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Trackmaster FVX325 Field Service Manual

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Use of the document and the information contained in it is strictly reserved for current Philips
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  Summary of Contents for Trackmaster FVX325

  • Page 1 Legal Notice: Use of the document and the information contained in it is strictly reserved for current Philips personnel and Philips customers who have a current and valid license from Philips for use by the customer’s designated in-house service employee on equipment located at the customer’s designated site.
  • Page 2 TREADMILL FIELD SERVICE MANUAL FVX No Control FVX__C Manual Control FVX__CP Programmable Control TMX No Control TMX__C Manual Control TMX__CP Programmable Control Revision Level 5 August, 2006 Refer equipment servicing to Full Vision, Inc. authorized service personnel only. Any unauthorized attempt to repair equipment under warranty voids that warranty.
  • Page 4 TRACKMASTER C O N T A C T I N F O R M A T I O N SERVICE DEPARTMENT Models: FVX325, FVX325C, FVX325CP TMX435, TMX425C, TMX425CP Service Line: 316-283-8110 Address: Full Vision Inc. 3017 Full Vision Drive Newton, Ks 67114...
  • Page 5 Printed in USA. TRACKMASTER is a registered trademark of JAS Manufacturing Co., Inc. TRACKMASTER is protected by the following US Patents: 5320589, 5431613. All other patents pending. Polar® is the registered trademark of Polar CIC Inc. FVX, TMX Series Service Manual...
  • Page 6: Table Of Contents

    FVX325 Series Initial Setup and Assembly ........
  • Page 7 FVX, TMX Series Verifying Belt Speed Calibration in the Field ....6 -4 FVX325, TMX425 Series Elevation Calibration Procedure No Control Unit..6 -5 FVX325C, TMX425C Series Elevation Calibration Procedure Manual Control Unit.
  • Page 8 TRACKMASTER Chapter 9 Product Requirements FVX, TMX Smart Power Supply ......9 -1 Introduction ..............9-1 Scope .
  • Page 9 FVX325 Series Elevation Assembly........
  • Page 10 TMX425 Series Maintenance Inspection Report ....... 1 5 -1 FVX325 Series Maintenance Inspection Report ....... 1 5 -3 Emergency Stop Button (ESB) Location Drawing .
  • Page 11 TRACKMASTER viii FVX, TMX Series Service Manual August, 2006...
  • Page 12: Introduction

    TRACKMASTER Introduction The purpose of this service manual is to supply authorized service providers and qualified technicians the information needed to maintain and repair the ® TRACKMASTER medical treadmills. A minimal understanding of basic electric and electronic theories is required along with a basic understanding of hand tools and there use.
  • Page 13: Drawings

    TRACKMASTER Caution Caution notices inform you of potential hazards that could result in equipment damage or injury, such as the following: CAUTION Do not use silicone sprays to wax your treadmill deck. Using silicone sprays may void the warranty. Such sprays can bring about surface changes that cause you to slip.
  • Page 14: Equipment Symbols

    TRACKMASTER Equipment symbols The following symbols appear on the treadmill. This symbol means that you must pay attention to the documents delivered with this equipment. It calls notice to the things to which you must pay special attention during operation and when the equipment is operated in conjunction with other equipment.
  • Page 15 TRACKMASTER FVX, TMX Series Service Manual August, 2006...
  • Page 16: Service Information

    FVX325, TMX425 – Medical Treadmill without controller. This treadmill can only be operated using testing software. FVX325C, TMX425C – Medical Treadmill with Manual Controller. This treadmill can be operated using testing software or manually.
  • Page 17: Explanation Of Serial Decal Information

    TRACKMASTER Serial Number Every TRACKMASTER treadmill has a unique serial number for identification. The serial number appears on the serial plate on the base of each unit. Serial plate location and Identification The serial plate is located on the right side rail of the treadmill.
  • Page 18: General Description

    TRACKMASTER General Description Intended Use The FVX325, TMX425 series treadmill is for use only with pre-tested and approved monitoring systems. The emergency stop switch is intended for emergency situations where immediately stopping the treadmill is required to deliver appropriate emergency care to the patient.
  • Page 19: Power Supply Relay Board Detail

    TRACKMASTER Power Supply Relay Board Detail FVX, TMX Series Service Manual August, 2006...
  • Page 20: Preparation For Use

    TRACKMASTER Preparation for use Safe handling guidelines Lift the end of the bed assembly to a comfortable height, keeping knees bent and backs straight as you lift. Rotate the treadmill in the direction you want to go (the treadmill will pivot on its wheels) and push forward.
  • Page 21: Fvx325 Series Initial Setup And Assembly

    TRACKMASTER FVX325 Series Initial Setup and Assembly FVX325 Series treadmills are shipped with handrail folded down for shipping. Tools required for assembly 5/16 Allen wrench 1. Rotate handrail to up right position. 2. Start 2~3/8-16 Socket head cap screw into lower legs.
  • Page 22: Tmx425 Series Initial Setup And Assembly

    TRACKMASTER TMX425 Series Initial Setup and Assembly Treadmills may be ordered broke down or fully assembled. If you have received one broke down please follow the instructions below. Tools required for assembly 1/4" Hex key 3/16” Hex key 1/4" Hex nut driver 1/2"...
  • Page 23: Check Unit For Operation

    TRACKMASTER Check unit for proper operation. If unit has no power check ESB (Emergency Stop Button) to assure the button is not pressed and wires are connected at board. To check unit for proper operation, perform Test Plug Procedure ref chapter 4-5...
  • Page 24: Test Plug Procedure

    TRACKMASTER Test Plug Procedure (RS232 Units Only) Turn the power “OFF” at the treadmill. Disconnect RS232 interface cable from the treadmill and plug in the test connector. Hold the button down on the test connector and turn treadmill power “ON”.
  • Page 25: Belt Tracking And Alignment

    The TRACKMASTER® patented MasterTrack® Belt Tracking System significantly reduces the need to adjust the belt on your TRACKMASTER® treadmill. However, when you operate your treadmill for the first time, you may need to adjust the tracking of the belt to conform to your floor.
  • Page 26: Belt Tension Adjustment

    TRACKMASTER Note: Uneven floors accelerate belt misalignment. This situation may require larger and more frequent adjustments to prevent belt damage. Note: When adjusting belt misalignments make sure V-Guide is not riding up on the front and rear roller. Belt Tension Adjustment The running belt may stretch and loosen with regular use.
  • Page 27: Drive Belt Tension Adjustment

    TRACKMASTER Drive Belt Tension Adjustment The drive belt may stretch and loosen with regular use. This looseness is noticeable when you may here a flapping noise. If the drive belt is loose, see illustration below. 1. Turn the treadmill’s power switch to OFF.
  • Page 28: Connector And Switch Locations

    TRACKMASTER Connector and switch locations The illustration below shows the various connectors and switches located on the base of the treadmill. August, 2006 FVX, TMX Series Service Manual...
  • Page 29: Power Requirements

    TRACKMASTER Power requirements Grounding Instructions This product is equipped with a three-wire ground-type plug. The plug will fit into only a grounding-type outlet. This is a safety feature – do not disable the plug’s third (grounding) pin with an adapter! Contact a qualified electrician if you are either (1) unable to insert the plug into your outlet, or (2) uncertain that the outlet is grounded and meets local codes.
  • Page 30: Operating And Storage Condition Recommendations

    TRACKMASTER Operating and Storage Condition Recommendations Operating Temperature Range: 0 to +40 deg. C (+32 to +105 deg. F). Storage Temperature Range: -20 to +70 deg. C (-4 to +158 deg. F). Operating and Storage Relative Humidity Range: 8% - 80%, non-condensing.
  • Page 31 TRACKMASTER 4-12 FVX, TMX Series Service Manual August, 2006...
  • Page 32: Operating Instructions

    Electrical safety tests The Electrical safety of the installation is the responsibility of the customer, not TRACKMASTER®. In hospitals, contact your in-house biomedical technician, electrician, or technically qualified personnel. Outside of hospitals, contact your hospital affiliation for these services. Otherwise contact Full Vision Inc. and open a customer-billable service call.
  • Page 33: Safe Operation Of Treadmill

