the belt is centered 3 Checking Belt Tensi
4. Installation SCIFIT is NOT responsible for the repair or replacement of any unit or part damaged during installation The customer is responsible for inspection of each unit and part for damage at the time of installation The customer is responsible for pursuing all damage claims with the installer Service Labor Where applicable the SCIFIT service consultant will arrange a local field service technician to provide field support Every effort will be made to schedule service during the two working days following notification of a problem or as soon as repair parts are available to the field service technician Where possible parts will be supplied in advance of the field service technicians so that the product is repaired with one call All jobs to be performed under labor warranty must have SCIFIT s prior written approval or they will not be paid Preventative Maintenance After training always wipe down your SCIFIT exercise product Perspiration that continuously settles on the frame casings and control panels may eventually cause rust or damage Damage resulting from lack of maintenance will NOT be covered under warranty To clean use mild soap and warm water Dry with a clean towel Preventative maintenance completed according to the schedule below will keep your SCIFIT equipment functioning properly We realize your time is valuable and have kept these maintenance items to a minimum This preventative maintenance schedule assum
5. button is pushed the selected parameter is held If the display deviates from the above pattern the software is corrupt The upper PCB controls the elevation system It measures the voltage drop across the Epot If there is a difference between the elevation entered by the user and the elevation shown by the Epot the upper PCB sends a signal to a relay on the lower PCB to switch on 220 VAC for the elevation circuit The voltage runs through the starter capacitor to the elevation limit switches and then to the elevation motor The motor runs until the elevation entered by the user and the elevation shown by the Epot are equal If there is a failure the upper PCB breaks the signal and it cannot be reestablished unless power is recycled and a new command issued 3 Stopping the treadmill Pressing the Stop button signals the software to go into idle mode after a 30 second pause period During this period the upper display window will cycle through the workout statistics while the two 2 lower display windows will flash It also shuts off the lower PCB and inverter Elevation cannot be adjusted when in idle mode Pulling the emergency stop magnet opens the 12VDC path from the lower PCB to the upper PCB This shuts down the upper PCB which shuts down the lower PCB Even though the LEDs get power from the lower PCB the LED drivers won t run without the 5VDC from the display VR1 IV Mechanical Troubleshooting A Mechanical Troub
6. J2 4 Run Cable connector P2206 Replace or N d Repair Cable o and connections Fli good at J4 Ip or connector Yes replace deck and No replace running i Replace s belt i Inverter es Contact Belt Deck Friction SCIFIT Test 17 lt gt Status Speed numbers Change on display Numbers Change in Inverter Window Hz with Display Key Command Yes Replace inverter Yes L Query Lights on Display Yes Does Belt move Yes Speed Up amp Dn Keys Work Replace No Display PCB Voltage across P Iso Spd Ref and TP Iso GND change with Display Key Command on lower pcb Yes Speed Ref Cable 2207 and connections good at J2 Yes Telco Cables and Connection Good Refer to No Lights on No Display flowchart Refer Belt Does Not Ne Move flowchart Membrane Connected to Display Yes Yy Replace membrane No Replace lower PCB Replace or No Repair Cable No gt Replace Telco s Action No Connect 18 gt Status oe Query Lights on Display yes lev Arrows change values on display No gt yes No gt Action Refer To No Light on Display flowchart Replace membrane y Refer to Test
7. Mode Instructions In Section V Advance to the Elevation Test parameter Resume Flowchart Troubleshooting Motor Elevates Voltage 208 245VAC at JP3 across Up Cable and Connection Good Starter Capacitor measures 9 5 10 5 uf S Telcos and Connections D2 Illuminates on lower pcb when llluminates on lower pcb when Pressed ReplaceTelcos No Cc Replace Display PCB Replace Limit Switch Assembly Yes _ Telcos and Motor onnections Cable amp good Replace or Repair Cable descends connections yes Starter Cap Connections Good __No gt Replace Starter Capacitor nes no gt Replace Elevation Motor If numbers don t change in Elevation Display window replace Elevation Potentiometer If the unit continually blows fuses replace the power supply lower board 19 C Lower PCB LED s and Test Points AC 7000M Lower PCB LED s LED Function Function Description 1 Elevation up Illuminated when up relay is activated 2 Elevation down Illuminated when down relay is activated 3 Not used 4 Not used 5 PWM Flashes when belt motor is on 6 Run Illuminated when belt motor is on T Power 12 to 18
8. P1436 Plate Mount Deck AC7000 Elevate the treadmill to 15 grade Unplug treadmill from the outlet The treadmill will remain elevated Place a solid object under the rear cross member P1513 of the treadmill to elevate the rear of the treadmill and give access to the underside If nothing is available flip the treadmill on its side before you flip the treadmill compile step 4 aaa A1249 Spacer Pad Foot AC7000 P1250 Pad Foot AC7000 Rear roller tension bolts P1513 Weldment Support Cross Rear 4 Remove motor hood P1252 which is held on by nine 9 Philips screws 39 5 Remove the two 2 rear end caps by removing two 2 5 16 bolts one 1 per side using a 2 wrench and socket Using a 9 16 wrench remove the 3 8 bolt on each side securing the foot pad and spacer to each side 6 Remove the two 2 running belt tensioning socket head cap screws one 1 on each side using a 5 16 Allen wrench 7 Remove the tension bracket from each side P1439 Bracket Tension Belt AC7000 Welded tab 8 Locate the guide roller assemblies P1242 There is one 1 guide roller assembly P1242 on the bottom side of each extrusion P1242 Assy Roller Guide Belt AC7000 runs up through the front roller cover A1917 the extrusion and into the guide roller bracket There is one 1 located on the underside of each extrusion A1917 Cover Roller Front 10 Slide guide roller assembl
9. PCB Faulty wireless heart rate PCB Verify chest strap Check and adjust as needed Replace wireless heart rate PCB See page 67 Contact heart rate displays zero 0 in window Not using both hands Loose connection Faulty contact heart rate PCB Faulty upper PCB Use both hands Check all contact heart rate connections from the upper board all the way to the handgrip connections Replace contact heart rate PCB See page 68 Replace upper PCB See page 64 65 B Troubleshooting Flowcharts Although it is impossible to foresee every eventuality the flowcharts on the following pages will cover the more common possibilies If further assistance is required please consult SCIFIT SYSYTEMS Inc Warning Disconnect power before making any test connections C gt Status oS Query Action No lights on the Replace Magnet Plug unit in Turn switch on Flip breaker or consult electrician Telcos Install la No properly Telco s installed 208 245 lt D7 12 oe AC across ACHOT illuminated on ae ACCOM on ower pcb Replace lower No PCB D7 bad across plugged Replace T P 12 amp T P into lower lower Yes Ground on Yes Fuge deed YES
10. PCB regulates the 12 VDC into 5 VDC for VR1 which powers the HR power pins and other components and 8 VDC for VR2 which powers C Safe and Cardio Key On start up the display will emit a beep and it will begin a startup sequence The upper display window will show how many times it has been turned on the left display window will show the software version and the right display window will show the system of measure English or metric units This information will be displayed for five 5 seconds and then the upper display window will show a racetrack pattern and zeros in the other windows 2 Starting the treadmill Pressing the Start button activates the processor to issue various commands to start the treadmill The processor starts the clock which is displayed on the upper PCB The processor issues a command to the lower PCB and the opto isolators switch sends 24 VDC to the inverter This tells the inverter to run and the run light on the inverter should display The belt enable light D6 should illuminate on the power supply at the same time The inverter signals the motor to start which runs the belt at 0 3 mph The inverter varies the frequency of the signal it sends to the motor to control the speed The upper middle LED window on the upper PCB displays six different parameters Time Distance Pace Calories Calories per Hour and Heart Rate The software displays the parameters in the above order If the Select
11. Red lant Green L an White lt DN L_ Black 5 Limit Switch AC7000 Power Supply m JP2 J2 O e z Red f Elevation 5 net 7 Pot J5 Black x 3 og as a S a ign Console E Black Brown Clear Red White Brown Black GND a HOT e Com creen eaan e eteejetee etted Whee aN _5 5HP Drive Inverter Filter Inverter AF 300 M II L3 Motor 1 Wire colors may vary _ J Green HOT Load Com ee L2 we HOT Com UV W nen ae Blue Brown Page 1 Note Use this wiring diagram if your treadmill is equipped with an IMO inverter VXS 220 1 mounted on top of the filter and has a four wire elevation motor 23 AC7000 VXS 4 Wire Block Diagram f k Wednesday December 03 2003 Pod a Wat Plug Cap Power Wires nonpolar Down ee switch S Be OTS GND Green L a a p Hot Com lt Com Elevation Brown 4 5 Motor Blue J U a OOO Ste a JP1 JP3 UP ame K Limit Switch IST Ls Green M White DN L Limit Switch Black Y AC7000 Power Supply White a
12. Select the maximum user speed by using the SPEED UP or SPEED DOWN keys After selecting the desired speed press the SELECT key to advance to the next setting Distance This function displays the distance since the deck was last flipped The top display will show FLIP The speed and elevation displays combine to show the distance with the speed display showing thousands of miles or kilometers and the elevation display showing hundreds of miles or kilometers If FLIP is displayed in the TIME window in normal operating mode and the deck has been flipped the following steps must be performed to clear the distance Press and hold the ELEVATION UP arrow for three 3 seconds to reset once 12 000 miles has been accumulated Press SELECT to exit the Club Mode and return to start mode If the treadmill is not displaying FLIP in the TIME window press SELECT to advance to Speed Calibration Calibrate Speed CALS will be shown in the top display This setting calibrates the speed of the treadmill After this calibration is completed the system will reboot load data and resume normal operation If you want to calibrate the elevation instead of speed press SELECT to bypass this Setting 32 Press the ELEVATION UP and ELEVATION DOWN switches simultaneously for three 3 seconds to enter the speed calibration subprogram SCAL will be shown in the top display Press START WARNING The belt will start moving at
13. VDC is present Illuminated when power is on AC 7000M Lower PCB Test Points Test Point Circuit Function Voltage to Ground T P ACCOM 110 VAC input leg of 220 VAC 110 VAC T P ACHOT 110 VAC input leg of 220 VAC 110 VAC T P ACCOM FUSED Circuit board side of fuse for input 110 VAC voltage T P ACHOT FUSED Circuit board side of fuse for input 110 VAC voltage T P 12 Provides 12 to 18 VDC to circuit 12 to 18 VDC board T P VLED1 Controls 2 of console LEDs 6 VDC T P VLED2 Controls 2 of console LEDs 6 VDC T P 5V Controls LEDs at console Will have 5 VDC sound T P ISOLATED Controls speed Variable based on GROUND speed T P ISOLATED SPD Controls speed Variable based on REF speed 20 D AC 7000M Upper Display PCB Jacks Jack PCB ID Function Interface Jack Type Pin1 Pin2 Pin3 Pin4 JP1 None CardioKey 4 pin Molex Xmit Rec 5 V Grd J1 None To Power Supply J6 8 pin Molex J2 None To Power Supply J5 6 pin Molex J3 None Not Used J4 Grip Contact HR 3 pin Molex Signal V Grd J5 Polar Polar HR 3 pin Molex Signal V Grd J6 None Not Used J7 None Not Used J8 None C Safe 8 pin Telco J9 None Jumped to J10 Single Blade J10 None Jumped to J9 Single Blade J11 Right Stop SW Not Used J12 Left Stop SW Not Used J13 Lower Console SW Switch interface 4 pin Molex J14 Upper Console SW Switch interface 7 pin Molex
14. customer s expense If requested SCIFIT will charge the customer s UPS or Federal Express account or COD the difference in freight cost between ground shipment and overnight or second day Return Parts In order to research problems and ensure they do not reoccur the rapid return of defective parts is our biggest help Thank you in advance for your assistance On electronics orders a 100 00 core charge is assessed to each printed circuit board This amount will be credited once the boards have been received by SCIFIT All defective parts must be returned to the SCIFIT factory within 20 days of receipt of replacement part for invoice credit Otherwise SCIFIT will expect payment on the parts invoice net 30 days Please follow these three easy steps for returning parts Step 1 Keep the box and packing material in which the new parts arrived Locate the enclosed prepaid UPS return label Step 2 Wrap the defective part and place in the box for a safe return Include a copy of the picking ticket that came with the replacement part Step 3 SCIFIT service will include a prepaid return label in the parts box for only those parts that need to be returned Call UPS at 800 742 5777 for pick up When ALL of the parts are received and inspected at the factory a credit will be issued for the original parts invoice Attention service companies Warranty labor invoices will NOT be paid until required defective parts are returned to the factory
