Vision Fitness T9200 Operating instructions

Date of last revision: 11.06
TROUBLESHOOTING
TREADMILL.TROUBLESHOOTING.2007.REV1
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TROUBLESHOOTING FOR 2007 TREADMILLS:
(T9200 SIMPLE, T9500 SIMPLE, T9600 SIMPLE, T9250 SIMPLE, T9450 SIMPLE)
(T9200 DELUXE, T9500 DELUXE, T9600 DELUXE, T9250 DELUXE, T9450 DELUXE)
(T9200 PREMIER, T9500 PREMIER, T9600 PREMIER, T9250 PREMIER, T9450 PREMIER)
(T9700S, T9700HRT, T9800S, T9800HRT)
TROUBLESHOOTING

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INDEX
1. Data cables
• Large data cable
• Small data cable
2. Error messages
• Elevation errors
• Speed errors
3. No running belt movement
• Console and elevation function properly
4. Running belt won't go over .5 MPH
• Cannot increase speed after start
5. Runaway running belt
• Zero to fast in seconds
• Accelerates normal (no stop)
• Treadmill running belt starts before the start button is pressed
6. Treadmill trips the circuit breaker on power up
• Breaker on the treadmill
• Breaker in the building
7. No power to the treadmill
• Power switch does not glow
• Blank console
8. Treadmill running belt surges
• Running belt surges
9. Treadmill drive motor stalls
• Treadmill running belt stops during workout
10. Elevation problems
• Elevation does not move when key is pressed
• Elevation does not reach minimum or maximum elevation
• Elevation jumps to maximum elevation on power up
• Elevation goes to maximum when start is pressed
11. Noise problems
• Knocking noise
• Squeaking or chirping noise under front motor cover
12. Deck and Belt problems
• Running belt slips
• Treadmill belt tracks to one side
• Deck squeaks, knocks or makes thunking noise
13. Heart-rate Function
• Dashes on console where heart rate is displayed
• Console displays a “0” in HR window
• Erratic signal
• No Heart Rate Training function
Troubleshooting: Treadmills
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Troubleshooting: Treadmills continued
DATA CABLE
Large Data Cable
The large data cable carries the communication between
the lower board and the upper board. The large data
cable has 8 pins (wires)
• 1 PWM
• 1 RPM/Sensor
• 1 Down Elevation
• 1 Up Elevation
• 1 Vcc (+5)
• 2 Grounds
• 1 Elevation Potentiometer signal
Small Data Cable
The small data cable carries power (11 volts) from the
lower board to the upper board. This is the only function
for the small data cable. The small data cable has 6 pins
(wires)
• 3 Power
• 3 Grounds
Always make sure your 11V or CNS LED is lit on the
lower board. The 11V or CNS LED is indication that the
lower board is sending power to the small data cable.
Have a spare set of data cables at all times: Damaged or defective data cables are the #1 cause of treadmill
failure. DATA CABLE DAMAGE IS NOT ALWAYS VISIBLE.
To properly test data cable:
1. Connect new data cable to the upper board.
2. Connect data cable to the lower board without pulling through mast.
3. Test the treadmill
DEFECTIVE DATA CABLE SYMPTOMS
Large Data Cable Symptoms
1. E5
2. E6
3. E9
4. No Elevation or speed function
5. No Elevation
6. No Speed
7. Deck goes to max at start
8. Run away speed
Small Data Cable symptoms
1. No power to the upper board
2. Loss of power to the upper board, intermittent shutdown
To troubleshoot a bad large data cable for most models - Enter engineering mode (see engineering mode for specific
treadmill). If the elevation window in calibrations reads 000 in Px there no signal from the lower board to the upper
console.
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Troubleshooting: Treadmills
ERROR MESSAGE CODES
If an error occurs during auto-calibration of new console, an override of the error may be necessary. Cycle power,
press “STOP”, then, on the speed key numeric press “5”, “9”, then “3”.
E4 Incline position is outside the tolerances
E5 Elevation stall condition
E6 Signal from elevation is lost
E7 Speed time out error
E9 Signal from speed sensor is lost
If the wrong product is selected during initial set up a console reset can be done by holding down the “9” speed key
for 10 seconds.
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Troubleshooting: Treadmills continued
E4: Solution
1. Check power to the treadmill, as insufficient voltage to the treadmill can cause this error to reoccur. Check the power
socket that the tread is plugged into. Eliminate any extension cords or surge protectors (plug the tread directly into
a functional power source). Make sure the circuit is not overloaded. Make sure the circuit is NON-GFI.
2. Calibrate (See engineering mode for specific treadmill).
3. If calibrations do not hold, replace upper console.
Note: Usually simultaneous with an E6.
