Core Fitness Systems 2003-2004 Treadmill Service Manual
Contents
1. board under the motor cover until the speed is approximately 0 5 mph or 05 mph in the Speed window Refer to diagram Speed Cube Once the speed cube is set to the proper setting press and hold the Stop button for three seconds to return to the Engineering Mode Menu 21 Step 2 Auto Calibration While in the Engineering Mode Menu press the Select button until Auto Set appears in the display Press Start to select Press Start to begin The treadmill running belt will begin moving and will automatically begin the auto calibration sequence to properly set and store the speed values Note This may take between 2 to 3 minutes to complete the auto calibration sequence Upon successful calibration there will be four beeps and it will automatically exit Engineering Mode and will return you to the original screen Troubleshooting If the Auto Calibration was unsuccessful Repeat Step 1 to confirm that the Speed Cube is adjusted to 0 50 mph or 0 05 mph 22 No Display on Console If the console only displays dashes in the display window follow the possible causes below Possible causes e Adjust the position of the safety key e Safety key polarity strength is not adequate Replace the safety key e Reed Switch inside console is defective Replace console If the console does not have any display and is totally blank follow the possible causes below Possible causes e Check v2. indicates the signal present PWM from the upper control board and will light up as the speed commands as being used LED 8 Power protect indicator LED 8 will be lit when the supplying power current to the lower control board too high In most cases this current limit LED will indicate excessive amp draw caused by inadequate AC service from the wall outlet or inadequate lubrication on the deck and running belt If this LED is lit the lower control board will automatically shut the machine down to prevent damage to any key electrical components 39 Manual Speed Calibration There are two ways to verify that the treadmill speed is set properly The first way is to count the running belt revolutions per minute At 0 5 mph the treadmill belt should make 4 5 revolutions per minute for the RT1 treadmill If the belt revolutions are incorrect adjust the speed dial located on the lower control board The other way to verify that the treadmill speed is set properly is to enter Diagnostics Mode To enter Diagnostics Mode follow the directions below With the treadmill power on and the safety key in position on the console press and hold the 1 amp 10 quick speed buttons for about 5 seconds to enter the Engineering Mode Menu The console should beep three times and Auto Set should be displayed once in the Engineering Mode Menu Hardware Test Use to check running belt speed and deck elevation While in the Engineering Mode Menu press
3. the Select button until Hardware Test appears in the display Press the Start button to select Press Start to begin At this time the running belt should begin moving The readout in the speed window will indicate the start speed of the treadmill which should be 0 5 mph or 05 mph Use Speed or to increase or decrease the speed Use Incline or to increase or decrease the elevation Press and hold the Stop button for three seconds to return to the Engineering Mode Menu 40 Manual Speed Calibration To adjust the speed setting of the treadmill turn the speed dial clockwise to increase speed or counterclockwise to decrease speed IR Comp Adjustment Speed Calibration The IR comp dial should only need to be adjusted if the treadmill belt is running in a jerky or choppy motion To adjust the IR comp turn the dial clockwise to increase voltage to motor or counterclockwise to decrease voltage to motor To verify proper adjustment start the treadmill at 0 5 mph and ride the treadmill belt from the front to rear roller If the treadmill does not have any apparent jerky or choppy movement the IR comp is set properly 41 INCLINE MOTOR TROUBLESHOOTING Incline function does not work Treadmill will incline up or down without command Incline does not reach minimum or maximum settings CONTENTS 42 No Incline Function Possible Causes e Verif
4. 4 mm between the sensor wire and the front roller pulley Loosen the sensor bracket attachment screws and position sensor bracket closer to front roller pulley if the distance is greater than 2 4 mm Verify that the sensor wire is attached to the sensor bracket properly The proper position would be so that the sensor wire is protruding from the left hand side of the sensor and sensor bracket while facing the treadmill Verify that the rpm magnet is positioned in the front roller pulley FIVE STEP DIAGNOSIS PROCESS Sensor Wire Function Verify that the lower control board is outputting the proper voltage 5 volts DC See Voltage checkpoints in table of contents for voltage measurement instructions Verify that the sensor wire is functioning properly in Diagnostics Mode To enter Diagnostics Mode follow the directions below Diagnostic Mode Instructions With the treadmill power on and the safety key in position on the console press and hold the 1 amp 10 quick speed keys for about 5 seconds to enter the Engineering Mode Menu The console should beep three times and Auto Set should be displayed once in the Engineering Mode Menu While in the Engineering Mode Menu press the Select button until Hardware Test appears in the display Press the Start button to select Press Start to begin At this time the running belt should begin moving The readout in the speed window will indicate the start speed of the tread
