Motus M770E 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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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
APPENDIX EXPLODED VIEW

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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

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1.1 System Block Diagram
Note: Dotted line is applied to M770EL/M770E
Membrane Overlay Key
Contact HR/
Wireless HR
PCB
MPU PCB
(Main
Processing
Unit)
Operation PCB
(Intensity Up/
Intensity Down/
Start/Enter)
Contact HR
PCB
A/D
PCB
LCD Screen
LCD Lamp Inverter PCB
OSD Button PCB for Channel/Volume/Power-on
Video & Audio Input
(Coaxial, RCA)
Back-Light
Audio Interface
Headphone Jack
SMPS-5V
LCD Power
Adapter
AC
100V/220V
Power ON/OFF
Switch
Switching Mode
Power Supply &
Brake Control
3-Phase
Rectifier with
DC Filter
Gener-
ator
Battery

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1.2 Troubleshooting Guide
SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION
Line voltage is not present at equipment. Check the main circuit breaker and wall outlet voltage at the Facility.
If wall outlet voltage is present, then replace line cord.
No power to
Console
(On M770EL) Power-on Switch is damaged. Replace Power-on Switch if the output voltage of Power Switch is not
present.
Defective SMPS-5V (MPU Power Supply) If no voltage, replace Defective SMPS-5V (MPU
Power Supply).
Defective Wire Harness If no voltage, verify that CBB3 interconnected with CBB4 cable is plugged into both MPU
Board and SMPS-5V. Replace if necessary.
LCD TV is normal,
but Dot-LED and
Numeric LED do not
light up
(On M770EL) Defective MPU Board
Measure the voltage
between pin 1 and
pin 4 on CN2.
If no voltage, replace MPU PCB.
Dot-LED and
Numeric LED are
normal, but LCD TV
does not light up or
is blank
Refer to 1.3 Troubleshooting Guide for LCD. Refer to 1.3 Troubleshooting Guide for LCD.
Using a Multi-meter, verify more than 6VDC at pin-7 and pin-8 on CN1.
If voltage is present, replace MPU board. If not, replace Drive board.
Faulty MPU board or Drive board Test with substitute MPU board or Drive board. Replace if necessary.
Cable connection or loose wire connection Verify that main cable CN1 is securely plugged into both MPU board and
Drive board. Replace if necessary.
Console LEDs are
not illuminating
(On M770E)
Worn or damaged wire harness Inspect wire harness. Replace worn or damaged harness.

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SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION
Faulty Battery, Note: Battery is used only for
M770E, self-powered model. Verify that Battery voltage is greater than 6 volts DC. Replace Battery if the voltage is lower than 6 volts DC.
Test with substitute MPU board. Replace if necessary.
Faulty MPU board or Drive board Test with substitute Drive board. Replace if necessary.
Cable connection or loose wire connection Verify that main cable CN1 is plugged into both MPU board and Drive
board. Replace if necessary.
Dot-LED or Numeric
LED lights up and
then fails.
(On M770E)
Worn or damaged wire harness Inspect wire harness. Replace worn or damaged harness.
Faulty Battery Verify that Battery voltage is greater than 6 volts DC. Replace Battery if
the voltage is lower than 6 volts DC.
Cable connection Verify that the cable connection at MPU board and Drive board or the connection between cables at midpoint is plugged in properly. Using a
Multi-meter, verify continuity on all cables. Replace any defective cables.
Unit does not Auto
Start
(On M770E)
Faulty Drive board If cable connection is verified as good, replace the Drive board.
Unit does not display
SPEED on Console Cable connection Verify that the cable connection at MPU board and Drive board or the
connection between cables at midpoint is plugged in properly. Using a
Multi-meter, verify continuity on all cables. Replace any defective cables.
Program intensity doesn’t challenge user ability. Select higher workout intensity.
Drive Belt is worn Replace Belt.
Drive Belt is excessively loose Inspect Belt tension. Adjust if necessary.
Cable connection or loose wire connection
Verify that the cable connection at MPU board and Drive board or the
connection between cables at midpoint is securely plugged in properly.
Using a Multi-meter, verify continuity on all cables. Replace any
defective cables.
Worn or damaged wire harness Inspect wire harness. Replace worn or damaged harness.
Faulty Button Switch or Operation Button board Verify that workout intensity on Console is increased or decreased by
pressing UP/DOWN button switch. Replace Button Switch or Operation
Button board if there is no change on intensity profile.
During exercise
program, pedaling is
insufficiently easy
without providing
adequate resistance.
Defective MPU board or Defective Drive board Test with substitute MPU board or Drive board. Replace if necessary.

