Keys Fitness Treadmill Service Manual
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Keys Fitness Treadmill Service Manual

Keys Fitness Treadmill Service Manual

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K E Y S
F I T N E S S
S E R V I C E
M A N U A L
TREADMILL
Rev. B- 12/04
1

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Summary of Contents for Keys Fitness Treadmill

  • Page 1 K E Y S F I T N E S S S E R V I C E M A N U A L TREADMILL Rev. B- 12/04...
  • Page 2 DISCLAIMER CAUTION: AC LINE AND HIGH DC VOLTAGES ARE PRESENT INSIDE THE TREADMILL QUALIFIED PERSONNEL ONLY! 1. CONNECT TREADMILL TO AC LINE. 2. LOCATE FRONT OF CONTROLLER. THERE IS A RED LAMP (LED) NEAR THE TOP/CENTER OF POWER CONTROL BOARD IT SHOULD BE LIT IF AC POWER IS PRESENT. TO CONFIRM AC OUT- LET IS OK, PLUG IN LAMP OR OTHER ELECTRICAL ITEM.
  • Page 3 STORES. USE ONLY A UL LISTED SURGE PROTECTOR, RATED AT 15 AMPS, WITH A 14-GAUGE CORD OF FIVE FEET OR LESS IN LENGTH. THIS TREADMILL MUST BE GROUNDED TO REDUCE THE RISK OF ELECTRICAL SHOCK. GROUNDING PROVIDES A PATH OF LEAST RESISTANCE FOR ELECTRIC CURRENT SHOULD THE TREADMILL MALFUNCTION.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Determining Model Numbers Trouble Shooting 8 - 9 Error Messages 10 - 12 Old Motor Controller Board Motor Controller LED Description Key 14 - 15 Motor Controller LED Troubleshooting 08-0050/51 M/C LED & Fuse Locations 08-0052 M/C LED & Connector Locations 08-0158 M/C LED &...
  • Page 5 Change to MPH or KPH Walking Belt Adjustment Maintenance Instructions Removing the Motor Motor Replacement Procedure- Boss Style 54 - 56 Boss Treadmill Upright Assembly Procedure Actuator Removal Front Roller Removal Procedure 59 - 62 Rear Roller Removal Procedure Walking Board Removal...
  • Page 6 Notes:...

  • Page 7: Determining Model Numbers

    Before working on any KEYS or IRONMAN treadmill, determine the model number of the treadmill you are servicing. To determine what model of treadmill you are servicing, look at the sticker on the front of the treadmill frame next to the reset button.

  • Page 8: Trouble Shooting

    C. Remove the Safety Key from the console and re-attach to console. D. Recalibrate treadmill. E. If the treadmill still won't operate, please call our toll- free HELPLINE. 3. The walking belt slows during use. A. Check to make sure you are using a UL-listed surge protector rated at 15 amps, with a 14-GAUGE cord of five feet or less.
  • Page 9 A. Adjust rear roller. center of roller 5. The walking belt slips or hesitates during use. A. Adjust rear roller. 6. Knocking noise from the front of treadmill. A. Check fan 1. Is fan hitting optical encoder? 2. Is fan hitting flywheel? B.

  • Page 10: Error Messages

    ERROR MESSAGES Error messages appear in incline window. To avoid possible damage to the treadmill it should not be operated until the problem is corrected. E 8.2 Belt will not move. Re-calibrate. B. If re- calibrate does not work replace console.
  • Page 11 D. Check to see if wiring harness wires are pinched or frayed. E. Re-calibrate. F. If re-calibration does not work treadmill has a bad motor controller of DC motor drive. E 33 The walking belt is moving at a faster speed than displayed in the speed window A.
  • Page 12 F. Check fuses on motor controller. Indicates that power up sequence was initiated with the treadmill in the upright folded position. A. Fold down the treadmill to normal operating position (treadmill should be folded down to the floor), try again.

  • Page 13: Old Motor Controller Board

    OLD MOTOR CONTROLLER BOARD 1. The OUT LED indicates if there is DC voltage available at the armature of the motor. If this LED is lit but the motor is not moving, check connections to the motor at the controller and at the motor. 2.

