Sears Canada Service Manual
Contents
1. 2008 Sears CA Treadmill Service Manual rev 1 0 41 Section Three Troubleshooting Treadmill Troubleshooting gt gt Noise Symptom Possible Cause Test Procedure Thumping sound when New treadmill running belt is engaged Let the treadmill run for about 30 min at bmph without a load to break in new running belt in Failed roller Replace front or rear roller as needed Rubbing or grinding sound from underneath motor cover Misaligned drive belt Optic disk is hitting the optic sensor guard Remove motor cover and verify alignment of drive belt Inspect for debris on drive motor pulley front roller pulley or on drive belt Run unit and look for optic sensor disk missalignment Align drive belt and or replace drive belt bend optic disk to straighten or replace optic disk Failed drive motor Replace drive motor bearings Motor brushes are not seated properly Unit not level Bent frame Banging or clunking sound 42 2008 Sears CA Treadmill Service Manual rev 1 0 Inspect motor brushes and commutator for abnormal wear Replace motor brushes and or stone commutator Check levelers and the floor Inspect frame for damage Adjust levelers Move unit to a level surface Place on rubber mat Section Three Exploded Drawings Exploded Drawing gt gt 30727 Note Drawings are updated periodically Contact Customer Tech Support f2. Digital Speed Sensor Connection Procedures Using a dc volt meter if non auto ranging set for the 20vdc range test the voltage at the red wire and again at the yellow wire using the blue black or black as ground The yellow wire should be measure twice once with the optic speed sensor obstructed and once not obstructed This can be done by slowly turning the motor and aligning the tines or open spaces of the optic disk with the sensor Desired Results The voltage charts contain typical desired results on a fully functional system A variance from the norm would indicate a defective component Checkpoint Voltage With Sensor Voltage With Sensor Not Obstructed Obstructed Walley Digual need cancer 5 0 4 0 4 vdeo Red Digital Speed Sensor 5 0 0 4 vdc 5 0 0 4 vdc 2008 Sears CA Treadmill Service Manual rev 1 0 19 Section Two Voltage Checks gt gt No Motor Movement Voltage Checkpoints Continued Drive Motor Connection Procedures Using a dc volt meter if non auto ranging set for the 200vdc range test the voltage at the red and black motor leads with the motor still attached Note This should be tested after the console cable and optic sensor points because they can give the same results as a defective lower board Note A non functional system may still have a voltage present with no motor attached For accurate results the motor must be attached when the voltage is checked Desired Results The v
3. To Motor Control Board SY v O O T On Off Switch Breaker 2008 Sears CA Treadmill Service Manual rev 1 0 17 Section Two Resetting The Incline Motor gt gt Resetting the Incline Motor after replacing the Motor Control Board Tools Required e Phillips Screwdriver e 177mm Socket e 177mm Combination Wrench Procedure 1 Turn off power to the treadmill and unplug power cord from wall outlet 2 Replace the Motor Control Board 3 Fold treadmill into locked position 4 Undo bolt that attaches the elevation tube to the bottom of the machine F1 17 mm Bolt Proper Zero ohaft Position 5 Power up the machine and let the incline spin freely in the tube until it reaches its zero position and then turn power oft 6 Spin shaft manually until it is almost flush with the incline motor casing and only about 1 thread is visible F2 7 Reinsert bolt and power up the machine 8 Test the incline function and calibrate the unit 18 2008 Sears CA Treadmill Service Manual rev 1 0 Section Two Voltage Checks gt gt No Motor Movement Voltage Checkpoints Upper Board Checkpoints Procedures Using a dc volt meter if non auto ranging set for the 20vdc range test the voltage at the grey and again at the white console cable connections using the yellow orange or red wires as ground Two tests are to be performed test once with power on before the treadmill is star
4. gt gt Treadmill Parts Diagram 30727 LCD Display opeakers Water Bottle Pocket Audio In Jack Console MP3 Pocket Reading Rack Console Fan Grip Pulse Handrails Handlebar Console Mast Cover safety Key Pl ir oupport Bar atlety Key riacemen Headphone Jack On Off Switch Console Mast Circuit Breaker Power Cord X Orthoflex Gel Cushion s Z Roller End Cap Motor Cover Foot Lock Latch Running Belt Running Deck oide Rail eg Rear Roller Adjustment Bolts Transport Wheel 2008 Sears CA Treadmill Service Manual rev 1 0 7 Section One Maintenance Maintenance gt gt Treadmill Preventative Maintenance Procedures Cleanliness of your treadmill and its operation environment will keep maintenance problems and service calls to a minimum For this reason we recommend that the following preventive maintenance schedule be followed AFTER EACH USE DAILY Clean and inspect following these steps e Turn off the treadmill with the on off switch then unplug the power cord at the wall outlet e Wipe down the running belt deck motor cover and console casing with a damp cloth Never use solvents as they can cause damage to the treadmill e Inspect the power cord If the power cord is damaged contact Horizon Fitness e Make sure the power cord is not underneath the treadmill or in a
5. Sears Canada Service Manual Treadmills Models 30750 30727 FITNESS Table of Contents gt gt Table of Contents Section One safety Instructions 3 Recommended Tools J Parts Diagrams gt gt 30750 6 gt gt 30427 7 Maintenance gt gt Preventative 3 gt gt Lubrication 9 gt gt Tensioning amp Alignment 10 Proper Heart Rate Usage 1H 2 2008 Sears CA Treadmill Service Manual rev 1 0 Section Two Horizon Fitness b Step Diagnostic Process Wiring Diagrams and Schematics hesetting the Incline Motor Voltage Checks Engineering Mode Section Three Troubleshooting Exploded Drawings gt gt 30750 gt gt 907A 13 15 18 19 26 20 43 44 Section One Safety Instructions Safety Instructions gt gt Treadmills WARNING STATEMENTS INDICATE A PARTICULARLY DANGEROUS ACTIVITY YOU SHOULD BE EXTREMELY CAUTIOUS WHEN DOING THE FOLLOWING e Removing power from the treadmill or removing the power cord from the wall outlet Always ensure that the treadmill is unplugged from the wall outlet when you inspect or adjust the treadmill or when you isolate remove or replace a treadmill component e Removing the motor cover exposes high voltage components and potentially dangerous machinery bxercise extreme caution when you perform maintenance procedures with the motor cover removed e During service operations you will be very close to moving machinery and high voltage components
