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Dyaco FT98A-YT41 Service Manual

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FT98A-YT41
Treadmill
Service Manual

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Summary of Contents for Dyaco FT98A-YT41

  • Page 1 FT98A-YT41 Treadmill Service Manual...

  • Page 2: Table Of Contents

    -------------------------------------------Table of Contents------------------------------------------- 1. Treadmill Outlines 2. Electronic Parts 2.1 Upper Controllers 2.2 Lower Controller and driver 3. Electrical Configuration 4. Product Operation 5. Unit Block Diagrams 6. Basic Connections and Wiring 6.1 Display Board Wire Connections 6.2 Display Board PCB Component Locations 6.3 Driver Board Wire Connections 6.4 Driver Board PCB Component Locations 6.5 Driver Board LED Indicator Locations...
  • Page 3 12. Disassembling and Assembling of Parts 12.1 Lower Controller Replacement 12.2 Console Replacement 12.3 Motor Replacement 12.4 Breaker Replacement 12.5 AC Power Switch Replacement 12.6 Front/ Rear Roller Replacement 12.7 Running Deck/ Belt & Cushion Replacement 12.8 Speed Sensor Replacement 12.9 Incline Motor Replacement...

  • Page 5: Treadmill Outlines

    1. FT98A Treadmill Outlines...
  • Page 6 Console Hand Pulse Sensor Speed adjustment button Incline adjustment button...
  • Page 7 Driving Motor Incline Motor Lower Controller...

  • Page 9: Electronic Parts

    2. Electronic Parts...

  • Page 10: Upper Controllers

    2.1 Upper Controllers DISPLAY Hand Pulse Hand Pulse Heart Sensors Heart Sensors...

  • Page 11: Lower Controller And Driver

    2.2. Lower Controller and Driver Motor Controller DC MOTOR INCLINE MOTOR...

  • Page 12: Electrical Configuration

    3. Electrical Configurations...
  • Page 13 AFETY KEY To fits on the Console that activate all functions. If no safety key, console can not be controlled. ONSOLE Interface that controls all functions of the treadmill. AIN CONTROLLER The circuit board consist of the DC power supply for console、incline driver and DC motor driver, link the console to output appropriate voltages for motor that control the treadmill functions.
  • Page 14 READMILL MOTOR It’s a variable speed on 0-180(0-90) volt DC motor.for 230V~ OR (120V~ model) Have three wires red, black and green. If there is DC voltage on the Red (white) wire (M+) the treadmill motor will turn clockwise. If there is DC voltage on the Black wire (M-) the treadmill motor will turn counter-clockwise. The higher the voltage the faster the motor turns The green wire is ground.

  • Page 15: Product Operation

    4. FT98A Treadmill Product Operation...

  • Page 16: Display Windows

    Display Windows LCD Display LCD Function display locations...
  • Page 17 Operation Window Display Mode OFF Mode When user doesn’t insert the SAFETY KEY on the console the treadmill enters the OFF Mode LCD Display off. READY Mode When the treadmill is ON and SAFETY KEY is inserted in console the treadmill enters the READY Mode. Press START button to start treadmill on Manual Mode.
  • Page 18 PULSE Displays the heart rate beat by using hand pulse or receiver. When use receiver, a chest belt must be worn. DISPLAY range is 0 to 999. WORK range is 30 to 210. In RUN Mode, if the treadmill doesn’t have a signal for 8 seconds then display value will become no display.
  • Page 19 Function Button Locations Incline quick keys Speed quick keys 1/2/3/4/5/6/7/8/9/10 1/2/3/4/5/6/7/8/9/10 PROGRAM ︽︾Key Choose Program FAST/Slow Key Adjustment Speed Select Key Switch Speed or Grace profile Up/down Key Enter Key Adjustment incline Set data function START Key To workout STOP Key End workout Safety Key Emergency function...
  • Page 20 Function Button In Main Mode READY MODE SAFETY KEY: Fit safety key in right position to power on the computer. When safety key is pulled away from its position, the computer will be automatically shut down. START button: Pressing “ START ” button to start treadmill, When pressing “START” button, there will be 3 second final count down on window display, then machine starts running.
  • Page 21 RUN MODE SAFETY KEY: When safety key is pulled away from its position, the computer will be automatically shut down. STOP button: press “STOP” button to stop treadmill. SELECT button: While running P1~U2 program, pressing this button switches between SPEED profile and GRACE profile. FAST button: Press the button to increase your speed and each increase is 0.1kph.