  • Page 14: Motor Controller Led Description Key

    MOTOR CONTROLLER LED DESCRIPTION KEY 1. RLY1, Yellow = Cap Fill Relay On at Power Up on 08-0050 and 220VAC motor controls, off after 10 seconds. 2. RLY2, Green = Main AC Relay On 10 seconds after power switch is activated. 3.

  • Page 15: Error Messages

    The SF/B LED indicates if the motor encoder is operating correctly. To check operation, with the treadmill plugged in but not powered up, slowly rotate the motor by hand by pushing the flywheel. The SF/B indicator should flash corresponding to the "teeth" on the plastic fan hub.

  • Page 16: Motor Controller Led Troubleshooting

    Motor Controller LED Troubleshooting LED OK, unit plugged into wall, but Power Key not activated- 08-0051, generally LCD display type treadmill- - LVS - RAIL - SF/B- may be on or not and should blink when the flywheel is rotated.

  • Page 17: 08-0050/51 M/C Led & Fuse Locations

    SF/B RAIL COMP POT FUSE F2 RLY2 RLY1 INC - INC + FUSE F1 08-0050/51 M/C LED & Fuse Locations...

  • Page 18: 08-0052 M/C Led & Connector Locations

    COMP ADJUSTMENT AC POWER ACTUATOR MOTOR CONNECTIONS CONNECTIONS CONNECTIONS 08-0052 M/C LED & Connector Locations...

  • Page 19: 08-0158 M/C Led & Fuse Locations

    FUSE F2 COMP POT INC + INC - SF/B RLY1 RAIL FUSE F1 RLY2 08-0158 M/C LED & Fuse Locations...

  • Page 20: 08-0158 M/C Connector Locations

    Motor - Motor + External AC External AC (Black) (Red) Transformer Secondary Transformer Primary Encoder Harness Console Harness Actuator Actuator Actuator AC COM AC HOT (Black) (Red) (White) (White) (Black) 08-0158 M/C Connector Locations...

  • Page 21: Blank- Future Use

    BLANK- FUTURE USE...

  • Page 22: Console Electronics With Membranes

    CONSOLE ELECTRONICS WITH MEMBRANES...

  • Page 23: Console Electronics- No Membranes (Dome Button)

    CONSOLE ELECTRONICS- NO MEMBRANES (DOME BUTTON)

  • Page 24: 18" Fold- 1.5 Hp Drive Motor, 08-0051 M/C

    18” FOLD- 1.5 HP DRIVE MOTOR, 08-0051 M/C...

  • Page 25: 20" Fold- Sensor- Si3 Code

    20” FOLD- SENSOR- SI3 CODE...

  • Page 26: 20" Fold- Motor Cover Removed

    20” FOLD- MOTOR COVER REMOVED (MOTOR, MOTOR CONTROLLER, ACTUATOR)

  • Page 27: 20" Fold- Safety Latch With Motor Cover Removed

    20” FOLD- SAFETY LATCH WITH MOTOR COVER REMOVED...

  • Page 28: Boss Units- Motor Cover Removed

    BOSS UNITS (KEYS 8800, ALL950HR, ALL920, ALL880, ALL850)- MOTOR COVER REMOVED (MOTOR, MOTOR CONTROLLER, ACTUATOR)

