Trackmaster FVX325 Quick start guide

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TREADMILL
FIELD SERVICE MANUAL
FVX No Control
FVX__C Manual Control
FVX__CP Programmable Control
TMX No Control
TMX__C Manual Control
TMX__CP Programmable Control
Revision Level 5 August, 2006
Refer equipment servicing to Full Vision, Inc. authorized service
personnel only. Any unauthorized attempt to repair equipment under
warranty voids that warranty.

TRACKMASTER
August, 2006 FVX, TMX Series Service Manual i
CONTACT INFORMATION
SERVICE DEPARTMENT
Models: FVX325, FVX325C, FVX325CP
TMX435, TMX425C, TMX425CP
Service Line: 316-283-8110
Address: Full Vision Inc.
3017 Full Vision Drive
Newton, Ks 67114
PARTS DEPARTMENT
Models: FVX325, FVX325C, FVX325CP
TMX435, TMX425C, TMX425CP
Service Line: 316-283-8110
Address: Full Vision Inc.
3017 Full Vision Drive
Newton, Ks 67114
Authorized Representative
In European Union
(Regulatory affairs only)
Emergo Europe
Molenstraat 15
2513 BH The Hague
The Netherlands
(31) (0) 70 345-8570 telephone
(31) (0) 70 345-7299 fax

TRACKMASTER
ii FVX, TMX Series Service Manual August, 2006
TRACKMASTER TREADMILLS
BY
FULL VISION INC.
Original Publication Date 9/5/02
TMX425 Series Treadmill
Field Service Manual
Part #317-07130 – 317-07135
TMX325 Series Treadmill
Field Service Manual
Part #317-07189 – 317-07191
Note: Due to continuing product innovation, specifications in this manual are subject
to change without notice.
Printed in USA. TRACKMASTER®is a registered trademark of JAS Manufacturing Co.,
Inc. TRACKMASTER is protected by the following US Patents: 5320589, 5431613. All
other patents pending. Polar® is the registered trademark of Polar CIC Inc.

TRACKMASTER
August, 2006 FVX, TMX Series Service Manual iii
Contents
Chapter 1 Introduction ............................................... 1-1
Notices ..................................................................... 1-1
Drawings ................................................................... 1-2
DirectionalOrientation ....................................................... 1-2
Responsibility of manufacturer ............................................... 1-2
EquipmentSymbols ......................................................... 1-3
Chapter 2 Service Information ....................................... 2-1
ServiceRequirements......................................................... 2-1
EquipmentIdentification...................................................... 2-1
SerialNumberLocation&Identification ....................................... 2-2
ExplanationofSerialDecalInformation........................................ 2-2
Chapter 3 General Description ...................................... 3-1
IntendedUse................................................................. 3-1
MotorDriveSystems ......................................................... 3-1
ElevationSystems ........................................................... 3-1
ElectronicAssembly.......................................................... 3-1
Power Supply Relay Board Detail.............................................. 3-2
Chapter 4 Preparation for Use .......................................4-1
SafeHandlingGuidelines ..................................................... 4-1
FVX325 Series Initial Setup and Assembly ..................................... 4-2
TMX425 Series Initial Setup and Assembly..................................... 4-3
CheckUnitforOperation ..................................................... 4-4
TestPlugProcedure .......................................................... 4-5
BeltTrackingandAlignment.................................................. 4-6
BeltTensionAdjustment...................................................... 4-7
DriveBeltTensionAdjustment................................................ 4-8
ConnectorandSwitchLocations............................................... 4-9
PowerRequirements.........................................................4-10
Operating and Storage Condition Recommendations............................4-11
Installation After Long Period of Storage ......................................4-11
Chapter 5 Operating Instructions ...................................5-1
ElectricalSafetyTests ........................................................ 5-1
OperatingControls ........................................................... 5-1
Controlling the Treadmill ..................................................... 5-1
SafeOperationofTreadmill................................................... 5-2
EmergencyStopButtonCheck ................................................ 5-3
Operation of Manual Treadmill Control ........................................ 5-4
Manual Treadmill Self Test Procedure ......................................... 5-5
FVX325C, TMX425C Manual Treadmill Controller Windows 98 and Older....... 5-8
FVX325C, TMX425C Manual Treadmill Controller Windows 95 and Newer...... 5-8
Manual Treadmill Control Console Programming Mode ......................... 5-9
Operation of Programmable Treadmill Control ................................ 5-14
Programmable Treadmill Self Test Procedure ..................................5-21
FVX325CP, TMX425CP Programmable Treadmill Controller...................5-26
FVX325CP, TMX425CP Programmable Treadmill Controller...................5-26
Programmable Treadmill Control Console Programming Mode .................5-27

