True Fitness 350 750 Users Manual Treadmill Service
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350750 397b8feb-b124-4e43-a333-8d182307dfe4 True Fitness Treadmill 350-750 User Guide |
2015-02-03
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True Fitness Service Manual Treadmills Models 350-750 True fitness technology, Inc. makes no representations or warranties regarding the contents of this manual. We reserve the right to revise this document at any time or to make changes to the product described within it without notice or obligation to notify any person of such revisions or changes. © 2004, True Fitness, Inc. All rights reserved. Printed in the United States of America. 865 Hoff Road. O’Fallon, MO 63366. 1-800-426-6570. Fax 636-272-3026. www.truefitness.com Revision 9/2004 Treadmill Preventative Maintenance Checklist Run calibration or run a manual program and watch and listen for anything out of the ordinary. Perform a push off test (page T-7) to check for proper lubrication. If excessive friction is found and lubrication doesn’t correct the problem perform the amp draw test (page T1-2) Inspect the belt surfaces, topside should still have texture for grip, bottom should be porous fabricnot glazed, smooth or hard. Inspect deck surface, should be free of scratches, abrasions or blistering. Listen for excessive bearing noise, from a standing position, in the front and rear roller and motor. Check for front roller/belt slippage and belt tension adjustment. Look for slippage on drive pulley. Inspect/ adjust tracking of belt. Vacuum out motor area, being careful not to damage PWM. Inspect drive belt for wear and cracking. Wipe down machine- leave it in better condition than you found it. True Fitness Treadmill Service Manual START Symptom guide Calibration Procedures Diagnostic Procedures Test Procedures Wiring Diagrams Part Manuals Page 1 SYMPTOM GUIDE Page 2 Error Code Definitions . . . . . . . . . . . . . . . . . . . . . . . . Page 3, 4 No Belt Movement Tread Belt Stops During Workout . . . . . . . . . . . . . . . . Page 7 Heart Rate Not Working / Erratic Readings . . . . . . . . Page 8 Elevation Not Functional . . . . . . . . . . . . . . . . . . . . .. . Speed Fluctuation: E2 Cal . . . . . . . . . . . . . . . . . . . . . . Page 10 Speed Fluctuation: S4, E5, E2 E3: EPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . Page 11 No Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 12 Circuit Breaker Trips at Start Up . . . . . . . . . . . . . .. . Page 13 Soft Select Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . Page 14, 15 Calibration Procedures . . . . . . . . . . . . . . . . . . . . . . . . Page 16 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . Page 5, 6 Page 9 Page 17 Symptom Probable Cause Corrective Action Recommended Tools ERROR MESSAGES: S1 L LUBE Indicates that the accumulated distance is such that the deck needs to be lubed S2 C CLEAN Indicates that the accumulated distance is such that the machine needs to be cleaned. S3 M MOTOR Indicates that the accumulated time on the treadmill is such that the motor brushes need to be changed/checked. • Lube deck with True Fitness liquid silicone lubricant. Inspect wax bar assembly on commercial models, if worn to less that ¼ inch in thicknessreplace wax bar. • Remove motor cover and vacuum dust from area. Wipe down the exposed area of the deck beside the straddle covers with a clean, dry cloth. • • Check/Replace motor brushes as needed. Reset timer. • Perform Speed Sensor Test page 21 SPEED SENSOR Cannot read speed sensor E1 S STALL Incline reading not changing when commanded • See Elevation Not Functional page 9. E1 I INCLINE Incline reading has changed without the incline being commanded. • See Elevation Not Functional page 9. E1 R RANGE Maximum or minimum elevation out of calibrated ranges • See Elevation Not Functional page 9. E5 S Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Liquid silicone single use pack Liquid Silicone Applicator. Vacuum Shop towel Fax: 636-272-7148 Page 3 Symptom Probable Cause Corrective Action ERROR MESSAGES: (cont’d) Multi-meter Phillips head screwdriver E2 O OVERSPEED Belt speed ramping too fast. Perform Amp Draw Test – Page 20. Perform Belt / Deck Wear Test – Page 24. E2 C CALIBRATE Micro-controller cannot adjust belt speed to target. Calibrate Treadmill – Page 16. See appropriate Symptom Guide – pages 10-11. Software error during treadmill startup diagnostics. Restart Treadmill, if error persists- replace control panel. Treadmill has lost calibration settings. Recalibrate Treadmill – Page 16. (If unit loses programs- replace control panel) E3 E EEPROM E2 R RECALIBRATE Page 4 Recommended Tools Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148 Symptom NO BELT MOVEMENT Probable Cause Treadmill in need of calibration. Corrective Action • Recommended Tools Run calibration. (page 16) Multi-meter PWM / Motor test cables -------Missing command to PWM. • Is PWM light blinking/ illuminated when fast button is pushed? NO- Check continuity on wire harness, if harness has continuity breaks replace the harness. If harness has continuity- replace the upper panel. Refer to wiring harness diagram for your model. YES- move on to next step, wire harness and control panel are OK. Note: All trouble shooting should be performed in calibration mode. Page 16 -------Missing/incorrect voltage to motor. • • • • • Damaged motor. With treadmill in calibration mode (page 16) Set speed at 4 MPH Check VDC across MTR 1 and MTR 2 with the motor leads connected to the motor the voltage should measure 10 VDC for every 1 MPH. If voltage is missing or low- Replace PWM. If voltage is