  • Page 22: Unit Block Diagrams

    5. FT98A Treadmill Unit Block Diagrams...
  • Page 23 Treadmill Configuration...

  • Page 24: Basic Connections And Wiring

    6. FT98A Treadmill Basic Connections and Wiring...

  • Page 25: Display Board Wire Connections

    6.1 Display Board wire Connections...

  • Page 26: Display Board Pcb Component Locations

    6.2 Display Board PCB Component Locations PCB Board Top...
  • Page 27 PCB Board Bottom...

  • Page 28: Driver Board Wire Connections

    6.3 Driver Board Wire Connections...

  • Page 29: Driver Board Pcb Component Locations

    6.4 Driver Board PCB Component Locations...

  • Page 30: Driver Board Led Indicator Locations

    6.5 Driver Board LED Indicator Locations MOTOR DRIVER LED CONTROLLER SHUT LIT：POWER ON DOWN. NOT LIT：NORMAL NO LIT：NORMAL LIT：SHUT DOWN POWER DICATOR LIT：VCC POWER CIRCUIT ON LIMIT THE CURRENT OF DC MOTOR. NO LIT：NORMAL LIT：OVER CURRENT Incline UP Incline DOWN SPEED Indicator PWM SIGNAL INDICATOR FLASHED LIT：WHEN MOTOR IS...

  • Page 31: Controller Indicator Led Debugging

    6.6 Controller Indicator LED debugging...

  • Page 32: Driver Board Function

    6.7 Driver Board function M+0~180Vdc TO MOTOR (RED WIRE) M-0~180Vdc TO MOTOR Transformer (BLACK WIRE) 110VAC IN INCLINE POWER 110VAC IN TORQUE BLACK INCLINE POWER WHITE NCLINE VR INCLINE CONNECTION TO CONSOLE POWER BLACK SPEED SENSOR...

  • Page 33: Main Connector Of The Console

    6.8 Main connector of the console DRIVER CABLE...

  • Page 34: Product Safety Instructions

    7. Product Safety Instructions...

  • Page 35: Important Safety Instructions

    7.1 Important Safety Instructions - To reduce the risk of electric shock disconnect your treadmill from the electrical outlet prior to cleaning and/or service work. - To reduce the risk of burns, fire, electric shock, or injury to persons, install the treadmill on a flat level surface with access to a 230-volt, 10-amp grounded outlet with only the treadmill plugged into the circuit.

  • Page 36: Error Messages / Troubleshooting For Electronic Issues

    8.FT98ATreadmill Error Messages / Troubleshooting for Electronic Issues...
  • Page 37 Error code items： Error Message Explain Display board CPU did not receive the RPM signal. The console board is not detecting the VR voltage value,or the voltage value has exceeded the range. Prepare： Picture Tool name Multi-meter...

