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Full Vision TRACK MASTER TMX428 Service Manual

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MEDICAL TREADMILL
SERVICE MANUAL
TMX428
TMX428CP
TMX58
TMX428 TMX428CP & TMX58 Service Manual
317-160-406 Rev 6
July 2023

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  • Page 1 MEDICAL TREADMILL SERVICE MANUAL TMX428 TMX428CP TMX58 TMX428 TMX428CP & TMX58 Service Manual 317-160-406 Rev 6 July 2023...

  • Page 3: Contact Information

    ECG and VO systems. If you have a question or need assistance, please contact your system integrator first. Manufactured by: (Regulatory affairs only) 3017 Full Vision Drive Emergo Europe Newton, KS 67114 USA Westervoortsedijk 60 http://www.full-vision.com 6827 AT Arnhem http://www.trackmastertreadmills.com...

  • Page 4: Publication Information

    Safety Information TRACKMASTER Publication Information The information in this manual applies only to the TMX428 Treadmill, and TMX428CP Treadmill. It does not apply to earlier versions. Due to continuing product innovation and state of the art design, specifications in this manual are subject to change without notice. ®...

  • Page 5: Table Of Contents

    TRACKMASTER Contents Content Table of Contents Contact Information ......................i Publication Information ...................... ii Chapter 1 Introduction......................... 9 Intended User ........................9 Intended Use ........................9 Regulatory and Safety Information ................... 10 Reporting of serious incident .................... 10 Safety Conventions ......................11 Safety Hazards ........................
  • Page 6 Contents TRACKMASTER Communication Ports......................27 Floor Surface Footprint ..................... 27 Operating and Storage Condition Recommendations ............27 Chapter 3 Power Requirements ....................28 Chapter 4 Hi-Pot Test Instructions ................... 30 Chapter 5 Uncrating, Setup and Assembly ................31 Uncrating Instructions ...................... 31 Initial Setup Instruciton.....................
  • Page 7 TRACKMASTER Contents Stop Buttons: ........................46 WORKOUT GRAPHICS ....................47 MANUAL OPERATION: ....................47 BUILT-IN PROGRAM OPERATION ................49 Pre-Programmed Protocol Workout Data ................. 49 Pre-Programmed Fitness Workout Data ................52 User Defined Programming ....................55 Chapter 7 Preventive Maintenance ................... 56 Reprocessing Instructions ..........
  • Page 8 Contents TRACKMASTER Self-test MODE ........................ 66 CALIBRATION ....................... 66 DIP SWITCH SETTINGS ....................66 ELECTRICAL INPUTS ....................67 ELECTRICAL OUTPUTS ....................67 ELECTRICAL CONNECTIONS ..................68 PHYSICAL REQUIREMENTS AND RESTRICTIONS ..........68 UNIVERSAL POWER SUPPLY BOARD 3.1 Edition (FGLF0495-1) ......69 UNIVERSAL POWER SUPPLY BOARD 4 Edition (FGLF0495-3) ......
  • Page 9 TRACKMASTER Contents Hood Removal Procedure TMX428 Series ..............93 Drive Motor Replacement TMX428 Series ..............94 Drive Replacement TMX428 Series ................. 96 Front Roller Replacement TMX428 Series ..............100 Rear Roller Replacement TMX428 Series ..............106 Running Belt Replacement TMX428 Series ..............107 Running Deck Replacement TMX428 Series ..............
  • Page 10 Contents TRACKMASTER Firmware Download FGLF0495-3 (4 Edition Smart Power Supply) ......139 Firmware Download FGLF0496 (3 Edition LCD Control) .......... 139 Firmware Download FGLF0698-00 (4 Edition LCD Control) ........140 Dip Switch Configuration ....................140 Log File Retrieval FGLF0495-3 (4 Edition Smart Power Supply) ......

  • Page 11: Chapter 1 Introduction

    TRACKMASTER Ch. 1 Introduction Introduction ® Congratulations on the purchase of your new TRACKMASTER treadmill. These fine machines have been in production since 1977 and represent state-of-the-art design for heavy-duty ® institutional use. The TRACKMASTER treadmill has gained worldwide recognition as one of the ®...

  • Page 12: Intended Use

    Introduction Ch. 1 TRACKMASTER Contraindications: • Acute myocardial infarction within 2 to 3 days • Unstable angina not previously stabilized by medical therapy • Uncontrolled cardiac arrhythmias causing symptoms or hemodynamic compromise • Symptomatic severe aortic stenosis • Uncontrolled symptomatic heart failure •...

  • Page 13: Safety Conventions

    TRACKMASTER Ch. 1 Introduction Safety Conventions A Hazard is a source of potential injury to a person, property, or the system. This manual uses the terms NOTE, CAUTION, and WARNING to point out hazards and to designate a degree or level of seriousness. Familiarize yourself with the following definitions and their significance.
  • Page 14 Introduction Ch. 1 TRACKMASTER • Show each user how to use the device as described in this manual. • Risk of personal injury – Keep children under the age of 13 away from device. • Ask each user to perform a supervised "test usage" at minimum belt speed to review and practice usage techniques.

  • Page 15: Classification Of Medical Device

    TRACKMASTER Ch. 1 Introduction The potential for foot crush injury at frontal end of treadmill at lift mechanism (landing gear) when treadmill is descending. Keep feet and hands away from this area at all times. Potential foot crush injury at rearward side rail, rear of side rail and rear roller exists when treadmill approaches full elevation.

  • Page 16: Me Systems

    Introduction Ch. 1 TRACKMASTER interference in which case the user will be required to correct the interference at owner’s expense. Table 1: Guidance and Manufacturer’s Declaration – Emissions The TMX428 Series is intended for use in the electromagnetic environment specified below. The customer or user of the TMX428 Series should ensure that it is used in such an environment.

  • Page 17: Systems That Is Not Life-Supporting

    TRACKMASTER Ch. 1 Introduction Table 4: Guidance and Manufacturer’s Declaration – Immunity ME Equipment and ME Systems that is NOT Life-supporting The TMX428 Series is intended for use in the electromagnetic environment specified below. The customer or user of the TMX428 Series should ensure that it is used in such an environment. Electromagnetic Environment –...

  • Page 18: Responsibility Of The Manufacturer

    Introduction Ch. 1 TRACKMASTER Responsibility of the Manufacturer Full-Vision Inc. is responsible for the effects of safety, reliability, and performance of the treadmill only if the following conditions are met: • Assembly operations, extensions, readjustments, modifications, or repairs are carried out by authorized personnel.

  • Page 19: Symbols

    TRACKMASTER Ch. 1 Introduction • Verify the Patient and Operator understands how to stop the machine in the event of malfunction or emergency. • Patient should not wear loose fitting nylon material when exercising on this treadmill to avoid generating Electrostatic Discharge. •...
  • Page 20 Introduction Ch. 1 TRACKMASTER Symbol Description/Definition Serial Number Indicates the manufacturer's serial number. Manufacturer Name, Address and Manufacturing (Year-Month-Day) Indicates the name and address for the manufacturer of this device. CAUTION: CONSULT ACCOMPANYING DOCUMENTS - There may be specific warnings or precautions associated with the device that are not otherwise found on the label.
  • Page 21 TRACKMASTER Ch. 1 Introduction Symbol Description/Definition This equipment complies with the EU WEEE marking requirement for proper disposal of electrical and electronic waste in accordance with the European Directive 2012/19/EU. This directive calls for separation and recovery or reuse of used electrical or electronic equipment upon end of life EEE disposal.
  • Page 22 Introduction Ch. 1 TRACKMASTER Symbol Description/Definition Authorized Representative In Switzerland United Kingdom Responsible Person Importer: Indicates the entity importing the medical device into the locale. Label Locations This section identifies the labels and their locations on the product and packaging. TMX428 &...
  • Page 23 TRACKMASTER Ch. 1 Introduction Shipping TMX428 & TMX428CP DETAIL 1 317-160-406 Rev 6 TMX428 TMX428CP & TMX58 Service Manual July 2023...
  • Page 24 Introduction Ch. 1 TRACKMASTER Item Label Location Description TMX428 on Identifies Reading of the center handrail Owner’s Manual TMX428CP center console Stop on RH or Identifies E-Stop LH end cap on handrail Identifies the Caution Front of the Electrical shock hazard device on the hood Identifies the Caution...
  • Page 25 TRACKMASTER Ch. 1 Introduction Identifies Unique Device Front of the Identifier device on motor pan & • (01) GTIN Number on Shipping • label. (11) Manufacture Date • (21) Serial Number On shipping Identifies the following container. information for shipping: •...