15. in the top display will advance The number in the top display will be shown in the sequence listed in the following table and the switches must be pressed in this sequence If the switches are not pressed in this sequence the test will not advance Number Switch Number Switch 1 Start 6 Elevation Down 2 Stop 7 Speed Up 3 Scan 8 Speed Down 4 Select 9 Heart Rate Up 5 Elevation Up 10 Heart Rate Down Grade Test When the Switch test is complete the system will automatically advance to the Grade test GrAd will be shown in the top display This test removes the software from the elevation control system It utilizes only the hardware of the system Press the ELEVATION UP arrow only or ELEVATION DOWN arrow only to determine if the elevation system is working properly WARNING Do not press both the ELEVATION UP and ELEVATION DOWN arrows at the same time in this mode severe damage will result 27 The speed display will show UP or dn depending on whether the treadmill s elevation is going up or down The elevation display will show the scale that is used by the software high numbers when the treadmill is down and low numbers when it is elevated When satisfied that the elevation system is working press STOP to advance to the next test Speed Test WARNING DO NOT TO STAND ON THE BELT IT WILL MOVE DURING THIS TEST bELt will be shown on the top display This te
16. is 25 0 The speed display will show UP2 The elevation display shows position in the 256 bit scale used by the software as indicated by the elevation potentiometer it should be more than 225 when the treadmill is completely elevated The treadmill will elevate to the high limit switch The top display will then change to 0 0 which is the low grade set in the Factory Settings Mode The speed display will show dn The elevation display should be less than 30 when the treadmill is completely lowered The treadmill will descend to the lower limit switch The software will automatically create a scale based on the difference in resistance of the potentiometer from the upper to the lower limit switches 33 When the elevation calibration is complete the top display will show ECAL and the speed display will show the lower grade limit and the elevation display will show the upper grade limit both in terms of the scale value Press START and the system will reboot load data and resume normal operation Club Mode Version 10 1 10 5 Serial Number 710 005122 and Up The Club Mode enables club owners and managers to customize certain features of the AC7000 treadmill Press the ELEVATION UP and ELEVATION DOWN keys simultaneously for three 3 seconds to enter this mode press the keys until Unlt is shown in the top display 1 Unit of Measure This setting determines whether English or metric units of measure
17. measure by using the SPEED UP SPEED DOWN ELEVATION UP or ELEVATION DOWN keys After selecting the desired unit of measure press the SELECT key to advance to the next setting 31 Duration This setting allows the owner manager to select the maximum workout time which will be available to the user The speed display will show dUr The range is from 0 to 90 minutes in increments of 5 minutes 0 is unlimited time and is the default setting The top display shows the time selected Select the duration by using the ELEVATION UP or ELEVATION DOWN keys After selecting the desired duration press the SELECT key to advance to the next setting External Communication This setting selects either the C Safe CSF or Cardio Key CAr communications protocol The top display will show S CO The speed display will show either CAr or CSF Use the SPEED UP or SPEED DOWN keys to toggle between the two If neither C Safe nor Cardio Key is used either setting will work After selecting the desired communication protocol press the SELECT key to advance to the next setting User Speed This setting allows the owner manager to select the maximum speed which will be available to the user The top display will show U SPd The range will depend on the factory settings the defaults of which are 0 3 to 10 0 MPH 1 to 16 KPH The speed display shows the value selected The default setting is 10 0 MPH 16 0 KPH
18. o PCB 4 Install la No installed on Replace No Plug Telco s Display PCB No fuse JP1 in T1 bad across Hot amp Com Yi Continuity across 412V on J Replace lower on JP1 plete cS magnetic switch w Display PCB pcb Y T pin 5 Replace Y Ghieck r Replace Aa es y No replace Switch 208 245 VAC Replace Replace y to lower PCB YS S across Power 7 N 0 ea Magetic Display Replace cable wite Switch PCB Telco s ed If the unit continually blows fuses replace the power supply lower board 16 lt gt Status Recalibrate Speed Speed Calibration DC Voltage across T P ISO GND and ISO peed Ref 1 6VDC on lower pcb See Club Setting Mode e Yes D5 pwm on lower PCB flashing lt gt Query Lights on Display Yes Start Button Work Yes elt Move When Speed is set to 3MPH D6 fwd illuminated lower pcb Action Refer to No Lights on Display flowchart Replace Switch Membrane Run Light on Inverter Illuminated on Yes Telcos and Nez Replace lower le Yes Connection ioci Replace yes PCB Good Telco s No Non zero See a No and connections No Hz pay good at the
19. on the running belt P1246 with your feet in positions 1 and 4 Position your toes so they are approximately 12 inches from the motor hood P1252 2 Place both hands on the handle bar A1793 3 Push on the handle bar to see if you can propel yourself backwards on the running belt Reminder Your full weight needs to be on the running belt and your feet in positions 1 and 4 4 Repeat step 1 3 with your feet in positions 2 and 3 instead of positions 1 and 4 Note If you can propel yourself without the belt binding up in either foot position set the belt and deck friction should not be a problem If the friction is significantly higher in one foot position set than the other or the belt to bind ups or sticks in either the belt needs to be replaced and the deck flipped or replaced 13 V Electrical Troubleshooting A Electrical Troubleshooting Tables Problem Possible Reasons Solutions Unit keeps blowing fuses on lower board Incoming voltage too high Relays sticking on lower board Defective lower PCB Verify voltage to the unit Replace lower PCB See pages 68 69 Replace lower PCB See pages 68 69 No lights on upper display Numerous See flowchart Page 16 Upper display lights are dim Improper wall voltage Faulty lower PCB Damaged Telco Check wall voltage Replace lower PCB See pages 68 69 Replace if needed When pressed buttons do not beep and
20. potentiometer cable has a gray jacket with a 4 pin Molex connector This plugs into JP2 e Two 2 gray cables run from the inverter to the lower PCB The cable with the white 3 pin large Molex header plugs into J4 The other cable has a white 4 pin large Molex header and connects to J2 e The 6 pin Telco cable plugs in where the board is labeled J5 e The 8 pin Telco cable plugs into J6 ONO 11 Verify all wires are connected 12 Restore power to the unit 13 Run through Test Mode on pages 27 28 to ensure that all other functions are working properly with the new lower PCB 14 Install motor hood Inverter Replacement For units equipped with the IMO VXS or G E AF 300 not E 11 inverter follow procedure 1 For units equipped with the G E AF 300 E 11 inverter follow step 2 Procedure 1 1 Turn off power to the treadmill at the switch 2 Remove the Philips screw on the lid of the inverter 3 Using a Philips and a small flat head screwdriver remove all wires from inside the inverter 4 Remove the four 4 flat head screws that mount the inverter 5 Mount the new inverter the same way the old one came out 6 Wire according to the appropriate diagram on pages 22 25 69 7 Verify all connections install inverter lid and then restore power to unit 8 All 60 Hz treadmills need to be auto tuned 50 Hz treadmills do not get auto tuned Start the Auto Tune process by pressing the PRG RESET key one time F00 wi
21. settings the defaults of which are 0 3 34 to 10 0 MPH 1 to 16 KPH The speed display shows the value selected The default setting is 10 0 MPH 16 0 KPH Select the maximum user speed by using the SPEED UP or SPEED DOWN keys After selecting the desired speed press the SELECT key to advance to the next setting Distance This function displays the distance since the deck was last flipped The top display will show FLIP The speed and elevation displays combine to show the distance with the speed display showing thousands of miles or kilometers and the elevation display showing hundreds of miles or kilometers If FLIP is displayed in the TIME window in normal operating mode and the deck has been flipped the following steps must be performed to clear the distance Press and hold the ELEVATION UP arrow for three 3 seconds to reset once 12 000 miles has been accumulated Press SELECT to exit the Club Mode and return to start mode If the treadmill is not displaying FLIP in the TIME window press SELECT to advance to Speed Calibration Calibrate Speed CALS will be shown in the top display This setting calibrates the speed of the treadmill After this calibration is completed the system will reboot load data and resume normal operation If you want to calibrate the elevation instead of speed press SELECT to bypass this Setting Press the ELEVATION UP and ELEVATION DOWN switches simultaneously for thre
22. show HI for high speed The elevation display shows the scale used by the software for 15 MPH the default is 162 Use the SPEED UP arrow to change the value to read 196 Let the treadmill run until the numerical display on the inverter stabilizes Press START The top display will show AUG for average speed The elevation display shows the scale used by the software for 6 MPH the default is 64 Use the SPEED UP arrow to change the value to read 77 Let the treadmill run until the numerical display on the inverter stabilizes Press START The top display will show SCAL and the elevation display will show PAS for pass for a few seconds The system will automatically reboot and resume normal operation 30 7 Calibrate Elevation If you have calibrated the speed you will need to reenter the Club Setting Mode again Press SELECT until CALE is shown in the top display This setting calibrates the elevation of the treadmill Press the ELEVATION UP and ELEVATION DOWN switches simultaneously for three 3 seconds to enter the elevation calibration subprogram ECAL will be shown in the top display Press START The top display will show the high grade selected the Factory Settings Mode which is 25 0 The speed display will show UP2 The elevation display shows position in the 256 bit scale used by the software as indicated by the elevation potentiometer it should be more than 225 when the trea
23. 0 horsepower three phase electric motor e The three phase terminals are labeled U W and V Ifa three phase motor run the wrong direction just flip any two of the three wires around e Turns the front roller via a HTD belt which turns the running belt 12 Hand Grip Contact Heart Rate HGHR The PCB has right and left grip inputs its own program and hardware that output a square wave to the display PCB Power and ground is provided by the upper PCB 13 Wireless Heart rate PCB Like the HG heart rate it also outputs a square wave Power and ground is provided by the upper PCB This PCB has a 30 range and position is critical System Functions 1 Turning on the treadmill The power cord must be plugged into a 240 VAC 20 amp dedicated circuit Turning on the rocker switch provides power 240 VAC 120 VAC on each line to the lower PCB and the inverter filter Power to the lower PCB is verified by observing a lighted LED D7 The lower PCB regulates 12 VDC into 6 VDC for VR1 which powers half the display LEDs 6 VDC for VR2 which powers the other half of the display LEDs and 5 VDC which powers the elevation pot Power from the inverter filter energizes the inverter turning on the fan and display The display should read 0 00 in the window and a light showing what kind of data it is displaying e g Hz volts current RPM Power 12 VDC is routed from the lower PCB to the upper PCB pin 5 of the 8 pin cable The upper
