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SCIFIT DC1000 Service Manual

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Table of Contents

I.
II.
III.
IV.
V.
VI.
VII.
Assembly Drawings and Part List

Table of Contents

Page
2-5
6
7-10
11-12
13-33
34-61
62-
1

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Summary of Contents for SCIFIT DC1000

  • Page 1: Table Of Contents

    Table of Contents Page General Information Set Up III. Theory of Operations 7-10 Mechanical Troubleshooting 11-12 Electrical Troubleshooting 13-33 Adjustments and Parts Replacement 34-61 VII. Assembly Drawings and Part List...

  • Page 2: General Information

    This manual provides information for the servicing of SCIFIT DC1000 treadmills. It uses systematic troubleshooting procedures to address problems that may arise with the DC1000. The actions taken to resolve problems must be performed in the order stated. Deviating from this sequence may cause damage to the equipment, lead to unnecessary repairs, or void the warranty.
  • Page 3 Wireless Heart Rate PCB/ Transmitter Freight and Shipping SCIFIT is NOT responsible for the repair or replacement of any unit or part damaged during transit or installation. Fire, flood, and acts of God are NOT covered under this warranty. The customer is responsible for pursuing all freight damage claims with the appropriate transit company.
  • Page 4 Include a copy of the picking ticket that came with the replacement part. Step 3: SCIFIT service will include a prepaid return label in the parts box for only those parts that need to be returned. Call UPS at (800) 742-5777 for pick-up.
  • Page 5 Preventative Maintenance Preventative maintenance, completed according to the schedule below, will keep your SCIFIT equipment functioning properly. We realize your time is valuable and have kept these maintenance items to a minimum. This preventative maintenance schedule assumes the equipment is utilized 6 to 8 hours per day.

  • Page 6: Set Up

    DC1000 Treadmill Power Requirements The DC 1000 Treadmill is a high performance machine with certain power requirements that must be maintained in the field for proper operation. Inadequate power to the DC 1000 may result in intermittent failure of the elevation system and improper speed valuation of the running belt.

  • Page 7: Theory Of Operations

    III. Theory of Operations DC1000 (120 VAC) The DC1000 is a dynamic DC treadmill designed for a wide range of applications that vary from the medical market to the sports performance market. This theory of operation encompasses all the electrical components, their functions, and how the components interact with each other.
  • Page 8 Contains the display LEDs and LED drivers. 12 VDC from the lower PCB is regulated to 5 VDC, which powers the LEDs. Contains five (5) and eight (8) VDC voltage regulators to power various circuits on the upper PCB. Contains the memory and processor components 4.
  • Page 9 System Functions 1. Turning on the treadmill The power cord must be plugged into a 120 VAC, 15 or higher amp dedicated circuit. Turning on the rocker switch provides power (120 VAC) to the lower PCB. Power to the lower PCB is verified by observing a lighted LED labeled “+12”...
  • Page 10 The upper PCB controls the elevation system. It provides the voltage to the EPOT by interfacing through the lower PCB and then measures the voltage drop across the EPOT. If there is a difference between the elevation entered by the user and the elevation measured across the EPOT, the display PCB sends a signal to a relay on the lower PCB to switch on 120VAC for the elevation circuit.

  • Page 11: Mechanical Troubleshooting

    IV. Mechanical Troubleshooting Mechanical Troubleshooting Table Problem Possible Reasons Solutions Front, rear, or guide roller Running belt over- Re-tension running belt. (Page 34) is making clicking, tensioned. grinding, or knocking noises. Bearings are bad. Replace roller. (Pages 44-47) Running belt slipping. Running belt is too Re-tension running belt.
  • Page 12 Deck / Belt Friction Test 1. With the treadmill either turned off or in idle mode, stand on the running belt (P1246) with your feet in positions 1 and 4. Position your toes so they are approximately 12 inches from the motor hood (P1252). 2.

