Dyaco CT900 Service Manual
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Dyaco CT900 Service Manual

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CT900
Service Manual
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Service Manual

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Summary of Contents for Dyaco CT900

  • Page 1 CT900 Service Manual Service Manual...

  • Page 2: Table Of Contents

    --------------------------------------------Table of Contents------------------------------------------- CT900 Outlines Electronic Parts Electrical Configurations Product Operation Unit Block Diagrams Basic Connections and Wiring Product Safety Instructions Error Messages / Troubleshooting Treadmill Folding/Unfolding and Transport 10. General Maintenance 11. Installation of the Incline Motor Serial Number Location 2.

  • Page 3: Ct900 Outlines

    Outlines CT900 Service Manual...
  • Page 4 Console Hand Pulse Service Manual...
  • Page 5 AC Motor Incline Inverter Motor Board Lower Control Board Service Manual...

  • Page 6: Electronic Parts

    2. Electronic Parts Service Manual...
  • Page 7 Upper Controllers Cooling FAN Safety key DISPLAY Service Manual...
  • Page 8 Lower Controller and Driver INCLINE MOTOR AC MOTOR INVERTER Service Manual...

  • Page 9: Electrical Configurations

    3.Electrical Configurations Service Manual...
  • Page 10 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 AC power supply for console、incline driver and motor driver, link the console to output appropriate voltages for DC control Board that control the Treadmill functions.
  • Page 11 MOTOR Control speed increases and decreases. NCLINE MOTOR This is a 220 volt AC motor. Have four wires, red, black, white and green. Has one 3 pins cable of position sensor. If there is AC voltage on the Red wire (UP) the incline motor will increase the incline. If there is AC voltage on the Black wire (DOWN) the incline motor will decrease the incline.

  • Page 12: Product Operation

    Product Operation CT900 Service Manual...
  • Page 13 Display Windows Service Manual...
  • Page 14 Operation POWER Power the treadmill on by plugging it into an appropriate wall outlet, then turn on the power switch located at the front of the treadmill below the motor hood. Ensure that the safety key is installed, as the treadmill will not power on without it. When the power switch is turned on the treadmill console will take around 10 seconds to power on.
  • Page 15 You must use both left and right stainless steel sensors to pick up your pulse. Pulse values are displayed any time the computer is receiving a Grip Pulse signal. You may use the Grip Pulse feature while in Heart Rate Control. The CT900 will also pick up wireless heart rate transmitters that are Polar compatible, including coded transmissions.
  • Page 16 PROGRAMMABLE FEATURES The Spirit Fitness CT900 offers a variety of exercise program options to choose from: Manual, Four Preset Programs (Hill, Fat Burn, Cardio, Interval), 5K Run, Heart Rate Control, High Intensity Interval Training (HIIT), and Nine Fitness Testing Protocols: Gerkin, WFI, Army (pft), Navy (prt), Air Force (prt), Marines (pft), Law Enforcement (peb), U.S.

  • Page 17: Unit Block Diagrams

    Unit Block Diagrams CT900 Service Manual...
  • Page 18 Treadmill Configuration Service Manual...

  • Page 19: Basic Connections And Wiring

    Basic Connections and Wiring CT900 Service Manual...
  • Page 20 Display Board PCB Component Locations PCB Board Top Service Manual...
  • Page 21 PCB Board Bottom Service Manual...
  • Page 22 The console back cover transfer PCB board Front of the board Service Manual...
  • Page 23 The console back cover transfer PCB board Behind the board. Service Manual...
  • Page 24 The console back cover transfer PCB board pin define Service Manual...
  • Page 25 DRIVER BOARD PCB Component Locations VFD015TM12A Service Manual...

  • Page 26: Product Safety Instructions

    7. Product Safety Instructions Service Manual...
  • Page 27 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 220-volt, 10-amp grounded outlet with only the treadmill plugged into the circuit.