24. 6 N 8 Lift the front roller back up slightly and slide to the right into the extrusion channel vacated by the spacer This will create enough of a gap on the left end of the front roller to remove your old belt 9 Slide the old belt off the front roller pulley and the motor pulley 10 Install your new belt around the two pulleys 11 Once the new timing belt is in place slide the front roller to the left until the threaded hole in the end of the roller shaft line up with the bolt hole for the front roller in the left extrusion 12 Insert the bolt and lock washer through the left extrusion and into the front roller Thread about of the bolt into the front roller 13 On the right side insert the bolt through the extrusion and nylon flange bushing if applicable On the inside of the extrusion place nylon thrust bearing if it originally had one onto bolt followed by the spacer 14 Line the threaded hole in the right end of front roller with the bolt coming through the spacer 15 Thread the bolt into roller and then tighten both front roller bolts 16 Restore power to the unit and tension the running belt according to the Treadmill Running Belt Tracking and Tensioning procedure Page 37 17 With the power off check the drive belt tension There should be approximately 3 8 travel when pressing down on top of the belt to put belt at its lowest position between the pulley then hooking a finger below the belt and pu
25. Black ae os HOT e Com bd thao ye r 4HP Drive Inverter Filter Inverter E 11 Com HOT Load Blue Brown HOT Com UVW L3 Motor L1 ere Page 1 Note Use this wiring diagram if your treadmill is equipped with a G E inverter AF 300 E 11 and a four wire elevation motor 25 AC7000 E 11 3 Wire Block Diagram Wednesday December 03 2003 ae eee tl E am D je aren Starter Wall Plug Cap Power Wires nonpolar Down o switch L F 0 GND Green eee Hot Com L Com l4 Elevation ee Motor Blue a J T ya U Se 7 OOO Pt SOOS H 5 JP3 UP Ia x Limit Switch Red S Green White DN _ Black Limit Switch J AC7000 Power Supply White aa m JP2 7 Je 2s E Red 4 levation a O a a Pot j J5 Se oa To J4 peck N 3 7 Sa x Console z Black Brown Clear Red White Brown Black ae Mig os HOT te Com Biot rae es _ 4HP Drive Inverter Filter Inverter E 11 L3 Motor L1 J HOT Load Com N 1 es HOT Com UV W ne Blue A 3 2 Brown
26. LEVATION DOWN keys After selecting the desired duration press the SELECT key to advance to the next setting 3 External Communication This setting selects either the C Safe CSF or Cardio Key CAr communications protocol The top display will show S CO The speed display will show either CAr or CSF Use the SPEED UP or SPEED DOWN keys to toggle between the two If neither C Safe nor Cardio Key is used either setting will work After selecting the desired communication protocol press the SELECT key to advance to the next setting 4 User Speed This setting allows the owner manager to select the maximum speed which will be available to the user The top display will show U SPd The range will depend on the factory settings the defaults of which are 0 3 to 10 0 MPH 1 to 16 KPH The speed display shows the value selected The default setting is 10 0 MPH 16 0 KPH Select the maximum user speed by using the SPEED UP or SPEED DOWN keys After selecting the desired speed press the SELECT key to advance to the next setting 5 Distance This function displays the distance since the deck was last flipped The top display will show FLIP The speed and elevation displays combine to show the distance with the speed display showing thousands of miles 29 or kilometers and the elevation display showing hundreds of miles or kilometers If FLIP was displayed in the TIME window in normal operating mode and
27. MA 6 20R Receptacle NEMA 6 20P Plug Theory of Operations This theory of operations is designed to give the service technician an understanding of how the different systems of the treadmill operate and how the systems work together Having an overall understanding of the treadmill systems enables the service technician to better trouble shoot the various problems that occur The AC7000M is an AC variable frequency drive controlled treadmill designed for a wide range of applications that vary from the medical market to the sports performance market This theory of operation encompasses all electrical components their functions and how the components interact with each other The following is a list of independent electrical components found in the treadmill 1 15A Rocker Breaker switch 2 Lower PCB 3 Upper Display PCB 4 Elevation System e Elevation motor e Starter cap e Elevation potentiometer Epot e Omron general purpose Limit Switches 5 Drive System e Inverter variable frequency drive e Filter e Ferrite ring e AC Three Phase Drive Motor 6 Hand Grip Heart rate PCB HG HR 7 Wireless Heart rate PCB Polar Component Functions 1 15A Rocker Switch The power cord is attached to a rocker style switch combined with a 15 Amp circuit breaker to prevent electrical damage to the electrical components If the breaker trips just turn it back on and the breaker resets The switch routes power to the lower PCB and the i
28. PCB If your treadmill is equipped with contact heart rate a black cable with a 3 pin Molex header will be coming from the left side of the console This plugs into the vertically mounted 3 pin header just below the wireless heart rate header Plug the 6 pin and 8 pin Telco cables into the black headers on the bottom center part of the upper PCB If your unit is equipped with Cardio Key there will be a gray cable with a 4 pin Molex header coming through the right side of the console This plugs into the vertically mounted header on the right backside of the upper PCB Broadcast Vision is another optional feature of the treadmill If your unit is set up for this option there is a black 8 pin Telco cable coming into the console housing Its location depends on where the user decided to mount the keypad This plugs into the black header that sits by itself on the right backside of the upper PCB 17 While making sure not to pinch any wires lay the display down into the console housing 18 Insert the four 4 display screws through the console back plate and into the standoffs 19 Snug these screws until secure Do not heavily torque 66 O 8 9 Wireless Heart Rate PCB Replacement f P1251 Console Display AC7000 65160 PCB Heartrate Rotary Antenna Turn off the power to the unit then remove magnet from upper display Using a Philips screwdriver remove the four 4 screws that mount the upper di
29. RESET once The inverter will now display is normal operating screen If any other values are displayed after performing the auto tuning function please consult SCIFIT at 1 800 745 1373 36 Once the treadmill has been performance tested replace the motor hood l Timing Belt Replacement P1247 Belt Timing 5M 25mm 670mm A1401 Spacer Roller Belt Front AC7000 Front roller bolt TA Front roller bolt P1246 Belt Running w Logo AC7000 A1244 Roller Drive Front AC7000 1 Elevate treadmill to 15 incline and turn off power to the unit 2 Using a Philips screwdriver remove the motor hood P1252 which is held on by nine 9 screws 3 Use a 5 16 Allen wrench to turn each rear roller tension bolt counterclockwise 6 10 full turns to release running belt pressure 4 Remove the left front roller bolt using a 9 16 wrench or socket 5 Loosen the right front roller bolt far enough to disengage bolt threads from the roller threads 6 Press down on the right side of the front roller until it is free of the front roller spacer A1401 7 Remove the Front roller spacer Newer models have a nylon thrust bearing P2046 between the spacer and extrusion Pull the bolt out of the extrusion Newer models have an additional nylon flange bushing P2045 inserted into the front roller bolt hole on the outside of the right extrusion 55 P2046 Bearing Thrust 7 16 ID 1 2 o P2045 Bushing Flange 3 8 ID 7 1
30. TIES OF SCIFIT INCLUDING DIRECT INDIRECT SPECIAL AND CONSEQUENTIAL DAMAGES OR PENALTIES EXPRESSED OR IMPLIED WHETHER ARISING OUT OF CONTRACT NEGLIGENCE OR OTHER TORT 5 Certain wear items are excluded from warranty coverage unless determined to be defective These items include but are not limited to Grips Decks Running Belt Rubber Foot Pads 6 The following items are covered for a period of one 1 year only Contact Heart Rate Grips Heart Rate Receiver Transmitter Freight and Shipping SCIFIT is NOT responsible for the repair or replacement of any unit or part damaged during transit or installation Fire flood and acts of God are NOT covered under this warranty The customer is responsible for pursuing all freight damage claims with the appropriate transit company If the customer signs for freight damaged goods without noting the damage on the bill of lading the customer is solely responsible for the cost of repair or replacement for such freight damage If freight damage is noted on the bill of lading the customer must pursue a claim with the freight carrier Parts Supply During the first 30 days warranty parts will be shipped via next day overnight delivery excluding international shipments Determination must be made before 2 00 p m CST on any given weekday for next day delivery After 30 days parts will be shipped via ground shipment The customer is welcome to request overnight or second day parts shipping at the
31. Using a 1 2 socket remove bolts holding safety pan A1446 on the bottom of the elevation assembly 61 oo A1446 Pan Safety AC7000 P1260 Switch Limit Elevation AC7000 On the backside of the bracket that the limit switches mount to remove the two 2 nuts holding the limit switches in place Remove switches Re attach wires in the same order on the new limit switches Replace the new limit switches through the same two 2 holes that the other ones were removed from Make sure the two 2 legs on the limit switches clear the elevation rack A1508 Elevation rack Limit switch legs Replace the two 2 4 40 machine nuts on the backside of the bracket Install the bolts back in the bottom of the safety pan Calibrate the elevation using the Elevation Calibration procedure explained in the Club Mode for your version of software Pages 28 36 Procedure 2 1 2 3 With the treadmill at 0 elevation turn power switch to the off position Using a Philips screwdriver remove the motor hood Disconnect the 6 pin and 8 pin Telco cables from the lower board 62 4 Disconnect the green static drain wire This wire comes out of the hole in the left upright and has a connector between the upright base and the lower board mounting plate 5 Using a socket and extension remove the four 4 bolts with washers and the four 4 nuts with washers from the upright bases 6 Remove the upright assembly by lifting it up ove
32. Vi VII Table of Contents General Information Set Up Theory of Operations Mechanical Troubleshooting Electrical Troubleshooting Adjustments and Parts Replacement Assembly Drawings and Part List Page 2 5 12 13 14 37 38 70 71 l General Information Purpose This manual provides information for the servicing of SCIFIT AC7000M treadmills It uses systematic troubleshooting procedures to address problems that may arise with the AC7000M The actions taken to resolve problems must be performed in the order stated Deviating from this sequence may cause damage to the equipment lead to unnecessary repairs or void the warranty Technical Support For further assistance in the service of SCIFIT products please call 800 745 1373 or 918 359 2000 ext 3 We can also be reached by fax at 918 359 2045 or by e mail at service scifit com The product support department is staffed from 7 AM to 6 PM CST Monday through Friday A voicemail service is available 24 hours daily for recording messages to request technical support and to order replacement parts Our mailing address is 5151 S 110 E Avenue Tulsa OK 74146 Please have the following information prior to calling product support e Model number of equipment e Serial number of equipment e Point of contact name address and phone number e Detailed description of symptoms encountered SCIFIT Statement of Warranty SCIFIT warranties new products against defecti
33. acility 1 Source voltage is between 208 245 volts AC on a dedicated 20 amp circuit Note Source voltage below 208 Volts may cause inconsistent operation of the elevation motor and or drive system 2 Dedicated circuits for each treadmill must be installed in accordance with current voltage drop standards set by NEC code See Table 1 below Table 1 shall be considered as a guideline only any questions should be brought to the attention of a licensed electrician Note A dedicated circuit is a power outlet reserved for the exclusive use of one and only one treadmill This includes hot neutral and ground wires This is done to provide proper frame ground drainage of the treadmill The outlet should not be shared with any other piece of equipment Table 1 Source Voltage Maximum Distance from Source Minimum Cable Size 240V 121 feet 36 3 meters 12 AWG 240V 193 feet 57 9 meters 10 AWG 240V 307 feet 92 1 meters 8 AWG 240V 488 feet 146 4 meters 6 AWG Calculations based on NEC code table 310 16 with 3 Voltage drop on a copper conductor 240V service 3 Have a proper outlet installed by a qualified electrician See plug diagram below Note DANGER Improper connection of the equipment grounding conductor can result in a risk of electric shock Check with a qualified electrician if you are in doubt as to whether the product is properly grounded Receptacle and Plug Diagram NE
