Table of Contents Page I. General Information 2-5 II. Set Up 6 III. Theory of Operations 7-10 IV. Mechanical Troubleshooting 11-12 V. Electrical Troubleshooting 13-33 VI. Adjustments and Parts Replacement 34-61 VII.
I. General Information Purpose This manual provides information for the servicing of SCIFIT DC1000 treadmills. It uses systematic troubleshooting procedures to address problems that may arise with the DC1000. The actions taken to resolve problems must be performed in the order stated. Deviating from this sequence may cause damage to the equipment, lead to unnecessary repairs, or void the warranty.
. SCIFIT’s warranty does not apply to parts requiring replacement or repair due to abnormal wear and tear, improper use, corrosion (perspiration), improper maintenance, improper rated grounded or dedicated electrical circuits, or improper storage, nor does it apply where all or part of the product has been altered from its original state. 4.
UPS or Federal Express account, or COD the difference in freight cost between ground shipment and overnight or second day. Return Parts In order to research problems and ensure they do not recur, the rapid return of defective parts is our biggest help! Thank you in advance for your assistance. On electronics orders, a $100.00 core charge is assessed to each printed circuit board. This amount will be credited once the boards have been received by SCIFIT.
Preventative Maintenance Preventative maintenance, completed according to the schedule below, will keep your SCIFIT equipment functioning properly. We realize your time is valuable and have kept these maintenance items to a minimum. This preventative maintenance schedule assumes the equipment is utilized 6 to 8 hours per day. If the equipment is utilized to a greater extent, the maintenance schedule must be adjusted accordingly. Machine Treadmills Weekly Clean exterior. See Note 1.
II. DC1000 Treadmill Power Requirements The DC 1000 Treadmill is a high performance machine with certain power requirements that must be maintained in the field for proper operation. Inadequate power to the DC 1000 may result in intermittent failure of the elevation system and improper speed valuation of the running belt. The following electrical parameters must be met when determining existing power in a facility: 1. Source voltage is between 108-132 volts on a dedicated 15 amp circuit. 2.
III. Theory of Operations DC1000 (120 VAC) The DC1000 is a dynamic DC treadmill designed for a wide range of applications that vary from the medical market to the sports performance market. This theory of operation encompasses all the electrical components, their functions, and how the components interact with each other. The following is a list of independent electrical components found in the treadmill: 1. 15A Rocker Breaker switch 2. Lower PCB (Motor Controller) 3. Upper (Display) PCB 4. 2.
D. E. F. Contains the display LEDs and LED drivers. 12 VDC from the lower PCB is regulated to 5 VDC, which powers the LEDs. Contains five (5) and eight (8) VDC voltage regulators to power various circuits on the upper PCB. Contains the memory and processor components 4. Elevation motor A 120 VAC motor with 345 inch-pounds of torque is attached to a 600-to-1 ratio gearbox. It draws 1.
System Functions 1. Turning on the treadmill A. The power cord must be plugged into a 120 VAC, 15 or higher amp dedicated circuit. B. Turning on the rocker switch provides power (120 VAC) to the lower PCB. C. Power to the lower PCB is verified by observing a lighted LED labeled “+12” at D5. D. Power (12 VDC) is routed from the lower PCB to the upper PCB (pin 5 of the eight-pin Telco cable).
E. The upper PCB controls the elevation system. It provides the voltage to the EPOT by interfacing through the lower PCB and then measures the voltage drop across the EPOT. If there is a difference between the elevation entered by the user and the elevation measured across the EPOT, the display PCB sends a signal to a relay on the lower PCB to switch on 120VAC for the elevation circuit. The voltage runs through the starter capacitor to the elevation limit switches and then to the elevation motor.