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SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION
Malfunction Overlay, Button Switch or Operation
Button board Replace Overlay, Button Switch or Operation Button board.Display Console Keys do not function
and unit does not
respond. Defective MPU board Test with substitute MPU board. Replace if necessary.
Defective MPU board Test with substitute MPU board. Replace if necessary.
Defective Drive board Test with substitute Drive board. Replace if necessary.
During MANUAL
program, excessive
resistance loading
occurs. Worn or damaged wire harness Inspect wire harness. Replace worn or damaged harness.
During MANUAL
program, resistance
variance occurs Pedaling is too slow Pedal faster.
Loose hardware Verify that unit is level on the floor. Verify that all hardware has been tightened. Apply Loctite where
necessary.
Worn bearings Replace bearings and associated shaft.
During exercise
program, loud noise
issuing from unit Drive Belt is too loose Inspect Belt. Replace Belt if necessary.

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SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION
Electromagnetic interference from television sets, cell phones,
refrigerator, or motor driven exercise equipment. Keep the treadmill away from the probable cause until the heart rate readings are accurate.
RF energy source from another chest straps. Keep another chest strap away more than 1 meter until
the heart rate readings are accurate.
Heart rate reading is
abnormally high or is
displayed even when
Chest Strap or
Contact Heart Rate
sensors are not in
use. Contact Heart Rate cables are pinched at handle bars. Replace damaged cables.
Chest strap electrodes are not wet enough to sense accurate
heart rate. Dampen the Chest strap electrodes with tap waters.
The distance between cardio equipments are too close. Maintain the distance more than 30 cm.
Chest strap electrodes are out of monitoring range. Make sure the chest strap is within 60cm from Wireless
HR PCB.
Chest strap battery is discharged. Replace chest strap or the battery.
Chest strap electrodes are not laid flat or horizontally across
your skin. Make sure the chest strap electrodes lies flat and horizontally across your skin.
Faulty chest strap. Replace chest strap.
Faulty Wireless HR PCB. Replace Wireless HR PCB.
Heart rate reading
using wireless chest
strap is erratic or not
displayed
Defective cable or bad connection between Wireless HR PCB
and MPU PCB. Check the cable and connection is no problem.
Faulty CHR PCB. Replace CHR PCB
Dirty handlebar sensors. Wipe stainless steel sensors with a clean soft cloth.
Defective cable or bad connection between CHR PCB and MPU
PCB. Check the cable and connection is no problem
Contact Heart Rate
reading is erratic or
not displayed.User may have an unusual heart rate condition. Let different user grasp sensors to detect any variances.

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1.3 Troubleshooting Guide for LCD
Symptom/Condition PROBABLE CAUSE CORRECTIVE ACTION
Air/cable setting is not
correct Follow the set up procedures in LCD manual.
TV signal source is not
supplied.
- Check if the TV signal source is correctly supplied
to A/D PCB from external source.
- Make sure the cable is properly secure.
- If external TV signal is correct, try to connect the
coaxial cable directly to the internal connector in AD
PCB of Console to check whether the internal
cables are wrong or not.
75 ohm coaxial cable is bad. Replace 75 ohm coaxial cable.
Snow and noise are scattering on LCD screen. Any picture is
not found even though channel-up button or channel-down
button is pressed.
A/D Board is damaged. Replace A/D Board with new one.
LCD screen is uniformly white Internal cable connection is
loose or disconnected.
Check if the connection between LCD screen and
A/D Board is tight. In other word, LVDS cable shown
in picture.
Vertical large white-stripe or Vertical stripe block on LCD
screen Problem with LCD screen Replace LCD screen
When LCD power is turned on by
pressing TV on/off, “VIDEO”, “S-VIDEO”
or “ANALOG” appears temporarily and
then disappears on the left upper corner
of LCD screen.
TV mode is not set-up.
1) Whenever you press Volume down button, words
are displayed in following order on the left upper
corner of LCD screen.
“ANALOG”=>”VIDEO”=>”S-VIDEO”=>”TV”
2) Press the button until “TV” is displayed.
3) As soon as “TV” is displayed, snow and noise will
be scattering on LCD screen or any picture will be
captured.
LCD screen is dark
or black.
When LCD power is turned on by
pressing TV on/off, “VIDEO”, “S-VIDEO”
or “ANALOG” is NOT displayed on the LCD Power Supply has a
problem. Power Supply is
used for supplying 12 VDC
Check if LCD Power supply is normally operated or
LED lamp on Power supply body is turned on.
If LED is off,