  • Page 13: Electrical Troubleshooting

    Electrical Troubleshooting Electrical Troubleshooting Table Problem Possible Reasons Solutions Unit keeps blowing fuses on Incoming voltage from the Verify voltage from the wall lower PCB. wall to the treadmill is too to the unit. high. Relays sticking on lower Replace lower PCB. (Page PCB.
  • Page 14 Electrical Troubleshooting Table (cont.) Problem Possible Reasons Solutions When pressed, buttons do not Ribbon cable from Plug in ribbon cables. beep and the numbers do not membrane to upper PCB change on upper display. unplugged. Faulty membrane. Replace membrane. (Pages 57-58) Upper display resets after Loose Telco connection.
  • Page 15 Troubleshooting Flowcharts Although it is impossible to foresee every eventuality, the flowcharts on the following pages will cover the more common possibilities. If further assistance is required, please consult SCIFIT SYSTEMS, Inc. Warning: Disconnect power in between making any test connections.
  • Page 16 Action Status Query DC1000 Belt Does Not Move Belt move D10 PWM LED Lights on Start button when speed set illuminated on Display? working? to 3mph? lower pcb? Recalibrate Speed. See Club Refer to No Light on Replace switch membrane Setting Mode Speed Calibration Display flowchart.
  • Page 18 (Note 1) Error codes Contact SCIFIT on display? Excessive Replace lower PCB. heat at motor terminals? Static Motor Replace Brushes brushes electricity good? (Note present? (Note 2) Replace Display PCB. Properly Adjust Contact SCIFIT for proper Correct Situation Belt static treatment.
  • Page 19 Note Query Action Status DC1000 Refer to Test Mode instructions in Lights Elev. Arrows Does Not Section V. Advance to Elevation on upper change values on Change Test parameter. Resume Flowchart display? display? Troubleshooting. Elevation Refer to No Lights Replace on Display membrane.
  • Page 20 Lower PCB LED’s and Upper PCB Jacks DC1000 Lower PCB (Motor Controller) LED’s LED Function Function Description Power 12 to 18 VDC is present. Illuminated when power is on. Speed Pick-Up Flashes when the drive motor is running. Belt Enable Illuminated when Run command is present.
  • Page 21 Lower PCB (Motor Controller) Diagram Label Description None Elevation Down Relay None Elevation Up Relay D7 (Belt) Belt Enable LED D8 (Down) Elevation Down LED D9 (Up) Elevation Up LED 8-Pin Telco Connector Elevation Potentiometer Connector D5 (+12) Power LED 6-Pin Telco Connector Speed Sensor Connector Speed Pick Up LED...
  • Page 22 Block Diagrams...
  • Page 25 Test Mode The Test Mode provides technicians with additional information for use in troubleshooting the DC1000 treadmill. Turn the power switch on the treadmill to the OFF position. Press the ELEVATION UP arrow and the ELEVATION DOWN arrow, and simultaneously turn the treadmill power switch to the ON position.
  • Page 26 numbers when it is elevated. When satisfied that the elevation system is working, press STOP to advance to the next test. Speed Test WARNING: DO NOT TO STAND ON THE BELT!! IT WILL MOVE DURING THIS TEST!! “bELt” will be shown on the top display. This test removes the software from the speed control system.
  • Page 27 Club Mode (Thru Version 1.2 Software) The Club Mode enables club owners and managers to customize certain features of the DC1000 treadmill. Press the ELEVATION UP and ELEVATION DOWN arrows simultaneously for three (3) seconds to enter this mode. (Press the keys until “UnIt”...
  • Page 28 the elevation display showing hundreds of miles (or kilometers). If “FLIP” is displayed in the TIME window in normal operating mode and the deck has been flipped, the following steps must be performed to clear the distance. Press and hold the ELEVATION UP arrow for three (3) seconds to reset (once 12,000 miles has been accumulated).
  • Page 29 Club Mode (Version 10.1-10.5 Software) The Club Mode enables club owners and managers to customize certain features of the DC1000 treadmill. Press the ELEVATION UP and ELEVATION DOWN arrows simultaneously for three (3) seconds to enter this mode. (Press the keys until “UnIt”...
  • Page 30 range is from 0 to 90 minutes in increments of 5 minutes. “0” is unlimited time and is the default setting. The top display shows the time selected. Select the duration by using the ELEVATION UP or ELEVATION DOWN keys. After selecting the desired duration, press the SELECT key to advance to the next setting.
  • Page 31 Make sure there is nothing on the treadmill belt. It will be moving at high speed on this next step. In SPEED CALIBRATION mode, the target speed appears in the speed window, while the actual speed appears in the time window.
  • Page 32 elevation potentiometer (it should be more than 225 when the treadmill is completely elevated). The treadmill will elevate to the high limit switch. The top display will then change to “0.0” which is the low grade set in the Factory Settings Mode.
  • Page 33 (.3 mph), average speed (4.5mph), and high speed (10.0 mph). Once “SCAL PAS” appears, press START to return to the main screen. 9. Test the operations of the treadmill. If there is a problem, please call SCIFIT Service @ 1-800-745-1373.

