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Motus M770E Service Manual

Elliptical crosstrainer
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See also: User Manual
M770E, M770EL
Elliptical CrossTrainer
SERVICE MANUAL
This service manual is for use by Motus trained service providers only.
If you are not a Motus Trained Servicer, you must not attempt to service any Motus product.
Ver 0.1, Oct., 2007
Motus Co., Ltd. All Rights reserved.
Unauthorized Reproduction and Distribution Prohibited By Law

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  • Page 1 SERVICE MANUAL This service manual is for use by Motus trained service providers only. If you are not a Motus Trained Servicer, you must not attempt to service any Motus product. Ver 0.1, Oct., 2007 Motus Co., Ltd. All Rights reserved.

  • Page 2: Table Of Contents

    Motus Elliptical Cross Trainers M770E and M770EL Table of Contents SECTION I TROUBLESHOOTING GUIDE SECTION II HOW TO REPLACE & REPAIR GUIDE General SECTION III HOW TO REPLACE & REPAIR GUIDE, Electronic PCB SECTION IV ELECTRONIC PCB, CONNECTOR AND CABLE OVERVIEW...

  • Page 3: Section I Troubleshooting Guide

    Motus Elliptical Cross Trainers M770E and M770EL SECTION I TROUBLESHOOTING GUIDE 1.1 System Block Diagram 1.2 Troubleshooting Guide 1.3 Troubleshooting Guide for LCD...
  • Page 4 1.1 System Block Diagram Note: Dotted line is applied to M770EL/M770E Operation PCB Battery (Intensity Up/ Intensity Down/ Start/Enter) 3-Phase Switching Mode Gener- Rectifier with Power Supply & ator DC Filter Brake Control Contact HR MPU PCB (Main Processing Contact HR/...
  • Page 5 Verify that main cable CN1 is securely plugged into both MPU board and Cable connection or loose wire connection (On M770E) Drive board. Replace if necessary. Worn or damaged wire harness Inspect wire harness. Replace worn or damaged harness.
  • Page 6 CORRECTIVE ACTION Faulty Battery, Note: Battery is used only for Verify that Battery voltage is greater than 6 volts DC. Replace Battery if M770E, self-powered model. the voltage is lower than 6 volts DC. Dot-LED or Numeric Test with substitute MPU board. Replace if necessary.
  • Page 7 SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION Display Console Malfunction Overlay, Button Switch or Operation Replace Overlay, Button Switch or Operation Button board. Keys do not function Button board and unit does not Defective MPU board Test with substitute MPU board. Replace if necessary. respond.
  • Page 8 SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION Heart rate reading is Electromagnetic interference from television sets, cell phones, Keep the treadmill away from the probable cause until abnormally high or is refrigerator, or motor driven exercise equipment. the heart rate readings are accurate. displayed even when Chest Strap or Keep another chest strap away more than 1 meter until...
  • Page 9 1.3 Troubleshooting Guide for LCD Symptom/Condition PROBABLE CAUSE CORRECTIVE ACTION Air/cable setting Follow the set up procedures in LCD manual. correct - Check if the TV signal source is correctly supplied to A/D PCB from external source. Snow and noise are scattering on LCD screen. Any picture is - Make sure the cable is properly secure.
  • Page 10 Overlay Bezel replace Power Adapter. Assembly. If LED is on, tighten midpoint (LCD Power Supply side) & endpoint (A/D Board side) connection. or make sure the voltage of end point is DC 12 volt. The cable related to LCD Lamp Inverter is loose in Check if the connection is secure.

  • Page 11: Section Ii How To Replace & Repair Guide

    Motus Elliptical Cross Trainers M770E and M770EL SECTION II HOW TO REPLACE & REPAIR GUIDE General 2.1 How to Replace the REAR COVER 2.2 How to Adjust the Drive Belt (or Pulley Belt) Tension 2.3 How to Replace the Drive Belt (or Pulley Belt) 2.4 How to Replace the Generator...