6. Check the soles of your shoes and remove any embedded stones Tie long hair back e Use care when getting on or off the treadmill Use the handrails whenever possible Do not get on or off the treadmill when the running belt is moving e Before starting the running belt straddle the belt by placing your feet firmly on the guide rails of the treadmill You should also step off the belt and onto the guide rails of the treadmill after turning off the running belt e Do not rock the unit Do not stand or climb on the handrails electronic console or motor cover e Do not set anything on the handrails electronic console or motor cover Never place liquids on any part of the treadmill e To prevent electrical shock keep all electrical components such as the drive motor power cord and circuit breaker away from water and other liquids e Do not use accessory attachments that are not recommended by the manufacturer such attachments might cause injuries e Turn off the treadmill when adjusting or working near the rear roller Do not make any adjustments to the running belt when someone is standing on the machine e Keep all loose items away from the treadmill running surface A treadmill running belt will not stop immediately if an object becomes caught in the belt or rollers 2008 Sears CA Treadmill Service Manual rev 1 0 3 Section One Safety Instructions a warnine Connect this unit to a properly grounded dedicated 20 amp
7. When you perform maintenance procedures with the hood removed remove jewelry especially from ears and neck tie up long hair remove neckties and do not wear loose clothing e When the treadmill is operating the capacitor will hold a lethal amount of charge Do not touch the Capacitor as serious injury or death might result e When the treadmill is turned off and the power cord is removed from the wall outlet the capacitor will hold voltage for 30 60 seconds Allow the capacitor to discharge for a period of one minute before you touch or work near the capacitor Do not attempt to discharge the capacitor by any other means e Fxercise caution when touching any wire or electrical component during treadmill operation e When it is necessary to lift the treadmill ensure that the treadmill has adequate support Do not lift the treadmill by the front SAFETY GUIDELINES YOU SHOULD KNOW AND FOLLOW INCLUDE e Read the owner s manual and follow all operation instructions e Operate the treadmill on a solid level surface Locate the rear of the treadmill at least four feet from walls or furniture Keep the area behind the treadmill clear e Visually check the treadmill before beginning service or maintenance operations If it is not completely assembled or is damaged in any way exercise extreme caution while operating and checking the treadmill e When operating the treadmill do not wear loose clothing Do not wear shoes with heels or leather soles
8. e Do not remove the treadmill motor cover or roller covers e Treadmill should be plugged into a dedicated 20 amp circuit for optimal performance 4 2008 Sears CA Treadmill Service Manual rev 1 0 Section One Recommended Tools gt gt Recommended Tools and Equipment The following list is a summary of the tools and equipment required by the procedures in this manual Tools are not supplied by Horizon Fitness e Phillips screwdrivers e Anti static wrist strap when handling electronic parts e Flat head screwdrivers e Digital multi meter e Drive belt tension gauge e Allen wrench set Metric e Open end wrenches of assorted sizes Metric e Clamp on amp meter e 1 2 drive ratchet and sockets of assorted sizes e Blue Thread Lock e Cable ties e Motor commutator stone e Needle nose pliers e Damp cloth e Rubber mallet e Hammer e Drop cloth e Ruler e Snap ring pliers e Wire cutters Available through Horizon Fitness at Cost 2008 Sears CA Treadmill Service Manual rev 1 0 5 Section One Parts Diagrams gt gt Treadmill Parts Diagram 30750 Console Water Bottle Pocket Control Panel safety Key Placement Console Mast On Off Switch Motor Cover Circuit Breaker Running Belt Running Deck oide Rail holler End Cap Rear Roller Adjustment Bolts 6 2008 Sears CA Treadmill Service Manual rev 1 0 Section One Parts Diagrams
9. Incline A or W will change the incline INFORMATION will scroll in the matrix or will be static in Quick incline keys will beep but do not function text box Incline motor will stop at minimum or maximum incline not Press ENTER to select tt 1 continue to move if A or V is held Auto Calibrate Eng2 ACCUMULATED will scroll in matrix Eng2 appears in the time window lime window will show accumulated time AUTO CALIBRATE will scroll in the matrix or will be static Distance window will show accumulated distance in text box If Time and Distance are in the same window the time will Press ENTER to select show FOO and the distance will show F01 Press A or Press START to begin W to change There should be no excessive speed overshoot If console has an accumulated reset function hold Start for 5 The engineering menu will be exited upon successful seconds to reset This will not apply to most models completion of the auto calibration Note T he auto calibration process takes about two minutes to complete 26 2008 Sears CA Treadmill Service Manual rev 1 0 Table of Contents gt gt Section Three Troubleshooting 28 Exploded Drawings 43 2008 Sears CA Treadmill Service Manual rev 1 0 27 Table of Contents Troubleshooting Failed Auto Calibration 29 Console Upper Board 30 Membrane Keypad Overlay Safety Key Reed Switch He
10. Rate Usage p23 Electromagnetic Check immediate area Remove interference interference for causes of from vicinity of the unit interference florescent lighting electric dog fences large electric motors etc 34 2008 Sears CA Treadmill Service Manual rev 1 0 Treadmill Troubleshooting gt gt Erratic Speed Model 30727 Only oymptom Possible Cause Test Procedure Erratic speeds Upon pressing start belt speed increases rapidly for a few second and then comes to a complete stop Erratic speeds Upon pressing start belt speed increases rapidly and does not stop Erratic speeds Running belt speed is not stable Failed optic sensor Failed motor control board MCB Machine not calibrated properly Inadequate power Failed or improper wiring Running belt is too loose or too tight Drive belt is too loose or too tight Test voltage from Optic sensor Reference p19 Run auto calibration Reference Eng Mode DZD Check for dedicated circuit 20 amp is ideal and check wall outlet voltage 120 VAC heference p13 Make sure machine is not on extension cord surge protector or GFCI CITOU Verify there are no pinches or cuts in the power cord power wires motor wires or console cable Verify the connections of above wires and cords The running belt should not slip at all when customer is using the machine Reference Belt Tensioning p10 The driv