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to LCD Overlay Bezel
Assembly.
zreplace Power Adapter.
If LED is on,
ztighten midpoint (LCD Power Supply side)
& endpoint (A/D Board side) connection.
zor make sure the voltage of end point is
DC 12 volt.
The cable related to LCD
Lamp Inverter is loose in
either side. Check if the connection is secure.
TV on/off button is wrong or
stuck. Replace OSD Button Board.
A/D Board is damaged. Replace A/D Board.
LCD Lamp inverter is
damaged. Replace LCD Lamp inverter.
LCD Back Light is damaged. Replace LCD screen.
left upper corner of LCD screen.
The connector or cable is
bad. Replace the connector or cable
Channels or Volume does not change Button to change channels
or volume does not work. Replace the button, OSD Button Board or harness related to it.
Air/cable setting is not
correct Follow the set up procedures in LCD manual.
Faulty headphones Replace headphones
No sound Faulty headphone jack
assembly or Audio Interface
Board. Replace Audio Interface Board or headphone jack.

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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
2.5 How to Replace the UNIT BEARING – UCF206
2.6 How to Replace the CRANK ASSEMBLY
2.7 How to Disassemble the PEDAL BASE, LOW JOINT CAP or HANDLE
PIVOT JOINT CAP
2.8 How to Replace the NEEDLE BEARINGS inside the PEDAL COUPLER
2.9 How to Replace the OILLESS BUSH inside the COUPLER FRAME
2.10 How to Replace the PEDAL SHAFT
2.11 How to Replace the HANDLE CRANK FRAME
2.12 How to Replace the Heart Rate SENSORS

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2.1 How to Replace the REAR COVER
The procedures to replace the REAR COVER are commonly applied when the replacements
below are done.
zHow to Adjust the Drive Belt Tension
zHow to Replace the Drive Belt
zHow to Replace the Unit Bearing-UCF206
zHow to Replace the Drive PCB
zHow to Replace the Battery
zHow to Replace the Generator
zHow to Replace the Crank Assembly

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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).
4) Remove two BUTTON CROSS BOLT (73) and two ALLEN BOLT (135) securing right REAR
COVER-R (136) to the Frame, and then remove right REAR COVER-R (136).
5) Remove six BUTTON CROSS BOLT (73) and then lift REAR COVER-C (139) up.
6) Replace the specific part while referring to “How to …” if required.
7) Install the REAR COVER-C, REAR COVER-R and REAR COVER-L in reverse order.

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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. Initial tension is set to 190
Hz. To decrease the tension, turn HEX NUT
(21) counterclockwise.
3) Make sure that PULLEY BELT does not
slip and then install the REAR COVER-C,
REAR COVER-R and REAR COVER-L in
reverse order.
2.3 How to Replace the Drive Belt (or Pulley Belt)
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. See “2.2 How to Adjust the
Drive Belt (or Pulley Belt) Tension”
3) Derail the slackened PULLEY
BELT (22) from the PULLEY (19).
4) Remove CAP HEX NUT (163) and PLANE WASHER (49) using 24 mm spanner.
5) Pull COUPLER FRAME (42) out of CRANK ASS’Y-230 (39) by lifting it off.
6) Remove H/S HEX BOLT (41) and HEX LOCK NUT (13) using 21 mm Spanner and then slide
CRANK ASS’Y-230 (39) off the Shaft of the Pulley (19).
7) Remove SQUARE KEY (161) from the Shaft.
8) Remove four H/S HEX BOLTs (25) using 17 mm spanner and then slide the BEARING-
UCF206 (23) off the Frame and Shaft of the Pulley (19).
9) To remove the CRANK ASS’Y-230 and BEARING-UCF206 in opposite side, repeat the same

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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. See “2.2 How to Adjust the Drive Belt (or Pulley
Belt) Tension”
2.4 How to Replace the Generator
1) Disconnect two cables from the
GENERATOR.
2) Loosen two HEX LOCK NUTs (11) a little
using 17mm spanner. See “2.3 How to
Replace the Drive Belt”
3) 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. See “2.3
How to Replace the Drive Belt”
4) Derail the slackened PULLEY BELT (22) from the PULLEY (19). See “2.3 How to Replace
the Drive Belt”
5) Remove ALLEN BOLT (15), HEX LOCK NUT (16) and PLANE WASHER (17) securing the
GENERATOR (14) to the GENERATOR FRAME (9) by using 4mm wrench and 10 mm spanner.
6) Remove the GENERATOR (14) from the GENERATOR FRAME (9).
7) Install new the GENERATOR (14) in reverse order.
8) If needed, adjust the Pulley Belt Tension. See “2.2 How to Adjust the Drive Belt (or Pulley
Belt) Tension”

