Xterra ET94, Service Manual

Page 1: ...E ET T9 94 4 T Tr re ea ad dm mi il ll l S Se er rv vi ic ce e M Ma an nu ua al l ...

Page 2: ...WARNING ALWAYS UNPLUG THE TREADMILL FROM THE ELECTRICAL OUTLET BEFORE SERVICING THE UNIT ...

Page 3: ...Layout 23 Figure 3 Mechanical Layout 23 Figure 4 Main Controller information voltages 24 Figure 5 Function JK1 connector on Main Controller 24 Figure 6 Wiring Diagram 25 Figure 7 Schematic Diagram 25 Figure 8 If Treadbelt slips 26 Figure 9 If tread belt shifts too far to the Right 26 Figure 10 If tread belt shifts too far to the Left 27 Figure 11 Resetting Reset switch 29 Figure 12 Fuse replacemen...

Page 4: ...fety key console can not be controlled b Console Interface that controls all functions of the treadmill c Main controller The circuit board consist of the DC power supply and takes input from the console and output appropriate voltages that control the treadmill functions d Treadmill motor This is a variable speed for DC motor To control the 0 90 volt on the main controller it can to increase or d...

Page 5: ...ack and green c If there is positive of DC voltage on the Red wire M the treadmill motor will turn clockwise d If there is positive of DC voltage on the Black wire M the treadmill motor will turn counter clockwise e The green wire is ground 5 INCLINE MOTOR a This is a 110 volt AC motor b Have four wires red black white and green c Has one 3 pins cable of position sensor d If there is AC voltage on...

Page 6: ...S Se er rv vi ic ce e M Ma an nu ua al l D De es sc cr ri ip pt ti io on n D De es sc cr ri ip pt ti io on n 6 6 Figure 1 Operational Flowchart ...

Page 7: ...l appear blank 2 READY MODE a When the treadmill is ON and SAFETY KEY is inserted in console the message window will show SELECT A PROGRAM OR PRESS START TO BEGIN WORKOUT b Press START button to start treadmill on Manual Mode 3 SLEEP MODE a In SLEEP Mode if START button is pressed then the treadmill enters READY Mode 4 RUN MODE a In RUN Mode pressing the STOP button and removing the SAFETY KEY wil...

Page 8: ...0 to 15 b DISPLAY range is 0 to 99 c WORK range is 0 to 15 d INCLINE preset value is 0 to 15 e Press UP or DOWN to adjust incline each increment or decrement is 1 3 TIME a TIME is either COUNT UP or COUNT DOWN System preset is COUNT UP if user sets the time then timer is COUNT DOWN b DISPLAY range is 0 00 to 99 99 c WORK range is 0 00 to 99 59 d COUNT DOWN setup range is 10 00 to 99 00 e When TIME...

Page 9: ...One lap of Playground is 0 25 Mile 5 DISTANCE a Display the current distance in Mile b DISPLAY range is 0 00 to 99 99 c WORK range is 0 00 to 99 99 6 CALORIES a Displays the cumulative calories burned at any given time during your workout b DISPLAY range is 0 0 to 999 9 c WORK range is 0 0 to 999 9 7 PULSE a Display the heart beat by using hand pulse or receiver If user wants to use receiver then ...

Page 10: ... using time Pre set PROGRAM can set using time and speed Heart Rate Control 1 2 can set time age and the value of heart rate User Program 1 2 can set time speed and incline e PROGRAM button Press PROGRAM button to select manual preset program user program and HRC program f SELECT button In program mode press SELECT button to choose speed profile incline profile or speed and incline profile g FAST ...

Page 11: ...FAST button Press the button to increase your speed and each increase is 0 1 kph If button is pressed continuously then speed increases to MAX SPEED quickly h SLOW button Press the button to decrease your speed and each decrease is 0 1kph If button is pressed continuously then speed decreases to MIN SPEED quickly i UP button Press the button to raise position and each increase is 1 the maximum inc...

