Tunturi J6F User manual

Service Manual

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TUNTURI
SERVICE MANUAL
_____________________________________________________________________________________ Version 1/2000
TABLE OF CONTENTS
DEAR READER, ......................................................................................................................4
1 METERS 5
1.1 EXTERNAL EXCITATIONS ...........................................................................................5
1.2 INTERNAL EXCITATIONS.............................................................................................5
1.3 CONTROL SIGNALS PRODUCED BY THE EQUIPMENT....................................................5
1.3.1 CONTROLS INSIDE THE EQUIPMENT .........................................................................5
1.3.2 CONTROLS OUT THE EQUIPMENT.............................................................................6
1.4 REPLACING THE METER..............................................................................................6
1.5 REPLACING THE PULSE RECEIVER ..............................................................................6
1.6 REPLACING THE MEMBRANE......................................................................................6
1.7 SERVICE MENU AND CONFIGURATION MODE..............................................................6
1.7.1 PAGE 1 TOTAL VALUES...........................................................................................6
1.7.2 PAGE 2 LIFT MOTOR CALIBRATION .........................................................................7
1.7.3 PAGE 3 SELECT VOLTAGE.......................................................................................7
1.7.4 PAGE 4 MOTORMAX. SPEED...................................................................................7
1.7.5 PAGE 5 DIAMETER OF THE ROLLERS........................................................................7
1.7.6 PAGE 6 SW VERSION..............................................................................................7
1.7.7 PAGE 7 START TEST PROFILE ..................................................................................7
2ELECTRONICS MODULE 8
2.1 TRANSFORMER...........................................................................................................8
2.1.1 MODULE CONNECTIONS.........................................................................................9
3CABLES, MAIN SWITCH AND SAFETY SWITCH 10
3.1 CABLES FROM THE CONTROL BOARD TO THE METER................................................10
3.1.1 FOLDAWAY- AND SAFETY SWITCH ........................................................................10
3.1.2 CONNECTIONTOTHEMETER ................................................................................10
3.1.3 SERIAL CONNECTION ...........................................................................................10
4LIFT MOTOR AND LIFT ARM 11
4.1 LIFT MOTOR.............................................................................................................11
4.1.1 LIFT MOTOR WIRING ............................................................................................11
4.1.2 REPLACING THE LIFT MOTOR ................................................................................12
4.1.3 CALIBRATING THE LIFT MOTOR.............................................................................12
4.2 LIFT ARM..................................................................................................................12
4.2.1 REPLACING THE LIFT ARM ....................................................................................12
4.2.2 LIFT ARM ROLLERS...............................................................................................12
5MOTOR AND TRANSMISSION 13

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SERVICE MANUAL
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5.1 MOTOR....................................................................................................................13
5.1.1 SPEED SENSOR (TACHO).......................................................................................13
5.1.2 THERMAL PROTECTOR OF THE MOTOR...................................................................13
5.1.3 COAL BRUSHES....................................................................................................13
5.1.4 OVERLOAD AND THERMAL PROTECTOR................................................................14
5.1.5 WIRING...............................................................................................................14
5.1.6 BELT WHEEL AND FLYWHEEL...............................................................................14
5.1.7 MOTOR FAN ........................................................................................................14
5.1.8 SPEED SENSOR.....................................................................................................14
5.1.9 REMOVING THE MOTOR.......................................................................................15
5.1.10 POSSIBLE MALFUNCTIONS OF THE MOTOR ..........................................................15
5.2 TRANSMISSION.........................................................................................................15
5.2.1 REPLACING AND ADJUSTING THE DRIVE BELT.......................................................15
5.2.2 BELT TIGHTENER.................................................................................................16
6FRAME, HAND RAILS, COVERS 17
6.1 MAIN FRAME............................................................................................................17
6.2 LANDINGS ............................................................... ERROR! BOOKMARK NOT DEFINED.
6.3 HAND RAILS: ATTACHMENT AND REPLACING..........................................................17
6.4 PLASTIC COVERS .....................................................................................................17
6.4.1 DUST COVER.......................................................................................................17
6.4.2 REAR ROLLER COVER ..........................................................................................17
6.4.3 FRONT ROLLER COVER.........................................................................................17
7ROLLERS 18
7.1 MATERIAL................................................................................................................18
7.2 BRACKETS................................................................................................................18
7.3 REPLACING ROLLERS ..............................................................................................18
8RUNNING DECK 19
8.1 RUNNING DECK.........................................................................................................19
8.1.1 REVERSING AND REPLACING ................................................................................19
8.2 RUNNING BELT.........................................................................................................19
8.2.1 BELT ALIGNMENT ................................................................................................19
8.2.2 NOTING THE BELT WEAR.....................................................................................20
8.2.3 RUNNING BELT TENSION AND REPLACEMENT .......................................................20
8.3 RE-LUBRICATION.....................................................................................................20
8.4 LUBRICATION PIPES .................................................................................................21
9FOLDAWAY 22
9.1 INFORMATION TO BE ADDED.................................... ERROR! BOOKMARK NOT DEFINED.
10 ERROR CODES 23