  • Page 38: Error Message： ： ： ： Ls1/Low Speed

    8.1 Error Message： ： ： ： LS1/LOW SPEED Definition：Display board CPU did not receive the RPM signal. Configuration：...
  • Page 39 Cause of LS1/LOW SPEED The motor doesn’t turn：LS1/LOW SPEED appears. Explanation The drive board did not sent voltage to the motor, so the motor didn’t operate. And the display board didn’t receiver the RPM sensor signal. Configuration...
  • Page 40 LCD display show LS1...
  • Page 41 LS1/LOW SPEED solution follow chart...
  • Page 42 Terminals for motor cable, Red for M+, Black for M- POWER LED PWM LED...
  • Page 43 LS1/LOW SPEED solution follow chart – check RPM sensor device procedure： ： ： ：...
  • Page 44 Is sensor cable connected properly? Checking the speed sensor Remove the motor cover hood. The speed sensor is located on the left side of the frame, right next to the front roller pulley (the pulley will have a belt around it that also goes to the motor). The speed sensor is small and black with a wire connected to it.
  • Page 45 LS1 issue troubleshooting form LS1 message Possible cause Things to check Solution The monitor hasn't receive any speed check the speed sensor cable is in good Make sure the good connection for signal for 8 seconds connection cables The speed sensor didn't detect signal Check the gap between speed sensor and To keep the gap-distance less than 3 The motor can not...
  • Page 46 8.2 Error Message： ： ： ： Err Definition：The console board is not detecting the VR voltage value,or the voltage value has exceeded the range.” Err” appears on the display. Configuration：...
  • Page 47 Case of Err Incline VR value exceeds the range. Err appears on the display. Incline motor isn’t operation up or down,making the VR value exceed the range. After turning on the unit,the display board detects that the incline VR voltage exceeds the range,so Err appears. Action Flow Chart...
  • Page 49 Troubleshooting Part Troubleshooting 1.Reconnect VR wires. Incline VR 2.Inspect whether the incline wires are broken or disconnected. 1.Inspect the incline wire and 12-pin cable connections. Display board 2.Test whether the VR voltage varies at the incline wire terminal. 1.Inspect the wire connections. 12-pin cable 2.Inspect whether wires are broken or crimped.
  • Page 50 Test configuration. The console to driver board connector pin define function The console to driver board connector pin define function: 1. Controller S／ ／ ／ ／ W 2. Incline down output 3. Incline up output 4. Vin 5. Speed up output 6.
  • Page 51 Test Configuration. Incline motor control function relate parts location 1. Controller S／ ／ ／ ／ W 2. Incline down output 3. Incline up output 4. Vin 5. Speed up output 6. Speed down output 7. GND The position sensor wires 8.
  • Page 52 Test Procedure： ： ： ： Run calibration again. Does the incline motor move at all? If no, do the Up/down lights on the incline board light? If they light, do the relays click on? If the relay clicks on but the motor doesn’t move: with the incline light and relay activated check the voltage between the neutral (white) wire and the Up (red) or down (black) wire, depending on which direction the motor is supposed to travel according to Up/Down lights on the board.

  • Page 53: Error Message: E1

    Error Message： ： ： ： Err Definition：During incline action,the display board CPU cannot read the VR value,so Err appears. Configuration：...
  • Page 54 Cause of Err Press the incline UP/DOWN key.The incline doesn’t operate. Err appears on the display. Explanation Press the incline UP and DOWN key.The driver board UP or DOWN indicator lights.The incline operates,moving the VR,which changes the VR value. The display board CPU reads the incline VR value.If there is no VR value change,to the CPU,the incline is not operating when it should be.
  • Page 56 Troubleshooting Part Troubleshooting 1.Press incline UP key.The driver board UP LED lights. Display board 2.Press incline DOWN key.The driver board DOWN LED lights. 3.If not as above,inspect the cable and connections. 1.Inspect whether the 12-PIN cable is connected well. 12-pin cable 2.Test by replacing the cable with a good one.

  • Page 57: Circuit Diagram

    8.3 Circuit diagram...

  • Page 58: Calibration Procedure

    8.4 CALIBRATION PROCEDURE Calibration Engineering Mode I: Calibration 1. Press and hold both START and FAST buttons at the same time then turn on the power to enter the calibration mode, or Press and hold both START and FAST buttons at the same time then put on the safety key to enter the engineering mode. 2.
  • Page 59 4. Press ENTER button after GS has been set and enter next step for SAFE MODE setting. The window will show “SAFE MODE ON”. Press FAST/SLOW button to choose SAFE MODE ON or OFF.(SAFE MODE ON means when the safety key is pulled off “PLEASE→INSTALL→SAFE KEY→TO START＂will be displayed;...