Page 12: ...to adjust SPEED window to 2 3 f Press START button to memorize above setting and enter next section of setting mode g Set Min speed Press FAST or SLOW button to adjust SPEED window to 0 5 h Press START button to memorize above setting and enter next section of setting mode i Set high speed Press FAST or SLOW button to adjust SPEED window to 12 0 j Set high incline position Press UP or DOWN button ...

Page 13: ...TING WARNING ALWAYS UNPLUG THE TREADMILL FROM THE ELECTRICAL OUTLET BEFORE SERVICING THE UNIT 1 GENERAL a Do a visual check of all wiring and connections looking for chafed wires or lose connections b Make sure any wiring is safely positioned and or secured away from moving parts c If you find a fuse blown on a circuit board replace the circuit board ...

Page 14: ...to outlet 2 Plug the power cord into unit 3 Check the voltage of outlet 4 Replace power cord 5 Replace power cord 6 Check if wire is disconnected connect it again 7 Press the small red button to return to original status 8 Replace breaker 9 Replace A C switch After turning on power treadmill has a popping sound 1 Incorrect input power varistor is blown broken on controller 1 Check the voltage of p...

Page 15: ...ey When press START treadmill doesn t start 1 Motor M or M wire isn t connected into right position 2 Controller is broken No power to motor 3 Motor is broken 4 Treadmill controller shut down and LED would be ON 1 Please check and plug again 2 Replace controller or MOSFET IRFP 260 and add the Silicone Heat Sink Paste suitably 3 Replace motor or check the wire and connector if it was broken 4 Turn ...

Page 16: ...otor wires red black aren t plugged into controller 3 Computer cables not connected properly 4 Computer cables are broken or damaged 5 Motor belt is broken 6 Controller is broken 7 Motor is broken 8 Console is broken 1 Turn off power and reset the treadmill 2 Plug wires again 3 Plug the wire again on controller connector and console 4 Replace with new wires 5 Replace with new motor belt 6 Replace ...

Page 17: ...le 7 Gray and purple wires got damage replace the wires 8 Replace console SPEED windows display is not 1 0 to 16 0 km 1 Monitor is not calibrated 1 Calibrate the console INCLINE windows display is not 0 to 10 1 Console is not calibrated 1 Calibrate the console The speed of the belt doesn t match console display 1 Console is not calibrated 1 Calibrate the console The incline position doesn t match ...

Page 18: ...again 2 Replace controller and calibrate it Erratic pulse display 1 Another chest belt in use around treadmill 2 Other magnetic field disturbance 3 Receiver is broken 1 Check for other chest belt use around treadmill 2 Change the position or direction of treadmill 3 Replace with new receiver After pressing START button the treadmill stop immediately 1 Controller was broken 1 Replace with new contr...

Page 19: ... with new cable 6 Replace with new cable UP DOWN button of INCLINE ADJUSTMENT SWITCH can t be used Incline button just can press UP can t press DOWN Incline button just can press DOWN can t press UP 1 The connector of INCLINE CABLE UPPER and CONSOLE not connected properly 2 The connector of INCLINE CABLE UPPER and INCLINE ADJUSTMENT SWITCH W CABLE not connected properly 3 The connector of INCLINE ...

Page 20: ...splayed on monitor 1 Chest belt not worn properly 2 Distance is too far and exceeds range of receiver 3 Chest belt battery is weak or dead 1 Check chest belt has proper contact with skin and is oriented correctly 2 User chest belt in front of console within 3 feet 3 Replace with new lithium battery type is CR2032 Chest belt too close to the treadmill Weak battery Replace with new lithium battery w...

Page 21: ...or cover 1 Worn brushes or bearings on motor 2 Front roller bearings are defective 3 Drive belt is misadjusted too tight or too loose 1 Replace with new motor 2 Replace with new front roller 3 Adjust motor position Noise in the rear of the treadmill 1 Rear roller bearings are defective 2 Rear roller misaligned 1 Replace with new rear roller 2 Adjust rear roller position ...