    TRACKMASTER® is listed by Engineering Testing Laboratories (ETL); however, all motorized equipment is potentially dangerous if used incorrectly. Before using the TRACKMASTER® treadmill, follow all precautions listed in this chapter, and read the entire Owner’s Manual thoroughly. Use the TRACKMASTER® treadmill only as described.
  • Page 34: Emergency Stop Button Check

    TRACKMASTER Serious injury or death could result from electric shock. To reduce the possibility of electric shock, carefully observe the following precautions. • Connect the treadmill only to a dedicated, properly grounded outlet. See “Grounding Instructions” on the next page.
  • Page 35: Operation Of Manual Treadmill Control

    TRACKMASTER Operation of Manual Treadmill Treadmill speed and elevation control is selected from the control console front panel. Basic description of the switches found on the manual control console. Switch Result Start Press to immediately start run belt start speed set to 0.5-1.0 mph.
  • Page 36 TRACKMASTER T R A C K M A S T E R TIME CALORIES CAL/MINUTE DISTANCE METS PACE CA / ♥ INCLINE SPEED SCAN WEIGHT SELECT COOL START STOP STOP DOWN TIME CALORIES To enter Self-Test Aτ E Σ τ...
  • Page 37 TRACKMASTER Press Incline + to increase elevation. Value in TIME CALORIES 1 0 0 0 the Time/Distance window increases as DISTANCE CAL/MINUTE elevation grade increases. > The numbers in METS PACE the Time/Distance window is the output of the elevation sensor as read by the control console.
  • Page 38 TRACKMASTER TIME CALORIES Advance to next test by pressing select DISTANCE CAL/MINUTE METS PACE Test is a processor test, which requires no user input. Observe EE displayed in Time/Distance window and PAS displayed in Speed window to verify successful test. >...
  • Page 39 TRACKMASTER FVX__C, TMX__C Manual Controller Software Download, Control Console Parameters, Speed/Elevation Calibration and Self-test The following procedures provide instructions to fully utilize the upgrade, diagnostic and calibration capabilities of the manual controller. Procedures requiring special tools and or personnel are identified at the beginning of the procedure.
  • Page 40 TRACKMASTER FVX__C, TMX__C Manual Controller Software Download, Control Console Parameters, Speed/Elevation Calibration and Self-test The following procedures provide instructions to fully utilize the upgrade, diagnostic and calibration capabilities of the manual controller. Procedures requiring special tools and or personnel are identified at the beginning of the procedure.
  • Page 41: Manual Treadmill Control Console Programming Mode

    TRACKMASTER Manual Control Console Programming Mode With main power ON and displays lighted, press the DOWN INCLINE key and the UP SPEED key at the same time. When successful, the Center display will read the following options: P 1 will appear in the Center Display. Choose “bri” for MPH -or- “Si" for KM/H.
  • Page 42 TRACKMASTER P 5 will appear in the Center Display with default setting of 15.0 in the Incline Window. Using the numeric keypad, change to 25.00 for medical units. For fitness units use default of 15.0. Press SELECT key. Center Display Action required...
  • Page 43 TRACKMASTER P11 will appear in the Center Display with default setting of 15:00 in the Speed Display. Parameter sets the number of minutes displayed in the Speed Display. If no change is needed press START key. If a change is needed, use SPEED arrow keys to make change, then press START key.
  • Page 44 CALE will appear in the Center Display. This function is used to reset the elevation grades. Press the down INCLINE key, and the up SPEED key simultaneously for calibration. Refer to Elevation Calibration Procedure. Press SELECT key to skip and go into normal workout mode. Refer to FVX325 and TMX425 Series elevation charts. Center...
  • Page 45 TRACKMASTER TMX425 Series Elevation Chart Dim. Grade Inches 3.04” [77.3mm] 3.36” [85.2mm] 6.59” [167.3mm] 10.72” [272.2mm] 14.85” [377.2mm] 18.22” [462.9mm] 21.71” [551.5mm] Figure 1-1 Figure 1-2 Reset Phase SW Version Phase (# resets) SCAN SELECT SCAN SELECT SW Version Number...
  • Page 46: Operation Of Programmable Treadmill Control

    TRACKMASTER Operation of Programmable Treadmill Access one of ten installed programs or up to 20 individual user programs by pressing the Program Select switch. QUICK START Press the START switch for a quick start of the treadmill, no user information required, a three-second count down is displayed before the treadmill belt begins to move.
  • Page 47 TRACKMASTER FOREST WALK 15 stage hill climbing workout, default maximum elevation setting 7.0%. Maximum elevation may be increased/decreased prior to and during workout. Speed default is 2.0 mph (3.2Kph), speed may be adjusted at any time during workout. Time default is 30 minutes.
  • Page 48 TRACKMASTER Press one of the STOP switches to bring the treadmill running belt to a stop; this will also reset the elevation. Press the COOL DOWN switch to begin a sixty-second cool down phase. Completion of time or distance will start a sixty-second cool down phase.
  • Page 49: Fitness Test

    TRACKMASTER Press either STOP switch to bring the treadmill running belt to a stop, this will also reset elevation. Press the COOL DOWN switch to begin a sixty-second cool down phase. Completion of time or distance will start a sixty-second cool down phase.
  • Page 50 TRACKMASTER Press the COOL DOWN switch to begin a sixty-second cool down phase. Completion of time or distance will start a sixty-second cool down phase. HRC FAT BURN Fat burn workout designed to maintain a target heart rate determined by user input. POLAR chest strap is required to use this program.
  • Page 51 TRACKMASTER Press the COOL DOWN switch to begin a sixty-second cool down phase. Completion of time or distance will start a sixty-second cool down phase. USER PROGRAMS 10 stage user created program. Each USER PROGRAM requires user to insert elevation speed and time requirements for each stage.
  • Page 52 TRACKMASTER 7. Press ENTER to advance to segment 2, repeat steps 4, 5 & 6 using desired settings for segment 2. 8. You may repeat this for up to 10 segments. 9. Once you have completed your desired number of segments press the START switch (ENTER WEIGHT) will appear.
  • Page 53: Programmable Treadmill Self Test Procedure

    TRACKMASTER Programmable Treadmill Self Test Procedure T R A C K M A S T E R INCLINE SPEED DISTANCE TIME COOL ENTER DOWN STOP STOP CLEAR PROGRAM START SELECT To enter Self-Test Turn treadmill off Turn Treadmill on. Press and hold Incline + and – until message center reads TEST MODE.
  • Page 54 TRACKMASTER Message Center Walking 8 test. Observe Message Center Display. > All the legs in one readout are lit. Lit readout moves from left to right until all 12 readouts have been lit and then returns to far left readout and lights each readout again. This will continue until test is ended by pressing any switch.
  • Page 55 TRACKMASTER 14x15 Tri Color Dot Matrix Test Observe Tri Color Dot Matrix > Horizontal test – Each horizontal line is sequentially tested in Red, Green, and Orange. Test will continue until ended by pressing any switch. Vertical test – Each vertical line is sequentially tested in Red, Green, and Orange. Test will continue until ended by pressing any switch.
  • Page 56 TRACKMASTER Advance to next test by pressing YES. Warning: Pressing the STOP switch will skip Grade Test and start the Belt Motor Test. Observe Message Center Display and Distance window. > Pressing the INCLINE UP switch elevates the treadmill. As the treadmill elevates the value in the DISTANCE window increases.
  • Page 57 TRACKMASTER Heart Rate Test Observe all display windows. > Serial – Indicates the choice of serial input vice pulse as selected in the programming parameters. The distance window displays HR using the Contact Grips. The Time window displays HR using a POLAR® Chest Strap or heart rate generator. The heart symbol displayed in the dot matrix will flash as a heart rate signal is received.
  • Page 58 TRACKMASTER FVX__CP, TMX__CP Programmable Controller The following procedures provide instructions to fully utilize the upgrade, diagnostic and calibration capabilities of the programmable controller. Procedures requiring special tools and or personnel are identified at the beginning of the procedure. Tools/Personnel Required: Laptop or Desktop PC with Downloading Software Windows 95 or newer, download program &...
  • Page 59 TRACKMASTER FVX__CP, TMX__CP – Programmable Controller Software Download, Control Console Parameters, Speed/Elevation Calibration and Self- test Control Console Programming Mode With main power ON and displays lighted, press the STOP key and the ENTER key at the same time. When successful, the message center will scroll the following options: Choose 1 for MPH -or- 2 for KM/H.
  • Page 60 TRACKMASTER Maximum Calibration Grade will appear in the Message Center with a default setting of 25.00 in the Incline Window. This parameter sets the calibration grade and does not limit elevation. For fitness units use numeric keypad and change to 15.00 and then press ENTER key.
  • Page 61 TRACKMASTER Serial H-rate will appear in the Message Center. This setting used when the treadmill has the Contact Heart-rate feature. If the treadmill only has the Polar ® Heart-rate feature, use incline arrows to change setting to POLAR H-RATE. Press ENTER key.
  • Page 62 Press STOP +ENTER key for calibration. Refer to Elevation Calibration Procedure. Press ENTER key to skip and go into normal workout mode. Refer to FVX325, TMX425 Series Elevation Charts. Controller Action Required...
  • Page 63 TRACKMASTER TMX425 Series Elevation Chart Dim. Grade Inches 3.04” [77.3mm] 3.36” [85.2mm] 6.59” [167.3mm] 10.72” [272.2mm] 14.85” [377.2mm] 18.22” [462.9mm] 21.71” [551.5mm] Figure 1-1 Figure 1-2 Reset Phase SW Version Phase 0311 0.53 SW Version Number Figure 1-3 Figure 1-4...
  • Page 64: Chapter 6 Preventative Maintenance