greater than 20 VDC/MPH motor may have open windings. -------• • • • With PWM LED Blinking/ Illuminatedmove the tread belt with your foot to see if motor begins to move on its own. If motor begins to move, inspect the condition of the brushes and the commutator. If brushes are bad- replace brushes If motor doesn’t turn or has a damaged com segment- replace motor. Continue on next page… Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148 Page 5 Symptom Probable Cause NO BELT MOVEMENT (cont’d) Motor turns but belt does not. Corrective Action • • Check belt tension. Set belt tension to 1/8-inch deflection or correct tension can be verified by twisting the belt almost to a 90-degree position. Recommended Tools Note: All trouble shooting should be performed in calibration mode. Page 16 -------- Belt cannot be moved manuallyforeign object under belt. Page 6 Support Services 800-883-8783 • Remove foreign object. Perform the Amp Draw Test (page 20) to check for excessive amp draw damage Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148 Symptom TREADBELT STOPS DURING WORKOUT Error Code displays: Go to page 3 & Page 4. Probable Cause Loose safety key connection Corrective Action • • Recommended Tools Check safety key to ensure that it is seating properly. Check connection sensitivity. -------- Belt movement issue • If treadmill will not reset with cycling the power go to NO BELT MOVEMENT (pages 5 & 6) -------- Worn Deck / Belt • Perform Belt / Deck Wear Test (page 24). Perform Amp Draw Test (page 20). Apply silicone. Replace Deck and Belt. -------- • • • Occurs when making changes to speed or elevation • May be related to electro static discharge. Contact Technical support for assistance. Liquid silicone single use pack Liquid silicone Applicator Multi-meter Socket set Note: All trouble shooting should be performed in calibration mode. Page 16 -------Overloaded house circuit • • Verify the treadmill is on a dedicated circuit with at least a 15 amp breaker Have customer supply a dedicated circuit -------Continuity, connection to motor • Reconnect or replace motor wires or connectors -------- Tread belt not centered or obstructed Support Services 800-883-8783 • • • Tension tread belt (page 22) Center tread belt Remove obstruction Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148 Page 7 Symptom Probable Cause HEART RATE NOT WORKING / ERRATIC READINGS Incorrect power source Corrective Action • • • Verify that the treadmill is connected to a dedicated line, 15-amp circuit, and not on an extension cord. Move to proper outlet. Test 110 VAC outlet for proper ground Recommended Tools Multi-meter Double sided tape Heart rate simulator -------Improper treadmill grounding • • Proper grounding is vitally important. Ensure that the pedestal wire harness ground lead is secure -------Improper heart rate receiver mount • Defective Chest Strap • • Ensure that the HR receiver is not touching metal and is mounted with the wires in a vertical position with the blue receiver facing the runner Note: All trouble shooting should be performed in calibration mode. Page 16 -------Does the receiver pick up a signal from the HR simulator? If yes, replace chest strap -------- Defective receiver • Does the heart rate LED on the control panel blink? If not then replace the receiver. -------- Radio Frequency Interference Page 8 Support Services 800-883-8783 • Locate RF sources and use process of elimination. Common sources of RF interference are: Invisible fences for pets; wireless networks; cordless phones, Cell phones, radios, home security sensors, etc. Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148 Symptom ELEVATION NOT FUNCTIONAL ( E1 ERROR) Probable Cause Improper grounding / Calibration (May cause unit to drift up & down without command) Corrective Action • • • Recommended Tools Test 110VAC outlet for proper grounding If unit has not been calibrated – calibrate Ensure that incline cables are secure on PWM Multi-meter Alligator clip -------Unit is stuck at full incline • • • • Verify the lower limit switch is properly connected to the PWM Remove the LLS wire from the PWM and short the two posts of the connector together with an alligator clip. Cycle the power. If the treadmill lowers itself then replace the lower limit switch. Perform Incline potentiometer calibration procedure (page 16) If incline nut is stripped- replace incline nut Note: All trouble shooting should be performed in calibration mode. Page 16 -------- Defective Start Capacitor • • • • • Do Up/Down command LED’s light? If No- skip to defective PWM section. If yes- does motor hum with no movement? If yes- check the leads to the capacitor for breaks, if no breaks- replace capacitor. If No- replace PWM. -------- Defective PWM • • • Support Services 800-883-8783 If no Up/Down LED’s light check continuity on data cables. If cables are good- replace Upper Panel. If cables bad- Replace data cables. Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148 Page 9 Symptom Probable Cause SPEED FLUCTUATION E2: CAL Speed Fluctuation (Due to high friction) Corrective Action • • Perform Push Off Test (page 24) Perform Amp Draw Test (page 20) • • • • Silicone Lubrication Packet Silicone Lubrication Applicator Check Line voltage for fluctuations. Have customer take corrective action. -------- Bad Data Feedback Multi-meter Socket Set -------- Speed Fluctuation (Due to Voltage fluctuation) Recommended Tools Verify tach feedback accuracy through out the speed range. If inaccurate perform speed sensor test (page 21) Note: All trouble shooting should be performed in Calibration Mode: See SG-12 -------- Incorrect Speed Sensor Gap • • Verify correct Speed sensor Gap. Gap should be equal to the thickness of (3) credit cards pressed together (approximately 1/8 to ¼ inch) ------ Page 10 Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148 Symptom SPEED FLUCTUATION Probable Cause Corrective Action Recommended Tools Multi-meter No Belt Movement • Go to page 5, 6. Socket Set -------- S4: Sensor E5: Speed Sensor E2: Overspeed E3: EPROM Error No/Intermittent Tach Feedback • • • • Silicone Lubrication Packet Enter Calibration mode (page 16) Verify speed feedback in speed display through out the speed range. [Speed display should never show 0 mph when belt is moving] If no tach feedback is available perform speed sensor test (page 21). Check continuity of tach feedback portion of the data cable (To identify tach feed back lines see wiring diagram section for specific model). -------- Overspeed Error • • • • Silicone Lubrication Applicator Note: All trouble shooting should be performed in calibration mode. Page 16 Check/Adjust tread belt tension (page 22) Perform speed sensor test (page 21) If speed sensor fails adjust gap, if still fails-replace speed sensor. Perform belt / deck wear test (page 24) If badly worn, replace belt and deck. Replace PWM -------- E3: EPROM Error Software error during treadmill startup Support Services 800-883-8783 • Restart unit- if error persists, replace control panel. Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148 Page 11 Symptom Probable Cause NO DISPLAY No power at the 110 VAC outlet. Corrective Action • • • Check home circuit breaker. Reset as necessary. Test for 110 VAC at outlet. Identify if outlet is a GFI. Note: Some brands of GFI outlets are too sensitive for treadmill use. Call the help line if encountering GFI issues. Recommended Tools Allen Key set. Phillips head screwdriver. Multi-meter. -------No power to the treadmill. • Check for AC light on PWM. (See diagram pages 23-30) • Check for 110 VAC at power cord. Replace if no power. • If Yes- Check for 110 VAC at tread power switch. Replace if no power. • If Yes-Check for 110 VAC at tread circuit breaker. Replace/ reset if necessary. • If Yes- Check for 110 VAC at PWM across AC1 & AC2. • If Yes- Replace PWM. Note: All trouble shooting should be performed in calibration mode. Page 16 -------No power to the control panel. Page 12 Support Services 800-883-8783 • Check status LED +11 VDC on PWM (See diagram pages 23-30). If not remove fuses and check continuity as replace as needed. • If Yes- Check wire harness connections at PWM and Control Panel. Reconnect as needed. • If Yes- Check voltage on harness at panel. Refer to wiring diagram for your machine type in wiring diagram section. If voltage is present– replace panel and recalibrate (page 16). If voltage is not present check voltage at PWM. If voltage is present at PWM replace pedestal wire harness. If 0 VDC replace PWM and recalibrate (page 16). Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148 Symptom CIRCUIT BREAKER TRIPS Probable Cause Possible short in treadmill wiring. Corrective Action • • Recommended Tools Power off the treadmill and inspect all wiring for shorts or burned areas. Secure all connectors. Allen Key set Needle nose pliers Socket set -------Motor issues. • • Multi-meter Disconnect motor leads from the PWM. Power on treadmill, press start. If the breaker does not trip check the motor brushes and perform the motor test procedure (page 22). Reconnect motor to the PWM, if the breaker trips- replace the motor. -------- Incline motor drawing treadmill down • • Unplug incline motor. Power on treadmill, if breaker does not trip- replace incline motor. Note: All trouble shooting should be performed in calibration mode. Page 16 -------Bad PWM • Unplug PWM, power on machine. If breaker doesn’t trip- replace PWM. -------- Too much tension on belt or obstruction under belt. • • Check for correct tension adjustment (page 22) Check for obstruction- remove obstruction. -------- Weakened circuit breaker or High belt/deck friction • • • Support Services 800-883-8783 Perform AC Amp Draw Test (page 20) at circuit breaker. If draw is less than 15 amps continuously - replace breaker. Perform Amp Draw test (page 20) If Amp draw is higher than recommended try push test (page 24) procedure. Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148 Page 13 Symptom Probable Cause Soft Select Malfunctions Corrective Action Control Panel Issues • • Enter calibration mode Is there a count value displayed in the distance window? If No replace control panel. If yes- continue to next step. -------- Mechanical Issues • Press and hold the softer button, release. Press and hold the firmer button to detect carriage movement in both directions. If the carriage cannot go full range from –220 and consistently stops in the same place, check for mechanical binding. Inspect the under pan for damage or areas that cause mechanical binding. Also inspect the carriage track in the side frame for binding. If the carriage cannot move to its full range and back in the time limit, check for mechanical binding. If the carriage is not moving and the motor is turning, check the set screws holding the drive shaft to the motor shaft. • -------Incorrect/ Missing Count Values • • • • Threaded shaft turns when commanded but the pulse count does not display/ or does not change. Physically check the hex cam located at the front of the shaft and on the motor shaft. Hex cam should be firmly attached. If hex cam slides freely super gluing it back onto the shaft can repair it. Hex cam moves but counter does not register. Ensure that the micro switch is properly adjusted and the switch is being made when the hex cam points