IV. Mechanical Troubleshooting A. Mechanical Troubleshooting Table Problem Possible Reasons Solutions Front, rear, or guide roller is making clicking, grinding, or knocking noises. Running belt slipping. Running belt overtensioned. Re-tension running belt. (Page 34) Bearings are bad. Running belt is too loose. Belt tracking off. Replace roller. (Pages 44-47) Re-tension running belt. (Page 34) Drive motor knocking or grinding. Guide roller missing. Pulley and flywheel are loose.
B. Deck / Belt Friction Test 1. With the treadmill either turned off or in idle mode, stand on the running belt (P1246) with your feet in positions 1 and 4. Position your toes so they are approximately 12 inches from the motor hood (P1252). 2. Place both hands on the handle bar (A1793). 3. Push on the handle bar to see if you can propel yourself backwards on the running belt. Reminder: Your full weight needs to be on the running belt and your feet in positions 1 and 4. 4.
V. Electrical Troubleshooting A. Electrical Troubleshooting Table Problem Possible Reasons Solutions Unit keeps blowing fuses on lower PCB. Incoming voltage from the wall to the treadmill is too high. Verify voltage from the wall to the unit. Relays sticking on lower PCB. Replace lower PCB. (Page 60-61) Defective lower PCB. Replace lower PCB. (Page 60-61) Replace lower PCB. (Page 60-61) Unit keeps blowing fuses in the terminal block. No lights on upper display. Relay sticking on lower PCB.
Electrical Troubleshooting Table (cont.) Problem Possible Reasons Solutions When pressed, buttons do not beep and the numbers do not change on upper display. Ribbon cable from membrane to upper PCB unplugged. Plug in ribbon cables. Faulty membrane. Replace membrane. (Pages 57-58) Fix or replace Telcos. Upper display resets after starting workout. Loose Telco connection. Power cord loose or has a bad ground. Fix loose connection. Outlet has a bad ground. Consult electrician. Faulty upper PCB.
B.
Status Action Query DC1000 Belt Does Not Move Lights on Display? Start button working? Yes Belt move when speed set to 3mph? No No Yes Refer to No Light on Display flowchart. Replace switch membrane Recalibrate Speed. See Club Setting Mode Speed Calibration Fix connection or wires, if possible. J2 6-pin header on Display PCB damaged? No Yes No Yes Motor lead wires and connections good? No Replace drive motor. Replace Lower PCB.
Query Status DC1000 Intermittently Shuts Down / Resets Note 1: Adjusting pot clockwise will increase torque. Counterclockwise will decrease torque. Adjust so the belt is not surging but is not lagging during foot plants. Yes Reliable power source (110-125 VAC w/dedicated circuit) and established power connections? Note 2: If static is present, users may experience a shock during use or on other metal objects in the area, i.e. door knobs.
Query Status DC1000 Does Not Change Elevation Lights on upper display? Yes Elev. Arrows change values on display? No No Refer to No Lights on Display flowchart Replace membrane. Refer to Test Mode instructions in Section V. Advance to Elevation Test parameter. Resume Flowchart Troubleshooting. Yes Yes Motor elevates? Yes D9 illuminates when Elev. Up button pressed? No Telcos & connections good? No 105-125 VAC at JP9 across Up & Com? No Yes Yes Note Action D8 illuminates when Elev.
C. Lower PCB LED’s and Upper PCB Jacks DC1000 Lower PCB (Motor Controller) LED’s LED Function Function Description D5 Power 12 to 18 VDC is present. Illuminated when power is on. D6 Speed Pick-Up Flashes when the drive motor is running. D7 Belt Enable Illuminated when Run command is present. D8 Elevation Down Illuminated when down relay is activated. D9 Elevation Up Illuminated when up relay is activated. D10 PWM Flashes (quickly) when PWM signal is present.
D. Lower PCB (Motor Controller) Diagram No.
E.