  • Page 28: Error Messages / Troubleshooting

    Error Messages / CT900 Troubleshooting Service Manual...
  • Page 29  Error code items： Error code Description Solution E1 OVER CURRENT E2 OVER VOLTAGE E3 IGBT OVER TEMP E4 MOTOR OVERLOAD E5 THERMAL OVERLOAD E6 EXTERNAL FAULT E7 EEPROM WR ERR E8 DRIVE HW ERR E9 HW INTERUPT ERR E10 ACCEL OVR CURR E11 DECEL OVR CURR E12 OVER CURRENT Please follow to AC MOTOR DRIVER...
  • Page 30 E29 INCORRECT DATA E30 COMM CMD ERR E31 COMM The communication transmission timeout Check each connector/wire for good TIMEOUT error between the console and the inverter. Please follow to AC MOTOR DRIVER Please follow to AC MOTOR DRIVER inverter E32 MOTOR TEMP inverter VFD-TM Error and Warning codes ' VFD-TM Error and Warning codes ' descriptions descriptions corresponding table...
  • Page 31  Prepare： Picture Tool name Multi-meter Service Manual...
  • Page 32 Error Message：E33  Definition：The console board is not detecting the VR voltage value, or the voltage value has exceeded the range.” E33” appears on the display.  Configuration： Service Manual...
  • Page 33 Case of INCLINE E33 Incline VR value exceeds the range. INCLINE E33 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 INCLINE E33 appears. Action Flow Chart Service Manual...
  • Page 34  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 console cable connections. Display board 2.Test whether the VR voltage varies at the incline wire terminal. 1.Inspect the wire connections. Console cable 2.Inspect whether wires are broken or crimped.
  • Page 35  Error Message：INCLINE E33 Definition：During incline action, the display board CPU cannot read the VR value, so INCLINE ERR appears. Configuration： Service Manual...
  • Page 36 Cause of INCLINE ERR  Press the incline UP/DOWN key. The incline doesn’t operate. INCLINE 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.
  • Page 37 Troubleshooting Part Troubleshooting 1.Press incline UP key. The driver board UP RELAY action. Display board 2.Press incline DOWN key. The driver board DOWN RELAY action. 3.If not as above, inspect the cable and connections. 1.Inspect whether the console cable is connected well. console cable 2.Test by replacing the cable with a good one.
  • Page 38 Maintenance Mode Press and hold the Start, Stop and Enter key at the same time, The MW will display MAINTENANCE MODE then PRESS ENTER The Maintenance Mode menu is: 1.3.1 KEY TEST (Enter to run) 1.3.1.1 MW shows PRESS ALL KEYS 1.3.1.2 As User presses keys show key number on MW ie: S1 1.3.1.3...
  • Page 39 Circuit diagram Service Manual...
  • Page 40 AC MOTOR DRIVER INVERTER VFD-TM Error and Warning Codes’ Descriptions 1 Display error signal. AUTO Fault 2 Display abbreviated error code. 3 Display error description. Oc at accel The factory setting of the control board is AUTO. List of Error Codes: Press RESET button to clear Error Code Display on Error...
  • Page 41 Internal EEPROM Check if the power board and control board inside the cannot be motor are properly installed. Press RESET key and set Fault programmed. up the parameters as factory setting. EEPROM read err Motor drive internal Check if the input the input voltage is right then restart error Fault the motor drive.
  • Page 42 the motor drive stops output. External Base Deactivate the external input terminal (B.B) to run the Block: When the AC motor drive. Fault external input terminal (B.B) is Base block active, the AC motor drive output will be turned off. Fault occurred on 1.
  • Page 43 1. Verify if the Modbus’ data address fits the Incorrect data Fault address communication specification of the motor drive. cE02 2. Verify the quality of the communication cable and the PC err address communication. 3. Clear the fault and then press RESET button. Incorrect data value 1.
  • Page 44 List of Warning Codes: Press RESET button to clear Warning Code Display on Warning Warning Corrective Actions KPC-CC01 Code # Description 1. Verify if the function codes of the ModBus fit the Communication specifications of the motor drive. command defected 2.
  • Page 45 maximum of main communication frequency. 2. Verify the settings of Pr03-12 and Pr03-14. Up and Down not 1. Verify the wiring between the up-down motor and responding the motor drive. 2. Verify the settings of Pr02-20 ~Pr02-30. InC1 3. Verify if the up-down reaches the impassable point.
  • Page 46 TROUBLESHOOTING 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 1) Tether cord not in position.
  • Page 47 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. 3 Check the voltage of outlet.
  • Page 48 The incline position doesn’t match console 1 Console is not calibrated. 1 Calibrate the console. INCLINE ERR ,INCLINE window displays “INCLINE 1 Turn off the AC switch and turn on power again. 1 Position sensor value of incline motor is 2.
  • Page 49 SWITCH is broken. 5. Replace the cable. 5. The connector of INCLINE CABLE or INCLINE ADJUSTMENT SWITCH CABLE 6. Replace the cable. got damage. 6. The connector of INCLINE CABLE or INCLINE ADJUSTMENT SWITCH CABLE damaged. Hand pulse lost its function. 1.