press against the roller. Disconnect the cable at J4 and check for continuity on cable. Cable should have continuity if the switch roller is in a flat area of hex cam. If no continuity- replace cable. If good continuity, place cable back on J4 and continue While in calibration mode place the multi-meter leads on J4 and check for 5 Volts. If no 5 Volts- replace board. -------- Defective Motor/ Start Capacitor • • Page 14 Support Services 800-883-8783 If command and count data/voltage are present and Led 1 indicates AC voltage is good but soft select motor does not respond. Set probes on TP 8 and TP3, press soft command (with soft select limit switch not activated) result should be 120 VAC. Set probes on TP8 and TP2 and press firm command (with soft select limit switch not activated) result should be 120 VAC. If no 120 VAC on either test point- replace soft select board. If voltage is correct- continue to next step. In calibration mode, place red lead on the larger red wire and post on the start capacitor of the soft select system and the black lead on the common black lead, press firm- the result should be 120 VDC. Next place the white lead on the larger white wire and post on the start capacitor of the soft select system and the black lead on the common black lead; press soft- the result should be 120 VDC. If voltage is correct- replace the motor. If voltage is incorrect- replace the start capacitor. Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148 Symptom Probable Cause Soft Select Malfunctions (continued) AC Power Issues Corrective Action • • Is AC power LED D3 lit? No- check F1 fuse. If F1 is good check for AC voltage between TP1 and TP5. If fuse and voltage are good- replace the board. -------- Wire Harness • Yes- While in calibration mode Press the Softer button- LED D1 should light, press the Firmer button- LED D2 should light. If the lights respond to the button then command is being sent from the upper board and received at the soft select board. If lights do not respond check or replace 6-pin data cable, if cable is ok- replace upper panel. ------- SOFT SELECT BOARD ILLUSTRATION Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148 Page 15 Calibration Procedures SS 100 PWM (5-xxxxx to 6-79999 serial numbers) Entering Engineering Mode: With safety key in, power up unit while holding Grade Up and Grade Down keys. Incline will reset to zero. Mode 1: Max Speed Press Select/Enter- 01 (C1 for 450) appears in Distance. Adjust speed using Fast and Slow buttons until 10 or 12 mph Verify speed by counting belt revolutions: 10mph= 102 Belt revs/per min. 12mph= 121 Belt revs/per min. Press Start/Reset to save max speed, wait for belt to stop. Mode 2: Speed Table Press Select/Enter-02 (C2 for 450) appears in Distance Press Start/Reset to set speed table. Treadmill will speed up and slow down on its own. Wait for belt to stop. Mode 3: Incline Press Select/Enter- 03 (C3 for 450) appears in distance Press Grade Up to upper incline limit, then back down slightly Save upper limit by pressing Start/Reset Turn treadmill off and then back on and check operation SS90 Calibration (6-8xxxx serial numbers and after) Enter Calibration Mode by holding the Up and Down keys while inserting the safety key In message center window displayed: Press Start to Calibrate NOTE: In Calibration mode, it is possible to check if the speed sensor is reading all the front roller magnets: the Met light will light when a magnet is in front of the sensor. Speed must be less than 1 mph. Press Start/Reset to begin calibration Treadmill will elevate and speed up/slow down. Wait for belt to stop. Message center window will display: Successful, or will indicate error area. Remove and re-insert safety key. Check operation of treadmill. Page 16 Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148 DIAGNOSTICS (Available only in SS90 Machines) To enter diagnostic mode, press and hold the FAST and SLOW buttons while pushing in the safety key. The control panel will show “Diagnostics”. Press the UP button: Total Hours (in whole hours) Press the UP button: Distance (in miles, two digits past decimal point) Press the UP button: Average Speed (in mph) Error List (This is an error log, but just a list of errors possible on the unit.) S1: Lube S2: Clean S3: Motor S4: Sensor E1: Minimum E2: Overspeed E2: Cal E3: EPROM Remove Safety Key to exit Diagnostics Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148 Page 17 Page 18 TEST PROCEDURES Grounded Outlet Test Page 20 Amp Draw Test Page 20 Speed Sensor Test Page 21 Voltage to Drive Motor Test Page 21 Drive Motor Test Page 22 Drive Belt Tension Test Page 22 Tread belt Tension Test Page 22 Incline Potentiometer Calibration Test Page 23 Voltage to Incline Motor Test Page 23 Belt / Deck Wear Test (Push Off Test) Page 24 Page 19 TEST PROCEDURES GROUNDED OUTLET TEST This test is very important for optimal HRC and incline operation. Set voltmeter for Volts AC Place 1 lead in the right side of the outlet (hot) Place 1 lead in the ground plug A properly grounded outlet will read 110 VAC AMP DRAW TEST This test is a good indicator of the wear condition of the belt and deck, and the need for lubrication. The treadmill circuit breaker will trip at 15 amps, so be sure the voltmeter you are using is rated for at least 15 amps when you are load testing the treadmill. This test can be performed either on one of the AC power cord leads or on one of the DC motor leads from the PWM to the motor. Testing the amp draw at certain speeds without load and with load will signal whether higher than normal amp draw is a result of PWM failure or increased friction from belt and deck wear. AC AMP DRAW PROCEDURE This procedure requires an AC clamp-on ammeter. Place the clamp around either of the power cord leads, black or white. Load test requires a person to walk on the tread belt for 5-10 minutes. 