  • Page 29: Flowcharts

    Flowchart Procedures Mechanical Problems No Belt No Belt No Belt Movement #3 Movement #2 Movement #1 (Unit has Power/ (Unit has Power/ (Unit has Power/ Display) Display) Display) Remove Motor Remove Motor Remove Motor Cover Cover Cover Front Roller is Verify Motor Step on unit and turning but the...
  • Page 30 Symptom #1 Symptom #2 INCLINE PROBLEMS Incline motor will Incline works in not work only one direction up or down up or down (Remove motor (Remove motor cover) cover) Perform Short Calibration Check F3 Replace Actuator (glass fuse) and M/C Board Press incline buttons (keypad or GOOD...
  • Page 31 INCLINE PROBLEMS Symptom #3 Incline motor will not work but stays on- hums, smells, gets hot, etc. (Remove motor cover) Tap on Relay 3 and 4 (AC Relays) Disconnect AC to unit and let Actuator cool down for about 30 minutes Connect AC to unit Press Incline...
  • Page 32 SI 1 Code If SI 1 Code is still present, check for Is Safety Key Attach Safety Key magnet inside the attached? Safety Key. Remove console cover and verify reed switch (if equipped) harness is connected If unit has no reed switch, Replace Console...
  • Page 33 E33 Code Re-Calibrate unit Adjust COMP pot counter-clockwise E33 Code? Unit is Fixed until it stops and re-calibrate E33 Code? Unit is Fixed Check Drive Motor with 12 VDC external battery source Does motor Replace M/C work? Board Replace Motor...
  • Page 34 SI 2 Code: Over-Voltage Protection Unit is ON, No Belt Movement Plug in unit, Check Drive Remove Motor Check M/C check for RAIL Motor wire 08-0050 08-0051 Cover Part Number LED (Remove connections on motor cover) M/C (M+,M-) RLY1 Sequence (10 sec.) RLY1 will be on at power up Power down unit- and stay on for a 10 second...
  • Page 35 3. If Ground wire is installed on the frame with bracket (“L”), make sure Ground wire is directly installed on frame chassis. Screw Ground Wire Bracket (green) Treadmill Frame Press Power Switch Does unit display any Unit is Fixed error codes?
  • Page 36 E11 or E22 Code: Belt Motor Errors Unit comes ON, No Belt Movement (<30 sec. w/error codes) E11/ E22 E11/ E22 E11/ E22 Belt moves for 30 seconds or Error message appears at No belt movement after less after Start/ Stop some point in time after 30 Start/ Stop initiated.
  • Page 37 NOTE: On KEYS 8800 Treadmill with M/C Part # 08- SI3 Code- Tilt Switch Trip 0016, replace console when unit displays an SI3 Code. Re-calibrate unit Check alignment Remove Motor of tilt switch sensor and Console Panel with magnet. Re- covers align if necessary.
  • Page 38 Press Power Key No Response and No Display Remove Motor Cover Push back in Check for Is Circuit and check LVS (yellow) Breaker operation tripped? Check AC source Remove and re- circuit breaker or install Console try new source Panel Wire and check Harness plug on operation again...

  • Page 39: Schematic Diagrams

    Schematic Diagrams...

  • Page 40: Schematic Diagrams

    SCHEMATIC DIAGRAM W/ 12-0023 MOTOR...

  • Page 41: Calibration Procedures

    Calibration Procedures Before performing the calibration, determine the Model # and if the treadmill has an OLD or NEW console display. Have SAFETY KEY on console. PRESS the RESET button once as shown below with an eraser end of pen- cil.

  • Page 42: Calibration New Style Console

    WARNING: Do not stand on or touch the treadmill during calibration. When the treadmill belt stops, push the POWER button 2 times. If the letter "F" appears in the SPEED or INCLINE window, the treadmill is indicating a failure in the SPEED or INCLINE...

  • Page 43: Calibration- 18" Fold And Conventional

    18” Fold and Conventional Treadmill Calibration 1. All 18” Fold treadmills that incline at the rear of the unit and have LCD display. MPH - 10 - FFF - 111 - AL2 - OPA 2. All 18” Fold treadmills that incline at the rear of the unit and have LED display.