  • Page 12: How To Replace The Rear Cover

    2.1 How to Replace the REAR COVER The procedures to replace the REAR COVER are commonly applied when the replacements below are done. How to Adjust the Drive Belt Tension How to Replace the Drive Belt How to Replace the Unit Bearing-UCF206 How to Replace the Drive PCB How to Replace the Battery How to Replace the Generator...
  • Page 13 1) The following tools are required. Philips Screw Driver, Wrench Sets, Snap Ring Pliers 2) Remove two BUTTON CROSS BOLT (134) securing left REAR COVER-L (133) to right REAR COVER-R (136). 3) Remove two BUTTON CROSS BOLT (73) and two ALLEN BOLT (135) securing left REAR COVER-L (133) to the Frame, and then remove left REAR COVER-L (133).

  • Page 14: How To Adjust The Drive Belt (Or Pulley Belt) Tension

    2.2 How to Adjust the Drive Belt (or Pulley Belt) Tension 1) Loosen two HEX LOCK NUTs (11) a little using 17mm spanner. 2) To increase the tension, turn HEX NUT (21) clockwise with a 19mm spanner while holding H/S HEX BOLT (12) with another 19mm spanner.

  • Page 15: How To Replace The Generator

    procedures as 4) thru 8). 10) Remove the PULLEY (19) combined with the Shaft by taking it out toward the front of the Machine. 11) Remove the PULLEY BELT (22). 12) Install the new PULLETY BELT (22) in reverse order. 13) If needed, adjust the Pulley Belt Tension.

  • Page 16: How To Replace The Unit Bearing – Ucf

    2.5 How to Replace the UNIT BEARING – UCF206 The procedure to replace the Bearing is same on both right side and left side. 1) Loosen two HEX LOCK NUTs (11) a little using 17mm spanner. 2) To loosen the PULLEY BELT (22), turn (21)

  • Page 17: How To Replace The Crank Assembly

    2.6 How to Replace the CRANK ASSEMBLY 1) Loosen two HEX LOCK NUTs (11) a little using 17mm spanner. 2) To loosen the PULLEY BELT (22), turn HEX NUT (21) counterclockwise with a 19mm spanner while holding H/S HEX BOLT (12) with another 19mm spanner. 3) Derail the slackened PULLEY BELT (22) from the PULLEY (19).

  • Page 18: How To Disassemble The Pedal Base, Low Joint Cap Or Handle

    2.7 How to Disassemble the PEDAL BASE, LOW JOINT CAP or HANDLE PIVOT JOINT CAP 2.7.1 How to Disassemble the PEDAL BASE 1) Remove the plastic PEDAL BASE (54) by loosening four PILLOW CROSS BOLTs (57). 2) Reassemble the parts in reverse order. 2.7.2 How to Disassemble the LOW JOINT CAP 1) Remove LOW JOINT CAP-T (144) by loosening four BUTTON CROSS BOLTs (146) using Phillips driver.

  • Page 19: How To Replace The Needle Bearings Inside The Pedal Coupler

    out of the engaged HANDLE PIVOT JOINT CAP-T (141) and HANDLE PIVOT JOINT CAP-B (142). 2) Remove the HANDLE PIVOT JOINT CAP-T (141) and HANDLE PIVOT JOINT CAP-B (142) from HANDLE CRANK FRAME (94) by opening these two parts while pushing the edge of the engaged HANDLE PIVOT JOINT CAP-T (141) and HANDLE PIVOT JOINT CAP-B (142).

  • Page 20: How To Replace The Oilless Bush Inside The Coupler Frame

    2.9 How to Replace the OILLESS BUSH inside the COUPLER FRAME 1) Disassemble the plastic PEDAL BASE. See “2.7.1 How to Disassemble PEDAL BASE” 2) Loosen the upper PEDAL SHAFT (52) and the upper HEX LOCK NUT (13) a little by using 17 mm spanner and 19 mm spanner each.