    TRACKMASTER Preventative Maintenance Inspection and Cleaning Belt tracking adjustments Calibration Inspection report Required tools and supplies Standard hand tools DVOM Sotcher leakage tester or equivalent Anti septic cleaner Dust remover (compressed air) Calibration software and a PC Inspection and cleaning...
  • Page 65: Belt Cleaning & Inspection

    TRACKMASTER Interior cleaning Tools Required ¼ inch hex nut driver or flat blade screwdriver Vacuum with hose and attachments Turn the treadmill main power switch to the off position. Unplug the Treadmill from the wall receptacle. Allow treadmill to discharge for 3 minutes.
  • Page 66: Belt Speed Calibration

    TRACKMASTER Belt Speed Calibration Procedure Tools Required Calibration Program (Trackmaster Precision Incline Smart Power Supply) Stop watch or watch with a second hand Chalk or some other temporary marking device Computer or laptop Serial Communication Cable Plug in treadmill to power supply Turn on Treadmill Connect notebook or laptop to treadmill RS232 port.
  • Page 67 TRACKMASTER FVX325 SERIES VERIFYING BELT SPEED CALIBRATION IN THE FIELD Tools Required Stop watch or watch with a second hand Chalk or some other temporary marking device Verify a point on the run belt that can be seen plainly with each full revolution, this could be the seam or a chalk line you make on the belt.
  • Page 68 Adjust incline to .5% grade. Remove front rail bolt and end cap on TMX425 Series. Using the tape measure verify the angle within spec. +/- 2% (Refer to FVX325, TMX425 Series Elevation Charts) If incorrect make adjustments to compensate in .5% grade box.
  • Page 69 TRACKMASTER If the angle reading is higher than 25%(14.1°). Take the following steps to correct: (Refer to illustration FVX325, TMX425 Series elevation actuator Adjustment.) Remove actuator top cover. Using a large (.375" wide) flat blade screw driver, rotate the lower switch cam counterclockwise the proper amount to assure the treadmill will not elevate past 25%.
  • Page 70 TRACKMASTER TMX425 Series Elevation Chart Dim. Grade Inches 3.04” [77.3mm] 3.36” [85.2mm] 6.59” [167.3mm] 10.72” [272.2mm] 14.85” [377.2mm] 18.22” [462.9mm] 21.71” [551.5mm] FVX325, TMX425 Series Elevation Actuator Adjustment August, 2006 FVX, TMX Series Service Manual...
  • Page 71: Fvx325C, Tmx425C Series Elevation Calibration

    TRACKMASTER FVX325C, TMX425C Series Elevation Calibration Procedure Tools Required Tape Measure 1/4” Allen Wrench Remove front rail end bolt and end cap on TMX425 Series. With power “ON”, press and hold the Speed + and Elevation - keys. After a few seconds “P 1"...
  • Page 72 Repeat process for all grades Pressing Select after “CALS” and “CALE” appear will take you out of Setup Check and back to normal operation. Replace end cap and bolt on TMX425 Series. FVX325 Series Elevation Chart Dim. Grade Inches 3.04”...
  • Page 73 TRACKMASTER FVX325CP, TMX425CP Elevation Calibration Procedure Tools Required Tape Measure 1/4” Allen Wrench Prior to performing the elevation calibration procedure, enter the programming mode and enter the elevation calibration grade and elevation limits. To perform elevation calibration, place the console in elevation calibration mode. A drawing and table are available to assist in determining percentage of elevation.
  • Page 74 TRACKMASTER FVX325 Series Elevation Chart Dim. Grade Inches 3.04” [77.3mm] 3.32” [84.3mm] 5.62” [142.8mm] 8.42” [223.8mm] 11.20” [284.5mm] 13.48” [342.4mm] 15.84” [402.4mm] TMX425 Series Elevation Chart Dim. Grade Inches 3.04” [77.3mm] 3.36” [85.2mm] 6.59” [167.3mm] 10.72” [272.2mm] 14.85” [377.2mm] 18.22”...
  • Page 75: Elevation Screw Lubrication

    TRACKMASTER Elevation Screw Lubrication This procedure requires the following tools: • Trackmaster grease (Part # 317-160-165) • Clean, lint-free cloth • Small paint brush Clean and lubricate the treadmill elevation screw once every year. In high-use environments, clean and lubricate it once every 6 months.
  • Page 76: Troubleshooting

    TRACKMASTER Troubleshooting Trouble Shooting Guide Symptom Possible Cause Corrective Action Green Power light Power switch off Turn power switch to on (-) position not lit Power cord unplugged Plug in power cord Service breaker tripped Reset Breaker Incorrect outlet wiring...
  • Page 77 TRACKMASTER Power Supply and Driver Circuit Board (FG309) FG309 PCB responds to commands from the Control console to start the belt motor, elevate treadmill up and down, and increase treadmill running belt speed. It also routes speed and elevation sensor information to control console. Trouble shooting the treadmill begins with understanding the direction signals travel and the voltage levels required to activate a circuit.
  • Page 78 TRACKMASTER Drive Circuit Board Manual Control (FG309) Drive Circuit Board Programmable Control (FG309) August, 2006 FVX, TMX Series Service Manual...
  • Page 79: Power Supply

    TRACKMASTER Power Supply The power supply circuit forms the +12 volts (unregulated) from input power (120/230VAC). The +12 volts is then used to form VLED, VCC and +5 volt signal used in the control console, sensor circuits and the motor drive circuits.
  • Page 80: Fg309 Change Belt Speed

    TRACKMASTER FG309 Change Belt Speed Speed Out (spout) received from control console at J5 pin 5. A set voltage level for testing is not available for this signal. The range of this signal at output of FG309 is in the range of 0.0 vdc to 7.5 vdc.
  • Page 81: Input From Fg309 To Control Console

    TRACKMASTER 0.0 volts Cathode (stripe side) D9 (input from control console) to DC ground (opposite side of D9) A/C scale 0.0 volts JP1 Pin 3 (red) to JP1 Pin 1 (white) A/C output to linear actuator Elevate Down (D4 Down Indicator Lamp lit) D/C scale 14.37 volts...
  • Page 82: Chapter 8 Removal And Replacement Of Components

    TRACKMASTER Removal and Replacement of Components Hood Removal Procedure FVX Series Tools Required 1/4” Hex Socket or Flat Blade Screw Driver Turn the treadmill main power switch to the off position. Unplug the Treadmill from the wall receptacle. Allow treadmill to discharge for 3 minutes.
  • Page 83: Hood Removal Procedure Tmx Series

    TRACKMASTER Hood Removal Procedure TMX Series Tools Required 1/4” Hex Socket or Flat Blade Screw Driver Turn the treadmill main power switch to the off position. Unplug the Treadmill from the wall receptacle. Allow treadmill to discharge for 3 minutes.
  • Page 84: Drive Motor Replacement Fvx Series