  • Page 44: Calibration By Model Number

    ALL 855 OB_________________________ MPH-12-UUU(15)-222-AL1-OPA-BLANK ALL 855 OB (220V)___________________MPH-12-UUU(15)-222-AL1-OPA-BLANK ALL 888 HR OB______________________MPH-12-UUU(15)-222-AL1-OPA-BLANK ALL 888 HR OB (220V)_______________ MPH-12-UUU(15)-222-AL1-OPA-BLANK ALL 900____________________________ MPH-10-UUU-222-AL1-OPA-BLANK ALL 900 (220V)______________________ MPH-10-UUU-222-AL1-OPA-BLANK ALL 910 HR_________________________ MPH-10-UUU-222-AL1-OPA-BLANK ALL 920 OB_________________________ MPH-10-UUU-222-AL1-OPA-BLANK ALL 920 OB (220V)___________________MPH-10-UUU-222-AL1-OPA-BLANK ALL 950 HR OB______________________MPH-12-UUU(15)-222-AL1-OPA-BLANK ALL 950 HR OB (220V)_______________ MPH-12-UUU(15)-222-AL1-OPA-BLANK BB 2000____________________________ MPH-8-FFF-111-AL2-OPA-a BB 2000T___________________________ MPH-8-FFF-111-AL2-OPA-a...
  • Page 45 EC 4000 C___________________________MPH-10-UUU-111-AL1-OPA-BLANK EC 4500 C___________________________MPH-10-UUU-111-AL1-OPA-BLANK EC 4800 COB________________________ MPH-10-FFF-111-AL1-OPA-BLANK EC 4800 OB_________________________ MPH-10-FFF-111-AL1-OPA-BLANK EC 5500_____________________________MPH-10-UUU-111-AL1-OPA-BLANK EC 6500 HRC________________________ MPH-10-UUU-111-AL1-OPA-BLANK EC 770______________________________MPH-10-UUU-111-AL2-OPA-BLANK EC 805______________________________MPH-10-FFF-111-AL2-OPA-BLANK EC 810 (CONV)______________________ MPH-10-UUU-222-AL2-OPA-BLANK EC 810 NB__________________________ MPH-10-UUU-222-AL2-OPA-BLANK EC 815_____________________________ MPH-10-FFF-111-AL2-OPA-BLANK EC 815 (220V)_______________________ MPH-10-FFF-111-AL1-OPA-BLANK EC 825_____________________________ MPH-10-FFF-111-AL2-OPA-BLANK EC 835 (HR)_________________________MPH-10-FFF-111-AL2-OPA-BLANK EC 835 (HR) (220V)___________________MPH-10-FFF-111-AL1-OPA-BLANK EC 850______________________________MPH-10-UUU (15)-222-AL2-OPA-BLANK...
  • Page 46 HT 800 HR__________________________ MPH-10-UUU-222-AL1-OPA-BLANK HT 9000 HR_________________________ MPH-10-UUU-222-AL1-OPA-BLANK HT 9000 HR C_______________________ MPH-10-UUU-222-AL1-OPA-BLANK HT501______________________________ MPH-10-FFF-111-AL1-OPA-BLANK HT601______________________________ MPH-10-FFF-111-AL1-OPA-BLANK HT701______________________________ MPH-10-UUU-222-AL1-OPA-BLANK HT801______________________________ MPH-10-UUU-222-AL1-OPA-BLANK HT901______________________________ MPH-10-UUU-222-AL1-OPA-BLANK Keys 4000___________________________ MPH-10-UUU-111-AL1-OPA-BLANK Keys 4000 (220V)_____________________MPH-10-UUU-111-AL1-OPA-BLANK Keys 800 (CONV)_____________________MPH-10-UUU-111-AL2-OPA-BLANK Keys 8500___________________________ MPH-10-UUU(15)-222-AL1-OPA-BLANK Keys 8500 (220V)_____________________MPH-10-UUU(15)-222-AL1-OPA-BLANK Keys 8500 OBC______________________ MPH-10-UUU(15)-222-AL1-OPA-BLANK Keys 8800 (HR)______________________ MPH-12-UUU(15)-222-AL1-OPA-BLANK Keys 8800 (HR) (220V)________________ MPH-12-UUU(15)-222-AL1-OPA-BLANK Keys 8800 (HR) OB___________________ MPH-12-UUU(15)-222-AL1-OPA-BLANK...
  • Page 47 MS 990_____________________________ MPH-10-FFF-111-AL2-OPA-BLANK PLATINUM HR______________________ MPH-10-FFF-111-AL2-OPA-BLANK PRO 1000___________________________ MPH-10-FFF-111-AL2-OPA-BLANK PRO 1000 (220V)_____________________ MPH-10-FFF-111-AL1-OPA-BLANK PRO 2000___________________________ MPH-10-FFF-111-AL1-OPA-BLANK PRO 2000 (220V)_____________________ MPH-10-FFF-111-AL1-OPA-BLANK PRO 3000 HR________________________ MPH-10-FFF-111-AL2-OPA-BLANK PRO 3000 HR (220V)__________________MPH-10-FFF-111-AL1-OPA-BLANK PRO 400____________________________ MPH-8-HHH- - -AL2-OPA-BLANK PRO 400 (220V)______________________ MPH-8-HHH- - -AL1-OPA-BLANK PRO 400 C__________________________ MPH-8-HHH- - -AL2-OPA-BLANK PRO 600____________________________ MPH-8-HHH- - -AL2-OPA-BLANK PRO 650____________________________ MPH-8-UUU-111-AL2-OPA-BLANK PRO 750____________________________ MPH-8-UUU-111-AL2-OPA-BLANK...