  • Page 34: Adjustments And Parts Replacement

    VI. Adjustments and Parts Replacement Running Belt Tracking and Tensioning 1. Checking Belt Tracking: a. Observe the location of the belt (P1246) on the deck (P1425 or A2352) relative to the side rails. b. Verify that the belt is centered between the side rails along the entire deck surface.
  • Page 35 Deck and Running Belt Replacement 1. Elevate the treadmill to 15% grade. 2. Unplug treadmill from the outlet. The treadmill will remain elevated. 3. Place a solid object under the rear cross member (P1513) of the treadmill to elevate the rear of the treadmill and give access to the underside. If nothing is available, flip the treadmill on its side (before you flip the treadmill, complete step 4).
  • Page 36 5. Remove the two (2) rear end caps by removing two (2) 5/16” bolts, one (1) per side, using a ½” wrench and socket. Using a 9/16” wrench, remove the 3/8” bolt on each side securing the foot pad (P1250) and spacer (A1249) to each side.
  • Page 37 these outside bolts. Do not do anything to the bolts that runs through the cross braces and into the deck. 13. Once the deck is free, remove the left front roller bolt using a 9/16” wrench. Then remove the right front roller bolt. Rotate the right side of the front roller (A1244) under the belt (P1246).
  • Page 38 the front roller the reverse of the way you removed it. Position the roller with motor belt in place and install the two (2) front roller bolts. The right side has a roller spacer (A1401) that goes between the front roller and frame.
  • Page 39 Cushioned Deck and Running Belt Replacement 1. Elevate the treadmill to 15% grade. 2. Unplug treadmill from the outlet. The treadmill will remain elevated. 3. Place a solid object under the rear cross member (P1513) of the treadmill to elevate the rear of the treadmill and give access to the underside. If nothing is available, flip the treadmill on its side (before you flip the treadmill, complete step 4).
  • Page 40 4. Using a Philips screwdriver, remove the motor hood (P1252). 5. Remove the two (2) rear end caps by removing two (2) 5/16” bolts, one (1) per side, using a ½” wrench and socket. Using a 9/16” wrench, remove the 3/8” bolt on each side securing the foot pad (P1250) and spacer (A1249) to each side.
  • Page 41 10. Slide guide roller assemblies out from under the extrusion and deck belt. 11. Using a 9/16” socket, remove the two (2) bolts holding front roller cover to the motor plate. This will allow you to remove the front roller cover. 12.
  • Page 42 26. Line up the holes in the end cap bracket with the holes in the extrusions and welded tabs of the rear cross member. 27. Insert the bolts for the foot pads and foot spacers on each side. This bolt will run from inside the extrusion on down through hole.
  • Page 43 Belt Replacement Walk-In Procedure 1. Once the deck has been flipped or replaced and a new belt has been installed, the combination must be “walked in”. The “walk in” in designed to distribute the phenolic wax on the deck evenly into the belt fibers and across the deck.
  • Page 44 Guide Roller Replacement 1. Elevate the treadmill to 15% grade. 2. Unplug treadmill from wall outlet. Treadmill will remain elevated. 3. Locate the guide roller assemblies. There is one (1) guide roller assembly (P1242) on the bottom side of each extrusion. 4.
  • Page 45 the roller threads. Rotate the right side of the front roller (A1244) under the deck and running belt. This will loosen the motor’s timing belt on the left side of the front roller and make it easy to slide off. Rotate the front roller approximately 90º...
  • Page 46 8. Remove the rear feet. Using a 9/16” wrench, hold the head of the bolt that runs through the center of the foot spacer (A1249) and into the foot pad (P1250). Rotate the foot pad until it unthreads completely from the bolt. Repeat this procedure for the other foot removal.
  • Page 47 24. Mount the guide rollers back into their normal positions. 25. Tension the running belt according to the “Running Belt Tracking and Tensioning” procedure (Page 34). Drive Motor Replacement 1. Elevate treadmill to a 15% grade and disconnect power at the outlet. 2.