    TRACKMASTER Drive Motor Replacement FVX Series Tools required 3/16” Hex wrench or Hex socket 3/32” Hex wrench or Hex socket 1/8” Hex wrench or Hex socket 7/16” wrench or socket 9/16” Open-end wrench 1/4” Hex nut driver or flat blade screw driver 3/32”...
  • Page 85 TRACKMASTER 22. With the insulators and Spacers still in place on the motor plate, set the new motor on the plate and reinstall the four bolts with nuts. Make sure the spacers and insulators all stay in place or the treadmill can become a shock hazard when in operation.
  • Page 86: Drive Motor Replacement Tmx Series

    TRACKMASTER Drive Motor Replacement TMX Series Tools required 3/16” Hex wrench or Hex socket 3/32” Hex wrench or Hex socket 1/8” Hex wrench or Hex socket 7/16” wrench or socket 9/16” Open-end wrench 1/2” Open-end wrench 1/4” Hex nut driver or flat blade screw driver 3/32”...
  • Page 87 TRACKMASTER Lift the motor off the plate making sure not to loose the four isolation spacers and the four shoulder insulators. Remove drive sprocket from motor shaft by loosening the two 3/32 set screws on its hub then sliding it off.
  • Page 88 TRACKMASTER Slide the belt back on to the sprocket. Reinstall the four nuts on the underside of the motor pan but leave loose until the belt is properly tensioned and tracked according to the drive belt tension and adjustment section in this manual.
  • Page 89: Front Roller Replacement Fvx/Tmx Series

    TRACKMASTER Front Roller Replacement FVX / TMX Series Tools Required 1/4 inch Allen wrench or socket 3/16 inch Allen wrench or socket Approximate Time to Complete – 45 Minutes Turn treadmill main power switch to the off position. Unplug treadmill plug from the wall receptacle.
  • Page 90: Rear Roller Replacement Fvx/Tmx Series

    TRACKMASTER FVX Series TMX Series August, 2006 FVX, TMX Series Service Manual...
  • Page 91 TRACKMASTER Rear Roller Replacement Tools Required 1/4 inch Allen wrench or socket 3/16 inch Allen wrench or socket Approximate Time to Complete – 45 Minutes Turn treadmill main power switch to the off position. Unplug treadmill plug from the wall receptacle.
  • Page 92 TRACKMASTER FVX Series TMX Series 8-11 August, 2006 FVX, TMX Series Service Manual...
  • Page 93: Running Belt Replacement Fvx Series

    TRACKMASTER Running Belt Replacement FVX Series Tools Required 1/4 inch Allen wrench or socket 3/16 inch Allen wrench or socket 1/2 Inch Wrench or socket with extension Jack stand or block capable of supporting the weight of the rear of the treadmill Approximate Time to Complete –...
  • Page 94 TRACKMASTER 20. Replace the rear roller; push the rear roller as far forward as possible. Do not replace or start the tensioning bolts at this time. Verify the guide for the belt deck and rollers is to the left during installation.
  • Page 95: Running Belt Replacement Tmx Series

    TRACKMASTER Running Belt Replacement TMX Series Tools Required 1/4 inch Allen wrench or socket 3/16 inch Allen wrench or socket 1/2 Inch Wrench or socket with extension Jack stand or block capable of supporting the weight of the rear of the treadmill Approximate Time to Complete –...
  • Page 96 TRACKMASTER 21. Replace the rear roller, push the rear roller as far forward as possible. Do not replace or start the tensioning bolts at this time. Verify the guide for the belt deck and rollers is to the left during installation.
  • Page 97: Running Deck Replacement Fvx Series

    TRACKMASTER Running Deck Replacement FVX Series Tools Required 1/4 inch Allen wrench or socket 3/16 inch Allen wrench or socket 1/2 Inch Wrench or socket with extension Jack stand or block capable of supporting the weight of the rear of the treadmill Approximate Time to Complete –...
  • Page 98: Running Deck Replacement Tmx Series

    TRACKMASTER Running Deck Replacement TMX Series Tools Required 1/4 inch Allen wrench or socket 3/16 inch Allen wrench or socket 1/2 Inch Wrench or socket with extension Jack stand or block capable of supporting the weight of the rear of the treadmill Approximate Time to Complete –...
  • Page 99: Deck Cushion Replacement Fvx Series

    TRACKMASTER Deck Cushion Replacement FVX Series Tools Required 1/4 inch Allen wrench or socket 3/16 inch Allen wrench or socket 1/2 Inch Wrench or socket with extension Jack stand or block capable of supporting the weight of the rear of the treadmill Approximate Time to Complete –...
  • Page 100: Deck Cushion Replacement Tmx Series

    TRACKMASTER Deck Cushion Replacement TMX Series Tools Required 1/4 inch Allen wrench or socket 3/16 inch Allen wrench or socket 1/2 Inch Wrench or socket with extension Jack stand or block capable of supporting the weight of the rear of the treadmill Approximate Time to Complete –...
  • Page 101: Motor Drive Belt Replacement Fvx Series

    TRACKMASTER Motor Drive Belt Replacement FVX Series Tools required 1/4” Hex wrench or Hex socket 7/16” wrench or socket 9/16” Open-end wrench 1/4” Hex nut driver or flat blade screw driver Approximate time to complete 1.5 hrs Elevate the treadmill to approximate 15% grade.
  • Page 102 TRACKMASTER FVX Series 8-21 August, 2006 FVX, TMX Series Service Manual...
  • Page 103: Motor Drive Belt Replacement Tmx Series

    TRACKMASTER Motor Drive Belt Replacement TMX Series Tools required 1/4” Hex wrench or Hex socket 7/16” wrench or socket 9/16” Open-end wrench 1/4” Hex nut driver or flat blade screw driver Approximate time to complete 1.5 hrs Elevate the treadmill to approximate 15% grade.
  • Page 104 TRACKMASTER TMX Series 8-23 August, 2006 FVX, TMX Series Service Manual...
  • Page 105: Elevation Actuator Replacement/Adjustment

    TRACKMASTER Elevation Actuator Replacement / Adjustment Tools Required 2 - 9/16” wrenches or sockets 3/8” wide Flat blade screwdriver Shipping blanket, carpet, or cardboard 1/4” Hex nut driver or flat blade screw driver Tape measure Moly based grease Approximate time to complete 1.5 hrs Turn the treadmill main power switch to the off position.
  • Page 106 TRACKMASTER FVX, TMX Series 8-25 August, 2006 FVX, TMX Series Service Manual...
  • Page 107: Power Supply Relay Board Replacement Fvx Series

    TRACKMASTER Power Supply Relay Board Replacement FVX Series Tools required Wire cutters or utility knife Grounding wrist strap 1/4” Hex nut driver or flat blade screw driver 3/32” flat blade electronics screwdriver Approximate time to complete 1.25 hrs 1. Turn the treadmill main power switch to the off position.
  • Page 108 TRACKMASTER FVX Series 8-27 August, 2006 FVX, TMX Series Service Manual...
  • Page 109: Power Supply Relay Board Replacement Tmx Series

    TRACKMASTER Power Supply Relay Board Replacement TMX Series Tools required Wire cutters or utility knife Grounding wrist strap 1/4” Hex nut driver or flat blade screw driver 3/32” flat blade electronics screwdriver Approximate time to complete 1.25 hrs Turn the treadmill main power switch to the off position.
  • Page 110 TRACKMASTER TMX Series 8-29 August, 2006 FVX, TMX Series Service Manual...
  • Page 111: Circuit Breaker Replacement

    TRACKMASTER Circuit Breaker Replacement Tools required 1/4” Hex nut driver or flat blade screwdriver 3/32” flat blade electronics screwdriver Approximate time to complete .25 hrs Elevate the treadmill to approximate 15% grade. Turn the treadmill main power switch to the off position.
  • Page 112: Inverter Drive Replacement Fvx Series

    TRACKMASTER Inverter Drive Replacement FVX Series Tools required 1/4” Hex nut driver or flat blade screw driver 3/32” flat blade electronics screwdriver #2 Phillips screwdriver Approximate time to complete 1.5 hrs Turn the treadmill main power switch to the off position.
  • Page 113 TRACKMASTER FVX Series 8-32 FVX, TMX Series Service Manual August, 2006...
  • Page 114: Inverter Drive Replacement Tmx Series