11. Results Symptoms If Wire Cut Constant up incline no down incline Incline value 0 no down incline Constant down in cline no up incline Incline value at max no up incline Incline value started one less than max pressed up once and value maxed out thereafter no up incline Constant down in cline no up incline Physical ENG 1 Test Results Symptoms If Wire Cut Up incline works no down incline Up incline works down does not Value increases does not decrease Down incline works until value 0 up does not Value decreases to 0 then no down incline does not increase Down incline works no up incline Neither up nor down func Neither up nor down function Value tion does not change Parameter Use functioning incline motor and remove one wire at a time to observe malfunction 2008 Sears CA Treadmill Service Manual rev 1 0 25 Section Two Engineering Mode Engineering Mode gt gt Model 30727 Only Model 30750 has no engineering mode Note At Any time Press and hold the STOP button to exit the engineering menu 1 Turn the treadmill power to ON 2 Place the safety key in position on the console 3 Simultaneously press and hold for about three seconds the incline A and speed V buttons 4 The console should beep three times and ENGO EN90 should be displayed in the time window ENGINEERING MENU scrolls in matrix or is static in
12. on Both incline lights are on and incline mo Yellow Digital n a ground TEES Hovde tor hums and gets hot quickly See below for voltage GND chart if both grounds removed Green RPM When speed sensor 5 0 vdc 0 0 vdc Everything works in normal mode but the console aligned to does not register a speed in Hardware Test or Auto magnet short 0 0vdc Calibration When sensor not aligned open 5 0 vdc lue Power 15 vdc constant 0 0 vdc 17 vdc If one removed no issues If both removed UCB does Voltage Range 15 to 17 vdc not turn on At UCB green measures 0 46 vdc white to UCB T MP Dn dic 17 vdc 1 4 vdc all others 0 0 vdc Range 15 to 17 vdc Speed 0 0 vdc before started 0 0 vdc b f start 0 8 vdc b f start No belt movement MCB relay clicks LCD 1 lights Command 0 5 vdc at 0 5 mph 4 0 36vdc aft start 0 7 vdc aft start no When measuring MCB voltage there is a slight belt PWM vdc at 10 mph Volt increases as change as console movement then stops age changes as speed console speed Speed increased changes increased 4 5 7 Grey LL C HO ey er H es D White Drive Motor 4 3 vdc before started 5 0 vdc b f start 1 4 vdc b f start No belt movement no click from MCB relay LED 1 Relay 0 0 vdc after started 0 0 vdc aft start 1 4 vdc aft start does not light m mA Pink Incline 0 0 vdc before started 0 0 vdc b f start Up incline functions no down incline LED s function Down 0 0 vdc wh
13. One Maintenance Maintenance gt gt Treadmill Lubrication 30727 Only EVERY 6 MONTHS OR 150 MILES It is necessary to lubricate your treadmill running deck every six months or 150 miles to maintain optimal performance of your treadmill Once the treadmill reaches 150 miles the console will prompt you to lubricate the treadmill Only use lubricant provided by Horizon Fitness e Turn off the treadmill with the on off switch then unplug the power cord at the wall outlet e Loosen both the rear roller bolts For best results place two removable marks on both sides of the frame and note roller position Once the belt is loosened take the bottle of lubricant and apply it to the entire top surface of the running deck Tighten both rear roller bolts matching up the marks for proper position to original position After you have applied lubricant plug in the power cord insert the safety key start the treadmill and walk on the belt for two minutes to spread the lubricant e Lubricate the air shocks with Teflon based spray e Once lubrication is complete reset the console by pressing and holding STOP and Speed A buttons for 5 seconds LUBRICATION Running Belt N Running Deck 2008 Sears CA Treadmill Service Manual rev 1 0 9 Section One Maintenance Maintenance gt gt lensioning and Aligning the Running Belt If you can feel a slipping sensation when running on the treadmill the running belt must be ti
14. Process Step 3 Proper Motor Function e Verify that the treadmill is properly lubricated and drive motor is operating at the proper amperage rating To verify the current draw place a clamp meter around the red motor wire e Remove the brush covers on the drive motor and inspect the brushes and the motor commutator for any uneven wear If the surface of the motor brush is pitted rough has burn marks or the commutator has a black residue on it replace the motor Step 4 Proper Speed Calibration e To ensure proper belt speed and proper calibration use engineering mode to verify that machine is running in MPH not KM e Auto calibrate the machine from engineering mode if the belt speed is erratic or the belt speed does not correspond to what is displayed on the console Step 5 Voltage Checkpoints e Verify that proper voltage is being transferred through the console cable 14 2008 Sears CA Treadmill Service Manual rev 1 0 Section Two Wiring Diagrams and Schematics gt gt Digital Drive Wiring Diagram 30727 e g g Qj Em t 9 ds jog B ICY 5 gigi RT eye d olol leis 5 ale O oO els as BIE Is UA lt 2 5vdc Optic Speed Sensor Ir BLUE GND lim BLACK GND WHITE PULSE Bik RED T5V BLACK GND Bil GP Speed Sensor Sa i HEN RNC RRRRNN Incline Motor WHITE i cea GREEN Drive Motor 0 90 VDC Power Cord 110 120 VAC LCD Bo
15. Reference Membrane Troubleshooting p32 2008 Sears CA Treadmill Service Manual rev 1 0 31 Section Three Troubleshooting Treadmill Troubleshooting gt gt Membrane Key Pad Overlay oymptom Possible Cause Test Procedure All or some of the keys on the console will not work Unit starts as soon as safety key is in place or console will reset itself after a few seconds of use Ribbon cables connecting the membrane keypad to upper board are not seated properly or are disconnected Membrane keypad defective Upper board defective Membrane keypad defective 32 2008 Sears CA Treadmill Service Manual rev 1 0 Verify the ribbon cables are connected securely into the upper board Keys are pressed some of the buttons may function but there are no corresponding beeps Put in EngO to chech button function Reference p26 Keys are pressed and there are corresponding beeps but console does not respond Sometimes the key will not beep until it is released Massage buttons on keypad to make sure that none are stuck Remove overlay and press keypad for proper function Put in EingO to chech button function Reference p26 Remove and reseat cables Replace membrane keypad Replace upper board Replace membrane keypad Section Three Troubleshooting Treadmill Troubleshooting gt gt Safety Key Reed Switch oymptom Possible Cause Test Procedure Co