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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 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).
4) Remove CAP HEX NUT (163) and PLANE WASHER (49) using 24 mm spanner.
5) Pull COUPLER FRAME (42) out of CRANK ASS’Y-230 (39) by lifting it off.
6) Remove H/S HEX BOLT (41) and HEX LOCK NUT (13) using 21 mm spanner and then slide
CRANK ASS’Y-230 (39) off the Shaft (18) of the Pulley (19).
7) Remove SQUARE KEY (161) from the Shaft.
8) Remove four H/S HEX BOLTs (25) using 17 mm spanner and then slide the BEARING-
UCF206 (23) off the SHAFT ASS’Y(18).
9) Install new BEARING-UCF206 (23) in reverse order.
10) If needed, adjust the Pulley Belt Tension. See “2.2 How to Adjust the Drive Belt (or Pulley
Belt) Tension”

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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).
4) Remove CAP HEX NUT (163) and
PLANE WASHER (49) using 24 mm
spanner.
5) Pull COUPLER FRAME (42) out of CRANK ASS’Y-230 (39) by lifting it off.
6) Remove H/S HEX BOLT (41) and HEX LOCK NUT (13) using 21 mm spanner and then slide
CRANK ASS’Y-230 (39) off the Shaft (18) of the Pulley (19).
7) Install new CRANK ASS’Y-230 (39) in reverse order.

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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.
2) Remove LOW JOINT CAP-B (145) by loosening four BUTTON CROSS BOLTs (146) using
Phillips driver.
3) Reassemble the parts in reverse order.
2.7.3 How to Disassemble the HANDLE PIVOT JOINT CAP
1) Remove HANDLE PIVOT JOINT CAP BADGE (143) by using sharp-tip screw driver to lift it

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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).
3) Reassemble the parts in reverse order.
2.8 How to Replace the NEEDLE BEARINGS inside the PEDAL COUPLER
(Or How to Replace the OILLESS BUSH inside the PEDAL COUPLER with
NEEDLE BEARINGS)
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. Slight
loosening through this process
makes it easy to remove lower
PEDAL SHAFT (52) securing the
PEDAL COUPLER (58) to the
PEDAL FRAME.
3) Remove the lower PEDAL SHAFT
(52) and the lower HEX LOCK NUT
(13) by using 17 mm spanner and 19 mm spanner each. Two PEDAL REAR SHAFT BUSHes
(62) are also removed.
4) Remove the SNAP RING (61) securing the PEDAL COUPLER (58) to the COUPLER FRAME
(42) by using snap ring pliers.
5) Remove the PEDAL FRONT SHAFT (59) by pulling out it. Two PEDAL FRONT SHAFT
BUSHes (60) are also removed.
6) Take out the PEDAL COUPLER (58), which is inside the pipe “COUPLER FRAME (42)”, from
the front side of the pipe.
7) Remove the NEEDLE BEARINGS (53, or oil-less bush before update) which are inside the
both end of the PEDAL COUPLER (58).
8) Install new NEEDLE BEARINGS in reverse order.

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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. Slight loosening through this process makes it easy
to remove lower PEDAL SHAFT (52) securing the PEDAL COUPLER (58) to the PEDAL
FRAME.
3) Remove the lower PEDAL SHAFT (52) and the lower HEX LOCK NUT (13) by using 17 mm
spanner and 19 mm spanner each. Two PEDAL REAR SHAFT BUSHes (62) are also removed.
4) Remove the SNAP RING (61) securing the PEDAL COUPLER (58) to the COUPLER FRAME
(42) by using snap ring pliers.
5) Remove the PEDAL FRONT SHAFT (59) by pulling out it. Two PEDAL FRONT SHAFT
BUSHes (60) are also removed.
6) Take out the PEDAL COUPLER (58), which is inside the pipe “COUPLER FRAME (42)”, from
the front side of the pipe.
7) Remove the PEDAL FRAME (51) from HANDLE CRANK FRAME (94) by loosening the
upper PEDAL SHAFT (52) and the upper HEX LOCK NUT (13) by using 17 mm spanner and 19
mm spanner each.
8) Remove the COUPLER FRONT
SHAFT (43) from the HANDLE
CRANK FRAME (94). Be careful
the COUPLER FRAME (42) can be
fallen out of the HANDLE CRANK
FRAME (94).
9) Remove the CAP HEX NUT
(163) from the COUPLER REAR
HOUSING (47) by using 24 mm
spanner.
10) Remove the COUPLER
FRAME (42) from the COUPLER REAR HOUSING (47) by lifting it up.
11) Remove the OILLESS BUSH (44, HB203040) or the OILLESS BUSH (53, HB1420).
12) Apply a bearing grease to the outer surface of the OILLES BUSH and then install the
OILLESS BUSH in reverse order.