  • Page 26: Serial Decal Information

    “B” applied parts Service Information This section provides information pertaining to the maintenance and servicing of the system. Familiarize yourself with this information before requesting service from Full Vision or its authorized representatives. Service Requirements Failure on the part of the responsible individual, hospital, or institution using this equipment to implement a satisfactory maintenance schedule may cause undue equipment failure and possible safety hazards.

  • Page 27: Training

    TRACKMASTER Ch. 1 Introduction Part Number Title TMX428 Owner’s Manual 317-160-284 Training This manual is intended as a supplement to, not a substitute for, thorough product training. If you have not received training on the use of the system, you should request training assistance from ®...

  • Page 28: Chapter 2 Specifications

    Ch. 2 TRACKMASTER Specifications Specifications Directional Orientation References to left, right, front, and rear are based on the assumption that you are standing on the treadmill (TMX-428), facing the control console (TMX-428CP). All parts listed below are considered Patient Applied Parts except where noted. Item Description Patient Grab Rails...

  • Page 29: Safety Systems

    TRACKMASTER Ch. 2 Specifications Safety Systems • Dual comparative speed sensors • Auto runaway shutdown • Auto communication loss shutdown • Manual twist lock Emergency Stop button • Patient Safety Tether Switch • Braking system for safe patient offloading TMX428CP Programmable Control •...
  • Page 30 Ch. 2 TRACKMASTER Specifications • Altitude: -50 to 5,280 feet, or about -15 to 1609 meters. TMX428 TMX428CP & TMX58 Service Manual 317-160-406 Rev 6 July 2023...

  • Page 31: Chapter 3 Power Requirements

    TRACKMASTER Ch. 3 Power Requirements Power Requirements The TMX428 and TMX428CP are designed to operate on a dedicated 110-120 VAC 20-amp power supply or optional 220/240 VAC 15-amp. Make sure that the treadmill is connected to an outlet that looks like the following illustration.
  • Page 32 Power Requirements Ch. 3 TRACKMASTER WARNING ® TRACKMASTER treadmills must be grounded to reduce the risk of electrical shock. If a malfunction occurs, earth grounding provides a path of least resistance for an electric current. Ungrounded connections must not be used. No other equipment may be used on the electrical circuit with the device.

  • Page 33: Hi-Pot Test Instructions

    TRACKMASTER Ch. 4 Hi-Pot Test Hi-Pot Test Instructions This test must only be performed by a qualified electrician. ® Your Trackmaster Treadmill has been Hi-Pot tested at the factory just prior to shipment and found to be within specifications. However, some facilities require Hi Pot test verification before the treadmill is put ®...

  • Page 34: Uncrating, Setup And Assembly

    Uncrating, Setup and Assembly Ch. 5 TRACKMASTER Uncrating, Setup and Assembly ® TRACKMASTER treadmills are shipped fully assembled and packaged in a knock down condition. They are designed to pass through a standard 36” door opening measuring at least 35½”. It will be necessary to remove the door from the jam in most cases if the door is not capable of opening fully parallel to door opening.

  • Page 35: Uncrating Instructions

    TRACKMASTER Ch. 5 Uncrating, Setup and Assembly Uncrating Instructions Tools recommended for uncrating • Safety Knife The treadmill is shipped in a cardboard box with a wood pallet. Cut the 3 nylon straps holding the cardboard cover to the wood pallet. Remove the cardboard box by lifting straight up from one end to clear the treadmill.

  • Page 36: Initial Setup Instruciton

    Uncrating, Setup and Assembly Ch. 5 TRACKMASTER When moving or relocating the treadmill use a furniture dolly or floor dolly. Position the dolly at the elevation pivot point to provide treadmill balance. Place Here NOTE: When moving to final destination you may experience a narrow passage or doorway. The treadmill can be tipped on the side with handrails in the folded position.
  • Page 37 TRACKMASTER Ch. 5 Uncrating, Setup and Assembly the crate. This prevents the internal wires running down the handrail mount to the motor pan from being cut. Swing the handrail assembly into the operating position and insert (2) 3/8-16 bolts and 3/8 lock washer each side and tighten securely.

  • Page 38: Tmx428Cp & Tmx58 Control Assembly

    Uncrating, Setup and Assembly Ch. 5 TRACKMASTER TMX428CP & TMX58 Control Assembly 3. Figure 5-2 shows the mounting components included with the shipment of the treadmill. The kit contains: • (4) ¼-20 bolts • (1) Black cover • (4) #10-32 Screws •...

  • Page 39: Location

    TRACKMASTER Ch. 5 Uncrating, Setup and Assembly Location Place the treadmill on a firm and level hard surface that is free of tile grout lines. The illustration below shows the minimum recommended clearances from the treadmill edges to any obstruction for dismount and safety purposes.

  • Page 40: Final Setup - Running Belt Tension Adjustment

    Uncrating, Setup and Assembly Ch. 5 TRACKMASTER Final Setup - Running Belt Tension Adjustment Your TRACKMASTER® running belt has been pre-tensioned at the factory and run for a minimum of 4 hours prior to shipment. It may, however, be necessary to adjust the belt tension when the treadmill is run in its final location.

  • Page 41: Final Setup - Test Plug Procedure

    TRACKMASTER Ch. 5 Assembly and Setup Final Setup - Test Plug Procedure ® Each TRACKMASTER TMX428 Series treadmill includes an RS- 232 test plug that enables you to test the operation of the treadmill without the ECG unit attached. The plug is located on the left side of ®...

  • Page 42: Communication Access Location

    Ch. 5 TRACKMASTER NOTE: Unsuccessful completion of the preceding testing procedure indicates a problem with the setup. Call Full Vision or one of their authorized agents to trouble shoot failure of test plug procedure. ® 9. Remove the test connector and place back on the Velcro holder.

  • Page 43: Chapter 6 Operating Instructions

    Before operating the TMX428 and TMX428CP, familiarize yourself with the following safety control features of the treadmills. Electrical Safety Tests The electrical safety of this installation is the responsibility of the customer, not Full Vision, Inc ® (TRACKMASTER ). In hospitals, contact your in-house biomedical technician, electrician, or technically qualified personnel.
  • Page 44 Operating Instructions Ch.6 TRACKMASTER Patient Safety Tether Switch The patient safety tether switch is a safety device for patient safety use in emergency situations to stop the treadmill. CAUTION: Activation of the patient safety tether while the treadmill is in motion, results in a controlled deceleration rate of 2.5 MPH per second to 0.0 MPH.
  • Page 45 TRACKMASTER Ch. 6 Operating Instructions seconds. Pressing the ESB or Patient Safety Tether activation will also serve the purpose of entering the “Power Up Sequence”. Note: Pressing down on the RED cap of the Patient Safety Tether for greater than 3/4 seconds will result in activation of the Patient Safety Tether.
  • Page 46 Operating Instructions Ch.6 TRACKMASTER elevation is maintained, and belt remains locked for 3 mins. The Host system may display “No Communication” momentarily, then reestablish communication. Press the “Start” button on the Host system to resume the Exercise test cycle at the speed and elevation as commanded by the Host system.

  • Page 47: Programmable Control Instructions Tmx428Cp

    TRACKMASTER Ch. 6 Operating Instructions Programmable Control Instructions TMX428CP ® The TRACKMASTER TMX428CP Programmable Control model is a dual purpose treadmill capable of operating for cardiac stress testing or a VO pulmonary evaluation. The display automatically changes from a blue, full information screen (typically found on fitness treadmills), to a black screen under controlled thru communication.
  • Page 48 Operating Instructions Ch.6 TRACKMASTER allows the user to simultaneously monitor: time, speed, incline, distance traveled, pace, current heart rate, calories burned and METS. The performance and feedback information provided on the blue display screen are defined as follows: Time: The elapsed time of your workout session, beginning with the initial movement of the belt and ending when the stop button is pressed.

  • Page 49: Control Panel Button Descriptions

    TRACKMASTER Ch. 6 Operating Instructions Control Panel Button Descriptions: Start button: The green start button is used to begin a workout session. When a new user steps onto the machine and the startup information is displayed on the screen, pressing the start button will immediately begin a 3 second countdown of the belt start at minimum belt speed.

  • Page 50: Workout Graphics

    Operating Instructions Ch.6 TRACKMASTER WORKOUT GRAPHICS 1. The entire workout is represented in the form of a colored bar graph which depicts increasing workout intensity as well as workout progression and current treadmill settings. These values can be displayed in either Metric or English measurements. 2.
  • Page 51 TRACKMASTER Ch. 6 Operating Instructions 6. Press the + or – button until the desired weight appears on the screen. 7. Press the ENTER button to continue. 8. Press the + or – button until the correct gender appears on the screen. 9.