16. ard 071206 HET TIL eee HET SERES SSS 5555 Tm O KEYPAD ba TRZSPCB ALE 071206 PCB SXT77 Upper Control Board LL refugee quicum 078691 Speaker L 070674 Speaker R ll 002671 A M deg peii AUDIO OUT AUDIO IN i 073705 Ogr z 8 067517 00 2008 Sears CA Treadmill Service Manual rev 1 0 15 Section Two Wiring Diagrams and Schematics gt gt Wiring Diagram 30750 my Lal ML ert Ake Console Cable inger Pulse Receiver EL QD HET ge LEEREN BE 2E Sot a AI Switch Key LI E 2 x em 1 LIT Lu vi r r3 J Lr I C J NG E ar T H 4 1 a r I F F zl nr S H afe Key nal i EXT oh T f mj e i F E 7 5i E aT i Lad ut hu Pa m 7 Speed Sensor kH Incline Motor Drive Motor 0 90 VDC Power Cord 110 120 VAC 16 2008 Sears CA Treadmill Service Manual rev 1 0 Section Two Wiring Diagrams and Schematics gt gt Power Source Wiring Diagram socket A Socket wire to breaker or on off switch Wire Length will determine connection point B Ground C Socket wire to breaker or on off switch Wire Length will determine connection point D On Off switch to motor control board E On Off switch to motor control board F On Off switch to breaker Note Wires A amp C are interchangeable
17. art Rate Erratic Speed 30727 Erratic Speed 30750 Elevation 30727 Elevation 30750 No Motor Movement Circuit Breaker Noise 28 2008 Sears CA Treadmill Service Manual rev 1 0 Section Three Troubleshooting Treadmill Troubleshooting gt gt Failed Auto Calibration 30727 Only oymptom Possible Cause Test Procedure Failed Auto Calibration Failed RPM sensor Put machine into Eng1 Replace RPM sensor Belt runs for a few Reference p26 and seconds and then stops check for slight and E1 message on fluctuation of speed in console speed window of display Speed should not fluctuate more than a few hundredths RPM sensor misaligned Adjust sensor bracket to correct position Magnet missing in front Replace magnet roller pulley Failed console cable Check voltage and Replace console cable continuity of console cable Reference p22 Failed Auto Calibration see troubleshooting for Belt never runs and E1 no motor movement message on console Reference p40 Failed Auto RPM sensor not aligned Verify positioning of Replace RPM sensor Calibration Board properly or has failed sensor wire Wire never sets speeds Belt coming from RPM will sensor points toward the continue to run and not front of the unit sensor Stop is as close as possible to the magnet in the pulley without touching and the sensor bracket 90 degree angle not bent in any way Put machine into Eng1 Refe
18. art rate e When you are breathing heavily during a workout e When your hands are constricted by wearing a ring e When your hands are dry or cold Try to moisten your palms by rubbing them together to warm them e Anyone with heavy arrhythmia e Anyone with arteriosclerosis or peripheral circulation disorder e Anyone whose skin on the measuring palm is especially thick 2008 Sears CA Treadmill Service Manual rev 1 0 11 Table of Contents gt gt Section Two Horizon Fitness b Step Diagnostic Process Wiring Diagrams and Schematics gt gt Digital Drive 30727 gt gt Wiring Diagram 30750 gt gt Power Source Resetting the Incline Motor Voltage Checks gt gt No Motor Movement gt gt Motor AC Wire gt gt Console Cable gt gt Speaker Amp Board gt gt 9 Wire Console Cable 80750 gt gt 12 Wire Console Cable 80727 gt gt Incline Wire Engineering Mode 30727 12 2008 Sears CA Treadmill Service Manual rev 1 0 13 To 16 LA 18 19 21 Le 22 29 24 29 26 Section Two Horizon Fitness 5 Step Diagnostic Process gt gt Horizon Fitness b Step Treadmill Diagnostic Process Wietelsav Wwhe a Horizon Fitness treadmill If followed correctly these checkpoints should help diagnos 9 the majority of problems that may be encountered The following steps are provided as routine checkpoints when diagnosing problems on Step 1 Proper suppl
19. but not up vdc while inclining 1 9 0 8 vdc after start 0 1 vdc after start vdc while declining Voltage constant while inclining declining 3 Orange GND n a ground 0 0 vdc 0 0 vdc Console will not turn on 4 Yellow Power 15 vdc constant range 0 0 vdc 14 55 vdc Console will not turn on Voltage to UCB 5 Green Drive Motor 1 6 vdc before started 0 0 1 4 vdc b f start 0 0 vdc b f start No belt movement Relay vdc after started 0 8 vdc after start 1 4 vdc after start Blue Stop Constant 0 53 vdc 0 69 vdc 5 0 vdc safe off 16 6 vdc safe off No physical symptoms were noticed when 3 6 vdc when the safety key 1 3 vdc safe on 0 0 vdc safe on this wire was removed is removed Will remain at 1 7 vdc running and running 3 6 vdc until Start is pressed 1 9 vdc paused 7 Purple Incline Pot 2 5 vdc at 0 0 incline 3 7 vdc b f start If the incline is changed from 0 0 the VREF 0 5 vdc at max incline 5 0 vdc after start motor will move constant up until the in Voltage changes with each cline on the console is returned to 0 0 It change in incline will then stop in place and NOT go down Grey Incline VCC 2 5 vdc constant 3 8 vdc b f start 2 5 vdc Incline constant up as soon as start is ELE 4 8 vdc after start pressed Incline will work in Hardware test White RPM When the speed sensor is 0 0 vdc Console will use default PWM value or aligned to the magnet short auto cal values Will not auto cal will not O 0vdc When the
20. e Wait 30 seconds then turn unit back on CC is loose unattached or Check CC at each Replace CC if damaged damaged connection point Unplug and reattach making sure the connection is secure Verify the CC is connected to the MCB Improper use of the Two Verify the customer is Touch membrane Keys confirming each selection The incline increases as MCB is defective Replace MCB soon as power is applied without pressing start The incline will only go up Buttons are stuck Test the Incline Buttons It is stuck either at the top Verify they are or the middle functioning ee CC is defective Verify The CC conections Replace CC 2008 Sears CA Treadmill Service Manual rev 1 0 39 Section Three Troubleshooting Treadmill Troubleshooting gt gt No Motor Movement oymptom Possible Cause Test Procedure Check for dedicated If the AC voltage is circuit 20 amp is ideal and check wall outlet voltage 120 VAC Make sure machine is not on extension cord or surge protector or GFCI heference p4 No Motor Movement Inadequate power Upon pressing start console responds normally keys respond normally and elevation works but no belt movement missing or incorrect check the AC service or consult an electrician Damaged or improper Verify there are no Replace parts as wiring pinches or cuts in the needed power cord power wires motor wires or console cable Verify conso