34. bolt will run from inside the extrusion on down through hole 28 Slide spacer onto each bolt followed by the flat washer and foot pad Place 9 16 wrench onto bolt head and turn foot pad clockwise until tight 29 Insert the bolts that run up through the welded tabs and the end cap brackets Put a 5 16 18 nylock nut on each bolt and tighten down Insert the front roller the reverse of the way you removed it Position the roller with motor belt in place and install the two 2 front roller bolts The right side has a roller spacer A1401 that goes between the front roller and frame A1401 Spacer Roller Belt Front AC7000 30 Slide deck to where it is to 1 from the front roller Tighten the ten 10 outer bolts that run through the cross braces on the bottom of the deck 31 Install the front roller cover Only insert and tighten the bolts going through the front roller cover and into the motor plate 32 Install the two 2 guide rollers Hook the roller housing inside the deck belt and place the flat side of the guide roller bracket on the innermost lip of the extrusion 33 Start the HCS 5 16 18 X and 5 16 lock washer up through the front roller cover extrusion and the guide roller bracket 34 Make sure the bracket is perpendicular 90 angle to the extrusion Tighten bracket in place 35 Install rear roller tensioning socket head cap screws one on each side the two 2 end caps and the two 2 footpad
35. d Short Front and Rear Deck Cross Braces A2080 oN Cushioned Deck and Running Belt Replacement A2352 Deck Cushioned Treadmill Deck front P2086 Spring Urethane 1 0 OD x 500 ID x 75 Long A2081 Nutbar Brace Cross Deck Cushioned A2080 Brace Cross Deck Cushioned 3 A2594 Strip Insulating Deck A2085 Spacer Deck Cushioned A2108 Pin Locating Deck Cushioned View with P2086 Urethane Spring removed P2087 Bearing Sleeve Nylon 50 OD x 375 ID x 75 Long 3 Centermost Deck Cross Braces A2080 A2121 Strip Foam Absorbing Deck Cushioned Long Elevate the treadmill to 15 grade Unplug treadmill from the outlet The treadmill will remain elevated Place a solid object under the rear cross member P1513 of the treadmill to elevate the rear of the treadmill and give access to the underside If nothing is available flip the treadmill on its side before you flip the treadmill complete step 4 43 A1249 Spacer Pad Foot AC7000 P1250 Pad Foot AC7000 Rear roller tension bolts P1513 Weldment Support Cross Rear Remove motor hood P1252 which is held on by nine 9 Philips screws Remove the two 2 rear end caps by removing two 2 5 16 bolts one 1 per side using a 2 wrench and socket Using a 9 16 wrench remove the 3 8 bolt on each side securing the foot pad and spacer to each side 6 Remove the two 2 running belt tensioning socket head ca
36. dmill is completely elevated The treadmill will elevate to the high limit switch The top display will then change to 0 0 which is the low grade set in the Factory Settings Mode The speed display will show dn The elevation display should be less than 30 when the treadmill is completely lowered The treadmill will descend to the lower limit switch The software will automatically create a scale based on the difference in resistance of the potentiometer from the upper to the lower limit switches When the elevation calibration is complete the top display will show ECAL and the speed display will show the lower grade limit and the elevation display will show the upper grade limit both in terms of the scale value Press START and the system will reboot load data and resume normal operation Club Mode Version 10 1 10 5 Thru Serial Number 710 005121 The Club Mode enables club owners and managers to customize certain features of the AC7000 treadmill Press the ELEVATION UP and ELEVATION DOWN keys simultaneously for three 3 seconds to enter this mode press the keys until Unlt is shown in the top display 1 Unit of Measure This setting determines whether English or metric units of measure will be displayed The top display will show Unit The speed display will show pri or SI brl represents British or English units miles and SI represents metric units kilometers Select the unit of
37. e 3 seconds to enter the speed calibration subprogram SCAL will be shown in the top display Press START WARNING The belt will start moving at the set low speed The top display will show LO for low speed The elevation display shows the scale used by the software for 3 MPH the default is 3 Let the treadmill run until the numerical display on the inverter stabilizes Press START WARNING The belt will start moving at the set high speed The top display will show HI for high speed The elevation display shows the scale used by the software for 15 MPH the default is 240 Let the treadmill run until the numerical display on the inverter stabilizes Press START The top display will show AUG for average speed The elevation display shows the scale used by the software for 6 MPH the default is 92 Let the treadmill run until the numerical display on the inverter stabilizes Press START 35 The top display will show SCAL and the elevation display will show PAS for pass for a few seconds The system will automatically reboot and resume normal operation Calibrate Elevation If you have calibrated the speed you will need to reenter the Club Setting Mode again Press SELECT until CALE is shown in the top display This setting calibrates the elevation of the treadmill Press the ELEVATION UP and ELEVATION DOWN switches simultaneously for three 3 seconds to enter the elevation calib
38. es the equipment is utilized 6 to 8 hours per day If the equipment is utilized to a greater extent the maintenance schedule must be adjusted accordingly Machine Weekly Monthly 6 Months 12 000 Miles AC7000M Clean exterior Vacuum interior amp Grease Racks Flip deck clean Treadmills See Note 1 blow off See Note 4 rollers See Note electronics See Note 2 3 Note 1 Clean the console with a damp cloth The rest of the machine can be cleaned using common household cleaners Note 2 Be careful not to vacuum the electronics Touching the electronics with any object can cause static damage Note 3 These maintenance items should be performed every 12 000 miles This schedule assumes a treadmill is operated 12 000 miles in one year The treadmill console will display FLIP in the top center window when 12 000 miles has been reached Note 4 We use Super Lube synthetic grease item no 82328 Any high quality industrial grease will do ll AC7000M Treadmill Power Requirements The AC7000 Treadmill is a high performance machine with certain power requirements that must be maintained in the field for proper operation Inadequate power to the AC7000 may result in intermittent failure of the elevation system low voltage shutdown of the variable frequency drive and improper speed valuation of the running belt The following electrical parameters must be met when determining existing power in a f
39. f the console Lift membrane up to expose wiring connections on the back of the upper PCB Warning Make sure you are grounded before handling electronics Failure to do so may result in static damage Disconnect all wires to the upper PCB by grabbing them at the connector and pulling away from the connector on the upper PCB While holding only the membrane remove the display assembly from the console Remove the eight 8 Philips screws holding upper PCB to the membrane Disconnect both ribbon cables from the membrane to the upper PCB Replace upper PCB and install the eight 8 Philips screws Reconnect the ribbon cables Reconnect the two 2 black wires from the magnetic switch These wires are not polarity sensitive 10 Rest bottom of membrane on the cutout in the upper console Tilt the top of the membrane back toward you This will create enough room for you to access the wires and the back of the upper PCB 11 Reconnect wires to the upper PCB e The wireless heart rate cable comes out of the left side of the console This component has a gray cable with the 3 pin Molex header and connects to the horizontally mounted 3 pin connector on the left backside of the upper PCB e f your treadmill is equipped with contact heart rate a black cable with a 3 pin Molex header will be coming from the left side of the console This plugs into the vertically mounted 3 pin header just below the wireless heart rate header e Plug the 6
40. ge the potentiometer if you turn it too far Then turn the gear clockwise of a turn 22 Mesh the potentiometer gear with the gear on the long shaft off the elevation motor Make sure they are properly aligned The teeth should be meshed together and the gears should line up with each other vertically 23 Reinstall and tighten the 72 bolt holding the potentiometer bracket 58 24 Check all bolts for tightness and all gears for alignment including how the pinions align with the elevation racks If the pinions do not align loosen the two 2 outermost bolts on whichever coupling does not line up Slide that shaft and pinion horizontally until it does Then re tighten the outermost bolts 25 Replace the lower PCB mounting plate using the four 2 head bolts Be careful not to pinch the potentiometer cable under the plate 26 Re install the lower PCB 27 Reconnect all eight 8 wires to the lower PCB Refer to pages 21 for lower PCB configuration The wiring connections are as follows e The limit switch cable is a cable assembly with a gray jacket and a white 5 pin mate n lock connector It plugs into the brown 5 pin socket which is not labeled e The power cable from the rocker switch is to lower PCB plugs is a cable assembly with a black jacket and a white 3 pin mate n lock connector This plugs into the socket labeled JP1 e The wires coming out of the elevation motor that tie together with the starter cap plug into the socke
41. he voltage and returns it 7 Omron General Purpose Limit Switches Are used for calibration and safety only They are attached to the right side of the frame next to the elevation rack They have one input and two outputs normally open N O or normally closed N C We only use the N O but the way we use it the N O switch is held closed and the switch opens when it hits the limits the indentations on the elevation rack 8 Inverter e ls a variable frequency drive VFD It has its own processor memory settings error codes inputs and outputs e Rectifies the input AC into DC and the processor uses a clock to fire insulate gate bipolar transistors IGBT in such an order that a synthetic AC wave is made Each output line is made 60 out of phase and that runs the three phase motor e All inputs and outputs are electrically isolated from the lower PCB and upper PCB via the opto isolators on the lower PCB 9 Filter The filter is an electromagnetic interference EFI filter that stabilizes the input voltage for the inverter which makes the inverter more dependable and the output to the motor cleaner 10 Ferrite Ring Is an inductor and opposes change in current hence it functions as a surge protector The ring is installed on the cable between the inverter and AC three phase drive motor 11 AC Three Phase Drive Motor e Is a Brook Crompton 5 5 horsepower three phase electric motor in older models Newer models have a 4
42. her P1250 Pad Foot AC7000 Tension bolts 49 5 Remove both guide rollers using a 2 wrench P1242 Assy Roller Guide Belt AC7000 6 With a 9 16 wrench remove the left side front roller bolt Loosen the right side front roller bolt far enough to disengage the bolt threads from the roller threads Rotate the right side of the front roller under the deck and belt This will loosen the motor belt on the left side of the front roller and make it easy to slide off Rotate the front roller approximately 90 from its original position Pull the roller out from under the treadmill 7 Place a solid object under the rear cross member P1513 of the treadmill This will allow access to the underside of the treadmill 8 Remove the rear feet Using a 9 16 wrench hold the head of the bolt that runs through the center of the foot spacer A1249 and into the foot pad P1250 Rotate the foot pad until it unthreads completely from the bolt Repeat this procedure for the other foot removal 9 Using a wrench and socket remove the bolts that hold the end cap brackets to the welded tabs of the rear cross member P1439 Bracket Tension Belt AC7000 Welded tab 10 Pull end caps out of the extrusions 11 Remove both rear roller tension bolts and the tension brackets 12 Slide the running belt to one side or the other 13 Pull the rear roller out of the treadmill 14 Install the two 2 1 rubber caps P1487 from
43. i Page 1 Note Use this wiring diagram if your treadmill is equipped with a G E inverter AF 300 E 11 and a three wire elevation motor 26 G TEST MODE The Test Mode provides technicians with additional information for use in troubleshooting the AC7000 treadmill Turn the power switch on the treadmill to the OFF position Press the ELEVATION UP arrow and the ELEVATION DOWN arrow and simultaneously turn the treadmill power switch to the ON position Continue to press ELEVATION UP and ELEVATION DOWN throughout the entire power up process and until tESt appears in the center display This process will take three 3 seconds T Display test Press any button The first test will illuminate each individual segment of all three displays in a racetrack pattern The LED to the sides of the top display as well as the LED between the heart symbols will be illuminated in turn Press any button The second test will illuminate the number 8 in sequence for all the displays and then illuminate all the LEDs Press any button The third test will illuminate all the displays and all the LEDs and keep them all on Press any key to end the test and advance to the Switch test Switch Test S and T will be shown in the top display The second number corresponds to the switches as shown in the table below Press the appropriate switch for the number displayed If the switch functions properly the number