  • Page 21: How To Replace The Pedal Shaft

    2.10 How to Replace the PEDAL SHAFT Disassemble plastic PEDAL BASE. See “2.7.1 How to Disassemble PEDAL BASE” 2) Loosen the upper PEDAL SHAFT (52) and the upper HEX LOCK NUT (13) a little by using 17 mm spanner and 19 mm spanner each.

  • Page 22: How To Replace The Heart Rate Sensors

    7) Remove the HANDLE CRANK FRAME (94) from the AXIS toward the longitudinal direction of the AXIS (960) and keep the PLANE WAHSER (95) in position as shown. 8) Install new HANDLE CRANK FRAME (94) in reverse order. 2.12 How to Replace the Heart Rate SENSORS - Pending -...

  • Page 23: Section Iii How To Replace & Repair Guide

    3.4 How to Replace the MPU Board in Model M770E 3.5 How to Replace the OPERATION BUTTON Board 3.6 How to Replace the LAMP INVERTER Board in Model M770E 3.7 How to Replace the Program BUTTON Board, OSD BUTTON Board &...
  • Page 24 3.1 How to Replace the LCD Screen in Model M770EL Fig 3a CONSOLE & POST...
  • Page 25 Fig 3b CONSOLE...
  • Page 26 Do the steps below while referring to Fig 3a CONSOLE & POST, Fig 3b CONSOLE and Section 4 ELECTRONIC PCB, CONNECTOR AND CABLE OVERVIEW. 1) Turn off the unit power at the switch and then unplug the line cord at wall outlet. 2) Remove the DISPLAY REAR COVER (74) from the DISPLAY PANEL BOTTM (72) by unscrewing four screws (75).
  • Page 27 3.2 How to Replace the A/D Board in Model M770EL Do the steps below while referring to Fig 3a CONSOLE & POST, Fig 3b CONSOLE and Section 4 ELECTRONIC PCB, CONNECTOR AND CABLE OVERVIEW. 1) Turn off the unit power at the switch and then unplug the line cord at wall outlet. 2) Remove the DISPLAY REAR COVER (74) from the DISPLAY PANEL BOTTM (73) by unscrewing four screws (75).
  • Page 28 3.3 How to Replace the MPU Board in Model M770EL Do the steps below while referring to Fig 3a CONSOLE & POST, Fig 3b CONSOLE and Section 4 ELECTRONIC PCB, CONNECTOR AND CABLE OVERVIEW. 1) Turn off the unit power at the switch and then unplug the line cord at wall outlet. 2) Remove the DISPLAY REAR COVER (74) from the DISPLAY PANEL BOTTM (72) by unscrewing four screws (75).
  • Page 29 3.4 How to Replace the MPU Board in Model M770E Do the steps below while referring to Fig 3a CONSOLE & POST, Fig 3b CONSOLE and Section 4 ELECTRONIC PCB, CONNECTOR AND CABLE OVERVIEW. 1) Remove the DISPLAY REAR COVER (74) from the DISPLAY PANEL BOTTM (72) by unscrewing four screws (75).
  • Page 30 3.5 How to Replace the OPERATION BUTTON Board Do the steps below while referring to Fig 3a CONSOLE & POST, Fig 3b CONSOLE and Section 4 ELECTRONIC PCB, CONNECTOR AND CABLE OVERVIEW. 1) If the machine is M770EL with LCD monitor, turn off the unit power at the switch and then unplug the line cord at wall outlet.