  • Page 52: Built-In Program Operation

    Operating Instructions Ch.6 TRACKMASTER BUILT-IN PROGRAM OPERATION There are 10 pre-programmed workouts within the control. Select from (5) Pre-Programmed protocols and (5) interval training routines. To access these programs, complete the following steps: The following (5) Pre-Programmed Protocols are explained here. 15.
  • Page 53 TRACKMASTER Ch. 6 Operating Instructions Gerkin Protocol (Firefighter’s Test) Speed Time KPM / MPH Incline Warm-up 3 min Stage 1 1 min Stage 2 1 min Stage 3 1 min Stage 4 1 min Stage 5 1 min Stage 6 1 min Stage 7 1 min...
  • Page 54 Operating Instructions Ch.6 TRACKMASTER Balke- Male Speed Time KPM / MPH Incline Warm-up 2 min Stage 1 1 min Stage 2 1 min Stage 3 1 min Stage 4 1 min Stage 5 1 min Stage 6 1 min Stage 7 1 min Stage 8 1 min...

  • Page 55: Pre-Programmed Fitness Workout Data

    TRACKMASTER Ch. 6 Operating Instructions Pre-Programmed Fitness Workout Data 17. To access Pre-Programmed Fitness Workouts, use the + / - key to highlight the selection and press the Yellow Enter button. 18. The screen at the right shows the (5) Fitness workouts the user can choose from.
  • Page 56 Operating Instructions Ch.6 TRACKMASTER SPEED INTERVAL WORKOUT Speed Time KPH / MPH Incline Warm-up 1.5 min Stage 1 0.5 min Stage 2 1.5 min Stage 3 0.5 min Stage 4 1.5 min Stage 5 0.5 min Stage 6 1.5 min Stage 7 0.5 min Stage 8...
  • Page 57 TRACKMASTER Ch. 6 Operating Instructions PEAK INTERVAL WORKOUT Speed Time KPH / MPH Incline Warm-up 1.5 min Stage 1 0.5 min Stage 2 1.5 min Stage 3 0.5 min Stage 4 1.5 min Stage 5 0.5 min Stage 6 1.5 min Stage 7 0.5 min Stage 8...

  • Page 58: User Defined Programming

    Operating Instructions Ch.6 TRACKMASTER User Defined Programming 19. To access User Defined menu, use the + / - key to highlight the selection and press the Yellow enter button. NOTE: Any of the User Defined Programs can be altered in intensity merely by pressing + / - for belt speed or incline.

  • Page 59: Chapter 7 Preventive Maintenance

    TRACKMASTER Ch. 7 Parts List with Part Numbers Preventive Maintenance ® Regular cleaning and maintenance is essential to keep your TRACKMASTER treadmill operating at its best for many years. We recommend that you record all maintenance and service in a log (as shown in Appendix A).

  • Page 60: Semiannual Maintenance

    Preventive Maintenance Ch. 7 TRACKMASTER Semiannual Maintenance • Evaluate the condition of the deck and belt. • Adjust the belt to assure proper alignment. • Check running belt adjustment. • Check drive belt tension adjustment. • Clean and lubricate the treadmill elevation screw. •...

  • Page 61: Running Belt Tension Adjustment

    TRACKMASTER Ch. 7 Parts List with Part Numbers Check the belt after 2 minutes, with the treadmill running at approximately 7.0 mph (11.3 km/h). If the belt does not correct itself, continue with slight turns until the belt is in the center of the rear roller.

  • Page 62: Drive Belt Tension Adjustment

    Preventive Maintenance Ch. 7 TRACKMASTER Drive Belt Tension Adjustment This procedure requires the following tool: 1/8” Allen Wrench • 3/4” Socket or Box Wrench • • 3/4” Wrench • Tape measure NOTE: Because this adjustment is not covered under your warranty, it is important that you review these instructions thoroughly before proceeding.

  • Page 63: Exterior Care

    TRACKMASTER Ch. 7 Parts List with Part Numbers Exterior Care The powder-coat finish on your treadmill is an extremely durable finish and requires minimal care. Do not allow perspiration to build up on your treadmill. Wipe the unit daily. (Refer to Appendix B Reprocessing Instructions) •...

  • Page 64: Chapter 8 Product Requirements

    Product Requirements Ch. 8 TRACKMASTER Product Requirements FG0495 Smart Power Supply INTRODUCTION The TMX428, TMX428CP Smart Power Supply Board (SPSB) treadmill control provides a means of controlling belt speed and elevation for the treadmill through the use of either an RS-232 serial port or USB port.

  • Page 65: Software Requirements

    TRACKMASTER Ch. 8 Product Requirements The first is a magnetic reed switch located on the motor side of the belt pulley, and the second is a speed reference supplied by the motor controller. A speed calibration is required to provide a target speed output for a given set point.

  • Page 66: Communication Hardware (Rs-232 Option)

    Product Requirements Ch. 8 TRACKMASTER COMMUNICATION HARDWARE (RS-232 Option) - DB9 Connector 9-pin PC/AT Style Description Transmit Data Receive Data Signal Ground - RS232 (+/- 10V) - 4800 Baud - No Parity - 8 Data Bits - 1 Stop Bit - Full Duplex COMMUNICATION HARDWARE (USB Option) - PC USB Host Port...

  • Page 67: B - Input Command Acknowledgement

    TRACKMASTER Ch. 8 Product Requirements B - INPUT COMMAND ACKNOWLEDGEMENT ASCII CODES DECIMAL B0 176 - Ack. Start Belt - Communication Disconnect Stop Enabled B1 177 - Ack. Start Belt - Communication Disconnect Stop Disabled B2 178 - Ack. Stop Belt B3 179 - Ack.

  • Page 68: Communication Notes

    Product Requirements Ch. 8 TRACKMASTER D1 209 - Current Belt Speed follows as 4 bytes of ASCII data (Note 3) D2 210 - Current Elevation follows as 4 bytes of ASCII data (Note 4) D3 211 - Current Set Belt Speed follows as 4 bytes of ASCII data (Note 3) D4 212 - Current Set Elevation follows as 4 bytes of ASCII data (Note 4) D5 213...

  • Page 69: Self-Test Mode

    TRACKMASTER Ch. 8 Product Requirements Self-test MODE On power-up, the UPS 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. Note that it is not possible to enter self-test using the USB port.

  • Page 70: Electrical Inputs

    Product Requirements Ch. 8 TRACKMASTER ELECTRICAL INPUTS A) Instrument Power: 230VAC or 120VAC supplied through (2) 1/4 Amp breakers in parallel for control board power. 230VAC or 120VAC supplied through (2) 3 Amp breakers in parallel for elevation motor power. B) Elevation Sensor Input: A two wire interface for detecting the presence of a closed micro- switch on the elevation motor.

  • Page 71: Electrical Connections

    TRACKMASTER Ch. 8 Product Requirements ELECTRICAL CONNECTIONS A) Input Power Header: An Amp - 641968-1 4-pin MATE & LOCK header is provided for instrument power. B) Elevation Output Header: An Amp 641968-1 3-pin MATE & LOCK headers is provided for output power to the elevation motor.

  • Page 72: Universal Power Supply Board 3.1 Edition (Fglf0495-1)

    Product Requirements Ch. 8 TRACKMASTER UNIVERSAL POWER SUPPLY BOARD 3.1 Edition (FGLF0495-1) TMX428 TMX428CP & TMX58 Service Manual 317-160-406 Rev 6 July 2023...

  • Page 73: Universal Power Supply Board 4

    TRACKMASTER Ch. 8 Product Requirements UNIVERSAL POWER SUPPLY BOARD 4 Edition (FGLF0495-3) 317-160-406 Rev 6 TMX428 TMX428CP & TMX58 Service Manual July 2023...

  • Page 74: Chapter 9 Troubleshooting

    Troubleshooting Ch. 9 TRACKMASTER Troubleshooting Incoming Power 110-240VAC Flow Chart 1A Turn treadmill power switch Verify Nameplate Voltage for to the off position (0). proper treadmill operating power. 110-120VAC or 220/240VAC. Disconnect power cord from treadmill and wall outlet. Verify power panel circuit breaker is turned on and voltage is available at wall receptacle.

  • Page 75: Incoming Power Inline Filter Flow Chart 1B

    TRACKMASTER Ch. 9 Troubleshooting Incoming Power Inline Filter Flow Chart 1B NOTE: There are two styles of Drives of which both lighting displays are as follows: Is the Green Is the Red D7 LED1 lit on LED lit on Smart Drive? Power Supply? DRIVE –...