  • Page 50: Treadmill Folding/Unfolding And Transport

    9. Treadmill Folding/Unfolding and Transport Service Manual...
  • Page 51 TRANSPORTATION INSTRUCTIONS Carefully lift the treadmill at the rear roller area, grasping the two side end caps, and roll the treadmill away. Service Manual...

  • Page 52: General Maintenance

    10. General Maintenance Service Manual...
  • Page 53 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 54 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 55 ATTENTION: DAMAGE TO THE RUNNING BELT RESULTING FROM IMPROPER TRACKING / TENSION ADJUSTMENTS IS NOT COVERED UNDER THE WARRANTY. Unplug treadmill before performing any maintenance. RECOMMENDED MAINTENANCE OF RUNNING BELT/DECK ● Please clean wax on roller during flipping deck or replacing belt/belt. Note: ●...
  • Page 56 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 57 Treadmill with noises 1. If the noise is coming from the rollers 2. If the noise is coming when the user is running on the treadmill with lowest level of incline it could be due to too much pressure with the incline cylinder. (only in case of the lowest incline level). 3.

  • Page 58: Installation Of The Incline Motor

    11. Installation of the Incline Motor Service Manual...
  • Page 59 Incline Range must be adjusted to 315 mm minimum prior to installation. Service Manual...

  • Page 60: Serial Number Location

    1. Serial Number Location Service Manual...

  • Page 61: Component Description

    2. Component Description AC Motor Incline Inverter Motor Board Lower Control Board Service Manual...
  • Page 62 Console Hand Pulse Service Manual...

  • Page 63: Preventative Maintenance

    3. Preventative Maintenance TO SET TREADBELT TRACKING: A 10 mm Allen wrench is provided to adjust the rear roller. Make tracking adjustments from the left side only. Set belt speed at approximately 3 to 5 kph. Remember, a small adjustment can make a dramatic difference! Turn the bolt clockwise to move the belt to the right.

  • Page 64: Part Replacement Guide

    4. Part Replacement Guide 4.1 Console Replacement 4.1.1 As shown in Figure 4.1.1, use the screwdriver to remove the LED chin cover 4 umbrella head screws. Figure 4.1.1 4.1.2 As shown in Figure 4.1.2, remove the electronic control cable connector, use the cross screwdriver to remove the electronic watch 4 umbrella head screws, you can remove the electronic form.

  • Page 65: Lower Control Board Replacement

    4.2 Lower Control Board Replacement 4.2.1 As shown in Figure 4.2.1, use the male screwdriver to loosen the eight umbrella head screws that secure the motor cover to remove the motor cover. Figure 4.2.1 4.2.2 Remove the lower controller by removing the controller-related line and using the cross screwdriver to remove the controller as shown in Figure 4.2.2.