5. Core Fitness Systems 2003 2004 Treadmill Service Manual CORE FITNESS SYSTEM RT1 CFS Series If you have any questions please call the Sears Parts and Repair Center at 1 800 488 1222 TABLE OF CONTENTS INN IN a deca A nl ae ts ace ele Re teach Safety Tmstructioms oc ccccccseeesccsssssssseesessssssssseeesssssssssnessesessssnueeseeesesanueessersesasees FROG O NTE CT CES socio caccectans etch ett comss vena ia s s clth gon ant coael a ates IVE AMIN enaA e a Pocono errr heats ke a haan ood tal hein pd ade tee Tensioning or Aligning the Running Belt cccsccsseeeescsesssssneeeessensssnnees Tensioning the Drive Belt Lubricating Procedures ocd lek Sis al Ohhh cant keene Os ok setae act se CFS 5 Step Diagnostic Process Upper Board Troubleshooting Console Cable Voltage Chart oii cccssssssssssssssssssssssessssssessssssssssesssseiessssneesssseseen Auto Calibration Instructions ooo ccssssssssssssssssssessssssseessesssseessesssseseessssseessesssseeesenssses Lower board troubleshooting Wiring Diagrams nm oana obec hve R A A AA Lower Control Board Diagnostic LED Chart Manual Speed Calibration icc ccccscsessssseesssssseesssssseesssssesssssseessssseeesssnstessssseess Incline Motor Troubleshooting occ cccccccscsssssesssssssssessssssseesssssssueessssssueessssases Drive Motor and Roller Troubleshooting Parts Replacement Get It fixed at your home or ours Your Home For repair in your home of all major brand appliances lawn and garden
6. Press Start to light entire display Press and hold the Stop button for three seconds to return to the Engineering Mode Menu Engl Hardware Test Use to check running belt speed and deck elevation While in the Engineering Mode Menu press Select button until Hardware Test appears in the display Press the Start button for three to select Press Start to begin At this time the running belt should begin moving The readout in the speed window will indicate the start speed of the treadmill which should be 0 5 mph or 05 mph Use Speed or to increase or decrease the speed Use Incline or to increase or decrease the elevation Press and hold the Stop button for three seconds to return to the Engineering Mode Menu 28 Heart Rate Control Function Does Not Work When holding the heart rate handlebars the display in the Pulse display window should register HR If this does not register follow the possible causes below Possible causes e Defective heart rate receiver heart rate grips Replace entire console e Defective upper board Replace entire console When holding the heart rate handlebars the display in the Pulse display window should register HR If this registers but the actual heart rate reading does not register or is erratic follow the possible causes below Possible causes e Try standing off to the side of the treadmill and use a loose cu
7. able marks on the left and right side of the deck and the running belt When reinstalling match up the marks for proper tension With the appropriate size Allen wrench remove the rear roller and replace it with a new one It is a good idea to note the position of the rear roller before removing Start the treadmill and run it to ensure proper belt tension and side to side belt tracking If there is a problem with the belt tension or tracking adjust the rear roller position 53 Motor Replacement Tools required Philips screwdriver Socket wrench 13mm Box wrench 8mm Allen wrench 6mm Procedure 9 Turn off the power to the treadmill and remove the power cord from the wall outlet 10 With a Philips head screwdriver remove the motor cover 11 Unplug the motor wires from the lower board 12 Before continuing it is a good idea to weight down the treadmill deck to prevent the treadmill from springing up Removing the weight of the motor will significantly reduce the weight in the front end of the treadmill 13 With a 13mm wrench remove the attachment nuts M08 and washers M09 holding the motor to the frame 14 With a 6mm Allen wrench loosen the two motor bracket attachment bolts M45 54 M46 15 With a 6mm Allen wrench remove the bolts M06 and washers M30 M25 holding the motor to the motor bracket and replace it with a new motor 16 Put the new motor in place on the frame taking cau
8. ction CONSOLE TROUBLESHOOTING CONTENTS Console Cable Voltage Chart cssssssssssessesssesseecesseseeeessesssssssesssssssnssssssssenssessess 20 Auto Calibration procedures ccsssssssssssscsssssssssssssssssssssssssssssssssessssesseceeeseeseesseeeee 21 No display on COMSOLG 5 52 6 scsi canthiahaaaeionch auaeaaaiadindahaadaeanieneaes 23 All or some of the Keys on console will not work 0 ssssssssecsssssssssssscessssssseteee 25 Error message E1 or E2 on COMSOLE cessssssscsssssssssssssssseesseessesssssssestsssessessesssee 26 Diagnostics Modez onakoa naaa o au nehna o aG 28 Heart rate control function does not WOrK ssssssssssssssssssssssessssessesseeeeeeseeeeee 29 Static shocks from upper board heart rate QripS ccesecceescccceeecccees 30 Console exploded diagram sseesssooosessesssesecscosseseossesssosesesssesssese 31 Console Cable Voltage Chart DC volts Elevation Elevation Speed control Ground Ground RPM pulse Power to console Power to console 0 volts PWM Motor SW Elevation Down Elevation Up CI CI CI CI Co mm immi ca Em CJ CI CORRECT VOLTAGE FOR WIRE HARNESS B1 Brown 5 volts B7 Blue 12 16 volts B2 Red 5 volts B8 Dark Green 12 16 volts B3 Pink O volts B9 Light Green 0 volts B4 Orange Ground B10 Black 5 volts B5 Yellow Ground B11 Grey action 5 volts Normal 0 volts B6 Purple 5 vo
9. e it with a new one screwing the new air shock into the bottom screw and then securing the top of the air shock with the 13 mm nut 65
10. e lubrication provided by Sears only e Lubricate the air shocks with a Teflon based spray Tensioning or Aligning the Running Belt Tensioning the Running Belt If you can feel a slipping sensation when running on the treadmill the running belt must be tightened In most cases the belt has stretched from use causing the belt to slip This is a normal and common adjustment To eliminate this slipping tension both the rear roller bolts with the appropriate sized Allen wrench turning both the left and right bolt 1 4 TURN as shown below Try the treadmill again to check for slipping Repeat if necessary but NEVER TURN the roller bolts more than 1 4 turn at a time NOTE The belt tension is set properly when the running belt is of an inch from the deck towards the rear roller Aligning the Running Belt 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 6 8 mph stand behind the treadmill and watch the movement of the running belt 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 If the running belt is not tracking properly follow the following procedures e Ifthe 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 runnin