44. ies out from under the extrusion and deck belt 11 Using a 9 16 socket remove the two 2 bolts holding front roller cover to the motor plate This will allow you to remove the front roller cover 12 Using a socket loosen the ten 10 outer bolts that run through the deck mount braces P1429 and cross braces P1274 on the bottom of the deck P1425 approximately three 3 to four 4 turns Only loosen these outside bolts Do not do anything to the bolts that runs through the cross braces and into the deck 13 Once the deck is free remove the left front roller bolt using a 9 16 wrench Then remove the right front roller bolt Rotate the right side of the front roller A1244 under the belt P1246 This will loosen the timing belt P1247 and make it easy to slide off The front roller will now be rotated almost 90 from its original position Pull out the front roller 14 Clean off any wax built up on the front roller with a straight edge 40 15 The rear roller A1245 will slide out the back of the treadmill Repeat cleaning procedure 16 Slide out deck and belt from the back of the treadmill 17 Remove the five 5 deck cross braces P1274 18 Remove T nuts in the deck and insert on the opposite side of the deck 19 Install the five 5 deck cross braces on opposite side of new deck Do not over torque bolts Use blue Loctite on these bolts 20 Mist the rubber frame strips A1441 on the deck frame braces P1440 wi
45. ieve tension from the running belt 48 6 With a 9 16 wrench remove the left side front roller bolt Loosen the right side front roller bolt far enough to disengage the bolt threads from the roller threads Rotate the right side of the front roller under the deck and belt This will loosen the motor s timing belt on the left side of the front roller and make it easy to slide off Rotate the front roller approximately 90 from its original position Pull the roller out from under the treadmill P1247 Belt Timing 5M 25mm 670mm A1401 Spacer Roller Belt Front AC7000 Front roller bolt Front roller bolt gt A A1244 Roller Drive Front AC7000 P1246 Belt Running w Logo AC7000 7 Install new front roller by reversing step 6 8 Put guide roller back in place using the Guide Roller Replacement procedure Page 48 9 Turn each rear roller tension bolt clockwise approximately 6 10 turns 10 Tension running belt according to the Running Belt Tracking and Tensioning procedure Page 38 G Rear Roller Replacement Elevate the treadmill to 15 grade Unplug treadmill from the wall outlet Treadmill will remain elevated Remove the motor hood using a Philips screwdriver Using a 5 16 Allen wrench turn each of the rear roller tension bolts counterclockwise approximately 6 10 turns to relieve tension from the running belt Poh A1249 Spacer Pad Foot AC7000 Fender was
46. install the two 2 front roller bolts The right side has a roller spacer A1401 that goes between the front roller and frame 41 A1401 Spacer Roller Belt Front AC7000 31 Slide deck to where it is 2 to 1 from the front roller Tighten the ten 10 outer bolts that run through the cross braces on the bottom of the deck 32 Install the two 2 guide rollers Hook the roller housing inside the deck belt and place the flat side of the guide roller bracket on the innermost lip of the extrusion 33 Start the HCS 5 16 18 X and 5 16 lock washer up through the extrusion and the guide roller bracket 34 Make sure the bracket is perpendicular 90 angle to the extrusion Tighten bracket in place 35 Install rear roller tensioning socket head cap screws one on each side the two 2 end caps and the two 2 footpads 36 Tension the running belt by tightening the rear roller tensioning socket head cap screws equally 37 Plug the treadmill power cord into the electrical outlet 38 Turn the unit on and press START to allow the unit to return to 0 grade 39 Tension the running belt according to the Running Belt Tracking and Tensioning procedure Page 38 40 After properly tensioning the running belt you must walk it in according to the Belt Replacement Walk In procedure Page 47 Failure to do so may result in damage to the deck 42 C A2109 Strip Foam Absorbing Shock Deck Cushione
47. ires to the lower board Refer to pages 21 for lower PCB configuration The wiring connections are as follows The limit switch cable is a cable assembly with a gray jacket and a white 5 pin mate n lock connector It plugs into the brown 5 pin socket which is not labeled The power cable from the rocker switch is to lower PCB plugs is a cable assembly with a black jacket and a white 3 pin mate n lock connector This plugs into the socket labeled JP1 The wires coming out of the elevation motor that tie together with the starter cap plug into the socket labeled JP3 The potentiometer cable has a gray jacket with a 4 pin Molex connector This plugs into JP2 There are two gray cable that run from the inverter to the lower PCB The cable with the white 3 pin large Molex header plugs into J4 The other cable has a white 4 pin large Molex header and connects to J2 The 6 pin Telco cable plugs in where the board is labeled J5 The 8 pin Telco cable plugs into J6 13 Calibrate the elevation using the Elevation Calibration procedure explained in the Club Mode for your version of software Pages 29 36 2 Limit Switch Replacement If your unit is equipped with a safety pan follow procedure 1 If your treadmill has a solid motor plate that extends all the way to the front of the unit go directly to procedure 2 Procedure 1 1 Elevate the treadmill to 15 grade Disconnect power by unplugging the treadmill power cord from wall socket
48. itself as it may do damage to the cable or the header on the lower PCB Remove the lower PCB mounting plate C1456 using a socket Using a 1 2 socket remove the 74 bolt that holds the potentiometer and mounting bracket Be careful with the cable as it is soldered to the potentiometer PON am P1485 Bracket Sensor Elevation AC7000 P1479 Pinion Sensor Elevation AC7000 P1269 Pot Elevator AC7000 7 Loosen the two 2 innermost bolts closest to the elevation motor on each coupling using a 5 32 Allen wrench Do not loosen the outer two bolts as this is not necessary and will lengthen the time needed for this job P1273 Motor Elevation 220V Innermost bolts Elevation Motor Mounting Bolts Potentiometer Assembly Short Shaft Side Long Shaft Side 8 Slide the long shaft and coupling off the elevation motor shaft by moving them horizontally and away from the elevation motor 57 9 Remove the three 3 elevation motor mounting bolts Earlier elevation motors were mounted using 14 20 x 5 button head bolts These require a 3 32 Allen wrench to remove bolts Later models used 4 20 x 5 with a 4 lock washer These require a 7 16 wrench to remove 10 Slide the elevation motor horizontally out of coupling on the short shaft side and remove from system Motor will slide towards left side of treadmill as if you were using the treadmill 11 Install the new elevation motor by sliding
49. ke pattern until you reach the front of walking surface Pattern is shown above 5 You may reverse the snakelike pattern until reaching the rear or step off and repeat the first pattern 6 Walk in must be performed for ten 10 minutes 47 Sey S Guide Roller Replacement Elevate treadmill to a grade of 15 Turn off power switch or unplug unit Locate the guide roller assemblies There is one 1 guide roller assembly P1242 on the bottom side each extrusion P1242 Assy Roller Guide Belt AC7000 Using a 1 2 wrench remove the bolt with lock washer that runs up through the extrusion and up into the guide roller bracket Slide guide roller assembly from under extrusion and running belt P1246 To install the new guide roller assembly hook the roller housing inside the deck belt and place the flat side of the guide roller bracket on the innermost lip of the extrusion Start the HCS 5 16 18 X bolt and 5 16 lock washer up through the extrusion and the guide roller bracket Make sure the bracket is perpendicular 90 angle to the extrusion Tighten bracket in place Front Roller Replacement Elevate the treadmill to 15 grade and unplug treadmill Unplug treadmill from the wall outlet Treadmill will remain elevated Remove the motor hood using a Philips screwdriver Using a 5 16 Allen wrench turn each of the rear roller tension bolts counterclockwise approximately 6 10 turns to rel
50. l position Pull out the front roller 14 Clean off any wax built up on the front roller with a straight edge 15 The rear roller A1245 will slide out the back of the treadmill Repeat cleaning procedure 16 Slide out deck assembly and belt out the back of the treadmill 17 Remove the four 4 urethane springs P2086 18 Flip the deck over if it hasn t been done before If the deck has been flipped once before install new deck Do not loose the nylon sleeves P2087 on the locating pins A2108 near the corners of the deck 19 Reinstall the urethane springs 20 Slide belt and deck back in place in the side frames 21 Install the 1 rubber caps P1487 on rear roller P1487 Cap End 1 ID AC7000 22 With the running belt slid over install the rear roller into the extrusions making sure the threads for the tension bolts can be seen 23 Position each tension bracket over the lips of the extrusion from which they were removed With a mallet tap the bracket onto lips of the extrusion Do the same to both sides 24 Insert the rear roller tension bolt through each tension bracket and into the rear roller When threads catch turn each bolt approximately 3 4 turns 45 25 Push each end cap bracket back into the appropriate extrusion 26 Line up the holes in the end cap bracket with the holes in the extrusions and welded tabs of the rear cross member 27 nsert the bolts for the foot pads and foot spacers on each side This
51. leshooting Table Problem Possible Reasons Solutions Front rear or guide roller is Running belt over Re tension running belt making clicking grinding tensioned See page 38 or knocking noises Bearings are bad Replace roller See pages 48 51 Running belt slipping Running belt is too loose Re tension running belt See page 38 Running belt running off to one side or the other Belt tracking off Guide roller missing or malfunctioning Re track running belt See page 38 Replace guide roller See page 48 Drive motor knocking or grinding Pulley and flywheel are loose Internal problems with motor Tighten the 9 16 head bolt in the end of motor shaft Replace motor See pages 52 55 Drive timing belt is slipping Not enough tension on motor Teeth missing from the belt Re tension motor See page 55 56 Replace drive timing belt See pages 55 56 Deck rattles Bolts on the bottom of the deck are loose Deck is cracked Tighten bolts on bottom of deck and cross braces See pages 39 46 Replace deck See pages 39 46 Elevation racks binding on the way up or down Racks need to be greased Grease racks B Running Belt to Deck Friction Test A1793 Weldment H Bar HR Contact P1252 Hood Motor P1246 Belt Running w Logo 1 With the treadmill either turned off or in idle mode stand
52. ll and tighten the 3 8 bolt 24 Mount the guide rollers back into their normal positions 25 Tension the running belt according to the Running Belt Tracking and Tensioning procedure Page 38 51 P1247 Belt Timing 670 5M A Optibelt Drive Motor Replacement P1431 Pulley Motor AC7000 P1449 Motor Drive Brook Hanson P2185 Pulley Motor Treadmill 4hp AC7000 P2186 Motor Treadmill 4hp AC7000 A1432 Flywheel Motor Casting AC7000 A2187 Flywheel Motor Treadmill 4hp AC7000 P1244 Roller Drive Front AC7000 If two part numbers are listed the top is for units with the 5 5 hp drive motor while the bottom number is for units equipped with the 4 hp drive motor If only one part number is listed the part is on both NO Elevate treadmill to a 15 grade and disconnect power at the outlet Using a Philips screwdriver remove the motor hood which is held on by nine 9 screws With a 9 16 wrench loosen the hex nut on the L shaped motor tension bracket A1428 approximately four 4 turns This is located between the motor and the elevation system we Bracket Motor Tensor AC7000 Using a 9 16 wrench and a 9 16 socket hold the wrench on the nuts at the base of the motor while placing the socket on the heads of the bolts under the treadmill motor plate Turn the bolts counterclockwise until they separate from the retaining nut The older models have two 2 slot cover plates under
53. ll appear on your inverter display Use the arrow up or arrow down until you see F74 appear in the inverter window Press the FUNC DATA button one time A value of 0 will be shown Make sure there is nothing on the belt and everything is clear of the motor Using the arrow up change the value to 1 Press FUNC DATA one more time You will hear three electrical pulses from the inverter to the motor The running belt will move approximately one inch F75 will be displayed in the inverter window Press PROG RESET once The inverter will now display is normal operating screen Procedure 2 1 Turn off power to the treadmill at the switch 2 Remove the top panel with the AF 300 E 11 stamped on it Using your index fingers reach down into the cavities on the sides of the top panel press in at the bottom and lift the panel off the inverter 3 Remove the inverter s side panel closest to the motor To remove you must press in on both sides and pull away from the inverter This action will expose the wire terminals 4 Using both 1 and 2 Philips screwdrivers loosen all terminals with wires pinched underneath them and remove wires from the inverter 5 The inverter is mounted to the motor plate by Allen bolts Using a 5 32 Allen socket and extension remove the Allen bolts 6 Remove the inverter from the treadmill Do not lose the four 4 nylon washers between the inverter and the motor plate 7 Install the ne