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10.1 GENERAL ON ERROR CODES....................................................................................23
10.2 ERROR CODES.........................................................................................................23
APPENDIXES
1. SPECIFICATION SHEETS
2. WIRING DIAGRAM
3. SPAREPART PICTURE AND LIST(TO BE ADDED)

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TUNTURI
SERVICE MANUAL
_____________________________________________________________________________________ Version 1/2000
Dear reader,
This service manual contains instructions and advice on service procedures with regard to
Tunturi’s treadmill models J6 / J6F and J8 / J8F.
The main objective of the service manual and the trouble shooting charts is to guide the service
person to find the component or entity of components, which cause the malfunction. To
facilitate the maintenance, error codes on display refer to internally found malfunctions: error
codes as such are no malfunctions, they merely point to the observed problem. As a general rule,
when the source of malfunction is located, it should not be repaired, but instead replaced with a
new component.

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SERVICE MANUAL
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Technical information
Operating voltage 24 VDC
1 METERS
1.1 External excitations
The meter has the same Polar heart rate receiver as all the other Tunturi wellness equipment.
The equipment is compatible with a coded transmitter.
The serial port type is RS-232C with a RJ45 module connector. The transfer speed is 9600 bps.
The protocol is a reworked Csafe –protocol.
1.2 Internalexcitations
The equipment uses the same speed sensor as T-Track; the speed sensor wheel has the same
number of teeth as there are in T-Track. The motor speed of 3400 rpm corresponds to a speed
of 16 km/h.
The models J8 / J8F have the same motor as in T-Track, accordingly the thermal protector is the
same. The motor of models J6 / J6F does not have the thermal protector.
The inclination sensor is a Hall sensor with a resolution of 22,2 beats / cm.
1.3 Control signals produced by the equipment
1.3.1 Controls inside the equipment
The belt motor is controlled by PWM -adjustment.
The lift motor is of DC type.
J6 / J6F –models have three (3) four-digit LCD –displays. J8 / J8F –models have three (3) four-
digit LCD -displays and a custom LCD –display module.
LEDs are used to indicate modes of the equipment and the values on display. There are 8 LED
controls. The LEDs indicating time and speed share a common control as well as those
indicating inclination and energy consumption. Other LEDs have their own controls.
The equipment has a PIEZO-buzzer, which can be set on or off with the software.

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1.3.2 Controls out the equipment
The serial port is of the same type as in T.I.E. interfaces: RS-232C with a RJ45 module
connector. The transfer speed is 9600 bps. The protocol is a reworked Csafe –protocol.
1.4 Replacing the meter
The meter covers are attached to each other and the hand rails with screws. The cables from the
control board (inside the rail) are attached with a Molex-type connector to the meter board. Also
the wires to the safety switch are run inside the handle bar. The electronics board, located in the
cover part of the meter, can basicly only be repaired by the manufacturer.
1.5 Replacing the pulse receiver
The pulse receiver is glued to the cover part of the meter. Easiest way to replace it is to cut the 3
wires from the circuit board and solder them to the wires of the new receiver.
1.6 Replacing the membrane
Remove the upper cover of the interface and detach the membrane connector from the circuit
board. Tear the membrane carefully off the upper cover and remove glue remains with denatured
alcohol, for example. Remove the cover paper from the back of the new membrane, push the
connector through upper cover opening and press the membrane evenly to the surface of the
upper cover; pay attention to the alignment. Attach the membrane connector to the circuit board
and re-attach the upper cover to the meter base.
1.7 Service Menu and configuration mode
Move to the configuration mode with the following key sequence:
Set / + /arrow up/arrow down/arrow right/arrow left/+
Each stage is indicated in the left hand display with a number 1, 2, 3 etc. Move from page to page
by entering OK- key.
In the service menu, the display in the centre shows the selected value of the page.
1.7.1 Page 1 Total values
The display in the centre shows the total hours of use and the display on the right hand side shows
the total distance.