  • Page 31 3.6 How to Replace the LAMP INVERTER Board in Model M770EL Do the steps below while referring to Fig 3a CONSOLE & POST, Fig 3b CONSOLE and Section 4 ELECTRONIC PCB, CONNECTOR AND CABLE OVERVIEW. 1) Turn off the unit power at the switch and then unplug the line cord at wall outlet. 2) Remove the DISPLAY REAR COVER (74) from the DISPLAY PANEL BOTTM (72) by unscrewing four screws (75).
  • Page 32 3.7 How to Replace the Program BUTTON Board, OSD BUTTON Board & AUDIO INTERFACE & DOWNLOAD Board in Model M770EL Do the steps below while referring to Fig 3a CONSOLE & POST, Fig 3b CONSOLE and Section 4 ELECTRONIC PCB, CONNECTOR AND CABLE OVERVIEW. 1) Turn off the unit power at the switch and then unplug the line cord at wall outlet.
  • Page 33 7) Install new AUDIO INTERFACE & DOWNLOAD Board (24) in reverse order.
  • Page 34 Make sure three cables are firmly connected to the DRIVE PCB (31). 3.9 How to Replace the BATTERY for M770E 1) Disconnect two cables from the BATTERY(33). 2) Remove the BATTERY (33) by loosening two BUTTON CROSS BOLTs (35). 3) Install new BATTERY (33) in reverse order.
  • Page 35 3.10 How to Replace the SMPS-5V (or MPU POWER SUPPLY) in M770EL Applicable to old version before Nov., 2007 1) Turn off the unit power at switch and then unplug the power cord at the wall outlet. 2) Remove the Badge (143) from the Handle Pivot Joint Cap (141, 142). 3) Remove the Handle Pivot Joint Cap (141, 142) by separating engaged Handle Pivot Joint Cap (141, 142) into two pieces.
  • Page 36 10) Disconnect all of cables from the SMPS (116). 11) Remove four Screws (117) securing the SMPS (116) to the SMPS-BRK (113). 12) Install new SMPS (116) in reverse order.
  • Page 37 3.11 How to Replace the LCD POWER ADAPTER (or LCD Power Supply) Applicable to old version before Nov., 2007 1) Turn off the unit power at switch and then unplug the power cord at the wall outlet. 2) Remove the Badge (143) from the Handle Pivot Joint Cap (141, 142). 3) Remove the Handle Pivot Joint Cap (141, 142) by separating engaged Handle Pivot Joint Cap (141, 142) into two pieces.
  • Page 38 10) Remove twelve Button Screws (75) securing the Front Inner Cover (118,119) and then remove the Front Inner Cover (118,119) from the unit. 11) Disconnect all of cables from the LCD Power Supply (15) and SMPS (116). 12) Remove four Button Cross Bolts (115) securing the SMPS-BRK (113) and then remove the SMPS-BRK (113) from the unit.