21. e belt should have approximately 3 8 of inch deflection 2008 Sears CA Treadmill Service Manual rev 1 0 35 Section Three Troubleshooting Replace optic sensor Replace MCB If unit fails to auto calibrate refer to auto calibration troubleshooting Reference p29 If the AC voltage is missing or incorrect check the AC service or consult an electrician Replace parts as needed set proper drive belt and running belt tension Section Three Troubleshooting Treadmill Troubleshooting gt gt Erratic Speed Continued Symptom Possible Cause Test Procedure Erratic speeds Inadequate lubrication Place hand underneath Apply silicone Running belt speed is on deck and running running belt and feel for not stable Continued belt adequate silicone application Reference Maintenance p8 Failed motor control heplace MCB board MCB Erratic Speeds belt In a program Remove safety key speed increases without then replace command but shows otart in P1 and see if change on display and reOcculs beeps stuck button Reference membrane keypad and overlay troubleshooting p32 Failed upper board a Replace UCB 36 2008 Sears CA Treadmill Service Manual rev 1 0 Treadmill Troubleshooting Section Three Troubleshooting gt gt Erratic Speed Running Belt Model 30750 Only oymptom Possible Cause Test Procedure Belt overshoots desired Failed speed sensor or sp
22. eed on console and console cable then slow back down This can happen during operation or when you first press start opeed of the belt will not match the displayed Speed Check to see if the oend speed sensor and speed sensor is properly console cable Replace connected to the lower parts as needed board Check position of sensor Wire coming from sensor points towards the front of the machine is a close to the front roller as possible without touching and the sensor bracket is at a 90 degree angle not bent in any way Verify there is a magnet in the front roller Check console cable for pinches and make sure it is connected properly to both the upper and lower boards Torque adjustment on Replace lower board lower board is incorrect Running belt is loose Tighten running belt Do not overtighten belt if it still feels choppy Tech in the field only Adjust torque pod until belt runs smooth Running belt feels choppy almost like it s stuttering when a cus tomer walks Torque Adjustment on Tech in field only heplace lower board lower board is incorrect Running belt continues to move even after stop Adjust torque pod until is pressed belt stops Why this happens If the speed sensor is defective then the belt will keep moving as it s trying to get that info It will speed up a little as it realizes there is no signal from the speed sensor then slow down to the defaul
23. g Elevation is stuck down and Failed console cable CC Verify console cable Replace console cable does not function Console connections Verify there is responsive to the buttons are no pinches or cuts in the being pressed cable Reference CC continuity p22 Failed elevation motor Put machine in hardware Replace elevation motor test Eng1 and press start Elevation doesn t respond when buttons are pressed You may see a value for elevation that reads 255 or 1023 That value will not change when the buttons are pressed Reference Eng Mode p26 Failed upper board Put machine in hardware Replace upper board test Eng1 and press start Incline will work in hardware test only Reference Eng Mode p26 Elevation is stuck at the Failed upper board lower Verify all wire connections Replace upper board console highest position and will board console cable and cable and elevation motor not come down Console is elevation motor responsive to the buttons be ing pressed The incline will go up but Failed lower board The incline will act normally Replace lower board not down very rare when going up bet when the down incline is pressed there is no movement 38 2008 Sears CA Treadmill Service Manual rev 1 0 Section Three Troubleshooting Treadmill Troubleshooting oymptom Possible Cause Test Procedure Incline is Stuck Up or Not Turn off the Unit at the Functioning bas
24. ghtened In most cases the belt has stretched from use causing the belt to slip This is a normal and common adjustment Make sure that the unit is turned off and not running 1o eliminate this slipping tension both the rear roller bolts with the appropriate sized Allen wrench turning both the left and right bolt 1 4 TURN as shown below Try the treadmill again to check for slipping Repeat if necessary but NEVER TURN the roller bolts more than 1 4 turn at a time Belt is too far to the left side Belt is too far to the right side 1 If the running belt moves rapidly to one side when performing the next step press the Stop button immediately e Turn on the treadmill With the treadmill speed between 3 4mph stand behind the treadmill and watch the movement of the running belt DO NOT STAND ON THE TREADMILL AND DO NOT TOUCH THE TREADMILL WHILE PERFORMING THIS PROCEDURE As you watch the running belt make sure that the belt runs without moving from one side to the other and that the belt is centered between the side rails 2 If the running belt is not tracking properly follow the procedures below e f the running belt tracks to the left turn the left roller bolt clockwise 1 4 of a turn keeping the belt tension in mind Over tightening the running belt may cause damage to the running belt and roller bearings e f the running belt tracks to the right turn the right roller bolt clockwise 1 4 of a turn keeping the belt tension in
25. ile inclining 5 0 vdc if press for up not for down If incline then decline motor 1 9 vdc while declining incline down does not move again until past incline point Ex If in Voltage constant while cline to 2 0 then back down to 0 the motor will not inclining declining move until 2 5 In Hardware Test only up incline value increases does not decrease 12 Light Incline Up 0 0 vdc before started 0 0 vdc if at 0 Down incline functions no up incline LED s function Blue 1 9 vdc while inclining 5 0 vdc if not at for down but not up In Hardware Test down incline 0 0 vdc while declining 0 or at console functions until value at 0 no up incline Similar height phenomenon to cut Pink wire if incline stopped not at 0 Note Wire colors are subject to change 24 2008 Sears CA Treadmill Service Manual rev 1 0 gt gt Incline Wire Voltage Chart Section Two Voltage Checks Small Connector cas m Color Before Start At 0 096 At 1096 Blue Brown 2 3900 0 6 vdc 0 6 vdc 2 4 vdc constant Orange The voltage changes as the incline changes After Start Large Quick Connects Not Inclining Or Before Start Declining B Incline 0 15 vac 0 15 vac 120 vac Down While Declining Black w white as ground 120 vac Red w white as ground Red w black as 186 vac 228 vac ground 2 4 vdc constant 2 4 vdc constant Physical ENG 1 Test