  • Page 66: Motor Replacement

    4.3 Motor Replacement 4.3.1 Refer to Step 4.2.1 to remove the motor cover. 4.3.2 As shown in Figure 4.3.1, use the screwdriver to remove the motor ground wire (green yellow) and the motor connected to all wires on the control panel. Figure 4.3.1 4.3.3 As shown in Figure 4.3.2, remove the motor under the cover button.
  • Page 67 Figure 4.3.3 4.3.5 Remove the four M10 caps using the 17th T-Shirt to remove the motor from the motor. Figure 4.3.4 4.3.6 Refer to Step 4.3.5 to replace the motor. The motor needs to push forward, the belt hook back. 4.3.7 Refer to Step 4.3.4, use 13 T-type sleeve, adjust the required belt tension, the value can be adjusted to 120 ~ 130HZ.

  • Page 68: Input Module Replacement

    4.4 A.C. Input Module Replacement 4.4.1 Refer to Step 4.2.1 to remove the motor cover. 4.4.2 Remove the AC power switch ground wire using a screwdriver as shown in Figure 6.4.1. Figure 4.4.1 4.4.3 Remove the AC power switch module with the cross screwdriver and switchboard 8 as shown in Figure 6.4.2.

  • Page 69: Front And Rear Roller Replacement

    4.5 Front and Rear Roller Replacement 4.5.1 As shown in Figure 4.5.1, use the screwdriver to remove the left and right side adjustment screw. Figure 4.5.1 4.5.2 As shown in Figure 4.5.2, use the No. 8 L-type hex wrench to remove the two rear wheel screws. Figure 4.5.2 4.5.3 Refer to Step 4.2.1 to remove the motor cover.

  • Page 70: Running Deck, Running Belt And Cushion Replacement

    4.5.5 As shown in Figure 4.5.3, remove the front roller with the No. 8 L-shaped hex wrench and remove the front roller. Figure 4.5.3 4.5.6 Replacement of the new front and rear rollers, and then assembled in the order of removal. 4.5.7 When assembled, adjust the running belt tension, so that running in the set.
  • Page 71 4.6.3 As shown in Figure 4.6.2, use the No. 6 L-shaped hex wrench to loosen the 8 screws of the retaining strip. Figure 4.6.2 Service Manual...
  • Page 72 4.6.4 As shown in Figure 4.6.3, remove the left and right trims in the direction of the arrow. Figure 4.6.3 4.6.5 As shown in Figure 4.6.4, use the No. 4 L-type hexagonal wrench to remove the running plate fixing screw. Set off the running board; choose to replace the running board or running belt. To change the cushion, as shown in Figure 6.6.5, and then remove the 8 buffer to replace the new, assembled and then removed in order to replace.

  • Page 73: Incline Motor Replacement

    4.7 Incline Motor Replacement 4.7.1 Refer to Step 4.2.1 to remove the motor cover. 4.7.2 As shown in Figure 4.7.1, Figure 4.7.2, Figure 4.7.3, move the machine up on the paper tube, use the No. 17 opening wrench 2 to remove the lifting motor The screws that are fixed to the lifting frame , Use the No.
  • Page 74 4.7.4 As shown in Figure 4.7.5, the assembly of the lifting motor should be replaced in the order of removal and connected to the control and grounding lines. Figure 4.7.5 Service Manual...

  • Page 75: Idler Replacement

    4.8 Idler Replacement 4.8.1 Refer to Step 4.3.1 to Step 4.3.5 and remove the motor. 4.8.2 As shown in Figure 4.8.1, remove the press pulley by removing the C with the tool. Figure 4.8.1 4.8.3 Replace the new product, and then replace the assembly in the order of removal. Service Manual...

  • Page 76: Hand Pulse Control Board And Hand Pulse Set Replacement

    4.9 Hand Pulse Control Board and Hand Pulse Set Replacement 4.9.1 Refer to Step 4.1.1 and Step 4.1.2 to remove the electronic watch group. 4.9.2 As shown in Figure 4.9.1, remove the 18 screws from the upper bracket of the fixed bracket with a screwdriver to remove the bracket cover.
  • Page 77 4.9.4 As shown in Figure 4.9.3, use the hexagonal wrench to remove the four hexagonal screws, you can replace the hand-held group, assembled and then removed in order to replace. Figure 4.9.3 Service Manual...

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