F. Test Mode The Test Mode provides technicians with additional information for use in troubleshooting the DC1000 treadmill. Turn the power switch on the treadmill to the OFF position. Press the ELEVATION UP arrow and the ELEVATION DOWN arrow, and simultaneously turn the treadmill power switch to the ON position. Continue to press ELEVATION UP and ELEVATION DOWN throughout the entire power up process and until “tESt” appears in the center display. This process will take three (3) seconds. 1.
numbers when it is elevated. When satisfied that the elevation system is working, press STOP to advance to the next test. 4. Speed Test WARNING: DO NOT TO STAND ON THE BELT!! IT WILL MOVE DURING THIS TEST!! “bELt” will be shown on the top display. This test removes the software from the speed control system. It utilizes only the hardware of the system. Press the Speed Up and Speed Down arrows to determine if the speed system is working properly.
G. Club Mode (Thru Version 1.2 Software) The Club Mode enables club owners and managers to customize certain features of the DC1000 treadmill. Press the ELEVATION UP and ELEVATION DOWN arrows simultaneously for three (3) seconds to enter this mode. (Press the keys until “UnIt” is shown in the top display) 1. Unit of Measure This setting determines whether English or metric units of measure will be displayed. The top display will show “UnIt”. The speed display will show “brl” or Sl”.
the elevation display showing hundreds of miles (or kilometers). If “FLIP” is displayed in the TIME window in normal operating mode and the deck has been flipped, the following steps must be performed to clear the distance. Press and hold the ELEVATION UP arrow for three (3) seconds to reset (once 12,000 miles has been accumulated). Press SELECT to exit the Club Mode and return to start mode. If the treadmill is not displaying “FLIP” in the TIME window, press SELECT to advance to Speed Calibration. 6.
7. Calibrate Elevation If you have calibrated the speed, you will need to reenter the Club Setting Mode again. Press SELECT until “CALE” is shown in the top display. This setting calibrates the elevation of the treadmill. Press the ELEVATION UP and ELEVATION DOWN switches simultaneously for three (3) seconds to enter the elevation calibration subprogram. “ECAL” will be shown in the top display. Press START. The top display will show the high grade selected the Factory Settings Mode, which is “25.0”.
range is from 0 to 90 minutes in increments of 5 minutes. “0” is unlimited time and is the default setting. The top display shows the time selected. Select the duration by using the ELEVATION UP or ELEVATION DOWN keys. After selecting the desired duration, press the SELECT key to advance to the next setting. 3. External Communication This setting selects either the C-Safe (CSF) or Cardio-Key (CAr) communications protocol. The top display will show “S.CO”. The speed display will show either “CAr” or “CSF”.
Make sure there is nothing on the treadmill belt. It will be moving at high speed on this next step. In SPEED CALIBRATION mode, the target speed appears in the speed window, while the actual speed appears in the time window. The elevation window displays a default variable set by the software on a 250-bit scale. Press the START button one (1) time to begin SPEED CALIBRATION. The belt will start to run at a very rapid speed. The target speed of “10.0” will appear in the speed window.
elevation potentiometer (it should be more than 225 when the treadmill is completely elevated). The treadmill will elevate to the high limit switch. The top display will then change to “0.0” which is the low grade set in the Factory Settings Mode. The speed display will show “dn4”. The elevation display should be less than 30 when the treadmill is completely lowered. The treadmill will descend to the lower limit switch.
7. Let the treadmill belt slow down completely before performing this next step. “Ir C” will be present in the speed window. The default value of “12” will be showing in the elevation window. This part of the procedure determines how the motor adjusts to having a load on the belt. The compensation variable appears in the elevation window. To make compensation adjustments, use the SPEED UP arrow to increase or SPEED DOWN arrow to decrease compensation.
VI. Adjustments and Parts Replacement A. Running Belt Tracking and Tensioning 1. Checking Belt Tracking: a. Observe the location of the belt (P1246) on the deck (P1425 or A2352) relative to the side rails. b. Verify that the belt is centered between the side rails along the entire deck surface. 2. Adjusting Belt Tracking: a.