E5: Solution
1. Check large data cable connections at the lower and upper boards
2. Check the elevation plug connection at the lower board.
3. Calibrate (See engineering mode for specific treadmill).
a)If dashes appear and it says DGA3 in profile reboot treadmill.
Reboot treadmill
Turn tread on
Remove safety magnet
Turn tread off
After 15 seconds turn tread on
Place safety magnet in the console
Or:
Turn power off
Remove Safety key
Unplug treadmill
After 15 seconds plug tread in
Turn tread on
Place safety magnet in the console
b)If console enters engineering check the calibrations of P4 and P5.
4. Test/change large data cable (use large data cable information provided in the data cable portion of this Guide)
5. Replace lower board
6. Replace elevation motor
E6: Solution
1. Check the elevation plug connection at the lower board.
2. Check ALL large data cable connection at the lower and upper boards.
3. Calibrate (See engineering mode for specific treadmill)
4. Test/change large data cable (use large data cable information provided in the data cable portion of this Guide).
5. Replace elevation motor
E7/E9: Solution
1. Certain lower boards have an LED that flashes when the magnet on the roller passes the sensor. Adjust sensor
position if LED does not flash. See lower board basic troubleshooting for lower boards with the LED.
2. Unplug RPM sensor at the lower board. Check continuity. Treadmill will operate without sensor but cannot Auto-
calibrate. Calibrate manually.
3. Replace RPM sensor
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TROUBLESHOOTING
Troubleshooting: Treadmills continued
Symptom
Console functions properly
Elevation functions properly
Solution
1. Check all connections, (large data cable and motor leads) at the lower board.
If drive motor leads look abnormal, replace drive motor and lower board
2. Check calibrations (See engineering mode for specific treadmill)
3. Check if PWM LED on lower board is not on after the treadmill is started.
Test /replace large data cable, then calibrate.
4. Check if PWM LED on lower board is on. Check Drive motor brushes and
commutator for debris or wear.
5. Check Drive motor for short.
6. Check running belt and deck for damage and proper wax.
7. Replace lower board
8. Replace drive motor
Please reference specific version of Lower Board basic troubleshooting: This can help you determine which
component may be defective. The LED's on the lower board are indications of how the PWM and other components
are functioning.
NO BELT MOVEMENT
MAINTENANCE MESSAGES:
The T9700 have maintenance messages programmed into the software. These messages indicate that the treadmill
has reached the recommended number of hours of use since the last lubrication (LUBE HRS) or the recommended
distance since the last cleaning (CLEAN) or the motor brushes (BRUSH) should be replaced. This is NOT an error
message and the treadmill can continue to be used, providing the user arranges for the appropriate service. The pur-
pose of the maintenance messages is to assist the user in observing a maintenance schedule that will help provide the most
reliable service for their treadmill.
Once the appropriate maintenance service has been performed, the hours or distance can be reset in Engineering Mode.
Symptom
Can not increase
speed after start
Solution
1. Check calibrations (See engineering mode for specific treadmill)
2. Replace touch pad (touch pad is not part of the overlay)
BELT MOVEMENT WON’T GO OVER .5 MPH
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Symptom
Breaker on the tread
Breaker in the building
Solution
1. Check all connections at the switch, power cord, breaker and the lower board
(See wiring diagram); replace Power Cord and Leads
2. Check running belt and deck for proper wax
3. Replace breaker
4. Replace lower board
1. Check the power socket that the tread is plugged into. Eliminate any extension
cords or surge protectors (plug the tread directly into a functional power source).
Make sure the circuit is not overloaded. Make sure the circuit is NON-GFI.
2. Check all connections at the switch, power cord, breaker and the lower board
(See wiring diagram)
3. Check Power Cord for damage
4. Replace lower board
TREADMILL TRIPS THE CIRCUIT BREAKER ON POWER UP
Troubleshooting: Treadmills continued
Solution
1. Replace lower board
• Lower board has a damaged component or moisture on it
2. Inspect and clean brushes and commutator. Replace worn brushes.
3. Replace power cord
1. Replace touch pad
2. Check calibrations (See engineering mode for specific treadmill)
3. Replace upper board
1. Check touch pad
2. Replace lower board
Symptom
Zero to fast in seconds
(Console does not reflect
increase in speed)
Accelerates normal (no stop)
(Console reflects increase
in speed)
Treadmill running belt starts
before start button is pressed
RUNAWAY BELT
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* Adjusting the IR comp (blue box on the lower board): Turn the IR comp pot clockwise and start the treadmill @
1MPH and adjust the IR comp pot counterclockwise until the tread belt surges. Turn the IR comp pot a little bit
clockwise until the tread belt stops surging.