54. lling to its highest point If this isn t correct loosen the nuts at the base of the motor and the motor tension bracket 18 Slide motor towards the front of the treadmill until the timing belt is taut and the motor and front roller pulley are aligned 19 Hold the motor in this position and slowly spin the flywheel to allow belt to seat properly on the pulleys If slack develops slide motor towards the front of unit to take up slack created when the belt seated 20 Once this alignment has been done and the belt is taut use a 9 16 wrench and ratchet with 9 16 socket to tighten the motor bolts 21 This action should create a little play in the timing belt Once the motor has been locked down snug the nut on the motor tension bracket The belt should have approximately 3 8 travel when pushed down and then pulled up on If this is too tight or too loose loosen motor and tension nuts and move motor slightly forward or backwards and retighten nuts Repeat this procedure until the tension is correct 22 Verify all nuts and bolts are tightened down 23 Restore power and test operation of the treadmill 24 Restore and fasten motor hood in place 56 Elevation Motor Replacement Make sure treadmill is at 0 elevation Turn power off to unit Remove motor hood which is held on by nine 9 Phillips head screws Disconnect all eight 8 wires connected to lower PCB P1500 Grab each cable at the connector Do not pull on the cable
55. nter bore of the flywheel with the key 16 Push flywheel on until it stops 17 Line the cutout in the pulley with the key in the motor shaft 18 Slide the pulley onto shaft hub side first 19 Take the retaining bolt with the lock washer and run it through the spacer P1443 and into the motor shaft 20 Tighten bolt using a 9 16 wrench 21 Set new motor in treadmill lining up the holes with the hole in the motor tension bracket and the three flat spacers Motor tension bracket and spacers are placed between the bottom of the motor and the motor plate 22 Insert each bolt with a lock washer up through the slot cover plates long side goes towards the front of treadmill motor plate spacers and motor mount base 23 Place the 3 8 lock washer onto bolt followed by the 3 8 locking nut Thread the locking nut by hand until it stops 24 Repeat steps 22 and 23 until all four 4 bolts are in place 25 Slide the motor towards the front roller 26 Re insert the motor cable and attach wires to terminal block The wiring connections from left to right are brown blue and green 27 Put the terminal block cover back onto motor 28 Install timing belt onto motor pulley 29 Slide motor towards the front of the treadmill until the timing belt is taut and the motor and front roller pulley are aligned 30 Hold the motor in this position and slowly spin the flywheel to allow belt to seat properly on the pulleys If slack develops
56. numbers do not change on upper display Ribbon cable from membrane to upper PCB unplugged Faulty membrane Plug in ribbon cables Replace membrane See page 65 66 Upper display resets after starting workout Loose Telco connection Power cord loose Faulty upper PCB Bad magnet positioning Fix or replace Telcos Fix loose connection Replace upper PCB See pages 64 65 Verify magnet stays in position Running belt does not move Faulty inverter or cable connection from inverter to lower PCB Loose Telco connection Faulty membrane Speed reference on lower PCB See flowchart Page 17 Fix or replace Telcos Replace membrane See page 65 66 See flowchart Page 17 Electrical Troubleshooting cont Problem Possible Reasons Solutions Running belt does not change speeds Faulty membrane Faulty lower PCB See flowchart Page 18 See flowchart Page 18 No elevation Bad relay on lower board Motor unplugged Bad starter capacitor Loose Telco connection Bad potentiometer Broken limit switch Limit switch cable unplugged See flowchart Page 19 See flowchart Page 19 See flowchart Page 19 See flowchart Page 19 See flowchart Page 19 See flowchart Page 19 See flowchart Page 19 Wireless heart rate displays zero 0 in window Chest strap isn t working Loose plug connection at upper
57. nverter actually the inverter filter 2 Lower PCB e Provides 240 VAC to the elevation system e Rectifies the 240 VAC to 12 6 and 5 VDC for various control circuits e Provides 12 and 6 VDC power to the upper PCB e Controls the input of the inverter via opto isolator components The opto isolators electrically isolate the lower PCB from the inverter e Contains relays that function as controllers for both motors 3 Display PCB e Powers the serial communications C Safe and Cardio Key e Powers the contact heart rate and wireless heart rate jacks e Powers the membrane switch e Contains the display LED drivers although the power for the drivers comes from the lower PCB e Contains the memory and processor components 4 Elevation Motor Consists of a 230 VAC motor with a torque of 345 inch lbs which is attached to a 600 to 1 ratio gearbox It draws 1 5 to 2 amps nominally but like all constant speed motors it draws five 5 to six 6 times it s nominal current when energized this is called inrush current Its duty cycle is two 2 minutes 5 Starter Cap Is a 10uf 370VAC oil capacitor that provides the immediate energy required for the inrush current for the elevation motor The value of this cap is critical 6 Elevation Potentiometer Is a 10 turn 2K ohm potentiometer that functions as the elevation servo positioning device It is fed a voltage from the lower PCB and depending on its position it variably drops t
58. o 2 N JP2 22 of a red h Elevation J6 a o 8a D Pot j Black AS 3 K J4 ee To a Console a y a Black Red White Brown Brown Clear GND pe HOT Line Com Green petty taal habitat A a a zl 5 5HP Drive Inverter Filter Inverter VXS220 1 L3 Motor L1 Wire colors may vary J Green Ze HOT Load Com ie L2 HOT Com UVW e Blue pn Brown Page 1 Note Use this wiring diagram if your treadmill has a G E inverter AF 300 MS mounted on top of the filter and has a four wire elevation motor 24 AC7000 E 11 4 Wire Block Diagram Wednesday December 03 2003 7 5 a JU tarter a Wall Plug Cap Wires nonpolar Down Power yr ay switch E a N GND Green p Elevation Hot Com om 4 5 Brown Motor J Blue J Zz U Wah CoS ESH oo UP JP3 Limit Switch B Red R Green i gt White P lt DN L_ Black IIS Limit Switch RD AC7000 Power Suppl Pply White oe 2 JP2 i 22 o 8 5 red h Elevation J6 a o 30 5 Pot j J5 b AS K oes Er dt Black 3 z 4 D o o Console S A a Black Brown Clear Red White Brown
59. of the console 3 Lift membrane up to expose wiring connections on the back of the upper PCB Warning Make sure you are grounded before handling electronics Failure to do so may result in static damage 4 Disconnect all wires to the upper board by grabbing them at the connector While holding only the membrane remove the display assembly from the console 5 Remove the eight 8 Philips screws holding upper PCB to the membrane 65 6 7 8 Using a 1 16 Allen wrench remove the two 2 4 40 X 2 screws holding 9 Disconnect both ribbon cables from the membrane to the upper PCB Remove upper PCB the magnetic switch in place Pull magnetic bracket loose and reinsert on the new membrane 10 Place the magnetic switch flat side down and start the two 2 4 40 X 1 2 screws through the slots in the switch 11 Slide switch completely to the right and tighten screws 12 Replace upper PCB and install the eight 8 Philips screws 13 Reconnect the ribbon cables 14 Rest bottom of membrane on the cutout in the upper console Tilt the top of the membrane back toward you This will create enough room for you to access the wires and the back of the upper PCB 15 Reconnect wires to the upper PCB The wireless heart rate cable comes out of the left side of the console This component has a gray cable with the 3 pin Molex header and connects to the horizontally mounted 3 pin connector on the left backside of the upper
60. old roller onto new roller 50 P1487 Cap End 1 ID AC7000 15 With the running belt slid over install the new rear roller into the extrusions making sure the threads for the tension bolts can be seen 16 Position each tension bracket over the lips of the extrusion from which they were removed With a mallet tap the bracket onto lips of the extrusion Do the same to both sides 17 Insert the rear roller tension bolt through each bracket and into the rear roller Once the threads catch turn each bolt approximately 3 4 turns 18 Push each end cap bracket back into the appropriate extrusion 19 Line up the holes in the end cap bracket with the holes in the extrusions and welded tabs of the rear cross member 20 Insert the bolts for the foot pads and spacers on each side This bolt will run from inside the extrusion on down through hole 21 Slide spacer onto each bolt followed by the flat washer and foot pad Place 9 16 wrench onto bolt head and turn foot pad clockwise until tight 22 Insert each of the bolts that run up through the welded tabs and the end cap brackets Put a 5 16 18 nylock nut on each bolt and tighten down 23 Install front roller by laying it inside the running belt at a 90 angle Once the pulley of the front roller clears the deck slide the drive belt over it Proceed to rotate roller until it gets to its normal mounting position Place the front roller spacer between front roller and the extrusion Insta
61. on a b c Run the treadmill at approximately 3 MPH 5 Km Hr Walk on the belt and grip the right and left handlebars firmly Attempt to stop the belt by planting the feet firmly Position the legs at a forward angle bend the knees moderately and pull upward on the handlebars to leverage moderate force against the belt Warning Do not lock knees straight as this can result in injury The belt should only slip from one half to one second before re engaging 4 Adjusting Belt Tension a b C NOTE Determine if the belt is too tight or loose using the Checking Belt Tension procedure Loosen or tighten the belt as needed Loosen the belt tension by turning both the left and right rear rollers Allen bolts equally in the counterclockwise direction Tighten the belt tension by turning both the left and right rear rollers Allen bolts equally in the clockwise direction Repeat the Checking Belt Tension and Adjusting Belt Tension procedures until optimal tension is achieved WARNING Over tensioning the running belt can cause premature belt deck and roller failure For this reason running belts and decks are considered as normal wear items that are not covered by warranty 38 B Deck and Running Belt Replacement P1425 Deck Inwood Phenolic aes i gt S D P1429 Plate Mount Brace Deck AC7000 A1275 Strip Rubber Brace Deck AC7000 A1441 Strip Rubber Frame Deck AC7000
62. ots up AC will appear in the time window Press the START button one time ECAL will appear in the time window Press the START button once more The treadmill will elevate to its highest point and will set a value It will stay at its highest point for approximately four 4 seconds The treadmill will then descend to its lowest point and retrieve a value Once ECAL is completed ECAL will show in the time window the lowest elevation value in the speed window and highest elevation value in the elevation window Press the START button one more time The display will flash ECAL PAS and then reboot back to the main screen Go into Club Mode to calibrate speed Press the ELEVATION UP and ELEVATION DOWN arrows simultaneously for three 3 seconds to enter this mode press the keys until Unlt is shown in the top display Press SELECT five times until CALS is displayed in the TIME window Press the ELEVATION UP and ELEVATION DOWN arrows simultaneously until CALS changes to SCAL in the TIME window Press START WARNING The belt will start moving at the set low speed The top display will show LO for low speed The elevation display shows the scale used by the software for 3 MPH the default is 3 Let the treadmill run until the numerical display on the IMO inverter stabilizes Press START WARNING The belt will start moving at the set high speed The top display will show
63. p screws one 1 on each side using a 5 16 Allen wrench 7 Remove the tension bracket from each side ast P1439 Bracket Tension Belt AC7000 Welded tab 8 Locate the guide roller assemblies P1242 There is one 1 guide roller assembly P1242 on the bottom side of each extrusion P1242 Assy Roller Guide Belt AC7000 9 Using a wrench remove the two 2 bolts with 5 16 lock washers that runs up through the front roller cover A1917 the extrusion and into the guide roller bracket There is one 1 located on the underside of each extrusion 44 A1917 Cover Roller Front 10 Slide guide roller assemblies out from under the extrusion and deck belt 11 Using a 9 16 socket remove the two 2 bolts holding front roller cover to the motor plate This will allow you to remove the front roller cover 12 Using a socket loosen the ten 10 outer bolts that run through the deck spacer A2085 deck cross braces A2080 and into the nut bar A2081 on the bottom of the deck A2352 approximately 3 4 turns Only loosen these outside bolts Do not completely remove them 13 Once the deck is free remove the left front roller bolt using a 9 16 wrench Then remove the right front roller bolt Rotate the right side of the front roller A1244 under the belt P1246 This will loosen the timing belt P1247 and make it easy to slide off The front roller will now be rotated almost 90 from its origina