26. le cable continuity heference p24 Verify the connections of above wires and cords Failed motor control Verify power from board MCB MCB Reference p19 Failed drive motor Measure voltage output Replace drive motor from motor Reference motor AC Wire Voltage Check p21 Failed optic sensor Verify voltage of digital Replace optic sensor sensor Reference p19 40 2008 Sears CA Treadmill Service Manual rev 1 0 Section Three Troubleshooting Treadmill Troubleshooting gt gt Circuit Breaker Symptom Possible Cause Test Procedure Machine will trip home _ Inadequate power Check for dedicated If the AC voltage is circuit breaker circuit 20 amp is ideal missing or incorrect and check wall outlet check the AC service or voltage 120 VAC consult an electrician Reference p4 Make sure machine is not on extension cord orotector or GFCI Inadequate lubrication Place hand underneath Apply Silicon on deck and running running belt and feel for lubrication Reference belt adequate silicone Lubrication p9 application Failed running belt Feel underside of Replace running belt running belt It should have a rough feel to it similar to denim Failed drive motor Perform AMP draw test Replace drive motor on motor Reference AMP Draw p14 Failed motor control Replace MCB board MCB Machine breaker will Failed circuit breaker NENNEN Replace circuit breaker trip
27. mind Over tightening the running belt may cause damage to the running belt and roller bearings 10 2008 Sears CA Treadmill Service Manual rev 1 0 Section One Proper Heart Rate Usage gt gt Proper Heart Rate Usage HAND GRIPS THUMB PULSE Place the palm of you hands directly on the grip pulse handlebars Both hands must grip the bars for your heart rate to register It takes 5 consecutive heartbeats 15 20 seconds for your heart rate to register accurately When gripping the pulse handlebars do not grip tightly Holding the grips tightly may elevate your blood pressure Keep a loose cupping hold You may experience an erratic readout if consistently holding the grip pulse handlebars Make sure to clean the pulse sensors to ensure proper contact can be maintained TROUBLESHOOTING HEART RATE Check your exercise environment for sources of interference such as fluorescent lights computers underground fencing home security systems or appliances containing large motors hese items may cause erratic heart rate readouts You may experience an erratic readout under the following conditions e Gripping the heart rate handlebars too tight Try to maintain moderate pressure while holding onto the heart rate handlebars e Constant movement and vibration due to constantly holding the heart rate handlebars while exercising If you are receiving erratic heart rate readouts try to only hold the grips long enough to monitor your he
28. nsole only displays safety key is positioned Remove safety key and Replace safety key dashes or Safety Key incorrectly or has failed reapply Off in the display Test magnet window Magnet style Failed reed switch Short the switch If the upper board still key or failed uper control connector on the upper displays dashes then board board by using a flat replace upper board blade screwdriver or by Otherwise replace placing a jumper switch reedswitch on the connector safety key will only Improperly aligned Remove glue from Test for proper function register if moved reedswitch reedswitch and and glue into place outside of the proper reposition position 2008 Sears CA Treadmill Service Manual rev 1 0 33 Section Three Troubleshooting Treadmill Troubleshooting gt gt Heart Rate Symptom Possible Cause Test Procedure Repair Heart rate erratic User error heference Proper Heart hate Usage p11 Failed heart rate Reference Proper Heart If proper heart rate receiver Rate Usage p11 instructions are followed and heart rate continues to be erratic replace heart rate receiver Failed upper board Reference Proper Heart Replace upper board Rate Usage p11 No heart rate function Failed heart rate grips Reference Proper Heart If there is absolutely no Hand Grips Rate Usage p11 heart response replace heart rate grips Heart rate erratic User error Reference Proper Heart
29. ny other area where it can become pinched or cut e Check the tension and alignment of the running belt Make sure that the treadmill belt will not damage any other components on the treadmill by being misaligned EVERY WEEK Clean underneath the treadmill following these steps e Turn off the treadmill with the on off switch then unplug the power cord at the wall outlet e Fold the treadmill into the upright position making sure that the lock latch is secure e Move the treadmill to a remote location e Wipe or vacuum any dust particles or other objects that may have accumulated underneath the treadmill e Return the treadmill to its previous position EVERY MONTH IMPORTANT e Turn off the treadmill with the on off switch then unplug the power cord at the wall outlet e nspect all assembly bolts of the machine for proper tightness e Turn off the treadmill and wait 60 seconds e Remove the motor cover Wait until ALL LED lights turn off e Clean the motor and lower board area to eliminate any lint or dust particles that may have accumulated Failure to do so may result in premature failure of key electrical components e Vacuum and wipe down the belt with a damp cloth Vacuum any black white particles that may accumulate around the unit These particles may accumulate from normal treadmill use Note Maintenance is NOT covered under manufacturer s warranty 8 2008 Sears CA Treadmill Service Manual rev 1 0 Section