2.5 mph w/out load 2.5 mph with load 5.0 mph w/out load 5.0 mph with load 2.0-2.5 AMPS AC 2.75-3.75 AMPS AC 3.5-4.0 AMPS AC 5.0-7.0 AMPS AC DC AMP DRAW PROCEDURE This procedure can be performed with an ordinary voltmeter. (Note: Be sure the voltmeter is rated to handle 15 DC amps.) Disconnect the red motor lead from MTR1 on the PWM. Connect the voltmeter to MTR 1 on the PWM and the other voltmeter lead to the red motor lead so that the voltmeter completes the connection of the PWM to the motor. 2.5 mph w/out load 2.5 mph with load 4.5-5.0 AMPS DC 7.0-8.0 AMPS DC 5.0 mph w/out load 5.0 mph with load 5.0-5.5 AMPS DC 8.5-9.0 AMPS DC Higher than normal amp draws without load may signal that belt tension is too tight or there is a problem in the Drive Motor or PWM. Perform the Drive Motor Test and visually check the motor brushes before replacing the PWM. Higher than normal amp draws with load after normal readings without load signal belt and deck friction which may require lubrication or replacement. Page 20 Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148 TEST PROCEDURES SPEED SENSOR TEST This test is used to verify sensor operation in conditions of speed fluctuation, E2: Cal error, S4: Sensor error, E2: Overspeed error or Unsuccessful Calibration. SS100 (Serial numbers 5-xxxx to 6-7999) Set voltmeter to Volts DC. Treadmill power on speed and speed at 0mph Attach voltmeter leads across outside 2 contacts at P2 on PWM With magnet in front of sensor, 0 VDC With no magnet in front of sensor, 3.0 VDC SS90 (Serial numbers 6-8000 and above) Set voltmeter to volts DC. Treadmill power on and speed at 0 mph Attach voltmeter leads across outside 2 contacts at J1 on PWM With magnet in front of sensor, 0 VDC With no magnet in front of sensor, 5 VDC Check the sensor on every magnet, adjust sensor until voltage shows In calibration mode before pressing Start, the tread belt can be moved manually and the Met light will blink when a magnet is in front of the sensor. VOLTAGE TO DRIVE MOTOR TEST This test is used to diagnose conditions of NO Belt Movement, or Speed Fluctuations Set voltmeter to volts DC and adjust speed on Control Panel to 4 mph Attach red voltmeter lead to MTR1 on PWM with motor wires attached Attach black voltmeter lead to MTR2 on PWM with motor wires attached 0 VDC signals no PWM output 166 VDC signals open circuit in motor or motor connection Operating voltage will lay between 0 VDC and 166 VDC NOTE: The reason that we do not narrow down PWM output voltage is that the PWM output is a pulse signal. The sampling rate of the voltmeter used will determine what output voltage the voltmeter is able to read. Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148 Page 21 TEST PROCEDURES DRIVE MOTOR TEST This test is used in conditions of No Belt Movement. Unplug treadmill and set voltmeter to volts DC Disconnect motor leads from PWM Place 1 voltmeter lead in each motor wire Gently spin the motor flywheel and check for voltage DC 2-5 VDC means normal motor operation 0 VDC means motor malfunction DRIVE BELT TENSION TEST This test is used in front roller replacement and in conditions of belt slipping. Place two fingers on top of the drive belt halfway between the front roller pulley and the drive motor pulley. With moderate pressure push down on belt If belt deflects down more than 1/8 “, tighten motor mounts If belt deflects down less than 1/8 “, loosen motor mounts. It is also possible to twist the belt; you should be able to twist the belt almost to a vertical position TREADBELT TENSION TEST This test will address belt slipping and is used in any roller replacement or deck replacement. Ensure that the drive belt is properly tensioned before adjusting tread belt tension. Belt and deck wear and/or lack of lubrication can cause the tread belt to show symptoms similar to loose tread belt tension- check these conditions before adjusting tread belt tension. Turn treadmill on and adjust speed to 2 mph Walk heavily on the belt pulling slightly against belt movement If hesitation or slip is detected, tighten tread belt tension bolts ¼ turn Repeat until no hesitation or slip is encountered. Check at higher speeds Tread belt tension is too tight if the belt feels stiff to touch with no give or the belt groans against the rollers. You should be able to insert your hand between the belt and deck palm up almost to your thumb when the belt is at proper tension. Page 22 Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148 TEST PROCEDURES INCLINE POTENTIOMETER CALIBRATION TEST This test can correct E1: Minimum conditions and aid in diagnosis of incline problems with finding zero or target incline. SS100 and SS90 Set voltmeter to Ohms (Ω) with treadmill unplugged from wall Place 1 voltmeter lead on pin 3 (Blue) and 1 lead on pin 2 (Orange) Check for 800 Ohms SS90 Only: In calibration mode before pressing Start, the Distance window displays the incline number. With the treadmill at zero, the number should be between 160 and 180. 