TRACKMASTER
iv FVX, TMX Series Service Manual August, 2006
Chapter 6 Preventative Maintenance ................................6-1
InspectionandCleaning ...................................................... 6-1
BeltCleaning&Inspection.................................................... 6-2
Calibration................................................................... 6-2
BeltSpeedCalibration ....................................................... 6-3
FVX,TMXSeriesVerifyingBeltSpeedCalibrationintheField ................. 6-4
FVX325, TMX425 Series Elevation Calibration Procedure No Control Unit....... 6-5
FVX325C, TMX425C Series Elevation Calibration
ProcedureManualControlUnit................................................ 6-8
FVX324CP, TMX425CP Series Elevation Calibration
ProcedureProgrammableControlUnit........................................ 6-10
ElevationScrewLubrication ................................................. 6-12
Chapter 7 Troubleshooting .......................................... 7-1
Trouble Shooting Guide ...................................................... 7-1
Power Supply & Drive Circuit Board (FG309).................................. 7-2
Power Supply ................................................................ 7-3
OutputfromControlConsoletoFG309........................................ 7-4
FG309BeltStart ....................................................... 7-4
FG309ChangeBeltSpeed .............................................. 7-4
FG309ElevationUp.................................................... 7-5
FG309ElevationDown................................................. 7-5
Input from FG309 to Control Console.......................................... 7-6
ElevationSensor ....................................................... 7-6
SpeedSensor........................................................... 7-6
Chapter 8 Removal and Replacement of Components ............8-1
Hood Removal Procedure FVX Series ......................................... 8-1
Hood Removal Procedure TMX Series ......................................... 8-2
DriveMotorReplacementFVXSeries......................................... 8-3
DriveMotorReplacementTMXSeries......................................... 8-5
FrontRollerReplacementFVX/TMXSeries.................................... 8-8
RearRollerReplacementFVX/TMXSeries ................................... 8-10
Running Belt Replacement FVX Series ....................................... 8-12
Running Belt Replacement TMX Series ....................................... 8-14
Running Deck Replacement FVX Series ...................................... 8-16
Running Deck Replacement TMX Series ...................................... 8-17
DeckCushionReplacementFVXSeries....................................... 8-18
DeckCushionReplacementTMXSeries...................................... 8-19
MotorDriveBeltReplacementFVXSeries.................................... 8-20
MotorDriveBeltReplacementTMXSeries ................................... 8-22
ElevationActuatorReplacement/Adjustment .................................. 8-24
Power Supply Relay Board Replacement FVX Series .......................... 8-26
Power Supply Relay Board Replacement TMX Series .......................... 8-28
CircuitBreakerReplacement................................................. 8-30
InverterDriveReplacementFVXSeries....................................... 8-31
InverterDriveReplacementTMXSeries...................................... 8-33

TRACKMASTER
August, 2006 FVX, TMX Series Service Manual v
Chapter 9 Product Requirements
FVX, TMX Smart Power Supply ..........................9-1
Introduction .................................................................. 9-1
Scope........................................................................9-1
OperationalOverview ........................................................9-1
SoftwareRequirements........................................................9-2
SpeedControl ..........................................................9-2
ElevationControl.......................................................9-2
Communication.........................................................9-2
CommandProtocol......................................................9-3
InputCommands........................................................9-3
InputCommandAcknowledgement ......................................9-3
StatusRequest..........................................................9-4
Status Response ........................................................9-4
CommunicationNotes...................................................9-5
SelfTestMode .........................................................9-6
Calibration .............................................................9-6
HardwareRequirements.......................................................9-7
Electrical Inputs ........................................................9-7
ElectricalOutputs.......................................................9-7
ElectricalConnections...................................................9-8
PhysicalRequirements&Restrictions ....................................9-8
Chapter 10 Production Qualification Description
FG302 Smart Power Supply ............................ 10-1
TestFixture................................................................ 10-1
TestFixtureConnections....................................................10-1
PCDirectedTestStep....................................................... 10-2
BoardPowerTest........................................................... 10-2
TestGrade ................................................................. 10-2
TestBelt................................................................... 10-2
TestEEprom............................................................... 10-2
TestVoltageSelectionSwitch ............................................... 10-2
CommunicationTest........................................................ 10-2
FG302 Diagram ............................................................ 10-3
Chapter 11 Leeson Inverter ......................................... 11-1
LeesonSpeedmasterSelf-Test ............................................... 11-1
LeesonInverterInspectionSheet............................................. 11-2
InverterParameters/SoftwareVersion301 .................................... 11-3
InverterParameters/SoftwareVersion402 .................................... 11-6
InverterParameters/SoftwareVersion403 .................................... 11-8
Inverter Parameters/Software Version 403 & Later ........................... 11-10