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SERVICE MANUAL
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1.7.2 Page 2 Lift motor calibration
If the lift motor is not calibrated, the calibration procedure will be automatically initiated when the
page 2 of the Service Menu is selected. Stages of the calibration:
Cal1 run down Cal2run up Done ready
The left hand side display shows the goal position 10 / -2 / 0.
The display in the centre shows the stage (Cal1, Cal2, Done).
The right hand side display shows the pulse counter value. The value will be resetted at the end of
stage Cal1, when position 10 (lower limit switch) is reached. At the end of calibration, the elevator
is driven to horizontal, e.g. position 0. The procedure can be re-initiated by pressing + key.
1.7.3 Page 3 Select voltage
Select operation voltage 230 or 115 V. the value 230/115 is shown in the display in the centre.
1.7.4 Page 4 Motor max. speed
Select motor speed 16/18/20, the display value 16, 18, 20.
1.7.5 Page 5 Diameter of the rollers
Select the roller diameter 58/60 mm, the display value 58/60. The value affects the distance and
speed displays.
The treadmill can use rollers of two different diameters. The 58 mm roller can be recognized by
the bearings at the level of the outer edge of the roller, whereas the 60 mm roller has the bearings
clearly inside the outer edge. The size of the rear roller has no effect on the speed or distance
display. When replacing the front roller, the diameter has to be recognized and the correct
corresponding setting value checked in the meter.
1.7.6 Page 6 SW version
The display in the centre shows the software version in use, e.g. 0.3.
1.7.7 Page 7 Start test profile
The display in the centre shows ProF. Start the profile by pressing the + key.

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SERVICE MANUAL
_____________________________________________________________________________________ Version 1/2000
Technical Information /
Power Board
Manufacturer Mariachi Oy, Finland
Diagnostics
Operating voltage 230VAC +12%/-15% 50Hz
115VAC +12%/-15% 60Hz (USA)
2ELECTRONICS MODULE
The electronics module is attached to the treadmill frame with four screws and it can be removed
after removing the dust cover. The module contains the control board, transformer and main
switch. Cables from the outside for these components are connected with quick connectors to
the module. All components contained by the module are separately replaceable.
2.1 Transformer
The transformer and the control board generate a 24 VDC, 3A current to the lift motor. The
transformer is placed inside the control board module. The transformer contains a thermal
protector (110° C), which releases if the transformer is overloaded.
Basic information on the transformer:
115 / 230 VAC primary
18 VAC secondary
50 VA power
110° C thermal protector

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2.1.1 Module connections
On the front side:
-external PC connection
-motor connection; notice the wiring
red black (wires from the drive motor)
On the right hand side:
-safety switch connection
On the back side:
-meter connection
- speed sensor connection
-thermal protector (J8) connection
-lift motor connection
to the user interface
to the speed sensor to the lift motor

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SERVICE MANUAL
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Technical Information
Safety switch
According to standardi EN60947-5-1
Main switch Equipped with 10 A overcurrent
protection
3
CABLES, MAIN SWITCH AND SAFETY
SWITCH
3.1 Cables from the control board to the meter
3.1.1 Foldaway- and safety switch
Two ABIKO-connectors. The net voltage phase is toured via the foldaway- and safety switches.
The main switch and the over current protector are located prior to the foldaway- and safety
switches, so that they cut off current from the entire equipment.
3.1.2 Connection to the meter
The control and meter boards are joined by a 6-pin ”phone line cable”. The connector is a 6-pin
modular-connector.
Cable colours and functions:
1White Motor supply voltage (+5V)
2Black Data from control board to meter, DIN
3Red Data from meter to control board, DOUT
4Green Clocking of syncronized serial transfer from control
board to meter, CLK
5Yellow Activating signal of serial transfer from control board
to meter, SELECT
6Blue Grounding of supply voltage, GND
3.1.3 Serial connection
As in T.I.E.; connector is an 8-pin modular-connector (RJ45).
Chart 3-1
Name Function / value
Audio Left Not in use
Audio Right Not in use
RX Incoming async. Data. RS-232 –levels
TX Outgoing async. Data. RS-232 –levels
RTS Programmable RS-output (no current feed to components)
CTS
Signal Ground
Shield