  • Page 39: Section Iv Electronic Pcb, Connector And Cable Overview

    Motus Elliptical Cross Trainers M770E and M770EL SECTION IV ELECTRONIC PCB, CONNECTOR AND CABLE OVERVIEW 4.1 Cable Connection Block Diagram 4.2 Electronic PCB, Connector and Pin Description 4.3 Cables & Connectors 4.4 Cable Diagram...
  • Page 40 4.1 Cable Connection Block Diagram 1) MPU PCB on M770EL MPU_FRONT (Display), MPU_BACK (MAIN)
  • Page 41 2) MPU PCB on M770E...
  • Page 42 3) A/D BOARD on M770EL...
  • Page 43 4) POWER BOARD 4-1) M770EL (DRIVE Board, SMPS-5V, LCD POWER ADAPTER) 4-2) M770E (DRIVE Board)
  • Page 44 Encoder Pulse Input Ground No Connection CN 2 : Not used Reserved Port TXD_PC Not used (RS-232) RXD_PC Not used Not used CN 3 : Serial Port (RS-232) TXD_PC Transmit data ( M770E RXD_PC Receive data( PC M770E ) Ground...
  • Page 45 Connector Location Pin Name Functional Description CN 4, CN 13 : Contact Signal 1 Sensor Plate signal 1 Heart Rate Sensor Signal 2 Sensor Plate signal 2 CN 5 : Step Sensor Not used STEP Not used Ground CN 6 : Not used VCC, Not used HR_TCH Not used...
  • Page 46 Connector Location Pin Name Functional Description CN 11 : Overlay button Data In 4 (or Membrane) Data In 3 Data In 2 Data In 1 Data Output 6 Data Output 5 Data Output 4 Data Output 3 Data Output 2 Data Output 1 CN 12 : Ground...
  • Page 47 Connector Location Pin Name Functional Description J1 : Display Interface Header 1 Chip Select 0 Chip Select 1 Chip Select 3 Chip Select 4 Chip Select 5 Chip Select 6 Chip Select 8 Ground Ground Ground J2 : Display Interface Address/Data 0 Header 2 Address/Data 1...
  • Page 48 1-2) MPU_FRONT ( or MPU_DISPLAY) Connector Location Pin Name Functional Description J1 : MPU Interface Header 1 Chip Select 0 Chip Select 1 Chip Select 3 Chip Select 4 Chip Select 5 Chip Select 6 Chip Select 8 Ground Ground Ground J2 : MPU Interface Address/Data 0...
  • Page 49 2) MPU PCB, M770E Connector Location Pin Name Functional Description CN 1 : Drive VCC 7.5V Main Cable Ground Drive VCC 7.5V No Connection PWM Output Encoder Pulse Input Ground Drive VCC 7.5V...
  • Page 50 Battery VCC 6V Battery Power Ground CN 4 : +5V, Not used Serial Port (RS-232), TXD_PC Transmit data ( M770E PC), Not used Not used RXD_PC Receive data( PC M770E ), Not used Ground, Not used CN 5, CN 15 : Contact...
  • Page 51 Connector Location Pin Name Functional Description CN 9 : T232/PDO Program Data Output Program Download Serial Clock R232/PDI Program Data Input RESET Receive data Ground CN 10 : Signal Signal from Heart Rate Board Heart Rate Signal Heart Rate +5V Heart Rate Ground CN 11 : Overlay Data In 4...
  • Page 52 Connector Location Pin Name Functional Description CN 13 : Not used Step Sensor STEP Not used Not used CN 14 : B+VCC Not used Test Power Not used Not used...
  • Page 53 3) Operation Button Board Connector Location Pin Name Functional Description CN 1 : Ground Operation Button Ground (Start/Stop, Intensity START/STOP Start/Stop Key Up, Intensity Down) Level UP Key DOWN Level Down Key ENTER ENTER Key SCAN Signal Scan 4) Program Button Board Connector Location Pin Name...
  • Page 54 5) A/D Board Connector Location Pin Name Functional Description CN 1 : Audio Out Audio Left Audio Left Ground Audio Right Audio Right Ground CN 2 : SVIDEO S-VIDEO Input CN 3 : DC In DC 12V/3.5A Input CN 5 : Video In Video Input (Yellow) CN 8 : Audio In Audio Input (Red)
  • Page 55 Connector Location Pin Name Functional Description CN 10 : DC 12V/3.5A Vcc LAMP Inverter DC 12V/3.5A Vcc Control DC 12V/3.5A Vcc Ground Ground Ground DIM CTRL Back Light Intensity Adjust (DC 0 ~ 5V) On/Off Back Light On/Off Control CN 11 : LED1 LDE Lamp OSD Key In...