30. oltage charts contain typical desired results on a fully functional system A variance from the norm would indicate a defective component Checkpoint Voltage Before Start Voltage After Start Voltage After Start 9 10 0mph 0 5mph Across Motor Out 0 0 22 5 vdc 0 0 22 5 vdc 0 0 22 5 vdc No Motor Attached Across Motor Out 0 0 vdc 2 5 0 vdc 80 100 0 vdc W Motor Attached Drive Motor Checkpoints Procedures Unplug the motor from the lower board Using a dc volt meter if non auto ranging set for the 20vdc range attach volt meter leads directly into the motor leads and turn the running belt Desired Results The motor should generate 5 15 vdc depending on the speed it is turned Procedures Unplug the motor from the lower board Using an ohm meter if non auto ranging set for the 200 ohm range attach ohm meter leads directly into the motor leads Desired Results The motor should read approximately 1 0 1 5 ohms 20 2008 Sears CA Treadmill Service Manual rev 1 0 Section Two Voltage Checks gt gt Motor Voltage Check Spin motor flywheel to produce voltage gt gt AC Wire Voltage Check AC Wires Jis 9 3 f o Q GAAT A TFAA A Tyr 7 T Q AVITILNA Nn IT AnTnitya l YaATtT 1 A 2008 sears CA Treadmill Service Manual rev 1 0 L J Section Two Voltage Checks gt gt Console Cable Voltage Check To check the voltage of a specific function i e eleva
31. or updated Drawing _ N52 N51 IM294 A04A 2007 05 25 ev 1 0 43 Section Three Exploded Drawings Exploded Drawing gt gt 30750 Note Drawings are updated periodically Contact Customer Tech Support for updated Drawing 44 2008 Sears CA Treadmill Service Manual rev 1 0 Horizon Fitness 1620 Landmark Drive Cottage Grove WI 53527 Phone 800 244 4192 Fax 608 839 1280 HORIZON FITNESS
32. outlet only eS see grounding instructions GROUNDING INSTRUCTIONS This product must be grounded Ifa treadmill should malfunction or breakdown grounding provides a path of least resistance for electrical current to reduce the risk of electrical shock This product is equipped with a cord having an equipment grounding conductor and a grounding plug The plug must be plugged into an appropriate outlet that is properly installed and grounded in accordance with local codes and ordinances Improper connection of the equipment grounding conductor can result in a risk of electric PAm Shock Check with a qualified electrician if you are in doubt as to whether the product is properly grounded Do not modify the plug provided with the product if it will not fit in the outlet have a proper outlet installed by a qualified electrician LA WARNING SS a S b S b Adapter Grounded Outlet Metal Screw Grounding Pin TAS For Grounding Screw Grounded Outlet Box SAFETY TIPS e Never use the treadmill before securing the safety tether clip to your clothing e f you experience chest pains nausea dizziness or shortness of breath stop exercising immediately and consult your physician before continuing e Do not wear clothes that might catch on any part of the treadmill e Keep power cord away from heated surfaces e Keep children off of treadmill at all times e Do not use treadmill outdoors e Unplug treadmill before moving it
33. r control board MCB continuity of console board cable Reference p22 Verify the power LED is lit on the MCB 30 2008 Sears CA Treadmill Service Manual rev 1 0 Treadmill Troubleshooting gt gt Console Upper Board Continued oymptom Possible Cause Test Procedure hunning belt stops and console resets during workout safety key or reed switch is positioned Verify that the safety key is in position and incorrectly or Safety key that it is secure is damaged Inadequate power Damaged or improper wiring Inadequate lubrication on deck and running belt Manually adjust the position of the reed switch trigger and or the plastic tab on the console shell Slot style safety key only Check for dedicated circuit 20 amp is ideal and check wall outlet voltage 120 VAC Reference p13 Make sure machine is not on extension cord or surge protector Verify there are no pinches or cuts in the power cord power wires motor wires or console cable Verify the connections of above wires and cords Place hand underneath running belt and feel for adequate silicone application Section Three Troubleshooting Replace safety key If plastic tab is broken replace console shell Slot style safety key only If the AC voltage is missing or incorrect check the AC service or consult an electrician Replace parts as needed Apply silicone Membrane keys
34. rence p26 and check for slight fluctuation of speed in speed window of display Speed should not fluctuate more than a few hundredths Failed motor control heplace MCB board MCB 2008 Sears CA Treadmill Service Manual rev 1 0 29 Section Three Troubleshooting Treadmill Troubleshooting gt gt Console Upper Board oymptom Possible Cause Test Procedure No display on the Circuit breaker in home Check for dedicated Reset breaker console and the power has tripped circuit 20 amp is ideal switch is dark and check wall outlet Note 30750 power voltage 120 VAC switch is not backlit heference p14 Failed power switch Make sure power heplace power switch if switch is turned on necessary Failed power cord Take voltage check of Replace power cord power cord Reference p13 No display on the con Breaker on machine has Reset breaker Replace breaker if sole and power switch tripped or has failed necessary on machine is lit Improper wiring or AC Check all wiring Connect wires correctly wires have failed coming in from the or replace as needed power switch to the motor control board and to the upper board Reference p17 Failed console cable Check console cable Replace console cable voltages at B7 B8 Reference p22 Failed upper board Check voltage and Replace upper board continuity of console cable Reference p22 Failed motor control Check voltage and Replace moto
35. speed show speed in Hardware Test sensor is not aligned open 5 0 vdc Note Wire colors are subject to change 2008 Sears CA Treadmill Service Manual rev 1 0 23 Section Two Voltage Checks gt gt 12 Wire Console Cable Voltage Chart DC Volts Model 30727 Incline VCC Incline POT Incline GND Digital GND Digital GND RPM Power Voltage to UCB Power Voltage to UCB Speed Command PWM B10 Drive Motor Relay B11 Incline Down B12 Incline Up Wire Console Cable Voltage at Voltage at MCB Physical Symptoms If Wire Cut Color Voltage UCB after wire s cut no wires cut no wires cut 1 Black Incline VCC 2 5 vdc After Start pressed constant down incline down LED constant on In Hardware Test the motor moves down but not up value always at maximum 2 Brown Incline Pot 2 5 vdc at 0 0 incline After Start pressed constant down incline down LED 0 5 vdc at max incline constant on In Hardware Test the motor moves down Voltage changes with but not up value always at maximum each change in incline d Constant up incline In Hardware Test motor moves up and down Incline value started low and went down to 0 but not up past 10 Value changes very Red Incline n a ground 2 b vdc grounded 0 0 vdc grounded at GND at MCB not UCB MCB not UCB slowly Orange Digital n a ground 0 0 vdc 0 0 vdc If one removed no issues If both removed UCB does GND not turn
