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

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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

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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

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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

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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

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viii FVX, TMX Series Service Manual August, 2006

TRACKMASTER
August, 2006 FVX, TMX Series Service Manual 1-1
Introduction
1
The purpose of this service manual is to supply authorized service providers and
qualified technicians the information needed to maintain and repair the
TRACKMASTER®medical treadmills. A minimal understanding of basic electric and
electronic theories is required along with a basic understanding of hand tools and there
use.
A multi meter capable of measuring AC/DC voltages up to 240 volts and the ability to
perform continuity checks is required. An amp probe capable of reading up to 20 amps is
recommended.
Specific hand tools required are listed at the beginning of all removal and replacement
procedures. A complete list of all tools required in this manual can be found in the
service technician’s feedback section of this manual.
This manual includes: maintenance and trouble shooting guides, parts list, illustrations of
assembly parts and some schematics.
Notices
Three different levels of notices throughout this manual alert you to important
information: Note, Caution, and Warning.
Note
Note statements provide additional information, such as the following:
Note: For maximum safety and efficiency, the treadmill must have its own dedicated
power outlet.

TRACKMASTER
1-2 FVX, TMX Series Service Manual August, 2006
Caution
Caution notices inform you of potential hazards that could result in equipment damage or
injury, such as the following:
CAUTION Do not use silicone sprays to wax your treadmill deck. Using silicone sprays may void
the warranty. Such sprays can bring about surface changes that cause you to slip.
Warning
Warning notices alert readers to hazards that will result in serious injury or death, such as
the following:
WARNING Never open the hood of the treadmill while it is plugged into a power outlet. Line voltage
will cause severe injury or death.
Drawings
Chapter 13, assembly drawings.
Directional Orientation
References to left, right, front, and rear are based on the assumption that you are standing
on the treadmill, facing forward.
Responsibility of Manufacturer
Full Vision, Inc. is responsible for the effects of safety reliability, and performance only
if:
•Assembly operations, extensions, readjustments, modifications or repairs are carried
out by persons authorized by Full Vision, Inc.
•The electric installation of the relevant room complies with the requirements of the
appropriate regulations.
•The equipment is used in accordance with the instruction for use.

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August, 2006 FVX, TMX Series Service Manual 1-3
Equipment symbols
The following symbols appear on the treadmill.
This symbol means that you must pay attention to the documents
delivered with this equipment. It calls notice to the things to
which you must pay special attention during operation and when
the equipment is operated in conjunction with other equipment.
Protective earth (ground)
Alternating current
Type B equipment is suitable for intentional
external and internal application to the
patient, excluding direct conductive
connection to the patient heart.
Warning and caution symbols

TRACKMASTER
1-4 FVX, TMX Series Service Manual August, 2006

TRACKMASTER
August, 2006 FVX, TMX Series Service Manual 2-1
Service Information
2
Service Requirements
Refer equipment servicing to Full Vision, Inc. authorized service personnel only. Any
unauthorized attempt to repair equipment under warranty voids that warranty.
It is the responsibility of the user to report the need for service to Full Vision, Inc.
Failure on the part of the responsible individual, hospital, or institution using the equipment to
implement a satisfactory maintenance schedule may cause undue equipment failure and possible
health hazards.
Regular Maintenance regardless of usage is essential to ensure that the treadmill will always be
functional when required.
Equipment identification
Below is a list of treadmills that are available for purchase. It is imperative when calling the
service line or speaking with a technician that you identify the model and serial number of the
treadmill in use.
FVX325, TMX425 – Medical Treadmill without controller. This treadmill can only be
operated using testing software.
FVX325C, TMX425C – Medical Treadmill with Manual Controller. This treadmill can
be operated using testing software or manually.
FVX325CP, TMX425CP – Medical Treadmill with Programmable Controller. This
treadmill can be operating using testing software, manually, or by established programs in
the controller.

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2-2 FVX, TMX Series Service Manual August, 2006
Serial Number
Every TRACKMASTER treadmill has a unique serial number for identification.
The serial number appears on the serial plate on the base of each unit.
Serial plate location and Identification
The serial plate is located on the right side rail of the treadmill.
Explanation of Serial Decal Information
Item Name Description
A Manufacture Full-Vision Inc.
B Model Number Identifies model of treadmill
C Part Number Manufacturers part number
D Voltage Specifies voltage of treadmill
E Hertz Specifies hertz of treadmill
F Amps Specifies amperage of treadmill
G Serial Number Manufacturers assigned serial number

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August, 2006 FVX, TMX Series Service Manual 3-1
General Description
Intended Use
The FVX325, TMX425 series treadmill is for use only with pre-tested and
approved monitoring systems.
The emergency stop switch is intended for emergency situations where
immediately stopping the treadmill is required to deliver appropriate emergency
care to the patient. It is not intended for routinely stopping the treadmill.
Motor drive system
The 2hp, AC motor is controlled by a 2hp AC inverter drive, which connects
directly to the front roller with a drive belt. A 10lb flywheel attached to the
motor’s drive shaft keeps “footfall” variance to a minimum. An “adjustment
plate” between the motor and the treadmill motor pan allows for belt tension
adjustment using adjustment studs.
Elevation system
The elevation system uses a linear screw actuator to raise and lower the treadmill.
The elevation actuator attaches to the motor pan and elevation assembly.
The upper and lower limit switches are an integral part of the actuator, located on
top of the actuated under an access cover. This design allows easy access and
adjustment of the limit switches.
Electronic Assembly
The motor pan contains the power supply relay board and the inverter drive.
These can be accessed by removal of the hood assembly and can be replaced
individual.
3

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3-2 FVX, TMX Series Service Manual August, 2006
Power Supply Relay Board Detail

TRACKMASTER
August, 2006 FVX, TMX Series Service Manual 4-1
Preparation for use
Safe handling guidelines
Lift the end of the bed assembly to a comfortable height, keeping knees bent and
backs straight as you lift.
Rotate the treadmill in the direction you want to go (the treadmill will pivot on its
wheels) and push forward.
When you have maneuvered the treadmill into its new location gently lower the end
of the bed assembly to the floor.
4