  • Page 56 Connector Location Pin Name Functional Description CN 13 : Power for LCD panel LVDS Control Power for LCD panel CN 13 : Power for LCD panel LVDS Control No Connection No Connection No Connection Ground E 3+ LVDS EVEN E 3- LVDS EVEN E CLK + LVDS EVEN...
  • Page 57 6) LAMP Inverter Board 6-1) Lamp Inverter Board for two-lamp LCD screen Connector Location Pin Name Functional Description CN 1 : DC 12V/3.5A Vcc Input Connector Ground On/Off Back Light On/Off Control CTRL Adjustment for Back Light Bright (DC 0 ~ Ground CN 2 : Lamp H1...
  • Page 58 6-2) Lamp Inverter Board for one-lamp LCD screen Connector Location Pin Name Functional Description CN 1 : Ground Input Connector CTRL Adjustment for Back Light Bright (DC 0 ~ On/Off Back Light On/Off Control DC 12V/3.5A Vcc Ground CN 2 : Lamp H1 High Voltage connection to high side of Output Connector 1...
  • Page 59 7) OSD Button Board Connector Location Pin Name Functional Description CN 3 : OSD Button No Connection KEY1 Key 1 Output (Volume_up, Channel_down, Channel_up) KEY2 Key 2 Output (Volume_down, Power) Vcc 5V Ground No Connection No Connection 8) RCA Jack Board Connector Location Pin Name...
  • Page 60 RCA-6A YELLOW Video Input...
  • Page 61 9) Audio Interface & Download Board Connector Location Pin Name Functional Description CN 4 : Audio Interface Audio_L Stereo Left Audio_R Stereo Right Ground CN 2 : PD-Out Program Data Output Program Download Serial Clock PD-In Program Data Input RESET Receive data Ground RJ1 :...
  • Page 62 10) Drive Board Connector Location Pin Name Functional Description CN 1 : U-phase input Voltage Source to Drive Board V-phase input Voltage Source to Drive Board W-phase input Voltage Source to Drive Board CN 2 : Brake Control PWM Output for brake Brake Control PWM Output for brake CN 3 :...
  • Page 63 4.3 Cables & Connectors Start Connec- Connector Length Cable No. End Board Housing Remark Board tor No. [mm] CB1+CB2+CB3 Driver Board 4640 SMH250-08 CB4+CB5+CB6 Battery 4540 CH1143-02 Touch-L 1300 SMH250-02 Touch-R 1300 YH025-02 Main CB13+CB15 CN15 Touch-L (Move) 1850 SMH250-02 (Dot) CB16+CB18 CN16...
  • Page 64 Start Connect Connector Length Cable No. End Board Housing Remark Board or No. [mm] CB24+CB24 Adaptor 2200 AD Board 2300 Yellow CB25+CB28 Terminal 2300 AD Board CB25+CB28 Plate 2300 White CB25+CB28 CB26-2+CB29 2210 NTSC Terminal AD Board CB26-1+CB30 2210 PAL/ Plate SECAM Adaptor...
  • Page 65 4.4 Cable Diagram Cable No. Cable Name Cable Spec Main Cable (Top) Main Cable (Middle) Main Cable(Bottom) Battery Cable(Top) Battery Cable(Middle) Battery Cable(Bottom) Adaoter Cable Touch HR Left Cable Touch HR Right Cable CB10 DownLoad Cable...
  • Page 66 Cable No. Cable Name Cable Spec CB11 POLAR Cable CB12 Tact Switch (Operation) Cable CB13 Moving Handle Touch HR Left Cable (Top) CB15 Moving Handle Touch HR Left Cable CB16 Moving Handle Touch HR Right Cable(Top) CB18 Moving Handle Touch HR Right Cable CB19 Program Key Cable...
  • Page 67 Cable No. Cable Name Cable Spec CB24 SMPS 12V Cable (TOP) CB25 RCA Cable (Bottom) CB28 RCA Cable (TOP) CB29 Coaxial Cable (NTSC-TOP) CB26-2 Coaxial Cable (NTSC-Bottom) CB30 Coaxial Cable (PAL/SECAM-TOP) CB26-1 Coaxial Cable (PAL/SECAM-Bottom) CB31 LVDS Cable CB32 LAMP Inverter Cable...
  • Page 68 Ver 0.1, Oct., 2007 Motus Co., Ltd. All Rights reserved. Unauthorized Reproduction and Distribution Prohibited By Law...

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