11. e proper AC voltage is present at the wall outlet Nominal 120 Vac may vary between approximately 105 Vac and 135 Vac If the AC voltage is missing or incorrect check the AC service or consult an electrician e Make sure that the treadmill is connected to a dedicated 20amp circuit with out the use of an extension cord e Verify that there are not any pinches or cuts in power cord motor wires or console cable Replace if necessary e Adjust IR Comp dial on lower board e Inadequate lubrication on deck and belt Refer to treadmill waxing procedures e If problem persists replace lower board 35 Lower Control Board Wiring Diagram Transformer green Console cable Elevation motor RPM sensor Elevation motor black Elevation motor red Elevation motor wire white AC1 Motor from on off switch Red AC2 from on off switch Transformer red Transformer red 36 Wiring Diagram ON OFF SWITCH SOCKET A SOCKET WIRE TO ON OFF SWITCH E ON OFF SWITCH TO LOWER BOARD AC1 B GROUND F ON OFF SWITCH TO BREAKER C SOCKET WIRE TO BREAKER D ON OFF SWITCH TO LOWER BOARD AC2 37 Lower Board LED Diagnosis Top layer of lower control board LED 5 amp 6 38 Lower Board LED Diagnosis LED 1 amp 2 Transfer indicators When the power switch is turned on LED 1 amp 2 ligh
12. e rear closet to the back of the treadmill 45 mm bolt and 13 mm nut that attaches the console assembly to the console mast ACO1 7 Remove the console mast plug P30 from the console mast 8 Attach the new console cable to the existing cable and fish the new cable through the console mast 9 Once the new console cable is installed through the console mast connect the plugs to the lower board and upper boards 10 Attach the console assembly to the console masts with the 45 mm bolts and 13 mm nut and attach the console mast covers 11 Attach the back panel on the upper board 12 Attach the motor cover ensuring that the console cable is not being pinched 59 Incline Motor Replacement Tools required Philips screwdriver Qty 2 wrenches 17mm Procedure 1 Turn off the power to the treadmill and unplug the power cord from the wall outlet 2 With a Philips head screwdriver remove the motor cover Disconnect the incline motor wires from the lower control board 3 Fold up the treadmill to the locking position 4 With two 17mm wrenches remove the bottom bolt attaching the motor shaft to the incline frame It may be helpful to tip the treadmill on its side to release pressure from the shaft bolt 5 Fold the treadmill down to the running position Remove the top bolt from the incline motor Remove the incline motor from the machine 6 When installing the new incline motor make sure the elevation shaft is fl
13. eck bolts Assemble the front roller first but do not tighten completely Then assemble the rear roller and drive belt idler 7 Finish tightening the front roller 8 Start the treadmill and run it to ensure proper belt tension and side to side belt tracking If there is a problem with the belt tension or tracking adjust the rear roller position 9 Install the sensor side rails and all the covers 52 Roller Replacement Tools required Philips screwdriver T handle Allen wrench 6mm 8mm Procedure Front roller l 2 With a Philips head screwdriver remove the motor cover With the Philips head screwdriver remove the speed sensor Press your finger against the drive belt and guide it towards the left until it is released from the front roller With the 6mm Allen wrench remove the front roller and replace it with a new one It is a good idea to note the position of the front roller before removing For best results place two removable marks on the left and right side of the deck and the running belt When reinstalling match up the marks for proper tension 4 Reassemble the front roller and the drive belt Install the motor cover Rear roller With a Philips head screwdriver remove the motor cover With a 6mm Allen wrench loosen and remove the front roller Itis a good idea to note the position of the front roller before removing For best results place two remov
14. equipment or heating and cooling systems no matter whe made it no matter who sold it For the replacement parts accessories and owner s manuals that you need to do it yourself For Sears professional installation of home appliances and items like garage door openers and water heaters 1 800 4 MY HOME 4 800 469 4663 Call anytime day or night iU 5 4 and Canada We We sears com Weve SoATS Ca Our Home For repair of carry in items like vacuums lawn equipment and electronics call or go on line for the location of your nearest Sears Parts amp Repair Center 1 600 488 1222 Call anytime day or night U S A only Wi Sears com To purchase a protection agreement U S A or maintenance agreement Canadai on a product serviced by Sears 1 800 827 6655 U S A 1 800 361 6665 Canada Para pedir servicio de reparaci n Au Canada pour service en francais a domicilio y para ordenar piezas 1 R00 LE FOYER 1 268 SU HOGAR 1 000 533 6937 1 888 784 6427 WW SESrs ca SEARS D Registered Trademark i Trademark Samica Warkof Sears Roebuck and Co Marea Registrada Mares da Fabrica Marca de Garvin da Sears Roebuck and Ca Marque de commerce 8 angus dipasia da Saars Abuk and Co Sear Roshuck and Co Important Safety Instructions Warning statements indicate a particularly dangerous activity You should be extremely cautious when doing the following Removing power from the treadmill the powe
15. ety tether clip to your clothing e Ifyou 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 e Do not remove the treadmill motor covers or roller covers Service should be performed by an authorized Sears service provider only Treadmill should be plugged into a dedicated 20amp circuit for optimal performance Required Tools and Equipment The following list is a summary of the tools and equipment required by the procedures in this manual Phillips screwdrivers anti static wrist strap when handling electronic parts flat head screwdrivers digital multi meter drive belt tension gauge Allen wrench set Metric open end wrenches of assorted sizes Metric clamp on AC amp meter 2 drive ratchet and sockets of assorted sizes blue loc tite cable ties Motor commutator stone needle nose pliers damp cloth rubber mallet drop cloth ruler snap ring pliers wire cutters PREVENTATIVE MAINTENANCE PROCEDURES Cleanliness of your CFS treadmill and its operating environment will keep maintenance problems and service calls toa minimum For this reason Sears recommends that the following preventive