  • Page 48: Calibration- Old Lcd Display

    Push ENTER. Replace Safety Key. Push ENTER button. After calibration is complete, push POWER button three times. Treadmill will turn off on its own. After electrical re-installation of motor actuator, motor controller or electronics, re-calibration is necessary. Calibration- LCD Display...

  • Page 49: Calibration- Old Led Display

    Push START button. Push ENTER. Replace Safety Key. Push POWER button (treadmill will take approximately eight minutes to calibrate). After calibration is complete, push POWER button three times. Treadmill will turn off on its own After electrical re-installation of motor actuator, motor controller or electronics, re-calibration is necessary.

  • Page 50: Change To Mph Or Kph

    1) Turn power OFF on the console. (Do not unplug treadmill.) Attach the magnet safety key to the console. 2) Activate the calibration mode switch by inserting the eraser end of a pencil into the opening in the backside of the console (see diagram below).

  • Page 51: Walking Belt Adjustment

    “Walking Belt Slipping” instructions. WALKING BELT IS SHIFTING TO THE RIGHT (Diagram 2) First, turn the treadmill on to run at 1 mph. Using the hex key pro- vided, turn the right rear roller adjustment bolt ¼ turn in the clock- wise direction.

  • Page 52: Maintenance Instructions

    6” from the front of the treadmill. Apply the silicone spray to the walking board, moving from the front of the treadmill to the rear. Repeat this on the other side of the belt. Spray approximately 4 seconds on each side.

  • Page 53: Removing The Motor

    Removing the Motor Unplug the treadmill. Remove Motor Cover by unscrewing eight #8x5/8" Phillips head screws. Fold treadmill into stored/upright position. Remove from bottom pan by unscrewing twelve #8x5/8" Phillips Head screws. Unfold treadmill into flat position. Unplug red & black wire running to Motor Controller.

  • Page 54: Motor Replacement Procedure- Boss Style

    5. See Figure 5 for location of mounting bolts on the front side of the unit. Make sure all wires are disconnected from motor controller and treadmill frame. Remove motor from bracket assembly. 6. Use hammer to tap bolts carefully out of bracket assembly. See Figure 6.
  • Page 55 7. Verify position of bolts to be moved as shown in Figure 7. 8. Push down on inside corner of base pan to remove bolts from current hole position. See Figure 8. Figure 7: Mounting Bolt Locations Figure 8: Push Down On Base Pan 9.
  • Page 56 13. Use a hammer to push forward (toward front of unit) to tighten the Poly V Belt. At the same time, tighten all (4) four mounting bolts as shown in Figure 13. 14.Re-connect all power wires to motor controller and install ground wire to frame as shown in Figure 14.

  • Page 57: Boss Treadmill Upright Assembly Procedure

    Use a screwdriver and slightly pry open on the side of the upright to help assist over the mounting bracket as shown in Figure 3. Figure 3: Upright Assembly w/ Screwdriver 4. Continue treadmill assembly as detailed in Owner’s Manual.