64. pin and 8 pin Telco cables into the black headers on the bottom center part of the upper PCB e If your unit is equipped with Cardio Key there will be a gray cable with a 4 pin Molex header coming through the right side of the console 64 N This plugs into the vertically mounted header on the right backside of the upper PCB e Broadcast Vision is another optional feature of the treadmill If your unit is set up for this option there is a black 8 pin Telco cable coming into the console housing Its location depends on where the user decided to mount the keypad This plugs into the black header that sits by itself on the right backside of the upper PCB 12 While making sure not to pinch any wires lay the display down into the console housing 13 Insert the four 4 display screws through the console back plate and into the standoffs 14 Snug these screws until secure Do not heavily torque 15 Calibrate the elevation using the Elevation Calibration procedure explained in the Club Mode for your version of software Pages 29 36 16 Complete Software Set Up Page 37 Membrane Replacement P1517 Switch Membrane New AC7000 Backside view P1609 Bracket Magnetic AC7000 P1522 Switch Magnetic AC7000 Turn off the power to the unit then remove magnet from upper display 2 Using a Philips screwdriver remove the four 4 screws that mount the upper display They are located on the bottom side
65. r the elevation racks and set it off to the side 7 Disconnect wires running to each limit switch P1260 P1260 Switch Limit Elevation AC7000 8 On the backside of the bracket that the limit switches mount to remove the two 2 nuts holding the limit switches in place Remove switches 9 Re attach wires in the same order on the new limit switches 10 Replace the new limit switches through the same two 2 holes that the other ones were removed from Make sure the two 2 legs on the limit switches clear the elevation rack A1508 Elevation rack Limit switch legs 11 Replace the two 2 4 40 machine nuts on the backside of the bracket 12 Set the upright assembly back in place Make sure not to catch the wires on the elevation racks 13 Reinstall and tighten the bolts washers and nuts to secure the uprights in place 14 Plug the Telco cables into the lower PCB 15 Reconnect the green static drain wire 16 Calibrate the elevation using the Elevation Calibration procedure explained in the Club Mode for your version of software Pages 29 36 63 Upper PCB Replacement P1517 Switch Membrane New AC7000 P1251 Console Display AC7000 P1568 Grip HR Contact 1 5 ID 52 Pair 4 display screws oo So Turn off the power to the unit then remove magnet from upper display Using a Philips screwdriver remove the four 4 screws that mount the upper display They are located on the bottom side o
66. ration subprogram ECAL will be shown in the top display Press START The top display will show the high grade selected the Factory Settings Mode which is 25 0 The speed display will show UP2 The elevation display shows position in the 256 bit scale used by the software as indicated by the elevation potentiometer it should be more than 225 when the treadmill is completely elevated The treadmill will elevate to the high limit switch The top display will then change to 0 0 which is the low grade set in the Factory Settings Mode The speed display will show dn4 The elevation display should be less than 30 when the treadmill is completely lowered The treadmill will descend to the lower limit switch The software will automatically create a scale based on the difference in resistance of the potentiometer from the upper to the lower limit switches When the elevation calibration is complete the top display will show ECAL and the speed display will show the lower grade limit and the elevation display will show the upper grade limit both in terms of the scale value Press START and the system will reboot load data and resume normal operation 36 K EWN Software Set Up After Upper PCB Replacement 10 1 10 5 Once the upper display has been replaced put the magnet in place and restore power to the unit Make sure not to press any buttons on the display when doing so Once the display board bo
67. res the software is functioning properly If the system passes the watchdog test dOG will be shown in the top display momentarily and the display will go back to the start mode If the system fails the watchdog test dOG will remain in the top display a continuous sound will be heard and the upper display board will need to be replaced 28 H Club Mode Thru Version 3 7 The Club Mode enables club owners and managers to customize certain features of the AC7000 treadmill Press the ELEVATION UP and ELEVATION DOWN keys simultaneously for three 3 seconds to enter this mode press the keys until Unlt is shown in the top display 1 Unit of Measure This setting determines whether English or metric units of measure will be displayed The top display will show Unit The speed display will show bri or SI brl represents British or English units miles and SI represents metric units kilometers Select the unit of measure by using keys After selecting the desired unit of measure press the SELECT key to advance to the next setting 2 Duration This setting allows the owner manager to select the maximum workout time which will be available to the user The speed display will show dUr The range is from 0 to 90 minutes in increments of 5 minutes 0 is unlimited time and is the default setting The top display shows the time selected Select the duration by using the ELEVATION UP or E
68. s 36 Tension the running belt by tightening the rear roller tensioning socket head cap screws equally 37 Plug the treadmill power cord into the electrical outlet 38 Turn the unit on and press START to allow the unit to return to 0 grade 39 Tension the running belt according to the Running Belt Tracking and Tensioning procedure Page 38 40 After properly tensioning the running belt you must walk it in according to the Belt Replacement Walk In procedure Page 47 Failure to do so may result in damage to the deck 46 D Belt Replacement Walk In 1 Once the deck has been flipped or replaced and a new belt has been installed the combination must be walked in The walk in in designed to distribute the phenolic wax on the deck evenly into the belt fibers and across the deck Not walking in a belt can cause chunks of wax to break loose from the deck and embed on the rollers causing a thumping noise and leaving an area of the deck with no wax which will cause a friction problem Failure to walk in the combination may result in damage to the deck 2 Start the treadmill and increase the speed to 10 MPH and let it run for five 5 to ten 10 minutes to warm up the new belt 3 Once the five 5 minutes has been completed decrease the speed to 1 5 MPH 4 While facing the display step onto left side of the belt approximately ten 10 to twelve 12 inches from the rear and walk in a snakeli
69. slide motor towards the front of unit to take up slack created when the belt seated 31 Once this alignment has been done and the belt is taut use a 9 16 wrench and ratchet with 9 16 socket to tighten the motor bolts 32 This action should create a little play in the timing belt Once the motor has been locked down snug the nut on the motor tension bracket The belt should have approximately 3 8 travel when pushed down and then pulled up on If this is too tight or too loose loosen motor and tension nuts and move motor slightly forward or backwards and retighten nuts Repeat this procedure until the tension is correct 33 Verify all nuts and bolts are tightened down 34 Plug the treadmill back into the wall and restore power to the unit 35 All 60 Hz treadmills need to be auto tuned 50 Hz treadmills do not get auto tuned Start the Auto Tune process by pressing the PRG RESET key one time F00 will appear on your inverter display 54 Use the arrow up or arrow down until you see F74 appear in the inverter window Press the FUNC DATA button one time A value of 0 will be shown Make sure there is nothing on the belt and everything is clear of the motor Using the arrow up change the value to 1 Press FUNC DATA one more time You will hear three electrical pulses from the inverter to the motor The running belt will move approximately one inch F75 will be displayed in the inverter window Press PROG
70. splay They are located on the bottom side of the console Lift membrane up to expose wiring connections on the back of the upper PCB Warning Make sure you are grounded before handling electronics Failure to do so may result in static damage Disconnect all wires to the upper PCB by grabbing them at the connector and pulling away from the connector on the upper PCB While holding only the membrane remove the display assembly from the console Using a Philips screwdriver remove the four 4 screws located in the sides of the console Tilt the top of the console towards the running belt area This will allow you access to the wireless heart rate PCB Make sure you are grounded i e use of a grounding strap before performing the steps below Remove the old wireless heart rate PCB which is held in with a two sided foam tape on each side and a tie wrap Clean the mounting surface 10 Secure new wireless heart rate PCB the same way the old one came out 11 Run wireless heart rate cable into console Place console into its normal mounting position Insert the four 4 screws through the sides of the console until snug Do not heavily torque 12 While making sure not to pinch any wires lay the display down into the console housing 13 Insert the four 4 display screws through console back plate and into standoffs 14 Snug these screws until secure Do not heavily torque 67 _ 8 9 Con
71. st removes the software from the speed control system It utilizes only the hardware of the system Press the SPEED UP and SPEED DOWN arrows to determine if the speed system is working properly The elevation display shows the scale that is used by the software with higher numbers for faster speeds When satisfied that the speed system is working press STOP to advance to the next test Heart Rate Test Hrt0 will be shown on the top display This test evaluates both the wireless and contact heart rate systems A heart rate transmitter belt must be worn for the wireless test The wireless heart rate will be shown in the Speed display which can be compared to another receiver such as a Polar wrist watch The Pace LED will flash in pace with the heartbeats received If contact heart rate is installed the contact heart rate will be shown in the Elevation display The heart symbol LED at the lower right of the top display will flash in pace with the heartbeat signal received When satisfied that the heart rate system s is working press STOP to advance to the next test EEPROM Tests EE will be shown in the top display If the EEPROM passes the test PAS will be shown in the Elevation display If it fails FAL will be shown and the upper display board will need to be replaced Press any key to end this test When the display goes back to the start mode the system will perform a watchdog test The watchdog circuit ensu
72. t labeled JP3 e The potentiometer cable has a gray jacket with a 4 pin Molex connector This plugs into JP2 e There are two gray cable that run from the inverter to the lower PCB The cable with the white 3 pin large Molex header plugs into J4 The other cable has a white 4 pin large Molex header and connects to J2 e The 6 pin Telco cable plugs in where the board is labeled J5 e The 8 pin Telco cable plugs into J6 28 Secure the elevation motor starter cap to the lower PCB mounting plate between the elevation motor and the lower PCB This can be done using clear silicone or 3M two sided tape on the bottom of the cap P1500 PCB Power Prime AC7000 y P1988 Capacitor 10uf 370VAC Mounting P1273 Motor Elevation 220V 29 Double check all wiring connections 30 Restore power to the treadmill 31 Calibrate the elevation using the Elevation Calibration procedure explained in the Club Mode for your version of software Pages 29 36 59 AON Potentiometer Replacement Make sure treadmill is at 0 elevation Turn power off to unit Remove motor hood which is held on by nine 9 Phillips head screws Disconnect all eight 8 wires connected to lower PCB P1500 Grab each cable at the connector Do not pull on the cable itself as it may do damage to the cable or the header on the lower PCB Remove the lower PCB mounting plate C1456 using a socket C1456 Plate End Front AC7000 Using a