B. Deck and Running Belt Replacement 1. Elevate the treadmill to 15% grade. 2. Unplug treadmill from the outlet. The treadmill will remain elevated. 3. Place a solid object under the rear cross member (P1513) of the treadmill to elevate the rear of the treadmill and give access to the underside. If nothing is available, flip the treadmill on its side (before you flip the treadmill, complete step 4). 4. Using a Philips screwdriver, remove the motor hood (P1252).
5. Remove the two (2) rear end caps by removing two (2) 5/16” bolts, one (1) per side, using a ½” wrench and socket. Using a 9/16” wrench, remove the 3/8” bolt on each side securing the foot pad (P1250) and spacer (A1249) to each side. 6. Remove the two (2) running belt tensioning socket head cap screws, one (1) on each side, using a 5/16” Allen wrench. 7. Remove the tension bracket (P1439) from each side. 8. Locate the guide roller assemblies (P1242).
these outside bolts. Do not do anything to the bolts that runs through the cross braces and into the deck. 13. Once the deck is free, remove the left front roller bolt using a 9/16” wrench. Then remove the right front roller bolt. Rotate the right side of the front roller (A1244) under the belt (P1246). This will loosen the timing belt (P1247) and make it easy to slide off. The front roller will now be rotated almost 90° from its original position. Pul l out the front roller. 14.
the front roller the reverse of the way you removed it. Position the roller with motor belt in place and install the two (2) front roller bolts. The right side has a roller spacer (A1401) that goes between the front roller and frame. 31. Slide deck to where it is ½” to 1” from the front roller. Tighten the ten (10) outer bolts that run through the cross braces on the bottom of the deck. 32. Install the two (2) guide rollers.
C. Cushioned Deck and Running Belt Replacement 1. Elevate the treadmill to 15% grade. 2. Unplug treadmill from the outlet. The treadmill will remain elevated. 3. Place a solid object under the rear cross member (P1513) of the treadmill to elevate the rear of the treadmill and give access to the underside. If nothing is available, flip the treadmill on its side (before you flip the treadmill, complete step 4).
4. Using a Philips screwdriver, remove the motor hood (P1252). 5. Remove the two (2) rear end caps by removing two (2) 5/16” bolts, one (1) per side, using a ½” wrench and socket. Using a 9/16” wrench, remove the 3/8” bolt on each side securing the foot pad (P1250) and spacer (A1249) to each side. 6. Remove the two (2) running belt tensioning socket head cap screws, one (1) on each side, using a 5/16” Allen wrench. 7. Remove the tension bracket (P1439) from each side. 8.
10. Slide guide roller assemblies out from under the extrusion and deck belt. 11. Using a 9/16” socket, remove the two (2) bolts holding front roller cover to the motor plate. This will allow you to remove the front roller cover. 12. Using a ½” socket, loosen the ten (10) outer bolts that run through the deck spacer (A2085), deck cross braces (A2080) and into the nut bar (A2081) on the bottom of the deck (A2352), approximately 3-4 turns. Only loosen these outside bolts. Do not completely remove them. 13.
26. Line up the holes in the end cap bracket with the holes in the extrusions and welded tabs of the rear cross member. 27. Insert the bolts for the foot pads and foot spacers on each side. This bolt will run from inside the extrusion on down through hole. 28. Slide spacer onto each bolt followed by the flat washer and foot pad. Place 9/16” wrench onto bolt head and turn foot pad clockwise until tight. 29. Insert the bolts that run up through the welded tabs and the end cap brackets.
D. Belt Replacement Walk-In Procedure 1. Once the deck has been flipped or replaced and a new belt has been installed, the combination must be “walked in”. The “walk in” in designed to distribute the phenolic wax on the deck evenly into the belt fibers and across the deck. Not “walking in” a belt can cause chunks of wax to break loose from the deck and embed on the rollers causing a thumping noise and leaving an area of the deck with no wax which will cause a friction problem.