    TRACKMASTER Inverter Drive Replacement TMX Series Tools required 5/16” hex socket with 6” extension 1/4” Hex nut driver or flat blade screw driver 3/32” flat blade electronics screwdriver #2 Phillips screwdriver Approximate time to complete 1.5 hrs Elevate the treadmill to approximate 15% grade.
  • Page 115 TRACKMASTER TMX Series 8-34 FVX, TMX Series Service Manual August, 2006...
  • Page 116: Product Requirements

    TRACKMASTER Product Requirment FVX, TMX Smart Power Supply INTRODUCTION The FVX, TMX Series treadmill control is to provide a means of controlling belt speed and elevation for the FVX, TMX Series treadmill through the use of an RS-232 serial port and established serial port protocol.
  • Page 117: Software Requirements

    TRACKMASTER SOFTWARE REQUIREMENTS SPEED CONTROL There are two outputs and one input required for speed control. The belt enable output must be fully energized to put the belt into a run mode. The speed control output is a 25hz 1024 count pulse width modulated output which is filtered to produce an analog voltage referenced to a fixed voltage supplied by the inverter.
  • Page 118: Command Protocol

    TRACKMASTER COMMAND PROTOCOL The Trackmaster Serial Communications Protocol consists of two types of commands, which are INPUT COMMANDS and STATUS REQUESTS. When a command is sent to the serial port, it is decoded and executed. The corresponding acknowledgement is then transmitted via the serial port.
  • Page 119: Status Request

    TRACKMASTER C - STATUS REQUEST ASCII CODES DECIMAL C0 192 - Xmit Belt Status C1 193 - Xmit Current Actual Speed C2 194 - Xmit Current Actual Elevation C3 195 - Xmit Current Set Speed C4 196 - Xmit Current Set Elevation...
  • Page 120: Communication Notes

    TRACKMASTER COMMUNICATION NOTES Note 1 - The Communication Disconnect Stop Enable mode is a safety feature that stops the belt when a command is not received from the host within 0.5 seconds. Note 2 - The Communication Disconnect Stop Disable mode allows the belt to run without sustained communication at 0.5 second intervals.
  • Page 121: Self Test Mode

    TRACKMASTER SELF TEST MODE On powerup, the SPS sends out a special test character ‘T’ and checks to see if it is returned. This is a check for a shorting jumper across the transmit and receive lines of the RS-232 serial port.
  • Page 122: Hardware Requirements

    TRACKMASTER HARDWARE REQUIREMENTS The SPS electronics hardware consists of one electronic control board. ELECTRICAL INPUTS A) Instrument Power: On 230VAC or 120VAC supplied through two 1/4 Amp breakers in parallel for control board power. On 230VAC supplied through two 2 Amp breakers, or 120VAC supplied thru two 1amp breakers, in parallel for elevation motor power.
  • Page 123: Electrical Connections

    TRACKMASTER ELECTRICAL CONNECTIONS A) Input Power Header : An Amp - 641968-1 four pin MATE & LOCK header is provided for instrument power. B) Elevation Output Header : An Amp - 641968-1 three pin MATE & LOCK header is provided for output power to the elevation motor.
  • Page 124: Chapter 10 Production Qualification Description

    TRACKMASTER Production Qualification Description FG302 Smart Power Supply The following is a description of the procedures that are followed to qualify every FG0302 production unit. In addition to these procedures, our quality department does a visual inspection on a sample lot of every work order shipment of not less than 5%. In addition, our primary customer, Full Vision, performs a 24 hour burn-in on every unit as assembled in the finished product.
  • Page 125: Pc Directed Test Step

    TRACKMASTER PC Directed Test Steps: After the connections have been made between the test fixture and the PC, between the dut and the test fixture, and between the dut and the PC, the PC software can be run by test personnel.
  • Page 126 TRACKMASTER Power Supply Board (FG302) 10-3 August, 2006 FVX, TMX Series Service Manual...
  • Page 127 TRACKMASTER 10-4 FVX, TMX Series Service Manual August, 2006...
  • Page 128: Chapter 11 Leeson Inverter

    TRACKMASTER Leeson Inverter Leeson Speedmaster Self-Test Press the Mode button. Observe inverter readout displays 00. Press the up arrow and change readout value to 135. Press the Mode button, observe readout value should change to P01 Press the up arrow and change the readout value to P05.
  • Page 129: Leeson Inverter Inspection Sheet

    TRACKMASTER Leeson Inverter Inspection Sheet Please complete and fax to 316-283-3350 Treadmill S/N Leeson S/N 1. Measure Input Power Neutral a. A/C Measure the Inverter A/C Input voltage 220VAC under three conditions. 240 VAC measure from L1 to L2 120 VAC measure from L1 to N...
  • Page 130: Inverter Parameters/Software Version 301

    TRACKMASTER Inverter Parameters/Software Version 301 Pass code 225(initial), after setting 135 Values that are different from factory specifications are in bold Italic. PARAMETER RANGE OF ADJUSTMENT FACTORY NAME DEFAULT (NOTE1) LINE VOLTAGE HIGH (01), LOW (02) HIGH (01) CARRIER 4kHz (01), 6 kHz (02), 8 kHz (03),...
  • Page 131 TRACKMASTER CONTROL TERMINAL STRIP ONLY (01) . REMOTE TERMINAL STRIP KEYPAD ONLY (02). TERMINAL STRIP ONLY (01) OR REMOTE KEYPAD (03) SERIAL LINK DISABLE (01), 9600, 8, N, 2 9600, 8, N, 2 WITH TIMER (02) WITH TIMER (02) 9600, 8, N, 2 WITHOUT TIMER (03)
  • Page 132 TRACKMASTER PROGRAM USER SETTINGS (01), OEM SETTINGS (02) USER SETTINGS (01) SELECTION , RESET OEM (03), RESET 60 (04). RESET 50 (05), TRANSLATE (06) FAULT HISTORY ( VIEW ONLY) (N/A) SOFTWARE CODE ( VIEW ONLY) ( N/A) DC BUS VOLTAGE...
  • Page 133: Inverter Parameters/Software Version 402

    TRACKMASTER Inverter Parameters/Software Version 402 Pass code 225(initial), after setting 135 Values that are different from factory specifications are in bold Italic. PARAMETER NAME RANGE OF ADJUSTMENT FACTORY DEFAULT LINE VOLTAGE HIGH (01), LOW (02) HIGH (01) CARRIER 4kHz (01), 6 kHz (02), 8 kHz (03), 10 kHz (04) 10 kHz (04)
  • Page 134 TRACKMASTER ROTATION FORWARD ONLY (01), FORWARD 17 ` FORWARD AND REVERSE (02) ONLY (01) ACCELERATION TIME 0.1 -3600.0 SEC 8.0 SEC DECELERATION TIME 0.1 - 3600.0 SEC 10.0 SEC DC BRAKE TIME 0.0 - 3600.0 SEC 0.0 SEC DC BRAKE VOLTAGE 0.0 - 30.0 %...
  • Page 135: Inverter Parameters/Software Version 403

    TRACKMASTER Inverter Parameters/Software Version 403 Pass code 225(initial), after setting 135 Values that are different from factory specifications are in bold Italic. PARAMETER NAME RANGE OF ADJUSTMENT FACTORY DEFAULT LINE VOLTAGE HIGH (01), LOW (02) HIGH (01) CARRIER 4kHz (01), 6 kHz (02), 8 kHz (08), 10 kHz (04) 6 kHz (05)
  • Page 136 TRACKMASTER UNITS EDITING TENTHS OF UNITS (01), WHOLE UNITS WHOLE UNITS (02) (02) 17 ` ROTATION FORWARD ONLY (01), FORWARD FORWARD AND REVERSE (02) ONLY (01) ACCELERATION TIME 0.1 -3600.0 SEC 8.0 SEC DECELERATION TIME 0.1 - 3600.0 SEC 10.0 SEC DC BRAKE TIME 0.0 - 3600.0 SEC...
  • Page 137: Inverter Parameters/Software Version 403 & Later