73. tact Heart Rate PCB Replacement Turn off the power to the unit then remove magnet from upper display Using a Philips screwdriver remove the four 4 screws that mount the upper display They are located on the bottom side of the console Lift membrane up to expose wiring connections on the back of the upper PCB Warning Make sure you are grounded before handling electronics Failure to do so may result in static damage Disconnect all wires to the upper PCB by grabbing them at the connector and pulling away from the connector on the upper PCB While holding only the membrane remove the display assembly from the console Remove the eight 8 Philips screws holding upper PCB to the membrane The contact heart rate PCB is the black box mounted inside the console Cut the tie wrap tab which holds this in place One 1 side of the contact heart rate PCB has one 1 wire coming out of it which connects to the upper PCB The other side of the contact heart rate PCB has two 2 wires coming out of it Follow the two 2 wires to the point where they connect to the two 2 wires leading to the contact grips Disconnect both wires at that point Plug the two 2 leads from the new contact heart rate PCB into the two 2 wires leading to the contact grips Mount the new contact heart rate PCB in position using a 4 tie wrap Once secure cut of the excess of the tie wrap 10 While making sure not to pinch any wires lay the display down in
74. th WD 40 to make the deck easier to slide 21 Slide belt and deck back in place in the side frames Be careful the rubber on the long deck braces does not bind while sliding 22 Install the 1 rubber caps P1487 on rear roller P1487 Cap End 1 ID AC7000 23 With the running belt slid over install the rear roller into the extrusions making sure the threads for the tension bolts can be seen 24 Position each tension bracket over the lips of the extrusion from which they were removed With a mallet tap the bracket onto lips of the extrusion Do the same to both sides 25 Insert the rear roller tension bolt through each tension bracket and into the rear roller When threads catch turn each bolt approximately 3 4 turns 26 Push each end cap bracket back into the appropriate extrusion 27 Line up the holes in the end cap bracket with the holes in the extrusions and welded tabs of the rear cross member 28 Insert the bolts for the foot pads and foot spacers on each side This bolt will run from inside the extrusion on down through hole 29 Slide spacer onto each bolt followed by the flat washer and foot pad Place 9 16 wrench onto bolt head and turn foot pad clockwise until tight 30 Insert the bolts that run up through the welded tabs and the end cap brackets Put a 5 16 18 nylock nut on each bolt and tighten down Insert the front roller the reverse of the way you removed it Position the roller with motor belt in place and
75. the deck has been flipped the following steps must be performed to clear the distance Press and hold the ELEVATION UP arrow for three 3 seconds to reset once 12 000 miles has been accumulated Press SELECT to exit the Club Mode and return to start mode If the treadmill is not displaying FLIP in the TIME window press SELECT to advance to Speed Calibration Calibrate Speed CALS will be shown in the top display This setting calibrates the speed of the treadmill After this calibration is completed the system will reboot load data and resume normal operation If you want to calibrate the elevation instead of speed press SELECT to bypass this setting Prior to performing Speed Calibration the inverter functions need to be verified Contact SCIFIT s Service Department 1 800 745 1373 for the current inverter values Press the ELEVATION UP and ELEVATION DOWN switches simultaneously for three 3 seconds to enter the speed calibration subprogram SCAL will be shown in the top display Press START WARNING The belt will start moving at the set low speed The top display will show LO for low speed The elevation display shows the scale used by the software for 3 MPH the default is 3 Use the SPEED UP arrow to change the value to read 4 Let the treadmill run until the numerical display on the inverter stabilizes Press START WARNING The belt will start moving at the set high speed The top display will
76. the elevation motor shaft into the coupling on the short shaft side Slide elevation motor until the mounting holes in the motor line up with the mounting holes in the plate 12 Install the three 3 elevation motor mounting bolts finger tight 13 Pull short shaft and coupling onto motor shaft as far as it will go The pinion and elevation rack should line up vertically If they do not slide the shaft horizontally until they do 14 Tighten the inner bolts on short shaft coupling 15 Slide the long shaft and coupling back onto the elevation motor shaft until there is about 1 32 between the coupling and the elevation motor s gearbox casing The pinion on the long shaft should line vertically with the elevation rack 16 Tighten the three 3 elevation motor mounting bolts 17 Turn the shaft on top of the elevation motor using a drill until the wheel on the short shaft side barely touches the floor Clockwise will raise the wheels and counterclockwise will lower the wheels 18 It is possible that you will have to pull the wheel on the long shaft side to the floor by hand because the coupling is not locked in place yet 19 Make sure racks are set using a level spot on the floor Both wheels should be making light contact with the floor at this point 20 When the racks are level tighten the inner bolts on long shaft coupling 21 With the potentiometer gear facing you gently turn the gear counterclockwise until it stops You can dama
77. the motor plate A1445 which the motor bolts run through 52 A1445 Plate Cover Slot Motor AC7000 6 Once you have removed the four 4 bolts that hold the motor P1449 P2186 in place slide the motor towards the front roller P1244 about 1 There are three 3 flat spacers under the motor to offset the motor tension bracket 7 Slide the timing belt P1247 off the motor pulley P1431 P2185 8 Using a Philips screwdriver remove the motor terminal block cover which is held on by four 4 screws Terminal block cover 9 Using a 7 16 socket remove the nuts fastening the wires to the terminals 10 Push the cable through the grommet in the bottom of the terminal block housing 11 Carefully remove the drive motor from the treadmill 12 Using a 9 16 wrench remove the bolt and motor spacer from motor shaft This will free the motor pulley and flywheel A1432 A2187 Key P1443 Spacer Motor Axle NI Motor Pulley Recessed side of flywheel 13 Slide the motor pulley and flywheel horizontally off motor shaft Occasionally this step might require the aid of a wheel puller to get the flywheel off Don t use a hammer to remove or install flywheel Use of a hammer can cause damage to the motor bearings 14 Make sure the key is inserted into the keyway on the motor shaft of the new motor 15 Slide the flywheel onto the new motor shaft recessed side first You must line up the notch in the ce
78. the set low speed The top display will show LO for low speed The elevation display shows the scale used by the software for 3 MPH the default is 4 Let the treadmill run until the numerical display on the inverter stabilizes Press START WARNING The belt will start moving at the set high speed The top display will show HI for high speed The elevation display shows the scale used by the software for 15 MPH the default is 249 Let the treadmill run until the numerical display on the inverter stabilizes Press START The top display will show AUG for average speed The elevation display shows the scale used by the software for 6 MPH the default is 96 Let the treadmill run until the numerical display on the inverter stabilizes Press START The top display will show SCAL and the elevation display will show PAS for pass for a few seconds The system will automatically reboot and resume normal operation Calibrate Elevation If you have calibrated the speed you will need to reenter the Club Setting Mode again Press SELECT until CALE is shown in the top display This setting calibrates the elevation of the treadmill Press the ELEVATION UP and ELEVATION DOWN switches simultaneously for three 3 seconds to enter the elevation calibration subprogram ECAL will be shown in the top display Press START The top display will show the high grade selected the Factory Settings Mode which
79. to the console housing 11 Insert the four 4 display screws through console back plate and into standoffs 12 Snug these screws until secure Do not heavily torque EONS Lower PCB Replacement Turn off all power to the unit Remove motor hood by removing nine 9 Phillips screws Make sure you are grounded i e use of an ESD grounding strap Disconnect all eight 8 wires that run to the lower PCB P1500 Transformer 68 a Remove the four 4 Philips screws in the corners and the two 2 in the top of the transformer on the lower PCB Put old board in anti static wrap or anti static bag Place new lower PCB on the lower PCB mounting plate C1456 Start the four 4 corner screws and two 2 transformer screws Tighten the corner screws and then lightly snug the transformer screws Do not over tighten the transformer screws as it may damage the lower PCB 10 Reconnect all the wires to the lower PCB Refer to page 21 for lower PCB configuration The wiring connections are as follows e The limit switch cable has a gray jacket and a white 5 pin mate n lock connector It plugs into the brown 5 pin socket e The power cable from the rocker switch to lower PCB plugs is a cable assembly with a black jacket and a white 3 pin mate n lock connector This plugs into the socket labeled JP1 e The wires coming out of the elevation motor that tie together with the starter cap plug into the socket labeled JP3 e The
80. ve workmanship and or materials under normal and proper use subject to the following limitations 1 SCIFIT s obligation to the original purchaser shall apply to both parts and cost of labor required to replace or repair a defective product for a period of one 1 year from the user purchase date as documented by the warranty card If the customer fails to return the warranty card the date of shipment from the factory is used Thereafter for a period of two 2 years such obligation shall extend only to the supply of replacement parts or products with any labor costs associated with such replacement or repair to be at the Buyer s expense 2 SCIFIT s obligation shall be limited to repairing or replacing defective parts No allowance shall be granted for repairs made by Buyer without SCIFIT s prior written approval The decision to replace or repair shall be solely at SCIFIT s election 3 SCIFIT s warranty does not apply to parts requiring replacement or repair due to abnormal wear and tear improper use corrosion perspiration improper maintenance improper rated grounded or dedicated electrical circuits or improper storage nor does it apply where all or part of the product has been altered from its original state 4 THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED ARISING BY LAW OR OTHERWISE INCLUDINGWARRANTY OR MERCHANTABILITY OF FITNESS FOR PARTICULAR PURPOSE AND IS IN LIEU OF ALL OTHER LIABILI
81. w inverter Make sure the nylon washers are line up with the mounting holes and placed between the motor plate and the inverter Insert the Allen bolts into the mounting holes and tighten down 8 Re wire the inverter according to the diagram on page 25 9 All 60 Hz treadmills need to be auto tuned 50 Hz treadmills do not get auto tuned Start the Auto Tune process by pressing the PRG RESET key one time F00 will appear on your inverter display Use the arrow up or arrow down until you see P04 appear in the inverter window Press the FUNC DATA button one time A value of 0 will be shown Make sure there is nothing on the belt and everything is clear of the motor Using the arrow up change the value to 1 Press FUNC DATA one more time Press START on the upper display When P05 appears on the inverter press STOP on the upper display Press PROG RESET once The inverter will now display is normal operating screen 70 VII Assembly Drawings and Part List 71
82. will be displayed The top display will show Unit The speed display will show brl or SP brl represents British or English units miles and SP represents metric units kilometers Select the unit of measure by using keys After selecting the desired unit of measure press the SELECT key to advance to the next setting Duration This setting allows the owner manager to select the maximum workout time which will be available to the user The speed display will show dUr The range is from 0 to 90 minutes in increments of 5 minutes 0 is unlimited time and is the default setting The top display shows the time selected Select the duration by using the ELEVATION UP or ELEVATION DOWN keys After selecting the desired duration press the SELECT key to advance to the next setting External Communication This setting selects either the C Safe CSF or Cardio Key CAr communications protocol The top display will show S CO The speed display will show either CAr or CSF Use the SPEED UP or SPEED DOWN keys to toggle between the two If neither C Safe nor Cardio Key is used either setting will work After selecting the desired communication protocol press the SELECT key to advance to the next setting User Speed This setting allows the owner manager to select the maximum speed which will be available to the user The top display will show U SPd The range will depend on the factory

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