  • Page 76: Incoming Power Drive Pc2303-012-N Flow Chart 1C

    Troubleshooting Ch. 9 TRACKMASTER DRIVE – KOLLMORGEN Incoming Power Drive Flow Chart 1C NOTE: There are two styles of Drives of which both lighting displays are as follows: Verify incoming voltage DRIVE – Quantum/TRUTECH 110-120VAC. Is the Green LED Light(s) lit on Drive? Verify treadmill power switch is in the off (0) position.

  • Page 77: Smart Power Supply Incoming Power 110-240Vac Flow Chart 1D

    TRACKMASTER Ch. 9 Troubleshooting Smart Power Supply Incoming Power 110-240VAC Flow Chart 1D Verify incoming voltage 110-120VAC Is the Red D7 LED lit on Smart Power Supply? Verify treadmill power switch is in the off (0) position. Red D7 LED Light should Is Voltage be lit on Smart Power between Red...

  • Page 78: Emergency Stop Flow Chart 1E

    Troubleshooting Ch. 9 TRACKMASTER Is the Red D13 Emergency Stop Flow Chart 1E Verify treadmill power switch LED lit on Smart is in the off (0) position. Power Supply? Verify the continuity of the Emergency Stop Harness with an OHM meter to Is the Red D13 ensure the wire is not damaged.

  • Page 79: Communication Rs232 Flow Chart 1G

    Connected? Communication should be restored. Reference 1G RS232 Press connect on the Turn treadmill power switch is Full Vision Calibration Software, in the on (1) position. does “Sent” display counting values? 317-160-406 Rev 6 TMX428 TMX428CP & TMX58 Service Manual...

  • Page 80: Communication Rs232 Flow Chart 1H

    Communication RS232 Flow Chart 1H Download the appropriate drive based on your computer When connecting Stress OS at http://www.ftdichip.com/Drivers/VCP.htm System or Full Vision owner’s manual. When ® refer to the TRACKMASTER Calibration Software, do you receive a missing connecting to the USB port, ensure port configuration driver error code? matches with your software port identification.

  • Page 81: Smart Power Supply Error Code Identification Flow Chart 1I

    TRACKMASTER Ch. 9 Troubleshooting Smart Power Supply Error Code Identification Flow Chart 1I Is the Red LED D13 Verify the error code by counting the flashes. flashing on the The error flashes are very consistent and then a Smart Power long pause.

  • Page 82: Smart Power Supply Error Code 1 Flow Chart 1J "Bad Speed Calibration

    4 second pause on the Smart Power be Operational. Smart Power Supply? Supply? Using the Full Vision Verify treadmill power switch Calibration software, connect is in the off (O) position. communication thru RS232 or USB. Select “Speed Cal” Tab...

  • Page 83: Smart Power Supply Error Code 2 Flow Chart 1K "Elevation Error

    TRACKMASTER Ch. 9 Troubleshooting Smart Power Supply Error Code 2 Flow Chart 1K “Elevation Error” (3 Edition) Is the Red LED D13 Is the Red LED D13 flashing 2 times with flashing on the Treadmill should 4 second pause on the Smart Power be Operational.

  • Page 84: Smart Power Supply Error Code 3 Flow Chart 1L "Missing Speed Signal From Motor Controller

    Troubleshooting Ch. 9 TRACKMASTER Smart Power Supply Error Code 2 Flow Chart 1KK “Elevation Error” (4 Edition) Is the Red LED D13 Is the Red LED D13 flashing 2 times with flashing on the Treadmill should 4 second pause on the Smart Power be Operational.
  • Page 85 Quantum/TruTech (6-Pin Connection) (11-Pin Connection) Was the harness Connect Harness properly connected? Using Full Vision Calibration Software, Select a Start Belt and increase speed to 1.0 MPH. Turn the treadmill power switch ON (-). Did the Replace Drive running belt...

  • Page 86: Smart Power Supply Error Code 4 Flow Chart 1M "Over Speed Error Based On Motor Controller Signal

    Turn the treadmill power switch OFF (O) for 10 seconds then turn the power switch ON (-). Is the Red LED D13 Using the Full Vision Calibration on the Smart Power Software, Select a Start Belt and Supply on increase speed to 10.0 MPH.

  • Page 87: Smart Power Supply Error Code 5 Flow Chart 1N "Missing Signal From External Speed Sensor

    4 second pause on the Smart Power be Operational. Smart Power Supply? Supply? Using Full Vision Calibration Turn the treadmill power switch Software, Select a Start Belt and OFF (O) for 10 seconds then increase speed to 1.0 MPH. turn the power switch ON (-).

  • Page 88: Smart Power Supply Error Code 6 Flow Chart 1O "Over Speed Base On External Speed Sensor

    Troubleshooting Ch. 9 TRACKMASTER Smart Power Supply Error Code 6 Flow Chart 1O “Over Speed Base On External Speed Sensor” Is the Red LED D13 Is the Red LED D13 flashing 6 times with flashing on the Treadmill should 4 second pause on the Smart Power be Operational.

  • Page 89: Smart Power Supply Error Code 7 Flow Chart 1P "Excessive Speed Mismatch

    TRACKMASTER Ch. 9 Troubleshooting Smart Power Supply Error Code 7 Flow Chart 1P “Excessive Speed Mismatch” Is the Red LED D13 Is the Red LED D13 flashing 7 times with flashing on the Treadmill should 4 second pause on the Smart Power be Operational.
  • Page 90 Troubleshooting Ch. 9 TRACKMASTER Smart Power Supply Error Code 7 Flow Chart 1P “Excessive Speed Mismatch” Continued Turn the treadmill power Verify the 10-pin harness between Drive and switch ON (-). Smart Power Supply is properly connected and not damaged. Kollmorgen Quantum/TruTech Is the Red LED D13...

  • Page 91: Smart Power Supply Error Code 8 Flow Chart 1Q "Motor Control Reports Fault

    TRACKMASTER Ch. 9 Troubleshooting Smart Power Supply Error Code 8 Flow Chart 1Q “Motor Control Reports Fault” Is the Red LED D13 Is the Red LED D13 flashing 8 times with flashing on the Treadmill should 4 second pause on the Smart Power be Operational.

  • Page 92: Smart Power Supply Error Code 9 Flow Chart 1R "Start Belt Command Received During Initialization

    Service. increase speed to 10.0 MPH. Red LED D13 on? Smart Power Supply Error Code 10 Consult the factory for trouble shooting. Full Vision Inc. 3017 Full Vision Drive Newton, KS 67114 USA http://www.full-vision.com Phone: (316)-283-3344 Fax: (316)-283-9522 Email: sales2@full-vision.com...

  • Page 93: Control Console Communication Flow Chart 1S

    TRACKMASTER Ch. 9 Troubleshooting Control Console Communication Flow Chart 1S Treadmill should be Operational. Turn the treadmill power switch OFF (O). Do you see the Welcome screen? Verify the harness between LCD Screen J8 connector and Smart Power Supply J12 connector is properly connected.

  • Page 94: Drive Pc2303-012-N Status Led Code List

    Troubleshooting Ch. 9 TRACKMASTER Drive PC2303-012-N Status LED Code List When the drive is faulted, the Status LED blinks out the fault code. The Status LED blinks the proper number of times, pauses with the Status LED off, and then repeats the blink code.
  • Page 95 TRACKMASTER Ch. 9 Troubleshooting 317-160-406 Rev 6 TMX428 TMX428CP & TMX58 Service Manual July 2023...

  • Page 96: Chapter 10 Removal And Replacement Of Components

    Removal and Replacement of Components Ch. 10 TRACKMASTER Removal and Replacement of Components Comprehensive Tool List Screwdrivers - Flat Head 3/32”, 1/4” & 3/8” blades, T15 Torx blade. Nut Drivers - 1/4”, 5/16”. Hex Key Wrenches - 1/8”, 5/32”, 1/4”, 3/16”, 5/16”. T-Handle Hex Key Wrenches - 1/4”, 5/16”.

  • Page 97: Drive Motor Replacement Tmx428 Series

    TRACKMASTER Ch. 10 Removal and Replacement of Components (5) Screw HHWHTS #8-32 x 3/8” Long Kollmorgen Drive Motor Replacement TMX428 Series Tools Required 1/4” Nut Driver or Flat Blade Screwdriver 7/16” wrench and socket 9/16” wrench and socket 3/4” wrench and socket 3/16”...
  • Page 98 Removal and Replacement of Components Ch. 10 TRACKMASTER 7. Turn the treadmill main power switch to the OFF position. 8. Unplug the treadmill from the wall receptacle. 9. Allow treadmill to discharge for 3 minutes. 10. Remove the (5) hood securing screws. 11.