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SERVICE MANUAL
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Technical information
Manufacturer Devert Motorized Systems, Saksa
Operating voltage 24 VDC
Strikelength 95 mm
Speed 6-11 mm/s depending on load and
inclination
Lift power 150 kg on rear roller
4LIFT MOTOR AND LIFT ARM
4.1 Lift motor
The lift motor is a 24 V DC motor, and can be used in both voltage areas (US and EU). The motor
gives a pulse information when in motion through a back switch. The electronics recognizes motor
overload, cuts off the control and notifies the meter. The thermal protector allows driving the lift
motor up and down five times in a row with the maximum load (150 kg on the rear roller) without
releasing.
4.1.1 Lift motor wiring
As in T-Track: 8-pin Molex connector has a 24 V motor controls and a 5 V connection of the
pulse sensor.
1Green Motor supply voltage (+) drive up
2Green Motor supply voltage (+) drive up
3Red Motor supply voltage (-) drive down
4Red Motor supply voltage (-) drive down
5Brown GND
6White GND
7Black Sensor pulse voltage +5 VDC
8Lilac Sensor pulse signals
Chart 4-1Lift motor cable colors and signals

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4.1.2 Replacing the lift motor
The lift motor is loosened both from the frame and the lift arm by removing the axles from these
points. Remove the lift motor wire from the connector X2. Tape the wire connector and tie a knot
with string. Pull the string with the wire out of the frame. Using the string, pull the wire of the new
lift motor inside the frame.
4.1.3 Calibrating the lift motor
When the lift motor is replaced, it must be calibrated. The calibration procedure will be
automatically initiated when the page 2 of the Service Menu is selected (see chapter 1.6). Stages of
the calibration:
Cal1 run down Cal2 run up Done ready
The left hand side display shows the goal position 10 / -2 / 0.
The display in the centre shows the stage (Cal1, Cal2, Done).
The right hand side display shows the pulse counter value. The value will be resetted at the end of
stage Cal1, when position 10 (lower limit switch) is reached. At the end of calibration, the elevator
is driven to horizontal, e.g. position 0. The procedure can be re-initiated by pressing + key.
4.2 Lift arm
4.2.1 Replacing the lift arm
The lift arm is attached with screws to the side profiles of the frame. The lift arm can be removed
by opening the screws and loosening the lift motor shaft.
4.2.2 Lift arm rollers
The plastic rollers are locked to their shafts with a locking sleeve.

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Technical information
Manufacturer Leeson, USA
Nominal voltage 130 VDC
Continuous duty power 1,8hv (J6,J6F) 2,2hv (J8,J8F)
Max. motor speed Appr. 3800 RPM
Protections Overcurrent and thermal protection
(J8, J8F)
Coal brushes Replaceable
5MOTOR AND TRANSMISSION Speed sensor Optic fork sensor (Omron)
5.1 Motor
The treadmill family uses two different motors (1,8 hp and 2,2 hp). Both the US and EU models
use the same, so-called combination motors. These are identical to the previous US model motor
(130 VDC), but has coal brushes manufactured of higher voltage material. The control electronics
must be separately adjusted for the US and EU environments. The electronics recognizes motor
overload, cuts off the control and notifies the meter (overload E15, thermal protector E11). The
output stage is protected against a short cut between the motor connectors’ poles.
5.1.1 Speed sensor (Tacho)
As in T-Track: 4-pin connector. If necessary, the motor’s optic fork and the cable’s shield can be
connected to this. Notice that the speed sensor is provided with an LED for easy registering of
signals and correct functioning of the speed sensor.
Pin 1 Feed current to optic fork 5V+/- 5%
Pin 2 Open-Collector-information from the optic fork
Pin 3 Shield GND
Pin 4 GND
5.1.2 Thermal protector of the motor
As in T-Track: 2-pin connector, which receives information from the motor’s thermal protector.
The models J8 / J8F have the same motor as in T-Track, accordingly the thermal protector is the
same. The motor of models J6 / J6F does not have the thermal protector.
5.1.3 Coal brushes
The coal brushes (2 pcs) are replaceable and available as spare parts. The coal brushes are
extremely durable, and consequently the need to change them is very limited. Should the brush
generate a crackling sound, the spring pressing the brush against the rotor surface need be
checked. If the brush generates a high-frequency sound at low rpm, the coal surfaces are polished
and hardened, and the surfaces need be roughened. Further, if there is dirt or coal dust in the
grooves of the rotor surface, this may generate a high-frequency sound and / or sparkling. This
situation necessitates a careful cleaning of the rotor surface and the environment.