Symptom
Running belt surges
Solution
1. Check the power socket that the tread is plugged into. Eliminate any extension
cords or surge protectors (plug the tread directly into a functional power source).
Make sure the circuit is not overloaded. Make sure the circuit is NON-GFI.
2. Adjust IR comp on the lower board*
3. Adjust running belt to proper tension
4. Adjust drive belt to the proper tension
5. Check front roller pulley for slippage
6. Check motor brushes
7. Replace lower board
8. Replace drive motor
TREADMILL RUNNING BELT SURGES
Symptom
Treadmill running belt stops
during a workout
Upper board and elevation
function properly.
Solution
1. Check running deck for any rough spots. Make sure to feel the middle where the
customer works out.
2. Wax the deck
3. Check Drive motor connections at the lower board. If drive motor leads look
abnormal, replace drive motor and lower board
4. Replace lower board
TREADMILL STALLS
Troubleshooting: Treadmills continued
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Symptom
Power switch does not glow.
Blank Console
Power switch is glowing
NOTE: - - - - on the console
is not a blank console. Insert
safety magnet.
T9500 ONLY (One LED on
the PWM)
Solution
1. Check the power socket that the tread is plugged into. Eliminate any extension
cords or surge protectors (plug the tread directly into a functional power source).
Make sure the circuit is not overloaded. Make sure the circuit is NON-GFI.
Make sure the tread is not on the power cord.
2. Check power cord, power switch and breaker for any damage or bad wiring
3. Check that the AC LED is lit on the lower board. If lit, tread has power. Replace
switch.
4. Check breaker, reset if necessary. (replace breaker)
5. Check continuity at switch, (if none replace switch)
1. Console Power Supply LED on the lower board (Refer to the specific version of
the lower board basic troubleshooting). If LED is not lit, check if Fuse F2 on lower
board is good. If fuse is good, replace lower board.
2. Check small data cable
3. Test reed switch *
4. Replace upper board
* Replace fuse in the lower board (3 amp slow blow)
NO POWER TO THE TREADMILL
Troubleshooting: Treadmills continued
* To test the reed switch: Remove the reed switch from the upper board. Use a standard screwdriver to short both pins
in the upper board. (If the console lights up, replace the reed switch)
NOTE: All treadmills with an Emergency stop button: Emergency stop button leads must be connected to the upper
board in order for the console to power up.
Symptom
Drive motor stops during
workout
Solution
1. Wax running deck
2. Check running belt and deck for debris
3. Check drive motor leads at the lower board. If the lead look abnormal replace
the motor and the lower board*
4. Check LED's on the lower board (See specific version lower board basic
troubleshooting)
5. Test/change large data cable (use large data cable information provided in the
data cable portion of this Guide)
6. Replace the lower board
7. Replace drive motor
TREADMILL DRIVE MOTOR STALLS
* Always change any leads for drive motor if they appear to be abnormal.
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Symptom
Elevation does not move
when key is pressed
Elevation does not reach
minimum or maximum
Elevation jumps to maximum
elevation on power up
Elevation goes to maximum
when start is pressed
Solution
1. Check data cable connections at the lower and the upper boards
2. Calibrate (See engineering mode guide for specific treadmill)
3. Check that the Up Elevation LED on lower board lights when the Up key is pressed
and the Down Elevation LED lights when the Down key is pressed.
4. Test/change large data cable (use large data cable information provided in the
data cable portion of this Guide)
5. Replace touch pad (touch pad is not part of the overlay)
6. Replace lower board
7. Replace elevation motor
1. Calibrate: enter engineering mode and reset elevation values (see engineering
mode guide for specific treadmill)
1. Test/change large data cable (use large data cable information provided in the
data cable portion of this Guide)
2. Calibrate: enter engineering mode and reset elevation values (see engineering
mode guide for specific treadmill)
3. Replace lower board
4. Replace elevation motor
1. Replace touch pad (touch pad is not part of the overlay)
ELEVATION PROBLEMS
Troubleshooting: Treadmills continued
Symptom
Knocking or thumping noise
Solution
1. Make sure that the machine is properly leveled.
2. Check wax build up on the front and rear rollers, scrape off excessive wax.
3. Loosen the rear roller adjustment bolts and retention the running belt (if the running
belt is over-tightened it will put an excessive load on the roller bearings)
4. Check drive (front) roller pulley
5. Check deck bolts
6. Lubricate pivot points
7. Replace roller
NOISE PROBLEMS
• Use the treadmill for about one week. This will sometimes let the roller bearings seat on the roller axle.
• The running belt can conform to the shape of the rollers while packaged. Use the tread for about one week
to smooth out the running belt.
Date of last revision: 11.06 TREADMILL.TROUBLESHOOTING.2007.REV1