  • Page 99: Drive Replacement Tmx428 Series

    TRACKMASTER Ch. 10 Removal and Replacement of Components 34. Replace the hood and screws (5). (4) 1/4”-20 Nuts (4) 1/4” Flat Motor Assembly Washer (4)Screw HHWHTS #8-32 x 3/8” lg (4) 1/4” Clamp Plastic (4) MTR Isolation Spacer (4) MTR Isolation Stem (4) 1/4”...
  • Page 100 Removal and Replacement of Components Ch. 10 TRACKMASTER CAUTION: Use ESD precautions, including wearing a grounding wrist strap that is connected to an exposed metal connection point on the treadmill chassis. 7. Detach the External Speed Sensor w/ Harness from the Motor Velcro mount. Carefully set Sensor aside.
  • Page 101 TRACKMASTER Ch. 10 Removal and Replacement of Components 17. Route the Motor Power 4-pin cable and connect to J2 on the Drive Board. 18. Reinstall the (2) 1/4” plastic clamps on the Motor Power cable and reinstall Zip Tie to secure 4-pin cable to Motor Pan frame.
  • Page 102 Removal and Replacement of Components Ch. 10 TRACKMASTER Kollmorgen Drive Board Replacement TMX428 Series Tools Required 1/4” Nut Driver or Flat Blade Screwdriver 5/16” SAE Socket with 6” Extension or Nut Drive Approximate time to complete 45 min 1. Elevate the treadmill to approximately 15% grade. 2.

  • Page 103: Front Roller Replacement Tmx428 Series

    TRACKMASTER Ch. 10 Removal and Replacement of Components Quantum/Trutech Drive Board Replacement TMX428 Series Tools Required 1/4” Nut Driver or Flat Blade screwdriver 5/16” SAE Socket with 6” Extension or Nut Drive Grounding Wrist Strap Approximate time to complete: 45 min 1.
  • Page 104 Removal and Replacement of Components Ch. 10 TRACKMASTER J3 Motor Encoder 10-Pin J4 SPS Interface-10 Pin Drive Assembly Loosen Back Screw & Nut J2 Motor Power J1 Incoming AC Power Drive Ground to Main Motor Pan Wire Harness Loosen Back Screw & Nut Remove 2 Front Nuts Conversion Kit Quantum/Trutech TMX428 Series Tools Required...
  • Page 105 TRACKMASTER Ch. 10 Removal and Replacement of Components 9. With the 3/4” Wrench and socket, loosen the belt tension and slide the belt off the sprocket, allowing the motor to pivot, gaining access to the motor mount bolts. 10. With the 1/4” Nut Driver or flat blade screwdriver, remove the (4) 1/4” plastic clamps on the Motor Feedback &...
  • Page 106 Removal and Replacement of Components Ch. 10 TRACKMASTER 27. Route the Motor Feedback 11-pin cable through Motor Pan routing holes. 28. Connect the Motor Feedback 11-pin cable to J3 on the Drive, and to the Motor Encoder. “Drive Belt Tension Adjustment”. 29.
  • Page 107 TRACKMASTER Ch. 10 Removal and Replacement of Components 32. With the 5/16” socket install the two front Drive Mount Frame nuts from beneath the Motor Pan and tighten the 1/4” rear screw from above. 33. Connect the 10-pin communication cable on J4 from the Drive Board. (FIG. A) J2 Motor Power J4 SPS Interface (FIG.
  • Page 108 Removal and Replacement of Components Ch. 10 TRACKMASTER 11. Push the front roller from the right side of the treadmill to the left side and lift roller up; slip timing belt off the front roller. Lift the front roller up and out of the treadmill. Use caution to avoid pinching the timing belt.

  • Page 109: Rear Roller Replacement Tmx428 Series

    TRACKMASTER Ch. 10 Removal and Replacement of Components Rear Roller Replacement TMX428 Series Tools Required 1/4” Hex Socket or Flat Blade Screwdriver 3/16” Hex Wrench or Hex Socket Approximate time to complete 45 min 1. Turn the treadmill main power switch to the OFF position. 2.

  • Page 110: Running Belt Replacement Tmx428 Series

    Removal and Replacement of Components Ch. 10 TRACKMASTER Running Belt Replacement TMX428 Series Tools Required 1/4” Allen wrench or socket 3/16” Allen wrench or socket 1/2” 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 111 TRACKMASTER Ch. 10 Removal and Replacement of Components 20. Replace the rear roller; push the rear roller as far forward as possible. Do not replace or start the tensioning bolts yet.. Verify the guide for the belt deck and rollers is to the left during installation. 21.

  • Page 112: Running Deck Replacement Tmx428 Series

    Removal and Replacement of Components Ch. 10 TRACKMASTER Running Deck Replacement TMX428 Series Tools Required 1/4” Allen Wrench or Socket 3/16” Allen Wrench or Socket 1/2” 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 113: Deck Cushion Replacement Tmx428 Series

    TRACKMASTER Ch. 10 Removal and Replacement of Components Deck Cushion Replacement TMX428 Series Tools Required 1/4”Allen Wrench or Socket 3/16” Allen Wrench or Socket 1/2” 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 114: Motor Drive Belt Replacement Tmx428 Series

    Removal and Replacement of Components Ch. 10 TRACKMASTER Motor Drive Belt Replacement TMX428 Series Tools required 1/4” Hex Wrench or Hex Socket 3/4" Open-end Wrench & Hex Socket 1/4” Hex Nut Driver or Flat Blade Screwdriver Tape Measure Approximate time to complete 1 hr 20min 1.

  • Page 115: Elevation Actuator Replacement/Adjustment Tmx428 Series

    TRACKMASTER Ch. 10 Removal and Replacement of Components Elevation Actuator Replacement/Adjustment TMX428 Series Tools Required Tape measure 1/4” Hex Nut Driver 2 - 9/16” Wrenches or Sockets 3/8” Wide Flat Blade Screwdriver Trackmaster Grease “Part Number 317-160-165 Shipping blanket, carpet, or cardboard Approximate time to complete 1 hr 30 min 1.

  • Page 116: Replacing The Speed Sensor From 2 Wire To 3 Wire

    Removal and Replacement of Components Ch. 10 TRACKMASTER Upgrading the Speed Sensor – 2 Wire to 3 Wire Tools Required 1/4” Hex Nut Driver or Flat Blade Screwdriver Long Nose Pliers Grounding Wrist Strap Approximate time to complete: 20 min 1.
  • Page 117 TRACKMASTER Ch. 10 Removal and Replacement of Components 8. With the long nose pliers remove the DC Fan negative from J2. CAUTION: Use ESD precautions, including wearing a grounding wrist strap that is connected to an exposed metal connection point on the treadmill chassis. 9.

  • Page 118: Replacing The Speed Sensor 3 Wire To 3 Wire

    Removal and Replacement of Components Ch. 10 TRACKMASTER Replacing the Speed Sensor – 3 Wire to 3 Wire Tools Required 1/4” Hex Nut Driver or Flat Blade Screwdriver Grounding Wrist Strap Approximate time to complete: 20 min 1. Turn the treadmill main power switch to the OFF position. 2.

  • Page 119: Smart Power Supply Relay Board Replacement Tmx428 Series

    TRACKMASTER Ch. 10 Removal and Replacement of Components Smart Power Supply Board (SPSB) Replacement TMX428 Series Tools required Wire Cutters or Utility Knife Grounding Wrist Strap 1/4” Hex Nut Driver or 3/32” Flat Blade Screwdriver 5/16” Hex Nut Driver Approximate time to complete 1 hr 15 min 1.

  • Page 120: Circuit Breaker Replacement

    Removal and Replacement of Components Ch. 10 TRACKMASTER Circuit Breaker Replacement Tools Required 1/4” Hex nut driver or 3/32” Flat blade electronic screwdriver Approximate time to complete 20 min 1. Turn the treadmill main power switch to the off position. 2.

  • Page 121: Relocate Emergency Stop Button (Esb) & Stop Tether Switch (Psts)

    TRACKMASTER Ch. 10 Removal and Replacement of Components Replace or Relocate Emergency Stop Button (ESB) & Patient Safety Tether Switch (PSTS) Tools Required PSTS 1/8” Allen Wrench 1/4” Flat Blade Screwdriver 2 Pair Flat Nose Pliers Approximate time to complete 1 hr 1.