36. t PWM value in the console For the units without auto cal there are some speeds that are preset in the upper board to keep it running It will try to use the speed sensor but if that is not working it will use the pre programmed values instead It works kind of like auto cal but the values are already programmed instead of set for each individual unit so they will not be as accurate 2008 Sears CA Treadmill Service Manual rev 1 0 37 Section Three Troubleshooting Treadmill Troubleshooting gt gt Elevation Model 30727 Only IMPORTANT See eS sectional console cables Symptom Possible Cause Test Procedure Elevation motor starts Failed lower board Turn on power Do not press Replace lower board running as soon as the power start Wait 30 60 seconds and is turned on Constant down see if motor is hot Use Or up caution Motor can get very hot Elevation motor bobs up and Failed elevation motor Replace elevation motor down with out command Elevation motor does not Failed elevation motor Verify there are no pinches Recalibrate elevation motor reach minimum or maximum Failed console cable CC or cuts on the elevation by hand Reference Resetting settings Improperly calibrated wires Reference CC the Incline Motor p18 elevation motor continuity p22 Replace elevation motor Verify the connections of above wires i i It s recommended to send console cables for elevation repairs on all models usin
37. ted and again after Start is pressed Desired Results The voltage charts contain typical desired results on a fully functional system A variance from the norm would indicate a defective component Checkpoint Voltage Before Start Voltage After Start Console Cable Grey to Yellow Gnd 0 0 vdc 0 3 3 vdc increases as speed increases as shown on console Console Cable White to Yellow Gnd 43 4 3 vdc Lower Board Checkpoints Console Cable Connection Procedures Using a dc volt meter if non auto ranging set for the 20vdc range test the voltage at the grey and again at the white console cable connections using the yellow orange or red wires as ground Two tests are to be performed test once with power on before the treadmill is started and again after Start is pressed Note this is the same procedure as the upper board console cable connection If results vary from the upper board the console cable is the likely cause and a continuity check should be performed Desired Results The voltage charts contain typical desired results on a fully functional system A variance from the norm would indicate a defective component Checkpoint Voltage Before Start Volatge After Start Console Cable Grey to Yellow Gnd 0 0 vdc 0 3 vdc increases as speed increases as shown on console Console Cable White to Yellow Gnd Note 2 75 Hp motors and higher the reading on the console cable white to yellow gnd is 1 6 or 3vdc
38. the text box Note To navigate through the engineering menu use the incline A and speed V buttons Display Button Test EngO Switch Function Eng3 EngO appears in the time window Eng3 appears in the time window DISPLAY TEST will scroll in the matrix or will be static in SWITCH FUNCTION will scroll in the matrix or will be text box static in text box Press ENTER to select Press ENTER to select When selected each display segment should be lit up If the treadmill has a Demo Mode then When pressed each button should have a unique display The brickyard will scroll DEMO ON or DEMO OFF change Default will be DEMO ON Stop button turns off all lights The A or Y buttons will change the Demo on off Start button turns all lights on settings Hardware Test Eng1 EngO appears in the time window HARDWARE TEST will scroll in the matrix or will be static in text box Press ENTER to select Press START to begin start Selects miles or km The display will show 0 for miles or 1 for km The display will scroll MILES OR KM when Start is pressed to change The new setting is automatically saved when Start is pressed no other buttons need to be pressed to save Speed A or W will change the speed Speed quick keys will change the speed Information Eng4 Preset to or within 20 Eng4 appears in the time window
39. tion motor control etc place the negative lead of your multi meter on pin B2 B4 or Bb and place the positive lead on the desired pin Follow the voltage charts on p23 9wire and p24 12wire Note 1 Wire colors are subject to change Note 2 It may be necessary to remove the glue from the console cable to access the pins gt gt Speaker Amp Board Voltage 30727 Only e Voltage In Voltage Out 22 2008 Sears CA Treadmill Service Manual rev 1 0 Section Two Voltage Checks gt gt 9 Wire Console Cable Voltage Chart DC Volts Model 30750 Incline Up Incline Down GND Power Voltage to UCB Drive Motor Relay Stop Incline Pot VREF Incline VCC ELE RPM Polarity tab will face User Wire Console Cable Voltage Voltage at UCB Voltage at MCB Physical Symptoms If Wire Cut Color no wires cut after wire s cut after wire s cut 1 Red Incline Up 0 0 vdc before started 1 9 2 5 vdc b f start 3 7 vdc b f start Incline motor will go up but not down vdc while inclining 0 0 vdc 5 0 vdc after start 0 0 vdc after start while declining Voltage constant while inclining declining 2 Brown Incline Down 0 0 vdc before started 0 0 2 5 vdc b f start 0 0 vdc b f start Incline motor will go down
40. ying power to treadmill e Make sure the treadmill is not on an extension cord surge protector or GFCI circuit Extension cords and surge protectors create energy loss which prevents proper voltage from being supplied to the treadmill e Make sure the treadmill is on a dedicated circuit Horizon Fitness recommends a 20 amp dedicated circuit but a 15 amp dedicated circuit may be sufficient e Make sure that proper voltage is being supplied from the wall outlet Je www Hazardous voltages will be tested in the following procedure Exercise extreme caution PNIS when performing these procedures Do not connect or disconnect any wiring Maa aS connectors or other components with the power applied to the treadmill e Disconnect the treadmill power cord from the wall outlet Using an AC voltmeter verify that the proper AC voltage is present at the wall outlet Nominal 120 volts AC may vary between approximately 105 volts AC and 135 volts AC If the AC voltage is missing or incorrect check the AC service or consult an electrician Step 2 Proper Wiring e Verity that all wires are secure and attached in the correct position e Verify that there aren t any pinches or cuts in any of the wires especially the console cable connecting from the motor control board to the upper board Replace any wires that are pinched or cut 2008 Sears CA Treadmill Service Manual rev 1 0 13 Section Two Horizon Fitness 5 Step Diagnostic
Download Pdf Manuals
Related Search