16. g belt may cause damage to the running belt and roller bearings e Ifthe running belt tracks to the right turn the right roller bolt clockwise 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 Tenstoning the Drive Belt Procedure 1 Turn off the power to the treadmill and remove the power cord from the wall outlet 2 With a Philips head screwdriver remove the motor cover 3 Unplug the motor wires from the lower board 4 Before continuing it is a good idea to weight down the treadmill deck to prevent the treadmill from springing up Removing the weight of the motor will significantly reduce the weight in the front end of the treadmill 5 With a 13mm wrench loosen the attachment nuts M08 and washers M09 holding the motor to the frame 6 With a 6mm Allen wrench loosen the two motor bracket attachment bolts M45 M46 and adjust to proper position 7 Tighten the two motor attach bolts M45 M46 with a 6mm Allen wrench 8 Verify the proper tension on the drive belt Using a timing belt tension gauge the proper tension should be between 65 to 75 lbs Ifa timing belt tension gauge is not available the drive belt should have approximately 3 8 of inch deflection If the drive belt tension is not set properly loosen the motor attachment bolts and adjust Treadmill Deck Lubrication Procedures There are three different app
17. h loosen the rear roller bolts on both the left and right side It is a good idea to note the position of the roller to reassemble properly For best results place two removable marks on the left and right side of the deck and the running belt When reinstalling match up the marks for proper tension It is not necessary to take off the roller just loosen it enough so that you can fit your hands underneath the belt comfortably 3 Once the belt is loosened take a small amount of silicon oil 20 cc squeeze bottle provided by Sears and apply it to the entire top surface of the running deck After the silicon oil has been applied to the top surface of the running deck the roller can be tightened to the proper position With a damp cloth wipe off any excessive silicon oil that may have seeped out from underneath the running belt 12 Lubricating the Air Shock Procedure 1 Fold the treadmill to the upright position making sure the treadmill is locked securely Add lubricating oil on the shaft of the air shock 3 Lift the frame up and down repeating this several times to allow the lubricating oil blend into air shock 13 FIVE STEP DIAGNOSIS PROCESS The following steps are provided as routine checkpoints when diagnosing problems on a CFS treadmill If followed correctly these checkpoints should help diagnosis the majority of problems that may be encountered 1 Proper supplying power to treadmill Make sure the treadmil
18. l is not on an extension cord Extension cords create energy loss which prevents proper voltage from being supplied to the treadmill Make sure the treadmill is on a dedicated circuit Sears recommends a 20 amp dedicated circuit but a 15 amp dedicated circuit may be sufficient Make sure that proper voltage is being supplied from the wall outlet Warning Hazardous voltages will be tested in the following procedure Exercise extreme caution when performing these procedures Do not connect or disconnect any wiring connectors or other components with the power applied to the treadmill Disconnect the 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 Ifthe AC voltage is missing or incorrect check the AC service or consult an electrician FIVE STEP DIAGNOSIS PROCESS Continued 2 Proper Wiring Verify that all wires are secure and attached in the correct position reference wiring diagrams in table of contents Verify that there aren t any pinches or cuts in any of the wires especially the console cable connecting from the lower board to the upper board Replace and wires that are pinched or cut 3 Proper Sensor Wire Function Verify that the rpm sensor wire is positioned as close to the front roller pulley as possible The factory standard is a distance or 2
19. lications in which you would be required to add lubrication to a CFS treadmill 1 MAINTENANCE A CFS treadmill does not need to be waxed regularly However Sears recommends that lubrication be applied once a year This is not always necessary but it will ensure long life of the treadmill 2 BELT REPLACEMENT When lubrication is added to a treadmill deck at the factory it is impregnated into the filament backing of the running belt providing a low friction long lasting coat When replacing the original belt on a treadmill this new belt will not be properly coated Always add lubrication when replacing the belt 3 BREAKER TRIPS With time the lubrication between the running deck and running belt of the treadmill will wear down The lack of lubrication between the deck and belt will cause a high amount of friction when running on the treadmill This in turn will cause the treadmill breaker to trip If this happens lubrication should be added These three applications should be the only times lubrication is ever added to a CFS treadmill Please contact the Sears service department to obtain the proper lubrication for reapplication Do not apply other manufacture s lubrication to a CFS treadmill PROCEDURES 1 For optimal results the running deck and belt should be warm before reapplication of lubrication It is recommended to run the treadmill at Smph for 10 15 minutes before proceeding 2 With the appropriate sized Allen wrenc
20. ll 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 operation the treadmill do not wear loose clothing Do not wear shoes with heels or leather soles Check the soles of your shoes and remove and embedded stones Tie long hair back e Use care when getting on of 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 sides of the treadmill You should also step off the belt and onto the sides 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 hood e Do not set anything on the handrails electronic console or hood 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 case injuries e Tu