  • Page 122: Validate Relocate Esb And Sts Operation

    Removal and Replacement of Components Ch. 10 TRACKMASTER Validate Relocate ESB and PSTS Operation Tools Required Test Plug Approximate time to complete 20 min 1. Plug treadmill power cord back into wall outlet. 2. Turn on the ON/OFF switch on the front of the treadmill. 3.

  • Page 123: Replacing The Right Or Left Handrail

    TRACKMASTER Ch. 10 Removal and Replacement of Components Replacing the Right or Left Handrail Tools Required 1/8” Allen Wrench 5/32” Allen Wrench 5/16” Allen Wrench Flat Blade Screwdriver Grounding Wrist Strap Approximate time to complete: 30 min NOTE: When replacing all the handrails, remove the center handrail before proceeding with the left and right handrails.

  • Page 124: Removing And Reinstalling The Handrails For Moving

    Removal and Replacement of Components Ch. 10 TRACKMASTER ESB or PSTS Assembly (4) 1/4”-20 Screws Wire Harness (2) Plastic Caps (3) 3/8”-16 Screws (2) 3/8” Lock Washer Nylon Washer Removing and Reinstalling the Handrails for Moving Tools Required 1/4” Hex Socket or Flat Blade Screwdriver 5/16”...

  • Page 125: Replacing The Main Power Switch

    TRACKMASTER Ch. 10 Removal and Replacement of Components 11. Reverse step 1 through step 10 to reinstall the replacement handrail. (2) Plastic Caps (3) 3/8”-16 Screws (2) 3/8” Lock Washer Nylon Washer Replacing the Main Power Switch Tools Required 1/4” Hex Socket or Flat Blade screwdriver 3/32”...

  • Page 126: Replacing The Ce Filter

    Removal and Replacement of Components Ch. 10 TRACKMASTER Tools Required 7/16” Open End Wrench or Hex Socket Approximate time to complete: 10 min Turn the treadmill’s power switch to the OFF position. Unplug the treadmill from the wall receptacle. Allow treadmill to discharge for 1 minute. With the 7/16”...

  • Page 127: Replacing The Relay

    TRACKMASTER Ch. 10 Removal and Replacement of Components Reverse step 1 through step 7 to reinstall replacement CE Filter. #8-32 Nut CE Filter #8-32 Screw Replacing the Relay Tools Required Flat Blade Screwdriver Pliers or Adjustable Wrench Grounding Wrist Strap Approximate time to complete: 30 min Turn treadmill main power switch to the OFF position.

  • Page 128: Established Component Replacement Time

    TRACKMASTER Ch. 11 Established Component Replacement Times 11 11 Established Component Replacement Time Hood Removal Procedure TMX428 Series ....... 1 0 m i n Drive Motor Replacement TMX428 Series .
  • Page 129 TRACKMASTER Ch. 11 Removal and Replacement of Components NOTE: Unless otherwise noted, all times are assumed to be for a treadmill fully assembled! In the event that components serviced share like disassembly procedure, both times will not apply. Example (with replacement of wire harness, speed sensor could also be replaced for no additional time). All other services not listed, including combinations of above listed services will be appointed a reasonable time by the manufacturer only! If in doubt call the manufacture before performing services (316)283-3344.

  • Page 130: Chapter 12 Calibration Tmx428 Series

    Chalk or some other temporary marking device Computer or laptop Serial Communication Cable USB Communication Cable If not already using it, open the Full Vision 4 Edition Calibration Software. In the lower left of the window, select the appropriate COM and press Open. For example:...
  • Page 131 TRACKMASTER Ch. 12 Removal and Replacement of Components Click OK. The running belt will pause for approximately 8 seconds and slowly increase speed, establishing multiple calibration points. This procedure may take approximately 10 to 15 seconds per calibration point, with the overall time of the speed calibration procedure taking up to 5 minutes to complete.
  • Page 132 TRACKMASTER Ch. 12 Established Component Replacement Times To validate the belt speed calibration, do the following: 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. Start the treadmill and adjust the speed to 1.0 MPH / 1.6 KPH.

  • Page 133: Belt Speed Calibration Procedure (Controller Interface)

    TRACKMASTER Ch. 12 Removal and Replacement of Components Belt Speed Calibration Procedure (Controller Interface) Tools Required Stopwatch or watch with a second hand Chalk or some other temporary marking device P R E S S “ E N T E R ” T O I N P U T U S E R I N F O R M A T I O N P R E S S “...

  • Page 134: Verifying Belt Speed Calibration (In The Field)

    TRACKMASTER Ch. 12 Established Component Replacement Times 9. Select START twice to start countdown 3, 2, 1 the running belt will start at 0.1 MPH. 10. Measure belt with MPH / KPH gauge or using “Verifying Belt Speed Calibration (in the field)”. Verify within specification +/- 2%.

  • Page 135: Elevation Calibration Procedure (Calibration Program)

    TRACKMASTER Ch. 12 Removal and Replacement of Components Elevation Calibration Procedure (Calibration Program) Tools Required Calibration Program (Full Vision Treadmill PS New Cal) Tape Measure ¼” Nut Driver or Flat Headed Screw Drive T15 Torx Screwdriver Computer or laptop Serial Communication Cable USB Communication Cable “Elevation Calibration Procedure”...
  • Page 136 TRACKMASTER Ch. 12 Established Component Replacement Times NOTE: The treadmill can have either a VonWeise or MSI Actuator. The only difference is how the zero position is adjusted. Do one of the following: ▪ If the position is low, adjust the upper cam (control for 0% elevation limit) with needle nose pliers clockwise into the limit switch “see note”.
  • Page 137 TRACKMASTER Ch. 12 Removal and Replacement of Components VonWeise Actuator MSI Actuator If the cam was turned to adjust the lower switch (control for 25% elevation limit); the upper cam (control for 0% elevation limit) will need to be reset to zero to allow the treadmill to park in the correct position.

  • Page 138: Elevation Calibration Procedure (Controller Interface)

    TRACKMASTER Ch. 12 Established Component Replacement Times Elevation Calibration Procedure (Controller Interface) Tools Required Tape Measure ¼” Nut Driver or Flat Headed Screwdriver T15 Torx Screwdriver 1. Plug treadmill to power supply. 2. Turn ON Treadmill. 3. To set the 0% Elevation and Upper Elevation Limits. 4.
  • Page 139 TRACKMASTER Ch. 12 Removal and Replacement of Components 6. To gain access to the parameter screen hold down for approximately 4 seconds. QUICK SPEED 7. Using the ENTER or PROGRAM SELECT to highlight with any + or – key. 8. Adjustment to 9.

  • Page 140: Elevation Chart Tmx428, Tmx428Cp, And Tmx58

    TRACKMASTER Ch. 12 Established Component Replacement Times 16. Using the tape measure verify the angle Elevation Chart TMX428, (Refer to TMX428CP, and TMX58). 17. If incorrect, make adjustments to compensate on parameter P15 = .5% elevation and then use any + or – key to adjust value. 18.

  • Page 141: Tmx428Cp & Tmx58 Parameter Screen

    TRACKMASTER Ch. 12 Removal and Replacement of Components TMX428CP & TMX58 PARAMETER SCREEN To gain access to the parameter screen hold down on for approximately 4 QUICK SPEED seconds. Parameter screen description: TMX428 VERSION 0.4C • P02 Stop History ENTER: NEXT PROG: PREV +- EDIT START: EXIT •...

  • Page 142: Firmware Download Fglf0495-1 (3 Edition Smart Power Supply)

    TRACKMASTER Ch. 12 Established Component Replacement Times Firmware Download FGLF0495-1 (3 Edition Smart Power Supply) 1. Copy the FVProg.ROM to a Micro SD card (consult factory for the correct firmware version). 2. Locate the main power switch and set the switch in the off position. 3.

  • Page 143: Firmware Download Fglf0698-00

    TRACKMASTER Ch. 12 Removal and Replacement of Components Firmware Download FGLF0698-00 (4 Edition LCD Control) 1. Copy the Console.ROM to a Mini Micro SD card (consult factory for the correct firmware version). 2. Locate the main power switch and set the switch in the off position. 3.

  • Page 144: Log File Retrieval Fglf0495-3 (4 Edition Smart Power Supply)

    TRACKMASTER Ch. 12 Established Component Replacement Times Log File Retrieval FGLF0495-3 (4 Edition Smart Power Supply) 1. Turn Power Switch to the “OFF” position on the treadmill. 2. Remove the motor pan hood screws to gain access to the Smart Power supply circuit board.