E. Guide Roller Replacement 1. Elevate the treadmill to 15% grade. 2. Unplug treadmill from wall outlet. Treadmill will remain elevated. 3. Locate the guide roller assemblies. There is one (1) guide roller assembly (P1242) on the bottom side of each extrusion. 4. Using a ½” wrench, remove the bolt with lock washer that runs up through the extrusion and up into the guide roller bracket. 5. Slide guide roller assembly from under extrusion and running belt (P1246). 6.
the roller threads. Rotate the right side of the front roller (A1244) under the deck and running belt. This will loosen the motor’s timing belt on the left side of the front roller and make it easy to slide off. Rotate the front roller approximately 90º from its original position. Pull the roller out from under the treadmill. 7. Install new front roller by reversing step 6. 8. Install guide rollers. 9. Turn each rear roller tension bolt clockwise, approximately 6-10 turns. 10.
8. Remove the rear feet. Using a 9/16” wrench, hold the head of the bolt that runs through the center of the foot spacer (A1249) and into the foot pad (P1250). Rotate the foot pad until it unthreads completely from the bolt. Repeat this procedure for the other foot removal. 9. Using a ½” wrench and socket, remove the bolts that hold the end cap brackets to the welded tabs of the rear cross member. 10. Pull end caps out of the extrusions. 11.
24. Mount the guide rollers back into their normal positions. 25. Tension the running belt according to the “Running Belt Tracking and Tensioning” procedure (Page 34). H. Drive Motor Replacement 1. Elevate treadmill to a 15% grade and disconnect power at the outlet. 2. Using a Philips screwdriver, remove the motor hood (P1252). 3. Loosen the motor tension bolt closest to the front roller, 3 to 4 turns, using a 5/32” Allen wrench. 4. Disconnect the red and black motor wires from the lower PCB. 5.
motor pulley, one (1) of the tension bolts will need to be tightened. If the belt is riding against the inside lip of the motor pulley, one (1) of the tension bolts will need to be loosened. Each time an adjustment is made, the flywheel needs to be spun to allow the belt to seat. 15. Once aligned the timing belt should appear taut. Tighten the bolts and nuts at the base of the motor. The timing belt should have approximately 3/8” travel when pushed down and then pulled up on.
6. Press down on the right side of the front roller until it is free of the front roller spacer (A1401). 7. Remove roller spacer. Newer models have a nylon thrust bearing (P2046) between the spacer and the extrusion. Then pull the bolt out of the extrusion. Newer models have an additional nylon flange bushing (P2045) inserted into the front roller bolt hole on the outside of the right extrusion. 8.
and move motor slightly forward or backwards and retighten nuts. Repeat this procedure until the tension is correct. 22. Verify all nuts and bolts are tightened down. 23. Restore power and test operation of the treadmill. 24. Restore and fasten motor hood in place. J. Elevation Motor Replacement 1. 2. 3. 4. Make sure treadmill is at 0% elevation. Turn power off to unit. Using a Philips screwdriver, remove the motor hood (P1252).
8. Remove the three (3), elevation motor mounting bolts. Earlier elevation motors were mounted using ¼-20 x .5 button head bolts. These require a 3/32” Allen wrench to remove bolts. Later models used ¼-20 x .5 with a ¼” lock washer. These require a 7/16” wrench to remove. 9. Slide the elevation motor horizontally out of coupling on the short shaft side and remove from system. (Motor will slide towards left side of treadmill, as if you were using the treadmill.) 10.
that shaft and pinion horizontally until it does. Then re-tighten the outermost bolts. 24. Reconnect the elevation motor and starter capacitor wires to the terminal block. • If you have a 4-wire elevation motor, the motor lead labeled “1” and one (1) of the starter capacitor leads connect under the top, left screw in the terminal block. The motor lead labeled “0” and the other starter capacitor lead connect to the left side screw that is located second from the top.