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5.1.4 Overload and Thermal Protector
The J6 / J6F motor is equipped with an overload protector, which is located on the circuit board.
If the motor is overloaded, the overload protector cuts the current to the motor. Under overload
the belt movement becomes jerky. The most common reason to the overload is insufficient belt
lubrication.watching the current limit. Further, it also has a thermal protector.
The J8 / J8F motor is equipped with an overload protector and a thermal protector. The thermal
protector is located inside the motor. The release of the protector is usually caused by motor
overload. Under overload the belt movement becomes jerky.
5.1.5 Wiring
Chart 5-1 presents belt motor wires, connectors and functions.
WIRE COLOR ADRESS ON THE
POWER BOARD CONNECTOR TYPE FUNCTION
Black X7 Quick connector GND
Red X6 Quick connector PWM (0-130 VDC)
Blue X4
Blue X1
Quick connector Information on the
Release of thermal
Protector
5.1.6 Belt Wheel and Flywheel
Both the belt wheel and the flywheel are push-tight on the shaft and locked with two Allen screws.
In order to facilitate removal, using an appropriate extractor is recommended.
5.1.7 Motor Fan
The plastic motor fan is push tight on the motor shaft.
5.1.8 Speed Sensor
The shaft of the speed sensor is attached to the motor casing. The toothed disc of the flywheel
must run in the center of the speed sensor fork (optic fork), at a distance of approximately 2 mm
from the bottom of the fork.

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Chart 5-2 Wiring: 4- pin connector, to which the motor’s optic fork is attached
Pin 1 Feed current to the optic fork 5V+/- 5%
Pin 2 Open-Collector- info from the optic fork
Pin 3 Protective casing GND
Pin 4 GND
5.1.9 Removing the Motor
The motor is attached to the frame with four screws. To remove the motor, the plastic frontal
protective casing has to be removed first. After loosening the two attachment screws above the
motor and the two below it, the motor can be pulled out from the front of the treadmill.
5.1.10 Possible Malfunctions of the Motor
overheating / smell: check the belt and running deck surfaces and lubrication
abrupt stop: check the overload and thermal protectors as well as the wiring
screaming motor sound: check coal brushes and possible coal dust on the rotor surface
rough motor sound: damaged brackets
uneven motor revolutions and sounds: short cut in the motor, defective coil
5.2 Transmission
5.2.1 Replacing and Adjusting the Drive Belt
The drive belt is 12 –grooved V-belt (406 J). The belt tightness is adjusted at the factory with a
vibration meter. You can re-adjuste the tension of the drive belt: the belt must give way
approximately 10 mm in the middle part when pushing it powerfully. Note that overtightness will
eventually damage both to the belt and the shaft bracket of the motor.

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5.2.2 Belt Tightener
The (belt) motor is locked in only one position, therefore the drive belt tension is always adjusted
by adjusting the belt tightener. The tightener is attached to the frame with a flexible joint. Brackets
of type 2x6203ZZ are used as tightener rolls. Only the complete belt tightener is available as a
spare part.