    TRACKMASTER Inverter Parameters/Software Version 403 & Later Using Version 1.9 Software Supply Relay Board Pass code 225(initial), after setting 135 Values that are different from factory specifications are in bold Italic. PARAMETER NAME RANGE OF ADJUSTMENT FACTORY DEFAULT LINE VOLTAGE...
  • Page 138 TRACKMASTER ROTATION FORWARD ONLY (01), FORWARD FORWARD AND REVERSE (02) ONLY (01) ACCELERATION TIME 0.1 -3600.0 SEC 8.0 SEC DECELERATION TIME 0.1 - 3600.0 SEC 3.0 SEC DC BRAKE TIME 0.0 - 3600.0 SEC 0.0 SEC DC BRAKE VOLTAGE 0.0 - 30.0 % 0.0 %...
  • Page 139 TRACKMASTER 11-12 FVX, TMX Series Service Manual August, 2006...
  • Page 140: Chapter 12 Established Component Replacement Times

    TRACKMASTER Established Component Replacement Times FVX/TMX Series Inverter replacement including recalibration of belt speed 1.5 hrs FVX/TMX Series Actuator replacement including grade calibration 1.5 hrs FVX/TMX Series Rear Roller replacement including belt tracking 1 hrs adjustments FVX/TMX Series Front Roller replacement including belt tracking .75 hrs...
  • Page 141 TRACKMASTER FVX/TMX Series Speed sensor replacement .5 hrs FVX/TMX Series Control panel replacement includes recalibration 1.75 hrs FVX/TMX Series End cap replacement 5 min FVX/TMX Series Rubber stripping on side channels .5 hrs FVX/TMX Series Wheels replacement, both 10 min FVX/TMX Series RS232 harness replacement .75 hrs...
  • Page 142: Chapter 13 Parts List With Part Numbers

    TRACKMASTER Parts List with Part Numbers FVX Series Inverter Assembly 220V Software Version 402/403/404 Item Description Part Number Inverter – Lesson 317-160-104 Inverter Signal Harness 317-160-036 Power Input Harness 317-160-069 Capacitor 317-160-118 Tie Wrap – 4” 317-160-075 13-1 August, 2006...
  • Page 143: Tmx Series Inverter Assembly 220V Software Version 301

    TRACKMASTER TMX Series Inverter Assembly 220V Software Version 301 Item Description Part Number Inverter – Leeson 317-160-008 Inverter Signal Harness 317-160-036 Power Input Harness 317-160-069 Capacitor 317-160-035 HN - #8 – 32 Nylon 001-1763 Isolation Mount 317-160-040 Tie Wrap – 4”...
  • Page 144: Tmx Series Inverter Assembly 115V Software Version 301

    TRACKMASTER TMX Series Inverter Assembly 115V Software Version 301 Item Description Part Number Inverter – Leeson 317-160-008 Inverter Signal Harness 317-160-036 Power Input Harness 317-160-069 Capacitor 317-160-035 HN - #8 – 32 Nylon 001-1763 Isolation Mount 317-160-040 Tie Wrap – 4”...
  • Page 145: Tmx Series Inverter Assembly 220V Software Version 402/403/404

    TRACKMASTER TMX Series Inverter Assembly 220V Software Version 402/403/404 Item Description Part Number Inverter – Leeson 317-160-104 Inverter Signal Harness 317-160-036 Power Input Harness 317-160-069 Capacitor 317-160-035 HN - #8 – 32 Nylon 001-1763 Isolation Mount 317-160-040 Tie Wrap – 4”...
  • Page 146: Fvx Series Inverter Assembly 110V Software Version 402/403/403

    TRACKMASTER FVX Series Inverter Assembly 110V Software Version 402/403/404 Item Description Part Number Inverter – Leeson 317-160-105 Inverter Signal Harness 317-160-036 Power Input Harness 317-160-069 Capacitor 317-160-035 HN - #8 – 32 Nylon 001-1763 Isolation Mount 317-160-040 Tie Wrap – 4”...
  • Page 147: Motor Mount Assembly

    TRACKMASTER Motor Mount Assembly Item Description Part Number SPROCKET DRIVE MOTOR 317-160-009 FLYWHEEL DRIVE MOTOR 317-160-072 BUSHING FLYWHEEL 317-160-032 SSS ¼-20 SUPPLIED WITH 317-160-032 MOTOR GROUND WIRE 317-160-072 DECAL CAUTION ELECTRIC 317-160-103 COLLAR ASSEMBLY 317-178-001 MOTOR LEESON 317-160-007 HNS 5/18-18 FLANGE 001-1398 SSS #10-32 X .125...
  • Page 148 TRACKMASTER Motor Mount Assembly FVX Series and TMX Series Alternative Item Description Part Number SPROCKET DRIVE MOTOR 317-160-009 FLYWHEEL WITH MAGNET 317-160-101 MOTOR BASE WELDMENT 317-378-001 BUSHING W/ SHOULDER 317-160-052 MOTOR GROUND WIRE 317-160-108 DECAL CAUTION ELECTRIC 317-160-103 WASHER DELRIN...
  • Page 149: Fvx Series Movable Esb Assembly

    TRACKMASTER FVX Series Movable ESB Assembly Item Description Part Number PUSHBUTTON 317-180-004 LABEL PLATE 317-180-006 SWITCH EMERGENCY STOP 317-180-005 HARNESS ESB SIDE 317-399-006 RIVET POP .125 DIA X .430 SS 001-239-007 ESB BOX DRILLED 317-399-004 MOUNT ESB 317-400-001 HWHTS #8-32 X 3/8 LG...
  • Page 150: Tmx Series Movable Esb Assembly

    TRACKMASTER TMX Series Movable ESB Assembly Item Description Part Number HARNESS TREADMILL SIDE 317-399-007 RIVET POP .125 DIA X .430 SS 001-239-007 HARNESS COIL CORD 317-399-008 PUSHBUTTON 317-180-004 LABEL PLATE 317-180-006 SWITCH EMERGENCY STOP 317-180-005 HARNESS ESB SIDE 317-399-006 ESB BOX DRILLED...
  • Page 151: Fvx/Tmx Series Elevation Assembly

    TRACKMASTER FVX/TMX Series Elevation Assembly Item Description Part Number FVX ELEVATION WELDMENT 317-617-001 TMX ELEVATION WELDMENT 317-373-001 HHCS 3/8-16 X 3.25 LG GR5 001-1519 SPANNER WHEEL 317-160-054 WHEEL LANDING GEAR 317-160-005 NLN 3/8-16 NUT 001-1430 13-10 FVX, TMX Series Service Manual...
  • Page 152 TRACKMASTER FVX/TMX Line Reactor Assembly Item Description Part Number LINE REACTOR 2 COIL MTE 317-160-126 HARNESS INVERTOR POWER 317-160-069 HARNESS HARMONICS OUTPUT 317-160-114 13-11 August, 2006 FVX, TMX Series Service Manual...
  • Page 153 TRACKMASTER FVX325 Series 220V Motor Pan Assembly Item Description Part Number FRAME 317-610-001 TRIM MINI BLACK 001-102-044 4.6” TRIM MINI BLACK 001-102-044 1.6” TRIM MINI BLACK 001-102-044 5.6” INVERTER SUPPORT 317-614-001 INVERTER SUPPORT BOTTOM 317-615-001 POP RIVET 5/32 X .50 GRIP...
  • Page 154 TRACKMASTER FVX325 Series 220V Motor Pan Assembly Item Description Part Number BREAKER 1/4AMP 317-160-024 HHWHTS #8-32 X .375 001-1744 MAIN WIRE HARNESS 317-160-113 SURGE PROTECTOR 317-160-129 LW #10 EXT TOOTH 001-1751 HH SCREW #10-32 3/8 GRD 317-160-076 DECAL GROUND 317-160-079...
  • Page 155 TRACKMASTER FVX325 Series 220V Motor Pan Assembly 13-14 FVX, TMX Series Service Manual August, 2006...
  • Page 156: Fvx325 Series Elevation Assembly

    TRACKMASTER FVX325 Series Elevation Assembly Item Description Part Number FRAME 220V MOTOR PAN ASSEMBLY 317-600-001-1 ELEVATION ASSEMBLY 317-626-001 HSHSS 5/8 DIA X 1” LG 001-1730 ELEVATION DERLIN SPACER 317-160-060 FW ½” DIA 001-1443 NLN ½-13 001-1676 HHCS 3/8-16 X 3” GR5...
  • Page 157: Fvx325 Series Frame Assembly