6. Install the new potentiometer (P1269) onto the old bracket (P1485). To do this step, loosen the set screw on the pinion (P1479), using a 1/16” Allen wrench and slide the pinion off the end of the potentiometer shaft. Using a ½” wrench, remove the nut that holds the potentiometer to the mounting bracket. Pull the old potentiometer out of the bracket and insert the new potentiometer with the wires facing the top of the bracket. Re-install the ½” nut and tighten.
3. Disconnect wires running to each limit switch (P1260). 4. On the backside of the bracket that the limit switches mount to, remove the two (2) nuts holding the limit switches in place. Remove switches. 5. Re-attach wires in the same order on the new limit switches. 6. Replace the new limit switches through the same two (2) holes that the other switches were removed from. Make sure the two (2) legs on the limit switches clear the elevation rack (A1508). 7.
5. Using a ½” socket and extension, remove the four (4) bolts with washers and the four (4) nuts with washers from the upright bases. 6. Remove the upright assembly by lifting it up over the elevation racks and set it off to the side. 7. Disconnect wires running to each limit switch (P1260). 8. On the backside of the bracket that the limit switches mount to, remove the two (2) nuts holding the limit switches in place. Remove switches. 9. Re-attach wires in the same order on the new limit switches. 10.
M. Upper PCB Replacement 1. Turn off the power to the unit then remove the safety magnet (S1744) from the upper display. 2. Using a Philips screwdriver, remove the four (4) screws mounting the upper display. They are located on the bottom side of the console. 3. Lift membrane (P1517) up to expose wiring connections on the back of the upper PCB (P1944). Warning: Make sure you are grounded before handling electronics. Failure to do so may result in static damage. 4.
This plugs into the vertically mounted header on the right, backside of the upper PCB. • Broadcast Vision is another optional feature of the treadmill. If your unit is set up for this option, there is a black, 8-pin Telco cable coming into the console housing. Its location depends on where the user decided to mount the keypad. This plugs into the black header that sits by itself on the right, backside of the upper PCB. 12.
7. Remove upper PCB. 8. Using a 1/16” Allen wrench, remove the two (2), 4-40 X ½” screws holding the magnetic switch (P1522) in place. 9. Pull magnetic bracket (P1609) loose and reinsert on the new membrane. 10. Place the magnetic switch flat side down and start the two (2), 4-40 X ½” screws through the slots in the switch. 11. Slide switch completely to the right and tighten screws. 12. Replace upper PCB and install the eight (8) Philips screws. 13. Reconnect the ribbon cables. 14.
O. Wireless Heart Rate PCB Replacement 1. Turn off the power to the unit then remove the safety magnet (S1744) from the upper display. 2. Using a Philips screwdriver, remove the four (4) screws mounting the upper display. They are located on the bottom side of the console. 3. Lift membrane up to expose wiring connections on the back of the upper PCB (P1944). Warning: Make sure you are grounded before handling electronics. Failure to do so may result in static damage. 4.
P. Contact Heart Rate PCB Replacement 1. Turn off the power to the unit then remove the safety magnet (S1744) from the upper display. 2. Using a Philips screwdriver, remove the four (4) screws mounting the upper display. They are located on the bottom side of the console. 3. Lift membrane (P1517) up to expose wiring connections on the back of the upper PCB (P1944). Warning: Make sure you are grounded before handling electronics. Failure to do so may result in static damage. 4.
• The cable from the power switch or filter (if equipped) has two (2) wires on the newer treadmill while the older treadmills have three (3) wires. The blue wire connects to BC4 Common, the brown wire to BC5 A/C IN, and the green wire (on the older treadmills only) to BC9 FRAME. • The cable from the lower PCB to the fuse block also differs. Newer treadmills have a gray-jacketed cable with a large white, Molex header. This plugs into the lower PCB at JP9.
VII.