  • Page 60: Fuse Replacement

    8.5 Fuse replacement FUSE For AC 110V is 15A For AC 220V is 10A...
  • Page 61 If your treadmill loses power or will not start, check the fuse located on the motor controller. DANGER: Turn the power switch off and unplug the treadmill to reduce the risk of an electric shock Remove the motor cover Remove and replace the fuse on the motor controller Replace the motor cover...
  • Page 62 8.8 Troubleshooting procedure matrix Condition Reason Solve When turn on power, ON/OFF switch isn’t lit. 1 Power cord isn’t plugged into outlet. 1 Plug the power cord into outlet. 2 Power cord isn’t plug into unit. 2 Plug the power cord into unit. 3 The voltage of outlet is too low.
  • Page 63 When press “START” button to start treadmill, running 1. Controller experienced unusual shut 1. Turn off power and reset the treadmill. belt isn’t running and window displays “LS1” error down; the Shut_DOWN light will be always message after 10 seconds. bright.
  • Page 64 UP/DOWN button of 1 The connector of INCLINE CABLE 1 Connect the wires again. and CONSOLE not connected properly. INCLINE ADJUSTMENT SWITCH can’t be used. 2. The connector of INCLINE CABLE 2. Connect the wires again. and INCLINE ADJUSTMENT SWITCH Incline button just can press UP, can’t press DOWN.

  • Page 65: Folding/Unfolding And Transport

    9. Folding/Unfolding and Transport...
  • Page 66 Do not attempt to move the unit unless it is in the folded and locked position. Be sure the power cord is secured to avoid possible damage. Use both handrails to maneuver the unit to the desired position. ■ Unfoldong The Treadmill: Apply slight forward pressure* on the treadmill running deck with one hand.

  • Page 67: General Maintenance

    10. General Maintenance...

  • Page 68: Tread Belt And Deck

    10.1 Tread belt and Deck Your treadmill uses a very high-efficient low-friction bed. Performance is maximized when the bed is kept as clean as possible. Use a soft, damp cloth or paper towel to wipe the edge of the belt and the area between the belt edge and frame. Also reach as far as practical directly under the belt edge. This should be done once a month to extend belt and bed life.
  • Page 69 Tighten the rear roller bolts only enough to prevent slippage at the front roller. Turn both tread-belt tension adjustment bolts in increments of 1/4 turn each and inspect for proper tension by walking on the belt at a low speed, making sure the belt does not slip. Keep tensioning the bolts until the belt stops slipping.
  • Page 70 ATTENTION: DAMAGE TO THE RUNNING BELT RESULTING FROM IMPROPER TRACKING / TENSION ADJUSTMENTS IS NOT COVERED UNDER THE WARRANTY. BELT/DECK LUBRICATION First, you want to clean between the belt and deck to remove any debris that may be trapped. Use a clean, non-fraying rag, t-shirt, or light towel. Halfway between the end of the treadmill and motor cover, shove the garment under the belt until you can grasp it on both sides of the belt.

  • Page 71: Service Troubleshooting Checklist - Diagnosis Guide

    10.2. Service Troubleshooting Checklist – Diagnosis Guide Before contacting your dealer for aid, please review the following information. It may save you both time and expense. This list includes common problems that may not be covered under the treadmill’s warranty. PROBLEM SOLUTION/CAUSE Display does not light...
  • Page 72 Treadmill will only achieve approximately This indicates motor should be receiving power to operate. Low AC voltage to treadmill. Do not use an extension cord. 10 kph but shows higher speed on display If an extension cord is required it should be as short as possible and heavy duty 16 AWG minimum. Low household voltage. Contact an electrician or your dealer.