21. ll run for about 30 minutes without load to break the treadmill in e Verify proper tension of the running belt Excessive noise may be created by an over tightened running belt e Verify that there is proper clearance between the rear roller and the bottom deck cover and frame e If problem persists replaced the rear roller 49 Upper Board Keypad Membrane Key Air Shock TREADMILL PARTS REPLACEMENT CONTENTS 31 53 54 56 57 58 60 61 63 65 50 Running Belt Deck Replacement Procedure Tools required Philips screwdriver T handle Allen wrench 5mm 6mm Procedure 1 With a Philips head screwdriver remove the motor cover rear roller end caps and left and right side rails 2 With the appropriate size Allen wrench remove the rear roller It is a good idea to note the position of the rear roller before removing For best results place two removable marks on the left and right side of the deck and the running belt When reinstalling match up the marks for proper tension 3 With the Philips screwdriver remove the speed sensor 4 With a 6mm Allen wrench remove the front roller It is a good idea to note the position of the rear roller before removing 5 Loosen the bolts that hold the deck to the frame and remove the running belt and deck Replace the deck and running belt with a new one 51 Running Belt Deck Replacement Procedure Continued 6 Tighten the d
22. lts B12 White action 5 volts Normal 0 volts To check the voltage of a specific function i e devation motor control etc place the negative lead of your multi meter on pin B4 or B5 and place the positive lead on the desired pin Follow the voltage chart above for the correct voltages Note Wire colors are subject to change 20 Auto Calibration Procedures The RT1 model have a built in auto calibration sequence into the software programming This will allow the rpm sensor reading to be detected and stored in the upper board This process is performed at the factory and will not need to be repeated unless replacing the upper board or lower board in your Horizon Series treadmill To perform the auto calibration sequence follow the instructions below Step 1 Adjusting the Speed Cube With the treadmill power on and the safety key in position on the console press and hold the 1 and 10 quick speed keys for about 5 seconds to enter the Auto Set Menu The console should beep three times and Auto Set should be displayed once in the Auto Set menu Press Select button until Hardware Test appears in the display Press the Start button to select Press Start to begin At this time the running belt should begin moving The readout in the speed window will indicate the start speed of the treadmill which should be 0 5 mph or 05 mph Ifthe speed is not within the proper start speed range adjust the Speed Cube located on the
23. maintenance schedule be followed After Each Use e Turn off the treadmill with the on off switch and unplug the power cord from the wall outlet Warning To remove power from the treadmill the power cord must be disconnected from 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 Sears e Make sure the power cord is not underneath the treadmill or in any 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 e Inspect all assembly bolts of the machine for proper tightness e Remove the motor cover and blow out the motor and lower board tray to remove any lint or dust particles that may have accumulated Each Year e Add lubrication to deck and running belt Us
24. mill which should be 0 5 mph or 05 mph Use Speed or to increase or decrease the speed co Ce Use Incline or to increase or decrease the elevation Press and hold the Stop button for three seconds to return to the Engineering Mode Menu FIVE STEP DIAGNOSIS PROCESS Continued 4 Proper Speed Calibration Press Start Verify that the treadmill motor begins moving within 1 second If the treadmill motor begins hesitates and starts moving after 1 second follow the auto calibration instructions listed in the table of contents Verify that the treadmill motor turns smoothly There should not be any jerky or choppy movement of the motor It may also be necessary to stand on the belt at a slow speed and ride the treadmill belt from the front roller to the rear roller to verify that the treadmill motor and running belt are traveling smoothly Verify start up speed 0 5 mph in Diagnostics Mode To enter Diagnostics Mode follow the directions below With the treadmill power on and the safety key in position on the console press and hold the 1 amp 10 quick speed keys for about 5 seconds to enter the Engineering Mode Menu The console should beep three times and Auto Set should be displayed once in the Engineering Mode Menu While in the Engineering Mode Menu press the Select button until Hardware Test appears in the display Press the Start button to select Press S
25. ocedure 9 Turn off the power to the treadmill and unplug the power cord from the wall outlet With a Philips head screwdriver remove the console from the console mast Remove the console cable from the console connection With a Philips head screwdriver remove the screws N22 that attach the top console case N01 to the bottom console case N02 Once all screws have been removed remove the side accent pieces N03 N04 and separate the top and bottom console cases Unplug all the cables connecting to the upper board N17 With the screwdriver loosen screws N21 and remove the upper board N17 Once the upper board has been removed remove the keypad and replace with new one Attach the upper board and secure with screws Reconnect the console cables 10 Attach the side accent pieces and top and bottom console cases together and secure with screws Take caution so internal wires are not pinched 11 Insert the console cable to the back of the console 12 Attach console to the console mast and secure with screws 63 Keypad Replacement 64 Air Shock Replacement Tools required Wrench 13mm Procedure 1 Fold treadmill to locking position 2 Use a 13mm wrench to loosen the nut that secures the top screws of the air shock to the frame 3 Unscrew the entire air shock counterclockwise to remove it from the bottom screw attachment screw 4 Remove air shock and replac