0 often indicates a wire harness misconnection or failure of signal to panel. As the unit inclines during calibration, watch the numbers in the Distance window, if they do not increase by at least 60 from the zero value, an E1: Minimum error will result. Then the zero value may need to be rest to a lower value. If incline potentiometer needs adjustment, remove swivel opines and twist incline motor shaft by hand for SS100 or use Up and Down keys for SS90. (See diagram on T-6) VOLTAGE TO INCLINE MOTOR TEST This test is utilized in conditions of No Incline Movement, Incline Fluctuation, or E1: Minimum. Set voltmeter to AC volts. To access incline plug, PWM screws may need to be removed. Place voltmeter leads across White and Black while pushing UP button 10 VAC indicates normal PWM output, 0 VAC signals no output Place voltmeter leads across Red and White while pushing Down button 110 VAC indicates normal PWM output, 0 VAC signals no output Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148 Page 23 TEST PROCEDURES Belt / Deck Wear Test This is a simple physical test to gauge the general level of friction present between the deck and belt. 1. While the treadmill is not running, inspect the condition of the underside of the tread belt. The fabric should be soft and porous. If the belt appears glazed- replace the belt. 2. While the treadmill is not running, slide your hand under the belt and feel the surface of the deck. The deck should feel smooth with no abrasions or scratches. If any abrasions or scratches are found- replace the deck. Push Off Test Place the machine in Calibration mode, elevate to the highest elevation- speed should be set to 0. Stand on the tread belt positioning yourself close to the console; push off with moderate force. The elevation combined with your weight and the force of the push should cause the belt to carry you all the way to the end of the machine*. If the test does not carry you to the end of the machine lubricate the belt using True Fitness liquid silicone. After lubricating the belt/deck perform the push off test again. If it does not pass the test after lubricating replace the belt and deck * Note: Residential treadmills may only carry about ¾ of the distance of the deck due to higher tension on the belt. Page 24 Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148 WIRING DIAGRAMS 350 Gray Page 26 350 Black Page 27 400 Page 28 450/500/700 Page 29 500CI/750CI Page 30 750 NON/P Page 31 750 Page 32 Page 25 350 Gray Wiring Diagram Page 26 350 Black Wiring Diagram Page 27 400 Wiring Diagram Page 28 450/500/700 Wiring Diagram Page 29 500CI/750CI Wiring Diagram Page 30 500CI/750CI Wiring Diagram Page 31 750 Wiring Diagram Page 32 Model 350-450 Parts List 350, P, HRC Page 34 350PB, HRCB Page 37 400, P, HRC Page 39 450, P, HRC (SS100-SS90) Page 41 Page 33 350P,350 HRC P, HRC PARTS LIST PART # DESCRIPTION CONTROL PANEL 70186311 350 P Board Only 350 Board Only 70186310 350 HRC Board Only (98- Present) (98-PRESENT) 70186401 350P CONTROL PANEL 98-now 70186402 350HRC CONTROL PANEL 98-NOW (HARDWARE) 70185400 70151900 70176000 70150000 70177400 HRC RECEIVER ASSY. 5/8" DOME PLUG FOR HR RECEIVER C.P. TAPE 3/8 DOUBLE COATED FOAM SAFETY SWITCH ASSY. SAFETY KEY ASSY. OVERLAYS 70186411 350P GRAY OVERLAY 70186412 350HRC GRAY OVERLAY PWM LOWER BOARD (PWM) 70013500 PWM SCREW 10-32 X 3/8 PPHTF 70350300 SPEED SENSOR 70202600 SPEED SENSOR 70350300 EXTENDER WIRE FROM SENSOR -PWM 70190800 SPEED SENSOR SCREW DATA CABLE 70138600 6- CONDUCTOR INTERFACE CABLE 70138700 8- CONDUCTOR INTERFACE CABLE 70190100 8- CONDUCTOR INTERFACE CABLE- HRC DRV MTR 70187600 DRIVE MOTOR ASSY. 70166600 MOTOR DRIVE PULLEY 70173400 MOTOR COVER DRV BELT 70127500 POLY-V-BELT ELEVATION MTR 70186800 70183600 70116700 70183700 70164800 70183200 Page 34 INCLINE MOTOR CLEVIS PIN 3/8 X 1 3/4 COTTER PIN 1/16 X 1 5/16 CLEVIS PIN 3/8 X 2 1/8 COTTER PIN 3/32 X 1/2 INCLINE CAPACITOR ELEVATION RACK 70184401 70176700 70182300 70115200 70209900 ELEVATION RISER ASSY. MOLDED WHEEL INCLINE RISER BOLT 5/16- 18 X 1 1/4 INCLINE RISER WASHER 3.8 I.D. X 7/8 O.D. INCLINE RISER NUT 5/16- 18 AUTOMATION GR. POWER CORD 70253100 9FT. POWER CORD 70008200 STRAIN RELEIF BUSHING ON / OFF SWITCH 70251100 ROCKER ON/OFF SWITCH CIRCUIT BREAKER 70017200 15 AMP CIRCUIT BREAKER TREADBELT 70208500 TREADBELT 18" X 107" DECK 70186700 FLEX DECK ASSY. 70020200 DECKSCREWS/BUMPER FEET 10- 32 X 1 1/4 PPH FRONT ROLLER 70217500 FRONT ROLLER ASSY. 70188500 FR ROLLER BOLT 1/4- 20 X 2 Gr. 5 Hex Hd. 70185300 FR ROLLER NUT 1/4- 20 NYLOC NUT REAR ROLLER 70188000 70175100 70175200 70104000 REAR ROLLER ASSY. REAR ROLLER COVER-LEFT REAR ROLLER COVER-RIGHT R ROLLER SCREW 10 X 1/2 PPH Tek Screw STRADDLE COVERS 70173301 STRADDLE COVER- L.H. 350P 70173302 STRADDLE COVER- R.H. 350P 70173303 STRADDLE COVER- L.H. 350 HRC 70173304 STRADDLE COVER- R.H. 350 HRC 70086700 70182400 70030900 70165400 STRADDLE COVER SCREW 6 X 1 INSIDE COVER SPACER 3/8 X 1/16 X Lg. DOUBLE STICK TAPE OUTSIDE COVER SPACER RAMRAILS 70188700 HANDRAIL ASSY. L.H. BLACK 70188800 HANDRAIL ASSY. R.H. BLACK Page 35 70212300 HANDRAIL ASSY. L.H. GRAY 70212400 HANRAIL ASSY. R.H. GRAY 70185100 LOWER HANDRAIL BUSHING 1/4- 20 X 3 3/4 70198900 LOWER HANDRAIL BUSHING 3/8 OD X 1" 70183101 H/BAR NUT PLATE PEDESTAL 70157000 70186600 70179901 70155900 PED. STAR WASHER 1/4 I.D.INTERNAL TOOTH WASHER PEDESTAL WELDMENT STRAP CLAMP PED. PED. SCREW 1/4- 20 X 5/8 BHSCS FRAME 70181901 FRAME WELDMENT 70160100 BUMPER ASSY 70155200 BUMPER- 1 1/2 X 2 X 1 1/8 Page 36 350PB, HRCB 350PB, HRCB PARTS LIST PART # CONTROL PANEL (350B) Board Only DESCRIPTION 70237311 70237310 350PB Board Only 350HRCB Board Only 70242000 70242001 350PB CONTROL PANEL 350HRCB CONTROL PANEL 70150000 70185400 70245100 70177400 SAFETY SWITCH ASSY. HEART RATE RECIEVER PLASTIC HRC COVER SAFETY KEY 70242010 70242011 350PB DOT/OVERLAY 350HRCB DOT/OVERLAY 70244200 PWM MOTOR CONTROLLER 70013500 PWM SCREW 10-32X3/8 70243203 CIRCUIT BOARD SPEED SENSOR 70243300 SPEED SENSOR SCREW 4-40X1/4 70264100 70264000 70190100 6COND./CORD DATA CABLE 350PB, HRCB 8COND/CORD DATA CABLE 350PB 8-CONDUCTOR INTERFACE CABLE(HRC) 70245600 