Page 22: ...he current of DC motor When current of motor exceed 25A the LCD will turn on If LIMIT light is bright for 3 to 5 seconds the S_D light will turn on Loading is too high on belt Operation is not correct motor lock Check mechanical drive system is not locked or jammed Replace controller Replace motor S_D shutdown Controller shut down If controller has unusual shut down the S_D light will be always br...

Page 23: ... an nu ua al l D Di ia ag gr ra am ms s a an nd d S Sc ch he em ma at ti ic cs s D Di ia ag gr ra am ms s a an nd d S Sc ch he em ma at ti ic cs s 2 23 3 DIAGRAMS AND SCHEMATICS Figure 2 Console Layout Figure 3 Mechanical Layout ...

Page 24: ...l l D Di ia ag gr ra am ms s a an nd d S Sc ch he em ma at ti ic cs s D Di ia ag gr ra am ms s a an nd d S Sc ch he em ma at ti ic cs s 2 24 4 Figure 4 Main Controller information voltages Figure 5 Function JK1 connector on Main Controller ...

Page 25: ... Se er rv vi ic ce e M Ma an nu ua al l D Di ia ag gr ra am ms s a an nd d S Sc ch he em ma at ti ic cs s D Di ia ag gr ra am ms s a an nd d S Sc ch he em ma at ti ic cs s 2 25 5 Figure 6 Wiring Diagram ...

Page 26: ...t slips The treadbelt is too loose Tighten both rear roller adjusting bolts 1 4 turn clockwise using allen wrench 1 4 TURN Figure 9 If tread belt shifts too far to the Right a Set the treadmill speed to 3 5 mph 5 6 km b Tighten the right adjusting bolt a 1 4 turn clockwise using allen wrench c Wait 15 seconds if no change turn the left adjusting bolt a 1 4 turn counter clockwise using allen wrench...

Page 27: ... 5 6 km b Tighten the left adjusting bolt a 1 4 turn clockwise using allen wrench c Wait 15 seconds if no change turn the right adjusting bolt a 1 4 turn counter clockwise using allen wrench d Repeat steps b and c until belt is centered IMPORTANT DO NOT OVERTIGHTEN TREADBELT If treadbelt is overtightened edges of treadbelt will begin to curl CAUTION DO NOT ALLOW ANYONE TO WALK ON TREADBELT WHILE Y...

Page 28: ...required If the surface is dry to the touch apply one packet of lubricant HOW TO APPLY LUBRICANT 1 Lift one side of treadbelt 2 Pour one half of the lubricant bottle under the center of the treadbelt on the top surface of the treadboard 3 Walk on the treadmill at a slow speed for 3 to 5 minutes to evenly distribute lubricant NOTE DO NOT over lubricate treadboard Any excess lubricant that comes out...

Page 29: ... C 2 29 9 APPENDIX C Figure 11 Resetting Reset switch 1 RESET SWITCH RESETTING a If the red button of reset switch is tripped it will protrude out from the face of the switch b Press in the red button of the switch c If the red button of reset switch is not tripped that means normal Tripped Normal ...

Page 30: ... Fuse replacement 1 FUSE REPLACEMENT If your treadmill loses power or will not start check the fuse located on the motor controller DANGER Turn the power switch off and unplug the treadmill to reduce the risk of an electric shock Remove the motor cover Remove and replace the fuse on the motor controller Replace the motor cover ...

Page 31: ...r distance the speed sensor and magnet may be misaligned Follow these steps to check and realign Remove the motor cover Check the spacing and alignment between the magnet on the right side of the front roller and the speed sensor on the frame The spacing must be 1 8 Loosened screw and slide speed sensor in or out of clamp Retighten screw Replace the motor cover 2 SERVICE QUESTIONS ...