    TRACKMASTER FVX325 Series Frame Assembly Item Description Part Number FRAME 220V MOTOR PAN ASSEMBLY 317-600-001-1 ROLLER FRONT 317-160-156 HSHCS 5/16-18 X 2” PLTD 001-1748 LW 5/16 DIA 001-1451 FW 5/16 DIA 001-1440 DRIVE BELT 317-160-142 DECK SUPPORT CHANNEL WELDMENT 317-379-001 DECK ISOLATOR 1.75”...
  • Page 158 TRACKMASTER FVX325 Series Frame Assembly 13-17 August, 2006 FVX, TMX Series Service Manual...
  • Page 159: Fvx325 Series Final Assembly

    TRACKMASTER FVX325 Series Final Assembly Item Description Part Number FRAME ASSEMBLY 317-600-001-2 HANDRAIL LEG RIGHT 317-627-001 HANDRAIL LEG LEFT 317-628-001 SPACER UHMW 317-611-001 HSHCS 3/8-16 X 1.0 LG PLT 001-1859 DOME PLUG 317-180-008 HANDRAIL NO CONTROL 317-613-001 HSHCS 3/8-16 X 1.0 LG PLT...
  • Page 160 TRACKMASTER FVX325 Series Final Assembly 13-19 August, 2006 FVX, TMX Series Service Manual...
  • Page 161: Tmx425 Series 115V Motor Pan Assembly

    TRACKMASTER TMX425 Series 115V Motor Pan Assembly Item Description Part Number MOTOR ASSEMBLY 317-179-001 WASHER NYLON 317-160-086 HNS 3/8-16 FLANGE 001-1399 NLN 3/8-16 001-1430 LINEAR ACTUATOR 115v 317-160-090 TRIM MINI BLACK 001-102-044 6’’ TIE CABLE .10 X 4.00 317-160-075 NOT PICTURED HHWHTS #8-32 X 3/8...
  • Page 162 TRACKMASTER TMX425 Series 115V Motor Pan Assembly 13-21 August, 2006 FVX, TMX Series Service Manual...
  • Page 163: Tmx425 Series 115V Motor Pan Assembly W/Ce Components

    TRACKMASTER TMX425 Series 115V Motor Pan Assembly w/ CE Components Item Description Part Number MOTOR ASSEMBLY 317-179-001 WASHER NYLON 317-160-086 HNS 3/8-16 FLANGE 001-1399 NLN 3/8-16 001-1430 LINEAR ACTUATOR 115v 317-160-090 TRIM MINI BLACK 001-102-044 6’’ TIE CABLE .10 X 4.00...
  • Page 164 TRACKMASTER TMX425 Series 115V Motor Pan Assembly w/CE Components 13-23 August, 2006 FVX, TMX Series Service Manual...
  • Page 165: Tmx425 Series 220V Motor Pan Assembly

    TRACKMASTER TMX425 Series 220V Motor Pan Assembly Item Description Part Number MOTOR ASSEMBLY 317-179-001 WASHER NYLON 317-160-086 HNS 3/8-16 FLANGE 001-1399 NLN 3/8-16 001-1430 LINEAR ACTUATOR 220v 317-160-029 TRIM MINI BLACK 001-102-044 6’’ TIE CABLE .10 X 4.00 317-160-075 TRIM MINI BLACK 001-102-044 3’’...
  • Page 166 TRACKMASTER TMX425 Series 220V Motor Pan Assembly 13-25 August, 2006 FVX, TMX Series Service Manual...
  • Page 167: Tmx425 Series 220V Motor Pan Assembly W/Ce Components

    TRACKMASTER TMX425 Series 220V Motor Pan Assembly w/CE Components Item Description Part Number MOTOR ASSEMBLY 317-179-001 WASHER NYLON 317-160-086 HNS 3/8-16 FLANGE 001-1399 NLN 3/8-16 001-1430 LINEAR ACTUATOR 220v 317-160-029 TRIM MINI BLACK 001-102-044 6’’ TIE CABLE .10 X 4.00...
  • Page 168 TRACKMASTER TMX425 Series 220V Motor Pan Assembly w/CE Components 13-27 August, 2006 FVX, TMX Series Service Manual...
  • Page 169: Tmx Series W/ Ce Option #317-01784

    TRACKMASTER TMX Series w/ CE Option #317-01784 13-28 FVX, TMX Series Service Manual August, 2006...
  • Page 170: Tmx425 Series Frame Assembly

    TRACKMASTER TMX425 Series Frame Assembly Item Description Part Number EXTRUSION ANTI-SKID RUBBER 317-160-055 RAIL WELDMENT LEFT HAND 317-164-001 ANTI SLIP SAFTY WALK 317-160-084 FW ∅ 1/4’’ 001-1439 LW ∅ 1/4’’ 001-1450 HHCS ¼-20 X ¾’’ GR5 001-1186 FOOT ASSEMBLY REAR...
  • Page 171 TRACKMASTER TMX425 Series Frame Assembly 13-30 FVX, TMX Series Service Manual August, 2006...
  • Page 172: Tmx425 Series Running Deck Assembly

    TRACKMASTER TMX425 Series Running Deck Assembly Item Description Part Number ROLLER FRONT 317-160-003 HSHCS 5/16-18 X 2” PLTD 001-1748 LW 5/16” DIA. 001-1451 FW 5/16” DIA. 001-1440 SPACER FRONT END CAP 317-160-049 HSBHCS 5/16-18 X 2.75” PLT 001-1741 FRAME ASSEMBLY 220V FULLY ASSEMBLED...
  • Page 173 TRACKMASTER TMX425 Series Running Deck Assembly 13-32 FVX, TMX Series Service Manual August, 2006...
  • Page 174: Tmx425 Series Final Assembly

    TRACKMASTER TMX425 Series Final Assembly Item Description Part Number ESB ASSEMBLY 317-180-001 TUBE CONECTOR 317-160-021 TUBE SPACER 317-160-047 CENTER HANDRAIL 317-172-001 LW 5/16’’ DIA. HI-COLLAR 001-1738 HSHCS 5/16-18 X 3’’ 001-1737 PLUG DOME 317-160-039 LEFT HAND HANDRAIL WELDMENT 317-174-001 CLAMP SUPPORT 317-160-092 LW 5/16’’...
  • Page 175 TRACKMASTER TMX425 Series Final Assembly 13-34 FVX, TMX Series Service Manual August, 2006...
  • Page 176: Chapter 14 Flowcharts & Instructions For Trouble Shooting

    TRACKMASTER Flowcharts & Instructions For Trouble Shooting Power Distribution 120 VAC Flowchart 1A Nameplate Turn treadmill power switch Turn treadmill power switch to the off position (0) to the off position (0) data voltage = 120 VAC? Unplug treadmill from wall...
  • Page 177: Power Distribution 208-240 Vac Flowchart 1B

    TRACKMASTER Power Distribution 208-240 VAC Flowchart 1B Turn treadmill power switch Turn treadmill power switch Nameplate to the off position (0) to the off position (0) data voltage = 208-240VAC? Unplug treadmill from wall receptacle, turn power Refer to 208-240 VAC...
  • Page 178 TRACKMASTER Power Distribution Flowchart 1C At FG302 Power Supply / Treadmill Driver Circuit PCB. Perform Voltage 120 FG 302 Elevation and VAC? Power Supply A/C Voltage Distribution Fault Isolation Instructions. Use voltmeter, test AC voltage from L1 to N at...
  • Page 179 TRACKMASTER Power Distribution Flowchart 1D At FG302 Power Supply / Treadmill Driver Circuit PCB. Perform Voltage 208- elevation and power supply 240 VAC? A/C voltage distribution test. Use voltmeter, test AC voltage from L1 to L2 at Leeson Speedmaster At FG309 Power Supply / Driver Circuit PCB.
  • Page 180 TRACKMASTER Power Distribution Flowchart 1E FVX, TMX Series No Control FG302 P/S Treadmill PCB, LED D6 Model? lit? FVX__C or FVX__CP, TMX__C or TMX__CP Emergency FG309 P/S Stop Button in PCB, LED D8 the down lit? position? Twist ESB button to the...
  • Page 181 TRACKMASTER Belt Start Command Flowchart 2A Prior to starting treadmill Does treadmill Is treadmill from external control, elevate when Power remove 3 screws retaining commanded at Indicator lamp motor cover. Lift and stress system? lit? secure motor cover FVX, TMX...
  • Page 182: Speed Sensor Fault Isolation Fvx, Tmx Series 2A1