26. oltage of wall outlet Warning Hazardous voltages will be tested in the following procedure Exercise extreme caution when performing these procedures Do not connect or disconnect any wiring connectors or other components with the power applied to the treadmill 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 Ifthe AC voltage is missing or incorrect check the AC service or consult an electrician 23 e Breaker is damaged Inspect the circuit breaker to see if it has tripped off If it is tripped off like diagram A reset the breaker vd aS A KO X mn gt 5 g gt e ON OFF switch is damaged Make sure the ON OFF switch is turned to the ON position and that the switch is lit If the switch is not lit check the power cord connection and function e Improper wiring Check all wiring coming in from the power switch to the lower board to the upper board Refer to wiring diagrams e Inspect diagnostic LED s on lower board Determine defective part according to chart e Check voltage of console cable Determine defective part by using console cable chart Refer to console cable voltage checkpoint in table of contents 24 All or Some of the Keys on Console Will not Work Possible causes e Keypad electrodes N74 are not c
27. oming into proper contact with upper control board N17 Remove keypad and reposition e The upper control board N17 is defect Replace entire console 25 E 1 Error message on the Upper Board If there is belt movement upon start up of the treadmill and an E 1 message occurs follow the possible causes below Possible cause e Check all wire connections e Verify that the sensor magnet is positioned in the front roller pulley e Verify the distance between the RPM sensor wire and the front roller pulley 2 4 mm Reposition the RPM sensor closer to the pulley if possible e Follow the auto calibration instructions reference auto calibration in table of contents e Verify the signal of the RPM sensor by entering Diagnostics Mode If there is no signal present check the continuity of the RPM sensor wire If there is no continuity replace the sensor wire e Ifthe problem persists replace the entire console If there is no belt movement upon start up of the treadmill and an E 1 message occurs follow the possible causes below Possible cause e Verify that all wire connections are properly attached e Follow the auto calibration instructions reference auto calibration in table of contents e Verify the diagnostic LED s on the lower board Reference diagnostic LED chart for possible causes e If problem persists replace the lower board 26 E 2 Error message on the Upper Board If there is belt m
28. ovement upon start up of the treadmill and an E 2 message occurs follow the possible causes below Possible cause e Check voltage of wall outlet Warning Hazardous voltages will be tested in the following procedure Exercise extreme caution when performing these procedures Do not connect or disconnect any wiring connectors or other components with the power applied to the treadmill 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 Vac may vary between approximately 105 Vac and 135 Vac If the AC voltage is missing or incorrect check the AC service or consult an electrician e Follow the auto calibration instructions reference auto calibration in table of contents e Ifthe problem persists replace the lower board and entire console 27 Diagnostics Mode With the treadmill power on and the safety key in position on the console press and hold the 1 amp 10 quick speed keys for about 5 seconds to enter the Engineering Mode Menu The console should beep three times and Auto Set should be displayed once in the Engineering Mode Menu LCD Test Display Button Check Use to check the display and buttons While in the Engineering Mode Menu press Select button until LCD Test appears in the display Press Start to select As any button is pressed there should be a beep and the display should change
29. plug the power cord from the wall outlet 2 With a Philips head screwdriver remove the motor cover 3 Verify that LED MTR is not lit on the lower board If this LED is lit please wait approximately 1 minute until the light is out This is an indication that the stored power has left the board Failure to do so may result in injury 4 Unplug all the wires and cables from the lower board It is a good idea to note the position of all wiring before removing 5 With a Philips head screwdriver remove the lower board and replace it with a new one 6 Reconnect all the wires to the lower board Please refer to lower control board wiring diagram 7 Install the motor cover 8 Re plug the power cord and turn power on 57 Console Cable Replacement Tools required Philips screwdriver Allen wrench 5mm 13 mm wrench Needle nose pliers Procedure 1 Turn off the power to the treadmill and unplug the power cord from the wall outlet 2 With a Philip head screwdriver remove the motor cover and disconnect the console cable from the lower control board 3 With a Philip head screwdriver remove the console AN1 from the console mast AN3 and unplug the console cable from the console 4 With a Philips screwdriver remove the back console assembly panels N57 58 5 Remove the console assembly from the console mast AC02 by removing the console mast covers on both the left and right side 6 Remove th
30. pping grip while pressing your palms against the heart rate handlebars e Ifthe problem persists replace the entire console 29 Static Shocks from Upper Board Heart Rate Grips Possible causes e Lubrication on running deck and running belt inadequate Contact Sears for lubrication application e Defective grounding fibers in running belt Replace running belt Note Improper grounding of the upper board or running belt may also cause other symptoms like erratic speed scrambled reading of the upper board resetting of the treadmill or erratic or non responsive heart rate function 30 Console Exploded Diagram 31 LOWER BOARD TROUBLESHOOTING CONTENTS Treadmill will not start Treadmill will reset Running speed is not stable Wiring diagram Lower board LED diagnosis Speed Calibration 33 34 35 36 38 40 32 Treadmill Motor Will Not Start Possible causes e Verify that all wire connections are properly connected e Follow the auto calibration instructions reference auto calibration in table of contents e Verify the diagnostic LED s on the lower board Reference diagnostic LED chart for possible causes e Measure voltage from motor reference voltage checkpoints in table contents If no voltage is present unplug the treadmill and visually inspect the motor brushes and springs to make sure they are installed properly Repeat voltage reading if necessary e If problem persist