DRIVE MOTOR Core charge included 70127500 1687J10 POLY-V-BELT 70186800 70183200 70183600 70116700 70183700 70164800 ELEVATION MOTOR-HUBBLE ELEVATION MOTOR CAPACITOR INCLINE MOTOR CLEVIS PINS 3/8X1 3/4 INCLINE MOTOR COTTER PIN 1/16X1-5/16 INCLINE MOTOR CLEVIS PIN 3/8X2-1/8 INCLINE MOTOR COTTER PIN 3/32X1/2 70184402 ELEVATION RACK OVERLAY PWM (99-PRESENT) SPEED SENSOR DATA CABLE DRV MTR DRV BELT ELEVATION MTR (HARDWARE) ELEVATION RACK Page 37 (NEW STYLE) 70176700 70182300 70115200 70209900 MOLDED WHEEL INCLINE RISER BOLT 5/16X1 1/4 INCLINE RISER WASHER 3/8 I.D. INCLINE RISER NUT 5/16-18 70253100 70008200 9 FOOT POWER CORD STRAIN RELIEF BUSHING 70251100 ON/OFF ROCKER SWITCH 70017200 15 AMP CIRCUIT BREAKER 70208500 TREADBELT 18" X 107" 70186700 70020200 70232700 FLEX DECK DECK SCREWS DECK BUMPERS 70260100 70188500 70185300 FRONT ROLLER W/8 MAGNETS FRONT ROLLER BOLT 1/4-20X2 GR. 5 FRONT ROLLER NYLOK NUT 1/4-20 70188000 70220800 70220900 70104000 REAR ROLLER REAR ROLLER COVER LH BLACK REAR ROLLER COVER RH BLACK 10X1/2 REAR ROLLER SCREW 70173305 70173306 70086700 70030900 LH STRADDLE COVER BLACK RH STRADDLE COVER BLACK STRADDLE COVER SCREW 6X1 DOUBLE SIDED STICK TAPE 70157000 70173401 70155200 70020200 70183101 PEDESTAL STAR WASHER MOTOR COVER BUMPER FEET BUMPER FEET SCREWS H/BAR NUT PLATE POWER CORD ON / OFF SWITCH CIRCUIT BREAKER TREADBELT DECK FRONT ROLLER (ADJUSTABLE) REAR ROLLER STRADDLE COVERS PEDESTAL Page 38 400P, HRC PARTS LIST Control Panels 7T007500 7T007501 7T007502 7T007503 7T008000 7T008001 400P Control Panel assy w/ Electronics 400HRC Control Panel assy W/ Electronics 400P Electronics Only 400HRC Electronics Only Upper Plastic Front and Rear (400HRC) Upper Plastic Front and Rear (400P) 7T010201 7T010200 7T014200 Panel Overlay 400P Panel Overlay 400HRC Panel Overlay T-400HRC 7T007400 7T008500 7T013900 PWM W/O Hardware Speed sensor PWM W/O Hardware (230V) 7T014800 7T014000 7T014100 Filter, EMI 400 250V/10A CP6-1022C Bracket, Filter 400 (T=2.0) Bracket Screw Phillips Head M5X0.8X6L UCP 7T014400 Choke, 400 3MH 220V 7T014900 Inductor (choke) 400 6MH 8A 7T007600 Wire Harness 7T007800 7T014300 2.75 HP Drive Motor 2.75 HP Drive Motor 230V 7T008400 Drive Belt 7T009600 7T009700 7T014500 Elevation Motor Front Wheel Elevation Motor 230V 1/6HP Overlays PWM Filter Choke Inductor Data Cable Drive Motor Drive Belt Elevation Motor Page 39 Power Cord 7T009800 Power Cord 7T014600 Power Cord 400 AC220V 1.5MM 2800MM 7T009900 On/Off Switch 7T010000 7T014700 Circuit Breaker Circuit Breaker 400 10A 220V 400RFMB Series 7T008300 Tread belt 7T008600 Deck, pre drilled 7T008100 Front Roller 7T008200 7T009200 7T009300 Rear Roller Roller Cover - L Roller Cover - R 7T009500 Straddle Cover Set 7T007900 Complete Hardware Kit On/Off Switch Circuit Breaker Tread belt Deck Front Roller Rear Roller Straddle Covers Hardware Kit Heart Rate Strap 7TMC0608006 HRC Strap Safety Key 7T010300 Page 40 Safety Key 450P, HRC (SS100-SS90) PARTS LIST PART # CONTROL PANEL (SS100) DESCRIPTION 70120000 70120100 70175900 450NON SS100CONTROL PANEL 450P SS100 CONTROL PANEL 450HRC SS100 CONTROL PANEL (450's) Board Only 70132418 70132417 70132416 450NON SS90 CONTROL Board Only 97-98 450P SS90 CONTROL Board Only 97-98 450HRC SS90 CONTROL Board Only 97-98 (97-98 STYLE) (OVERLAYS) 70161011 70161013 70161012 450NON SS90 OVERLAY 97-98 450P SS90 OVERLAY 97-98 450HRC SS90 OVERLAY 97-98 (99-PRESENT) 70242110 70242111 70242112 450NON DOT OVERLAY 99-PRESENT 450P DOT OVERLAY 99-PRESENT 450HRC DOT OVERLAY 99-PRESENT 70113900 MOTOR CONTROLLER (SS100) 70132500 70013500 MOTOR CONTROLLER SS90 PWM SCREW 10-32 X 3/8 70104200 70154800 SPEED SENSOR (SS100) SPEED SENSOR W/ WIRE AND BRACKE 70243200 70243300 CIRCUIT BOARD SPEED SENSOR SP. SENSOR SCREW 4-40 X 1/4 70337900 70337800 450NON AND PROG. DATA CABLE 450 HRC DATA CABLE 70325500 3HP DRIVE MOTOR 10 MPH 70006300 210J10 POLY-V DRIVE BELT 70113200 70115500 70116700 INCLINE MOTOR 3/8 X 1 1/2 CLEVIS PIN 1/16 DIA. X 1 5/16 COTTER PIN PWM (SS100) (SS90) SPEED SENSOR (SS100 STYLE) (SS90 STYLE) DATA CABLE DRV MTR DRV BELT ELEVATION MTR (ELEVATIONHARDWARE) Page 41 70118900 70183200 70013500 TORQUE ARM SWIVEL PIN START CAPACITOR FOR INCLINE MOTOR SCREW FOR START CAPACITOR 70121000 LOWER LIMIT SWITCH 70125700 70120500 LLS SCREW 10X 1/4 LLS TO PWM WIRE 70281001 70176700 ELEVATION RISER SUB ASSY. BEFORE AUG 99 70253100 70008200 9 FT. POWER CORD STRAIN RELIEF BUSHING 70251100 ROCKER ON/OFF SWITCH 70017200 15 AMP CIRCUIT BREAKER SWITCH 70159300 17 3/4" X 107 3/4" 2 PLY TREADBELT 70157700 70020200 FLEX DECK DECK SCREW 10/32 X 1 1/4 FRONT ROLLER (SS100-NARROW) 70123800 FRONT ROLLER (SS100) (96-xxxx - 99) 70217000 450 FRONT ROLLER(6-8XXXX-99) (99-81023G TO) (PRESENT) REAR ROLLER 70359200 450 ADJ. ROLLER 70359000 70158900 70159000 REAR ROLLER ROLLER BOLT 5/16 INTERNAL TOOTH LOCK WASHER 70162000 70030900 70243400 LT & RT STRADDLE COVERS 3/8 X 1/16 X 108 FT. DBL. STICK TAPE BLUE TAPE 1/2 X 150 FT. ROLL 70176800 70233200 70155900 Pedestal Weldment, 450 W/ end caps ROUND PEDESTAL WELDMENT PEDESTAL SCREWS 70255903 70155200 70020200 FRAME WELDMENT ADJ. FRONT ROLLER BUMPER FEET BUMPER FEET SCREW 10/32X1 1/4PPH LLS ELEVATION RACK WHEEL POWER CORD ON / OFF SWITCH CIRCUIT BREAKER TREADBELT DECK STRADDLE COVERS PEDESTAL (98 style) (99- 00 style) FRAME Page 42 Model 500-550 Parts List 500, P, HRC (SS100-SS90) Page 44 500Z & ZT, P, HRC Page 48 540, P, HRC, CI (NON Z) Page 51 540Z, ZT, P, HRC, CI Page 54 550, P, HRC Page 57 550z, P, HRC, CI Page 59 550 ZTX, P, HRC, CI Page 61 Page 43 500P, HRC (SS100-SS90) PARTS LIST PART # DESCRIPTION CONTROL PANEL 500 Boards Only (SS90) Up to 98 with a letter 70132415 70132414 70132413 70176911 