  • Page 58: Actuator Removal

    Actuator Removal Unplug treadmill. Remove Motor Cover by unscrewing seven #8x5/8" Phillips Head Screws. Fold treadmill into upright/stored position. Remove Rear Roller Cover by unscrewing seven #8x5/8" Phillips Head Screws. Remove Mid Bottom Pan by unscrewing nine #8x5/8" Phillips Head Screws.

  • Page 59: Front Roller Removal Procedure

    7/16” Wrench, Phillips Screwdriver and Allen Wrench (supplied with treadmill). 1. Remove motor cover screws from front of treadmill. See Figure 1. 2 Power up treadmill and set incline to 12%. Unplug power cord from surge protector or wall out- let. See Figure 2.
  • Page 60 7. Continue to push Poly V Belt off front roller pulley and motor assembly. See Figure 7. 8. Loosen front roller allen bolts by using 7/16” Wrench and Allen Wrench (supplied with treadmill). Hold lock nut and turn allen wrench counter-clockwise as shown in Figure 8.
  • Page 61 Figure 16: Tighten Nut on Allen Bolt 17.Installation and alignment should look similar to Figure 17 below. 18.Slide motor cover back in position as shown in Figure 18. Plug unit back in and treadmill will decline. Figure 17: Completed Roller Installation...
  • Page 62 19. Install motor cover screws as shown in Figure 19. 20..Installation is complete. Figure 20: Completed Installation Figure 19: Install Motor Cover Screws...

  • Page 63: Rear Roller Removal Procedure

    You will need the following tools for installation: Phillips Screwdriver and Allen Wrench. 1. Remove end caps (Left and Right) from rear of treadmill. See Figure 1. 2 .Locate both allen bolts on each side of the roller assembly as shown in Figure 2.

  • Page 64: Walking Board Removal

    DO NOT unscrew the 5th bolt that is closest to the front of the treadmill. With treadmill in folded or up position, ONLY remove the top 4 bolts (starting from the top work your way down. Again DO NOT remove the 5th bolt down. That is your deck lift spring. Do not touch? CONVENTIONAL (non-folding) treadmills do not have the lift spring.

  • Page 65: Walking Belt Removal Procedure

    You will need the following tool for removal: 7/16” Socket. 1. With treadmill in the upright position, remove the (4) four 7/16” hex bolts from the left side of treadmill. On the 18” models, do not remove the bottom hex bolt or the one closest to the motor cover.

  • Page 66: Foot Latch Release Procedure

    Foot Latch Release Procedure 1. The foot latch release mechanism is located above the latch and inside mover cover assembly. Please see Figure 1 for a detailed view of where the release button is located. You do not need to remove the cover to release the foot latch. Figure 1 is for illustrative purposes only. FIGURE 2: Foot latch with cover FIGURE 1: Release button location 2.

  • Page 67: Overlay Removal And Installation

    Treadmill Overlay Removal and Installation Please perform these steps to remove and install new overlay on console assembly. 1. Use a box cutter or sharp object to lift one corner of overlay from console- See Step 1. 2.After corner is lifted, gently peel back the overlay from side to side. See Step 2 and 3.

  • Page 68: Rear Elevation Wheel Installation

    Rear Elevation Wheel Installation 1. Hammer Push-Nut Hat onto one side of the axle. See Figure 1. 2. Install one (1) wheel assembly on axle. See Figure 2. Figure 1 Figure 2 3. Insert the axle through elevation mounting bracket. See Figure 3. 4.

  • Page 69: Toggle Switch Removal And Replacement

    Toggle Switch Removal and Replacement Rotating toggle switches in the handrail housing assembly. The connectors used for the speed and incline switches on the console assembly PC board are keyed (one direction) and therefore may need to be reversed at the handrail location. After the calibration procedure is complete, attempt to use the speed and incline switches on the handrail.
  • Page 70 Customer Service (888) 340-0482 Keys Fitness Products 4009 Distribution Drive Suite 250 Garland, TX 75041 www.keysfitness.com...

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