  • Page 145: Parts List With Part Numbers

    TRACKMASTER Ch. 13 Parts List with Part Numbers Parts List with Part Numbers Motor Mount Assembly (Kollmorgen) NOTES: WHEN INSTALLING THE FLYWHEEL & DRIVE SPROCKET, TIGHTEN SET SCREWS ON KEY WAY FIRST, AND THEN TIGHTEN THE SECOND SET SCREW TO MOTOR SHAFT. WHEN TIGHTENING ITEMS 5 &...
  • Page 146 Parts List With Part Numbers Ch. 13 TRACKMASTER Motor Mount Assembly 317-759-001S (TruTech) NOTES: WHEN INSTALLING THE FLYWHEEL & DRIVE SPROCKET, TIGHTEN SET SCREWS ON KEY WAY FIRST, AND THEN TIGHTEN THE SECOND SET SCREW TO MOTOR SHAFT. WHEN TIGHTENING ITEMS 5 &...

  • Page 147: Rd Edition Circuit Board Assembly

    TRACKMASTER Ch. 13 Parts List with Part Numbers Edition Circuit Board Assembly NOTES: APPLY BLUE LOCKTITE THREADLOCKER TO ITEM 8 Item Description Part Number Qty Bracket Circuit Board 317-709-001 Board FG0495-0 Universal Power Supply 317-160-199 HN #8-32 Nylon 001-1763 Mount Inverter Isolation 317-160-040 HHWHTS #8-32 x .375 001-1744...

  • Page 148: Th Edition Circuit Board Assembly

    Parts List With Part Numbers Ch. 13 TRACKMASTER Edition Circuit Board Assembly Item Description Part Number BOARD FG0495-3 317-160-199S UNIVERSAL PWER SUPPLY For Reference – Manufacture’s Description for individual items Item Description Bracket Circuit Board Board FG0495-3 Universal Power Supply HN #8-32 Nylon Mount Inverter Isolation HHWHTS #8-32 x .375...

  • Page 149: Elevation Assembly

    TRACKMASTER Ch. 13 Parts List with Part Numbers Quantum Drive Assembly 317-761-001S Item Description Part Number DRIVE 317-761-001S ASSEMBLY QUANTUM For Reference – Manufacture’s Description for individual items Item Description Drive Bracket Quantum Drive – Quantum 800—0011470R01 HN- #8-32 X .50 GR 2 – Clear Zinc Plt Mount –...

  • Page 150: Pull Tether Assembly

    Parts List With Part Numbers Ch. 13 TRACKMASTER Item Description Part Number Qty Elevation Weldment TMX428 317-702-002 Spanner Wheel 317-160-054 Wheel Landing Gear 317-160-005 HHCS 3/8-16 x 3.25 LG GR5 001-1519 NLN 3/8-16 001-1430 Patient Safety Tether Assembly NOTE: There are two approved styles of the Patient Safety Tether Switches 1.
  • Page 151 TRACKMASTER Ch. 13 Parts List with Part Numbers Magnetic Tether Assembly Item Description Part Number Qty BOARD PCB TETHER 317-160-441 TETHER-CLIP MAGNET 317-160-447 (Can be ordered Separately) Cap 1.50 x 4.00 LPDE BLK ELEVATOR BOLT 317-160-448 GROUND CABLE PCB TETHER 317-160-449 NLN- 1/4-20 001-1427...

  • Page 152: Emergency Stop Assemblies

    Parts List With Part Numbers Ch. 13 TRACKMASTER Emergency Stop Assemblies Item Description Part Number Qty Emergency Stop IDEC (Not Sold Individually) 317-160-268 Cap 1.50 x 4.00 LPDE BLK Modified 317-160-230 (Not Sold Individually) Emergency Stop Assembly 317-722-001 (Sold as Assembled Kit) Emergency Stop RAFI (Alternative E-Stop) 317-160-212 Bolt HHCS 1/4-20 x 3/4”...

  • Page 153: Motor Pan Assembly

    TRACKMASTER Ch. 13 Parts List with Part Numbers Motor Pan Assembly (Kollmorgan) DC MOTOR MOUNT ASSEMBLY CIRCUIT BOARD MOUNT ASSEMBLY ALTERNATIVE RESITOR TAP 10-32 HOLE AND SAND POWDER COAT MATERIAL FOR PROPOR GROUND CONNECTION ALTERNATIVE SWITCH 317-160-406 Rev 6 TMX428 TMX428CP & TMX58 Service Manual July 2023...

  • Page 154: Motor Pan Assembly

    Parts List With Part Numbers Ch. 13 TRACKMASTER Motor Pan Assembly (Kollmorgan) continued Item Description Part Number Qty Motor Pan Weldment 317-700-001 HHCS ¼-20 x 1.25 LG GR 2 001-1159 FW ¼” Dia (Above) 001-1439 Fender Washer ¼” Dia 1” OD (Bellow) 001-1888 Motor Isolation Stem 317-160-216...

  • Page 155: Motor Pan Assembly Wiring

    TRACKMASTER Ch. 13 Parts List with Part Numbers Motor Pan Assembly Wiring (Kollmorgan) DC DRIVE MOTOR DC MOTOR ASSEMBLY CONNECTOR PE,W,V,U DC DRIVE MOTOR FEEDBACK CONNECTOR 115V CONFIGURATION 220V CONFIGURATION BLACK (110-120) BLANK BLANK BLACK (208-240) BROWN (HOT) BROWN (HOT) BLANK BLANK RESITOR OMITE...

  • Page 156: Motor Pan Assembly Wiring

    Ch. 13 TRACKMASTER Parts List With Part Numbers Motor Pan Assembly Wiring (Kollmorgan) continued HARNESS CONNECTOR BLACK BREAKER 3 AMP HARNESS CONNECTOR BREAKER 1/4 AMP DRIVE BROWN CIRCUIT BOARD ASSEMBLY CONNECTOR COLOR CONFIGURATION RED (INCLINE COMMON) DRIVE GROUND ON WHITE (AC COMMON NYLON STANDOFF FILTER CORCOM F4635 BLUE (INCLINE HOT)

  • Page 157: Motor Pan Assembly Wiring

    TRACKMASTER Ch. 13 Parts List with Part Numbers Motor Pan Assembly Wiring (Kollmorgan) continued Item Description Part Number Qty Screw HHWTS #8-32 x .375 LG 001-1744 Clamp Plastic 1/4” ID 317-160-227 Harness 110V DC Treadmill 317-160-261 Harness 220V DC Treadmill 317-160-262 Harness Resistor 417-160-026...
  • Page 158 Ch. 13 TRACKMASTER Parts List With Part Numbers Motor Pan Assembly (TruTech) Motor Assembly TruTech Drive Assembly Quantum Circuit Board Assembly TAP 10-32 HOLE AND SAND POWDER COAT MATERIAL FOR PROPOR GROUND CONNECTION TMX428 TMX428CP & TMX58 Service Manual 317-160-406 Rev 6 July 2023...
  • Page 159 TRACKMASTER Ch. 13 Parts List with Part Numbers Motor Pan Assembly (TruTech) continued Item Description Part Number Qty Motor Pan Weldment 317-700-001 HHCS 1/4-20 x 1.25 LG GR 2 001-1159 FW 1/4” Dia 001-1439 Motor Isolation Stem 317-160-216 Motor Isolation Spacer 317-160-217 NLN 1/4-20 001-1427...
  • Page 160 Ch. 13 TRACKMASTER Parts List With Part Numbers Motor Pan Assembly Wiring (TruTech) 3-Wire Speed Sensor MOTOR ASSEMBLY Quantum Motor Connector TRUTECH PE, W, V, U TruTech Motor Feedback Connector 115V CONFIGURATION 220V CONFIGURATION Black (110-120) Blank Blank Black (208-240) Brown (HOT) Brown (HOT) Blank...
  • Page 161 TRACKMASTER Ch. 13 Parts List with Part Numbers Harness Connector Black Breaker 3 Amp Harness Connector Brown Breaker 1/4 Amp Drive Circuit Board Assembly Connector Color Configuration RED (Incline Common) White (AC Common) Filter Corcom 10EHT1 Blue (Incline Hot) Brown (AC Hot) Power Switch Assembly Harness Jumper (Brown) Harness Jumper (Black)

  • Page 162: Frame Assembly

    Parts List With Part Numbers Ch. 13 TRACKMASTER Item Description Part Number Qty Screw HHWTS #8-32 x .375 LG 001-1744 Clamp Plastic 1/4” ID 317-160-227 Harness 110V DC Treadmill 317-160-261 Harness 220V DC Treadmill 317-160-262 Zip Tie 4: LG – (Not Shown) 317-160-075 3-Wire Speed Sensor Hall Effect 317-160-404...
  • Page 163 TRACKMASTER Ch. 13 Parts List with Part Numbers APPLY TRACKMASTER GREASE 2X Frame Assembly continued 317-160-406 Rev 6 TMX428 TMX428CP & TMX58 Service Manual July 2023...