    TRACKMASTER Speed Sensor Fault Isolation FVX, TMX Series 2A1 FVX, TMX Series No Control What is the Does D7 flash At FG302 P/S PCB treadmill model when the belt verify operation of number? motor is Speed Sensor LED operating? Perform FVX,...
  • Page 183: Fvx, Tmx No Control Series Belt Motor Start Operation-Self Test 2B

    TRACKMASTER FVX, TMX No Control Series Belt Motor Start Operation – Self Test 2B Perform Treadmill Move Test Plug directly to At FG302 P/S self test procedure power supply, FG302 PCB, D10 LED lit? Does treadmill Perform Treadmill self test...
  • Page 184: Fvx, Tmx Control Series Belt Motor Start Operation-Self Test 2C

    TRACKMASTER FVX, TMX Control Series Belt Motor Start Operation – Self-Test 2C Does treadmill operate from Set console parameters, control verify RS232 port is console?. turned on Operate Belt motor locally at Verify Leeson Leeson Speedmaster Speedmaster parameters keyboard Replace Leeson...
  • Page 185: Leeson Speedmaster - Parameter Inspection And Self-Test 2D

    TRACKMASTER Leeson Speedmaster – Parameter Inspection and Self-Test 2D Operate Belt motor locally at Verify Leeson Leeson Speedmaster Speedmaster parameters keyboard Replace Leeson Perform Treadmill Speedmaster Inverter Drive self test procedure Does treadmill run belt start? Does treadmill run belt start?
  • Page 186: Treadmill Elevation Flowchart 3A

    TRACKMASTER Treadmill Elevation Flowchart 3A FVX, TMX Prior to starting elevating from Series external control, remove 3 No Control screws retaining motor cover. Treadmill Lift and secure motor cover Model Number? FVX__C or FVX__CP, Does treadmill TMX__C or elevate when...
  • Page 187 TRACKMASTER Treadmill No Elevation FVX, TMX No Control Series Elevation Flowchart 3B At FG302 P/S PCB, observe Perform treadmill Replace FG302 P/S LED 3 (Up) and LED 4 self-test (Down) as the elevation is selected When elevation When elevation selected is At...
  • Page 188 TRACKMASTER Treadmill No Elevation FVX, TMX Control Series Elevation Flowchart 3C At FG309 P/S PCB, observe Select elevation Replace FG309 P/S LED 9 (Up) and LED 10 using Control (Down) as the elevation is console selected When elevation When elevation...
  • Page 189 TRACKMASTER Power Distribution Fault Isolation (1) 120VAC Instructions 1. Use ohmmeter, measure continuity from connectors of power indicator to output of C/E filter. Repair break in wire or proceed to next step. 2. Measure continuity through C/E filter, replace C/E filter if defective or proceed to next step 3.
  • Page 190 TRACKMASTER FG 309 Elevation and Power Supply A/C Voltage Distribution Fault Isolation Instructions 1. Turn treadmill power switch off (0) 2. Use ohmmeter, measure continuity from output of C/E filter to A/C and Elevation voltage input of power supply JP2. Use the 120 / 208-240 VAC table as required to troubleshoot and repair fault.
  • Page 191 TRACKMASTER FG 302 Elevation and Power Supply A/C Voltage Distribution Fault Isolation Instructions 1. Turn treadmill power switch off (0) 2. Use ohmmeter, measure continuity from output of C/E filter to A/C and Elevation voltage input of power supply JP4. Use the 120 / 208-240 VAC table as required to troubleshoot and repair fault.
  • Page 192 TRACKMASTER ESB Circuit Fault Isolation Instructions FVX, TMX No Control FVX, TMX Manual Control FG302 P/S FG 310 Controller Emergency Stop Emergency Stop ESB SW – N/C ESB SW – N/C 1. Use Ohm Meter to test continuity from 1. Use Ohm Meter to test continuity from...
  • Page 193 TRACKMASTER Speed Sensor Fault Isolation – FVX, TMX No Control 1. Verify sensor is connected at FG302, J2; connect if necessary. 2. Verify speed sensor distance is no greater than1/8” from magnet; adjust as necessary 3. Stop run belt, measure DC voltage at FG302, J2, pin 1 to pin 2. Move belt motor flywheel slowly by hand and verify voltage drop of 5 VDC as magnet passes sensor.
  • Page 194 TRACKMASTER Speed V-Guide 10.92’ (3.33m) RPM’S RPM’S Speed Belt Length Speed Belt Length Km/H 10.92 Km/H 3.33m 1.61 0.62 2.41 12.1 1.24 3.22 16.1 1.86 15.0 4.02 20.1 2.49 20.0 4.83 24.2 3.11 25.0 5.63 28.2 3.73 29.8 6.44 32.2 4.35...
  • Page 195 TRACKMASTER Perform FVX__C, TMX__C, Incorrect Belt Speed Fault Isolation 1. Determine if the speed unit required by stress system, mph or Km/h 2. Use belt rpm table to determine if the running belt speed is correct. 3. Verify correct settings at Leeson Speedmaster, use Leeson Speedmaster...
  • Page 196 TRACKMASTER Test Plug Procedure (FVX, TMX No Control Units Only) 1. Turn the power “OFF” at the treadmill. 2. Disconnect ECG Cable from the treadmill and plug in the test connector. 3. Hold the button down on the test connector and turn treadmill power “ON”.
  • Page 197 TRACKMASTER 14-22 FVX, TMX Series Service Manual August, 2006...
  • Page 198 TRACKMASTER Treadmill Report/Service Log Series TMX425 Treadmill Maintenance Inspection Report Complete and FAX to 316-283-3350 Customer Date Technician Phone Serial # Configuration TMX425 Emergency Stop Button TMX425C TMX425CP Tools Multi-meter Service Manual Standard Hand Tools Visual Inspection Running Belt Connectors...
  • Page 199 TRACKMASTER Checkout Procedure Perform appropriate checkout procedures before leaving treadmill. Increase and decrease speed from minimum to maximum using controlling unit to verify operation. Raise and lower elevation from 0% to 25% using controlling unit to verify operation. Depress emergency stop switch while unit is running at 3 m.p.h. to verify operation.
  • Page 200 TRACKMASTER Series FVX 325 Treadmill Maintenance Inspection Report Complete and FAX to 316-283-3350 Customer Date Technician Phone Serial # Configuration FVX325 Emergency Stop Button FVX325C FVX325CP Tools Multi-meter Service Manual Standard Hand Tools Visual Inspection Running Belt Connectors Handrail Hardware...
  • Page 201 TRACKMASTER Checkout Procedure Perform appropriate checkout procedures before leaving treadmill. Increase and decrease speed from minimum to maximum using controlling unit to verify operation. Raise and lower elevation from 0% to 25% using controlling unit to verify operation. Depress emergency stop switch while unit is running at 3 m.p.h. to verify operation.
  • Page 202 TRACKMASTER TMX Series Emergency Stop Button (ESB) Location Drawing 15-5 August, 2006 FVX, TMX Series Service Manual...
  • Page 203: Log Sheet

    TRACKMASTER FVX325 Series Treadmill Field Service Manual Log Sheet Please complete and return by fax to Full Vision Service Dept. at 316-283-3350 Company: Name: Title: Phone Number: Fax: Email: Revision Sent: Date Sent: Address for Updates: Signature of Recipient: Electronic Version...
  • Page 204 TRACKMASTER TMX425 Series Treadmill Field Service Manual Log Sheet Please complete and return by fax to Full Vision Service Dept. at 316-283-3350 Company: Name: Title: Phone Number: Fax: Email: Revision Sent: Date Sent: Address for Updates: Signature of Recipient: Electronic Version...
  • Page 205 TRACKMASTER 15-8 FVX, TMX Series Service Manual August, 2006...

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