31. r cord being disconnected 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 Removing the motor cover exposes high voltage components and potentially dangerous machinery Exercise extreme caution when you perform maintenance procedures with the hood removed During service operations you will be very close to moving machinery and high voltage components When you perform maintenance procedures with the hood removed remove jewelry especially from ears and neck tie up long hair remove neck ties and do not wear loose clothing When the treadmill is operating the capacitor will hold a lethal amount of charge Do not touch the capacitor as serious injury or death might result When the treadmill is turned off and the power cord is 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 Exercise caution when touching any wire or electrical component during treadmill operation 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 a
32. rn off the treadmill when adjusting o working near the take up 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 WARNING Connect this appliance to a properly grounded dedicated 20 amp outlet only 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 DANGER Improper connection of the equipment grounding conductor can result in a risk of electric shock Check with a qualified electrician of serviceman if you are in doubt as to whether the product is properly grounded Do not modify the plug provided with the product if it will not fit in the outlet have a proper outlet installed by a qualified electrician GROUNDED OUTLET ADAPTER ae METAL SCREW a gt a TAS FOR GROUNDED GROUNDING SCREW QUTLET BOX GROUNDING PIN SAFETY TIPS e Never use the treadmill before securing the saf
33. s replace the lower board 33 Treadmill Will Stop and Reset e Check voltage of wall outlet Warning Hazardous voltages will be tested in the following procedure Exercise extreme caution when performing these procedures Do not connect or disconnect any wiring connectors or other components with the power applied to the treadmill 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 Vac may vary between approximately 105 Vac and 135 Vac If the AC voltage is missing or incorrect check the AC service or consult an electrician e Make sure that the treadmill is connected to a dedicated 20amp circuit with out the use of an extension cord e Verify all wire connections for proper connection including power cord e Inadequate lubrication on deck and belt Refer to treadmill waxing procedures 34 Running Speed Is Not Stable erratic speeds e Verify that the running belt and drive belt tensions are adequate preventing belts from slipping e Check voltage of wall outlet Warning Hazardous voltages will be tested in the following procedure Exercise extreme caution when performing these procedures Do not connect or disconnect any wiring connectors or other components with the power applied to the treadmill e Disconnect the treadmill power cord from the wall outlet Using an AC voltmeter verify that th
34. s are removed from the drive motor e After you replace a motor brush make sure the brush is seated securely and makes full contact with the commutator before you plug in the power cord and turn on the treadmill e Ifthe problem persists replace the drive motor or front roller 47 Stoning the Motor Commutator e Unplug the power cord from the wall outlet e Remove the brush covers on the drive motor and inspect the brushes and the motor commutator for any uneven wear e Ifthe surface of the motor brush is pitted rough or has burn marks replace the motor brush e Do not plug in the power cord and do not turn on the treadmill when the motor brushes are removed from the drive motor e With the brushes removed inspect the motor commutator for any unusual wear or burn marks If there is any abnormal marks or wear stone the motor commutator Make sure to blow any dust or particles from the motor commutator when finished e After you replace a motor brush make sure the brush is seated securely and makes full contact with the commutator before you plug in the power cord and turn on the treadmill e Run the treadmill for 15 minutes at 3 5 mph to seat the brushes properly Inspect the motor commutator again for any unusual wear Repeat stoning process if necessary 48 Noises Generating From the Rear of the Treadmill Possible causes e If this problem is being experienced on a new treadmill let the treadmi
35. t up meaning that power is supplied to the lower board These LED s should remain on while operating the drive motor and elevation motor If the LED s are not lit check the AC service from the wall outlet LED 3 Motor indicator The LED goes on when the drive motor is operating If the LED is not lit voltage is not being supplied to the motor and the lower board may need to be replaced LED 4 AC power indicator When the power switch is turned on LED 4 it will be lit meaning that power is supplied to the lower board This LED should remain on while operating the drive motor and elevation motor but while shut off if an error message E 1 E 2 is shown on the upper board If this LED is not lit and there is not an error message displayed on the upper board verify that all wire connections have been properly attached Ifthe problem persists check the AC service from the wall outlet LED 5 amp 6 Incline Motor Indicator When the upper board is commanding the incline motor to move UP or DOWN the LEDs go on LED 5 is for the UP function and LED 6 is for the DOWN function If the user is commanding the incline motor to increase decrease and the LED 5 LED 6 is not lit verify that all wire connections have been properly attached If the problem persists check the voltage of the console cable and reference the chart for possible causes If the problem persists replace the upper and lower boards LED 7 PWM signal indicator LED 7