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Technical information
Main frame Steel profile
Landings Steel profile
Dimensions J6/J6F 153x82x142 cm
Dimensions J8/J8F 153x88x142 cm
6FRAME, HAND RAILS, COVERS
6.1 Main Frame and Landings
Powder coat finished frame is compiled of steel profiles by welding.
Landings are powder coat finished steel profiles, and constitute part of the frame structure. Large
stickers with a rough surface for good foot hold are attached on top of the landings.
6.2 Hand Rails: Attachment and Replacing
The hand rails (aluminum profile in J8) are attached to the frame with a flexible joint. In the
package the hand rails are resting against the running deck; when the treadmill is assembled, the
rail is turned up and locked with two bolts, one on either side of the frame (see Owner’s Manual).
When replacing the rails, pay attention to the wiring inside the rail and to that of the meter.
J6F and J8F models require the attachment of the FoldAway frame to the hand rails. This frame is
not ready assembled, and the attachment takes place with screws (see Owner’s Manual). The
FoldAway frame serves as a supporting element in storage position.
6.3 Plastic Covers
6.3.1 Dust Cover
The cover is injection moulded of polystyrene and attached to the frame with screws. The material
is fire-proof, class V-0. Removing the dust cover will reveal the major electronic components.
6.3.2 Rear Roller Cover
The cover is injection moulded of polystyrene and attached to the rear roller shaft with two screws.
Repositioning the rear roller will not affect the distance between the cover and the belt.
6.3.3 Front Roller Cover
The cover is injection moulded of polystyrene and it is fire-proof, class V-0. The cover is attached
to the frame with four screws. Prior to the removal of the cover, the motor dust cover must be
removed.

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Technical information
Length mm 516,50 front; 484 rear
Diameter mm 60
Material Anodised steel
Front roller drive wheel Diameter 63 mm
Brackets 4 pcs 6204 ZZ
7ROLLERS Precision class
7.1 Material
The rollers are manufactured of steel and anodized against corrosion. The belt wheel (diameter 63
mm) is pressed on the front roller. The belt wheel can not be replaced.
7.2 Brackets
The roller brackets (type 6204 ZZ) are protected, and extremely durable in use. The brackets do
not require any maintenance, and in case of a bracket damage, the roller must be replaced.
7.3 Replacing Rollers
7.3.1 Front Roller
Remove the motor dust cover and the front roller cover. Remove the attachment screws of the
roller shaft. Loosen the drive belt tightener and belt so that the belt can be removed from the drive
shaft. Remove the roller from either side.
7.3.2 Rear Roller
Remove the rear roller cover. Remove the adjustment bolts of the roller shaft. The rear roller can
only be removed after the front roller is removed so that the belt becomes loose enough.

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Technical information
Deck material Finnish plywood
Thickness 18 mm
Surface Phenolic sheet
Belt
1-ply, PVC-surfaced; polyester fibre on
backside
Running area 134x45 cm
8RUNNING DECK
8.1 Running deck
The running deck is made of Finnish plywood; the deck is coated with a phenolic sheet. This
running deck material has proved to be the best in tests carried out by Tunturi and various
partners. To ensure a comfortable running feeling, the running deck is attached to the frame with
six elastic rubber bumpers. The bumpers dampen the shocks of running feet to the frame.
8.1.1 Reversing and Replacing
Both sides of the running deck are identical and can be used. The running deck must be reversed if
the surface shows any signs of wearing. If the hard phenolic sheet surface is worn out (light
plywood is visible) or there are longitudinal grooves on the deck surface, the belt lubrication will
no longer function and the treadmill use loads excessively the transmission system.
Reversing the deck requires removing the rollers. When the attachment screws of the running deck
are removed, both the deck and the belt can be pulled out from the rear of the treadmill.
8.2 Running Belt
8.2.1 Belt alignment
The belt is aligned by adjusting the rear roller position with the attachment bolts at the back of the
treadmill. If the belt drifts to the right, turn the right adjustment bolt approximately 0,25-0,50 turn
clockwise and the left adjustment bolt anticlockwise approximately half as much as you turned the
right bolt. Correspondingly, if the belt drifts to the left, the procedure is done vice versa. Adjusting
both bolts simultaneously is necessary so that the belt tension will not be much altered. The belt
alignment ought to be done at a speed of 5-6 km/h, and the effect of adjustment should be
followed for a few minutes.