  • Page 164: Deck Assembly

    Parts List With Part Numbers Ch. 13 TRACKMASTER ACTUATOR INSTALLATION NOTES: PRIOR TO INSTALLATION OF BOLT, TURN ACTUATOR END CLOCKWISE UNTIL IT STOPS. NEXT TURN COUNTER CLOCKWISE 1 ½ TURN OUT PLUS ANY ADDITIONAL REVOLUTION TO ALLOW BOLT ALIGNMENT. WHEN TIGHTENING ELEVATION BOLT AND NUT, THE WASHERS MUST MOVE FREELY.
  • Page 165 TRACKMASTER Ch. 13 Parts List with Part Numbers STRETCH ADJUSTMENT MARKS 4X SEE NOTE 2 INSTALL CAMBER SEE NOTE 3 SEE NOTE 1 NOTES: ADJUSTMENT SCREWS MUST BE MATCH TIGHTENED. PROPER TENSION IS ACHIEVED WHEN BELT CAN’T SLIP ON PULLEYS WHEN IN OPERATION ACHIEVED ADJUST DRIVE BELT TENSION PULLING ALL FREE PLAY OUT OF BELT.
  • Page 166 Parts List With Part Numbers Ch. 13 TRACKMASTER Item Description Part Number Qty Frame Assembly TMX428 317-Various Belt Running with V-Guide 317-160-002 Bolt HHCS 5/16-18 x .75” LG 001-1167 Lock Washer 5/16” Dia 001-1451 Flat Washer 5/16” Dia 001-1440 Deck Support Channel Weldment 317-379-001 Deck Isolator 1.75”...

  • Page 167: Final Assembly

    TRACKMASTER Ch. 13 Parts List with Part Numbers NOTE: The pull tether clip needs to be seated OR magnet needs to be in place for the treadmill to operate as designed. Final Assembly CONNECT CABLE TO PULL TETHER Pull Tether Connection: CONNECT CONTACT I&I ROTE THRU Connect Black and Gray Wires LEFT HANDRAIL...
  • Page 168 Parts List With Part Numbers Ch. 13 TRACKMASTER Final Assembly continued Item Description Part Number Qty Pull Tether Assembly 317-720-001 Emergency Stop Assembly RAFI 317-721-001 Emergency Stop Assembly IDEC 317-722-001 Riv-Nut ¼”-20 001-1686 Power Cord 110-120 VAC C-19 NEMA 5-15 317-160-219 Power Cord 220-240 VAC C-19 NEMA 6-15 317-160-242...

  • Page 169: Rd Edition Tmx428Cp Controller Assembly

    TRACKMASTER Ch. 13 Parts List with Part Numbers Edition TMX428CP Controller Assembly CONNECT CABLE TO PULL TETHER CONNECT CONTACT I&I ROUTE THRU LEFT HANDRAIL OUTSIDE CONTACT CONNECT TO ESB HANRESS CONNECT TO J8 ON LCD SCREEN CONNECT TO J10 ON LCD SCREEN 317-160-406 Rev 6 TMX428 TMX428CP &...
  • Page 170 Parts List With Part Numbers Ch. 13 TRACKMASTER Edition TMX428CP Controller Assembly Continued Item Description Part Number Qty Console Plastic LCD Configuration 317-160-270 Membrane TMX428 Overlay 317-160-232 E-Stop Kill Switch LS500 317-160-226 Harness Jumper Pull Tether 317-160-266 Board FG0960-0 Console 417-160-017 RHMS #6-32 3/8”...

  • Page 171: Th Edition Tmx428Cp Controller Assembly

    TRACKMASTER Ch. 13 Parts List with Part Numbers Edition TMX428CP Controller Assembly CONNECT TO J10 ON LCD SCREEN 317-160-406 Rev 6 TMX428 TMX428CP & TMX58 Service Manual July 2023...
  • Page 172 Parts List With Part Numbers Ch. 13 TRACKMASTER Edition TMX428CP Controller Assembly Continued Item Description Part Number Console Plastic LCD Configuration 317-160-270 Membrane TMX428 Overlay 317-160-232 Board FG0960-0 Console 417-160-017 RHMS #6-32 3/8” LG 001-1745 Back Plate Fitness Panel 317-731-001 Fastener 1/4-20 UNC Riv-Nut 001-1686 Rubber Control Dampener...

  • Page 173: Tmx58 Controller Assembly 3

    TRACKMASTER Ch. 13 Parts List with Part Numbers TMX58 Controller Assembly 3 Edition Configuration CONNECT CABLE TO PULL TETHER CONNECT CONTACT I&I ROUTE THRU LEFT HANDRAIL CONNECT TO OUTSIDE CONTACT ESB HANRESS CONNECT TO J10 ON LCD SCREEN CONNECT TO J8 ON LCD SCREEN 317-160-406 Rev 6 TMX428 TMX428CP &...
  • Page 174 Parts List With Part Numbers Ch. 13 TRACKMASTER TMX58 Controller Assembly 3 Edition Configuration Continued Item Description Part Number Qty Console Plastic LCD Configuration 317-160-270 Membrane TMX428 Overlay 317-160-232 E-Stop Kill Switch LS500 317-160-226 Harness Jumper Pull Tether 317-160-266 Board FG0960-0 Console 417-160-017 RHMS #6-32 3/8”...
  • Page 175 TRACKMASTER Ch. 13 Parts List with Part Numbers TMX58 Controller Assembly 4 Edition Configuration CONNECT TO ESB HANRESS CONNECT TO J8 ON LCD SCREEN 317-160-406 Rev 6 TMX428 TMX428CP & TMX58 Service Manual July 2023...
  • Page 176 Parts List With Part Numbers Ch. 13 TRACKMASTER TMX58 Controller Assembly 4 Edition Configuration Continued Item Description Part Number Qty Console Plastic LCD Configuration 317-160-270 Membrane TMX428 Overlay 317-160-232 Not Used Not Used Board FG0960-0 Console 417-160-017 RHMS #6-32 .375 LG 001-1284 Not Used Back Plate Fitness Panel...

  • Page 177: Appendix A Maintenance Log

    Appendix Maintenance Log Serial #_______________________________Date Purchased_______________ Purchased From ________________________Phone_______________________ DATE HOURS SERVICE COMPLETED COST 317-160-406 Rev 6 TMX428 TMX428CP & TMX58 Service Manual July 2023...
  • Page 178 TMX428 TMX428CP & TMX58 Service Manual 317-160-406 Rev 6 July 2023...

  • Page 179: Appendix B Reprocessing Instructions

    Appendix Reprocessing Instructions The following reprocessing instructions apply to all treadmills. The treadmill is neither sterile nor can it be sterilized. Manufacturer: Full Vision Inc Symbol: Device(s): Treadmills WARNINGS Before cleaning the device, turn the main power switch to OFF and disconnect the treadmill from its power outlet.
  • Page 180 Step 1 – Turn the main power switch to OFF and disconnect the treadmill Cleaning: Manual from its power outlet. Step 2 – Use 20 mL (0.68 oz) of an alkaline cleaner or similar mild, non- abrasive detergent (ex. Spray 409) on a soft, clean, lint-free 25 x 25 cm (9.8 x 9.8 in) size cloth / paper towel and manually clean item 1, 2, &...
  • Page 181 Sterilization Not applicable Storage Additional No additional requirements Information Manufacturer Full Vision Inc. Contact 3017 Full Vision Drive Newton, KS 67114 USA www.trackmastertreadmills.com Phone: (316) 283-3344 Fax: (316) 283-9522 Email: sales@full-vision.com Item Description Emergency Strop Button Patient Grab Handrails Patient Safety Tether Switch...
  • Page 182 The instructions provided have been validated by the manufacturer of the medical device as being capable of preparing a medical device for reuse. It remains the responsibility of the processor to ensure that the processing, as actually performed using equipment, materials and personnel in the processing facility, achieves the desired result.
  • Page 183 Full Vision Inc. 3017 Full Vision Drive Newton, KS. 67114 www.full-vision.com www.trackmastertreadmills.com Assembled in Newton, KS. U.S.A. © 2023 Full Vision Inc.

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