36. tart to begin At this time the running belt should begin moving The readout in the speed window will indicate the start speed of the treadmill which should be 0 5 mph or 05 mph Use Speed or to increase or decrease the speed Use Incline or to increase or decrease the elevation Press and hold the Stop button for three seconds to return to the Engineering Mode Menu The start speed of the treadmill can also be determined by counting the revolutions minute of the running belt At 0 5 mph the treadmill belt should make 4 5 revs minute for the RT1 If the belt revolutions are incorrect adjust the speed dial located on the lower control board see speed calibration in table of contents FIVE STEP DIAGNOSIS PROCESS Continued 5 Voltage Checkpoints Diagnostic LED s Verify that the lower board is functioning properly by referencing the Diagnostic LED s located on the lower control board A complete description for each Diagnostic LED can be found by referencing the lower control board Diagnostic LED chart in the table of contents Verify that proper voltage is being transferred through the console cable reference console cable voltage chart in the table of contents If the techniques described in the five step diagnostic process did not resolve the problem reference the symptoms in the table of contents and review other possible causes in the troubleshooting se
37. tion to properly align the motor flywheel pulley and the front roller pulley Tighten with a 13mm wrench 17 Place the drive belt on the drive motor making sure that the motor pulley is aligned with the roller pulley 18 Tighten the two motor attach bolts M45 M46 with a 6mm Allen wrench 19 Verify the proper tension on the drive belt Using a timing belt tension gauge the proper tension should be between 65 to 75 Ibs Ifa timing belt tension gauge is not available the drive belt should have approximately 3 8 of inch deflection If the drive belt tension is not set properly loosen the motor attachment bolts and adjust 55 Motor Brush Replacement Tools required Flat blade screwdriver Procedure 1 Turn off the power to the treadmill and unplug the power cord from the wall outlet 2 Remove the motor brush cover and the carbon brushes with a flat blade screwdriver 3 Check the surface of the motor brush Ifthe surface of carbon brush is pitted rough or has burn marks replace the motor brush 4 Stone the surface of the motor commutator and blow out particles inside motor with an air compressor 5 Install the motor brush and the motor brush cover 6 Plug in the treadmill and let the treadmill run for about 1 hour at Smph to allow the proper seating of the brush 56 Lower Board Replacement Tools required Philips head screwdriver Procedure 1 Turn off the power to the treadmill and un
38. tor shaft should be flush with the bottom of the motor housing If the position of the shaft is to close to the bottom motor housing the shaft may have become jammed To correct this remove the bottom bolt from the elevation motor and spin the shaft manually tube has to close here tube 45 DRIVE MOTOR AND ROLLER TROUBLESHOOTING CONTENTS Thumping noises generating from under Motor COVED eenn 47 Cleaning the motor o sect aces cane ceca Bs ck ace cease te mea cs ae tate dart aat eat 48 Thumping noises generating from rear of treadmill r 49 46 Noises Generating From Under Motor Cover Possible causes e Verify proper tension of the running belt Excessive noise may be created by an over tightened running belt e Remove motor cover and verify alignment of drive belt e Inspect for debris on drive motor pulley front roller pulley or on drive belt e If this problem is being experienced on a new treadmill let the treadmill run for about 30 minutes without load to break the treadmill in e Remove the brush covers on the drive motor and inspect the brushes and the motor commutator for any uneven wear Make sure the treadmill is turned off before doing this procedure e Ifthe surface of the motor brush is pitted rough or has burn marks replace the motor brush and stone the motor commutator e Do not plug in the power cord and do not turn on the treadmill when the motor brushe
39. ush with the motor casing See diagram below 7 Install the top bolt to the incline motor 8 Install the bottom bolt to the incline shaft 9 Reconnect the incline motor wires to the lower control board 10 Attach the motor cover 60 Upper Board Replacement Tools required Philips screwdriver Note Diagram on following page Procedure 1 Turn off the power to the treadmill and unplug the power cord from the wall outlet 2 With a Philips head screwdriver remove the console from the console mast 3 Remove the console cable from the console connection 4 With a Philips head screwdriver remove the screws N22 that attach the top console case N01 to the bottom console case N02 5 Once all screws have been removed remove the side accent pieces N03 N04 and separate the top and bottom console cases 6 Unplug all the cables connecting to the upper board N17 7 With the screwdriver loosen screws N21 remove the upper board N17 and replace it with a new one 8 Reconnect the console cables 9 Attach the side accent pieces and top and bottom console cases together and secure with screws Take caution so internal wires are not pinched 10 Insert the console cable to the back of the console 11 Attach console to the console mast and secure with screws 61 Upper Board Replacement 62 Keypad Replacement Tools required Philips screwdriver Note Diagram on following page Pr
40. y that all wire connections are properly attached e Inspect console cable for damage e Check voltage of console cable Determine defective part by using console cable chart e Verify diagnostic LED s on lower board Reference Diagnostic LED chart for possible causes e Verify elevation motor shaft position The elevation motor shaft should be flush with the bottom of the motor housing If the position of the shaft is to close to the bottom motor housing the shaft may have become jammed To correct this remove the bottom bolt from the elevation motor and spin the shaft manually Ifthe elevation shaft has become jammed and can not be spun free to the proper position replace the elevation motor tube has to close here tube e Ifproblem persists replace the lower and upper boards 43 Treadmill Will Incline Up or Down Without Command Possible causes e Verify that all wire connections are properly attached e Inspect console cable for damage e Check voltage of console cable Determine defective part by using console cable chart e Verify diagnostic LED s on lower board Reference Diagnostic LED chart for possible causes e Replace console cable e If problem persists replace lower board and entire console 44 Incline Does Not Reach Minimum or Maximum Settings Possible causes e Incline motor is not installed properly e Verify elevation motor shaft position The elevation mo
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