TRACKMASTER
vi FVX, TMX Series Service Manual August, 2006
Chapter 12 Established Component Replacement Times ........ 12-1
FVX, TMX Component Replacement Times ...................................12-1
Chapter 13 Parts List with Part Numbers .......................... 13-1
FVX Series Inverter Assembly 220V Software Version 402/402/404 ............ 13-1
TMX Series Inverter Assembly 220V Software Version 301.................... 13-2
TMX Series Inverter Assembly 115V Software Version 301.................... 13-3
TMX Series Inverter Assembly 220V Software Version 402/403/404 ........... 13-4
FVX Series Inverter Assembly 110V Software Version 402/403/403 ............ 13-5
MotorMountAssembly..................................................... 13-6
AlternativeMotorMountAssemblyFVX/TMXSeries......................... 13-7
FVXSeriesMovableESBAssembly......................................... 13-8
TMXSeriesMovableESBAssembly......................................... 13-9
FVX/TMXSeriesElevationAssembly ...................................... 13-10
FVX/TMX Line Reactor Assembly CE Component........................... 13-11
FVX325 Series 220V Motor Pan Assembly w/ CE Components ............... 13-12
FVX325 Series Elevation Assembly......................................... 13-15
FVX325 Series Frame Assembly............................................ 13-16
FVX325 Series Final Assembly ............................................. 13-18
TMX425 Series 115V Motor Pan Assembly.................................. 13-20
TMX425 Series 115V Motor Pan Assembly w/CE Components ............... 13-22
TMX425 Series 220V Motor Pan Assembly.................................. 13-24
TMX425 Series 220V Motor Pan Assembly w/CE Components ............... 13-26
TMXSeriesw/CEOption#317-01784...................................... 13-28
TMX425 Series Frame Assembly ........................................... 13-29
TMX425 Series Running Deck Assembly.................................... 13-31
TMX425 Series Final Assembly ............................................ 13-33
Chapter 14 Flowcharts & Instructions for Trouble Shooting ..... 14-1
Flowcharts................................................................. 14-1
PowerDistribution120VACFlowchart1A................................ 14-1
Power Distribution 208-240 VAC Flowchart 1B............................ 14-2
PowerDistribution120VACFlowchart1C................................ 14-3
Power Distribution 208-240 VAC Flowchart 1D............................ 14-4
Power Distribution Low Voltage Power Supply Flowchart 1E ............... 14-5
BeltStartCommandFlowchart12A ...................................... 14-6
SpeedSensorFaultIsolationFVX,TMXSeries2A1........................ 14-7
FVX, TMX No Control Series Belt Motor Start Operation–Self Test 2B ...... 14-8
FVX,TMXControlSeriesBeltMotorStartOperation-SelfTest2C.......... 14-9
LeesonSpeedmaster–ParameterInspectionandSelf-Test2D.............. 14-10
Treadmill Elevation Flowchart 3A ....................................... 14-11
Treadmill No Elevation FVX, TMX No Control Series
ElevationFlowchart3B ................................................. 14-12
Treadmill No Elevation FVX, TMX Control Series
Elevation Flowchart 3C
................................
.................
14
-
13

TRACKMASTER
August, 2006 FVX, TMX Series Service Manual vii
Chapter 14 Flowcharts & Instructions for Trouble Shooting ..... 14-1
Instruction for Trouble Shooting ............................................ 14-14
Power Distribution Fault Isolation (1)120 VAC ........................... 14-14
Power Distribution Fault Isolation (2) 208-240 VAC ...................... 14-14
Power Distribution Fault Isolation (3)120 VAC ........................... 14-14
Power Distribution Fault Isolation (4) 208-240 VAC ...................... 14-14
FG 309 Elevation and Power Supply A/C Voltage Distribution
FaultIsolationInstruction ............................................... 14-15
FG 302 Elevation and Power Supply A/C Voltage Distribution
FaultIsolationInstruction ............................................... 14-16
ESBCircuitFaultIsolationInstruction.................................... 14-17
SpeedSensorFaultIsolationFVX,TMXNoControlSeries................ 14-18
InteriorInterfaceCableFaultIsolationFVX,TMXNoControlSeries....... 14-18
Perform Incorrect Belt Speed Fault Isolation FVX, TMX No Control Series . 1 4 -18
SpeedSensorFaultIsolationFVX,TMXControlSeries ................... 14-18
SpeedV-Guide10.92’(3.33m)........................................... 14-19
SpeedV-Guide8.45’(2.56m)............................................ 14-19
Perform FVX, TMX Manual Control Series Incorrect
BeltSpeedFaultIsolation ............................................... 14-20
Perform FVX, TMX Programmable Control Series Incorrect
BeltSpeedFaultIsolation ............................................... 14-20
TestPlugProcedure(FVX,TMXNoControlSeriesUnitsOnly) ........... 14-21
Elevation Sensor FVX, TMX No Control Series Fault Isolation Procedure . . . 1 4 -21
ElevationSensorFVX,TMXControlSeriesFaultIsolationProcedure ...... 14-21
Chapter 15 Treadmill Report/Service Log .......................... 15-1
TMX425 Series Maintenance Inspection Report ............................... 15-1
FVX325 Series Maintenance Inspection Report ............................... 15-3
EmergencyStopButton(ESB)LocationDrawing ............................. 15-5
FVX325 Series Treadmill Field Service Manual Log Sheet..................... 15-6
TMX425 Series Treadmill Field Service Manual Log Sheet .................... 15-7