  • Page 73: Installation Of The Incline Motor

    11. Installation of the Incline Motor...
  • Page 74 Incline Range must be adjusted to 210 mm minimum prior to installation.

  • Page 75: Disassembling And Assembling Of Parts

    12. Disassembling and Assembling of Parts...

  • Page 76: Lower Controller Replacement

    12.1 Lower Controller Replacement (1) Remove motor cover (2) Disconnect all lower controller wirings (3) Use Phillips head Screwdriver to remove, replace with new lower controller and reconnect all wirings.

  • Page 77: Console Replacement

    12.2 Console Replacement When replacing console, use Phillips head screw driver to remove 4 Phillips Head Screws underneath the console. Use M5L Allen wrench to release six Button Head Socket Bolts.
  • Page 78 Disconnect console wirings and replace with new console.

  • Page 79: Motor Replacement

    12.3 Motor Replacement Use Phillips head screwdriver to remove 4 Tapping screw securing the motor cover. Remove motor grounding wire (greenish yellow), motor wire (+) red and motor wire (-) black.
  • Page 80 Use 14mm T-shaped socket wrench to loosen 4 screws, use 14mm open end wrench to loosen 1 belt tension screw, remove motor and replace with new. Reassemble in reverse order of disassembly, re-hook belt (readjust belt to be parallel with main frame after re-hooking). Do not tighten 4 securing screws yet.

  • Page 81: Breaker Replacement

    12.4 Breaker Replacement Remove Breaker connection wiring, replace part and reconnect wiring. 12.5 AC Power Switch Replacement Disconnect wiring to AC power switch, replace AC power switch and reconnect wiring.

  • Page 82: Front/ Rear Roller Replacement

    12.6 Front/ Rear Roller Replacement 1. Use Phillips head screwdriver to loosen 2 screws on the rear adjustment base. 2. Use M6 L Allen wrench to loosen 2 screws on the rear roller. 3. Remove motor cover, use 14mm T-shaped socket wrench to loosen 4 screws. Use 14mm open end wrench to loosen 1 belt tension screw and loosen drive belt.
  • Page 83 4. Use 13mm wrench to loosen front roller screws, remove front and back rollers, and replace with new. Reassemble in reverse order of disassembly. 5. When reassembled, running belt tension needs to be adjusted and centered. Belt tension also needs to be adjusted (refer to 12.3-5 above)

  • Page 84: Running Deck/ Belt & Cushion Replacement

    12.7 Running Deck/ Belt & Cushion Replacement(Please take the cylinder before replacement) 1. After running board has been folded, use M5 L Allen wrench and 12m/m wrench to remove securing screws on cylinder and remove the cylinder. 2. Perform step #12.6 and remove front and rear rollers. 3.
  • Page 85 4. User Phillips head screwdriver to remove the 8 screws securing the running board. Remove the running board and replace running board or running belt. If cushions need to be replaced, remove 6 cushions and replace. Reassemble in the reverse order as disassembly.

  • Page 86: Speed Sensor Replacement

    12.8 Speed Sensor Replacement(including the wire) 1. First remove motor top cover. 2. Remove speed sensor wiring and proceed with parts replacement. 3. After replacement, a test to check if the sensor registers the magnet is required.

  • Page 87: Incline Motor Replacement

    12.9 Incline Motor Replacement Zeroing the incline motor before take it apart from the machine or assemble it onto the frame. The ※ zeroing distance is 210mm.) 1. First remove the motor cover and adjust treadmill to folded position, then proceed with old incline motor replacement.
  • Page 88 2. Use 14mm wrench to assemble new incline motor.
  • Page 89 3. Connect incline motor wiring with controller Red wire Connect to “UP” White wire Connect to “COM” Black wire Connect to “DOWN”...

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