  • Page 48 motor pulley, one (1) of the tension bolts will need to be tightened. If the belt is riding against the inside lip of the motor pulley, one (1) of the tension bolts will need to be loosened. Each time an adjustment is made, the flywheel needs to be spun to allow the belt to seat.
  • Page 49 6. Press down on the right side of the front roller until it is free of the front roller spacer (A1401). 7. Remove roller spacer. Newer models have a nylon thrust bearing (P2046) between the spacer and the extrusion. Then pull the bolt out of the extrusion.
  • Page 50 and move motor slightly forward or backwards and retighten nuts. Repeat this procedure until the tension is correct. 22. Verify all nuts and bolts are tightened down. 23. Restore power and test operation of the treadmill. 24. Restore and fasten motor hood in place. Elevation Motor Replacement 1.
  • Page 51 8. Remove the three (3), elevation motor mounting bolts. Earlier elevation motors were mounted using ¼-20 x .5 button head bolts. These require a 3/32” Allen wrench to remove bolts. Later models used ¼-20 x .5 with a ¼” lock washer. These require a 7/16” wrench to remove. 9.
  • Page 52 that shaft and pinion horizontally until it does. Then re-tighten the outermost bolts. 24. Reconnect the elevation motor and starter capacitor wires to the terminal block. • If you have a 4-wire elevation motor, the motor lead labeled “1” and one (1) of the starter capacitor leads connect under the top, left screw in the terminal block.
  • Page 53 6. Install the new potentiometer (P1269) onto the old bracket (P1485). To do this step, loosen the set screw on the pinion (P1479), using a 1/16” Allen wrench and slide the pinion off the end of the potentiometer shaft. Using a ½”...
  • Page 54 3. Disconnect wires running to each limit switch (P1260). 4. On the backside of the bracket that the limit switches mount to, remove the two (2) nuts holding the limit switches in place. Remove switches. 5. Re-attach wires in the same order on the new limit switches. 6.
  • Page 55 5. Using a ½” socket and extension, remove the four (4) bolts with washers and the four (4) nuts with washers from the upright bases. 6. Remove the upright assembly by lifting it up over the elevation racks and set it off to the side. 7.
  • Page 56 Upper PCB Replacement 1. Turn off the power to the unit then remove the safety magnet (S1744) from the upper display. 2. Using a Philips screwdriver, remove the four (4) screws mounting the upper display. They are located on the bottom side of the console. 3.
  • Page 57 This plugs into the vertically mounted header on the right, backside of the upper PCB. • Broadcast Vision is another optional feature of the treadmill. If your unit is set up for this option, there is a black, 8-pin Telco cable coming into the console housing.
  • Page 58 7. Remove upper PCB. 8. Using a 1/16” Allen wrench, remove the two (2), 4-40 X ½” screws holding the magnetic switch (P1522) in place. 9. Pull magnetic bracket (P1609) loose and reinsert on the new membrane. 10. Place the magnetic switch flat side down and start the two (2), 4-40 X ½” screws through the slots in the switch.
  • Page 59 Wireless Heart Rate PCB Replacement 1. Turn off the power to the unit then remove the safety magnet (S1744) from the upper display. 2. Using a Philips screwdriver, remove the four (4) screws mounting the upper display. They are located on the bottom side of the console. 3.
  • Page 60 Contact Heart Rate PCB Replacement 1. Turn off the power to the unit then remove the safety magnet (S1744) from the upper display. 2. Using a Philips screwdriver, remove the four (4) screws mounting the upper display. They are located on the bottom side of the console. 3.
  • Page 61 • The cable from the power switch or filter (if equipped) has two (2) wires on the newer treadmill while the older treadmills have three (3) wires. The blue wire connects to BC4 Common, the brown wire to BC5 A/C IN, and the green wire (on the older treadmills only) to BC9 FRAME.
  • Page 62 VII. Assembly Drawings and Parts Replacement...

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