500NON Board Only 500P Board Only 500HRC Board Only 500CI Board Only 500 (99 Style Board Only) (98 with a letter) 70237523 70237522 70237612 500P Board Only 500HRC Board Only 500CI Board Only 500A (2000) Style Board Only 70237415 70237414 70237413 500A NON Board Only 500A P Board Only 500A HRC Board Only 70018100 70150000 70177400 70020400 70020600 70185400 70138500 70284100 70240503 CHERRY SWITCH (SS100) SAFETY SWITCH-ASSY SAFETY KEY SAFETY SWITCH SCREWS SAFETY SWITCH NUTS HEART RATE RECEIVER POLAR HEART RATE CHEST STRAP Old 500 EXTRUSION-PANEL CLIP 26 3/4" 70119301 70119901 70179701 500 NON OVERLAYS-SS100 500P OVERLAYS-SS100 500 HRC OVERLAYS-SS100 (98 OVERLAY) 70160811 70160813 70160812 500 NON SS90 OVERLAY 98 STYLE 500 P SS90 OVERLAY 98 STYLE 500 HRC SS90 OVERLAY 98 STYLE (99 OVERLAY) (98 with a letter) 70242211 70242212 DOT/OVERLAY ASSY, 500P DOT/OVERLAY ASSY, 500HRC (2000 STYLE) 70265100 70265011 70265012 70242410 DOT / OVERLAY ASSY, 500A DOT / OVERLAY ASSY, 500A HRC DOT / OVERLAY ASSY, 500A P DOT / OVERLAY ASSY, 500CI 70113900 PWM MOTOR CONTROLLER-SS100 70132500 SS90 PWM MOTOR CONTROLLER OVERLAY (SS100 OVERLAY) Page 44 PWM (SS100) 70183500 500CI PWM [96-80000]-[98-80000]SS95 70154800 SPEED SENSOR ASSY.-SS100 70243200 SS90 SPEED SENSOR NEW STYLE 70119400 70120400 DATA CABLE-SS100 NON, P, HRC LOWER WIRE HARNESS-SS100 70337900 70337800 INTF. CABLE ASSY 500 N/P SS90 INTF. CABLE ASSY 500 HRC SS90 70155101 70155102 DRIVE MOTOR-2.0 10MPH DRIVE MOTOR-2.5 12MPH 70325500 DRIVE MOTOR 3HP SS90-Z SERIES 70125600 DRIVE MOTOR-CARRIAGE BOLT 70006300 DRIVE BELT 210J10-V BELT 70113200 70118900 70183200 70115500 70116700 70022600 ELEVATION MOTOR SWIVEL PIN INCLINE START CAPACITOR CLEVIS PIN 3/8 DIA. 1 1/2" LONG COTTER HAIR PIN .062 DIA. SET SCREW, INCLINE, SWIVEL PIN 70121000 70120500 LOWER LIMIT SWITCH WIRE-PWM TO LOWER LIMIT SWITCH 70281002 70154600 70126200 ELEVATION RACK INCLINE BEARING BLOCK FLANGED INCLINE BEARING 70176700 70003100 MOLDED WHEEL, 2 1/4" DIA. 3/8 HOLE SHOULDER BOLT-FRONT WHEEL 3/8 X 1" 70176701 70174300 MOLDED WHEEL, 2 1/4" DIA 1/2" HOLE 1/2" X 1" SHOULDER BOLT 70253100 70013900 70008200 POWER CORD, 120 VAC BUSHING-3/8"BLACK STRAIN RELIEF BUSHING SPEED SENSOR DATA CABLE (SS100) DRV MTR (SS100) DRV BELT ELEVATION MTR LLS ELEVATION RACK WHEEL / BOLTS (NEW STYLE) POWER CORD Page 45 ON / OFF SWITCH 70251100 70261000 ON/OFF SWITCH 220V ON/OFF SWITCH 70017200 15 AMP CIRCUIT BREAKER 70159400 70058100 70058200 70068500 TREADBELT STRETCH-TREADBELT ORTHO-TREADBELT-20X108 ROL-TOP ORTHO-STRETCH TREADBELT 70072800 70072700 DECK ASSY STRETCH DECK ASSY 70157900 70157800 FLEX DECK ASSY. 500/WELDED STRETCH DECK ASSY, 500S/WELDED 70232700 70086700 70020200 DECK BUMPER-ASSY. DECK BUMPER SCREWS DECK SCREW 10-32 X 1 1/4" 70119500 70207800 FRONT ROLLER-95 WIDE WITH 4 MAG. ROLLER SCREW 70217300 FRONT ROLLER ASSY, '99 70255400 70188500 70185300 70256800 70190900 FRONT ROLLER ASSY, ADJ. '00 BOLT 1/4-20 / ADJ. END NUT 1/4-20 FLAT WASHER FLANG BOLT 1/4-20 FIXED END 70073600 REAR ROLLER ASSY SS100 70157400 REAR ROLLER ASSY, WELDED SS90 CIRCUIT BREAKER TREADBELT DECK (SS100) (DECK HARDWARE) FRONT ROLLER (SS100) HARDWARE - ADJ. REAR ROLLER (SS100) STRADDLE COVERS (SS100) 70074700 70074900 Page 46 STRADDLE COVER-RIGHT SIDE STRADDLE COVER-LEFT SIDE 70162101 70162102 STRADDLE COVER ALM. '99 STYLE STRETCH STRDL. CVR. ALM. '99 STYLE 70263900 STRADDLE COVER PLASTIC 500A,P,HRC 97 PEDESTAL (SS100) ('98 STYLE) 70122200 70070200 70155900 70013500 PEDESTAL ASSEMBLY-VINYL HANDLEBAR PEDESTAL SCREW HANDLEBAR SCREWS #10-32X3/8 70179600 70179500 PED.-WELDMENT 500NON,P,HRC '98 PED.-WELDMENT 500CI '98 ('99-'00 / '98 W/LETTER) 70233300 70233400 70204200 PED.-WELDMENT 500 NON,P,HRC '99-'00 PED.-WELDMENT 500CI '99-'00 RAM RAILS NON CHR FRAME 70155200 BUMPER FEET 70348900 70349000 LUBE STICK SILICONE PACKET (1 APPLICATION) 70204200 RAM RAILS NON CHR 70155200 BUMPER FEET 70348900 70349000 LUBE STICK SILICONE PACKET (1 APPLICATION) LUBRICATION FRAME LUBRICATION Page 47 500Z & ZT, P, HRC PARTS LIST PART # CONTROL PANEL (500ZT's) Overlay Only 70327510 70327511 Z also (500ZT'S) BOARDS ONLY 70328016 70328015 70328014 (500ZT EX'S) BOARDS 70328056 70328055 ONLY International 70328054 SAME PANELS AS NEW 500ZT SERIES. DESCRIPTION 500ZT NON/P Overlay Only 500ZT HRC Overlay Only 500ZT NON CONTROL BOARD ONLY 500ZT P CONTROL BOARD ONLY 500ZT HRC CONTROL BOARD ONLY 500ZTEX NON CONTROL BOARD ONLY 500ZTP EX CONTROL BOARD ONLY 500ZTHRC EX CONTROL BOARD ONLY 70328100 70328101 70328200 500Z,ZT NON PANEL 500Z,ZT P PANEL 500Z,ZT HRC PANEL 70290601 70294301 70290801 70290701 70290801 70331000 PANEL, BOTTOM CONSOLE PANEL LF.LWR. GRIP CLOSURE PANEL RT.LWR. GRIP CLOSURE HANDLE LT. CONSOLE HANDLE RT. CONSOLE MAGNET SAFETY KEY 70132500 PWM - MOTOR CONTROLLER PWM 500 ZT SERIES SPEED SENSOR 70342900 7/21/2003 PWM - MOTOR CONTROLLER 70243200 CIRCUIT BOARD SPEED SENSOR 70243300 SPEED SENSOR SCREW 70337900 70337800 500Z NON DATA CABLE ,P 500Z HRC DATA CABLE 70341300 20 PIN DATA CABLE 70325500 3HP DRIVE MOTOR 70341500 500ZT DRIVE MOTOR 70006300 DRIVE BELT 210J10 DATA CABLE 500 ZT SERIES DRIVE MOTOR DRV BELT Page 48 ELEVATION MTR 70113200 ELEVATION MOTOR 70183200 70115500 70116700 70013500 70118900 ELEVATION START CAPACITOR 3/8X1 CLEVIS PIN COTTER PIN 10-32 X 3/8 PPH SCREW TORQUE ARM SWIVEL PIN 70121000 LLS 70120500 LLS wire assy. To PWM 70281002 ELEVATION RISER ASSY. 70154600 ELEVATION BLOCK ASSY. 70253100 9FT. POWER CORD 70251100 ROCKER ON/OFF SWITCH 70017200 15 AMP CIRCUIT BREAKER 70159400 22 X 119 3/4 2PLY TREADBELT 70321600 NEW ZT 20"X112 1/4" TREADBELT 70157900 FLEX DECK 70324300 500ZT FLEX DECK 70255400 70352200 70190900 ADJ. FRONT ROLLER NEW NUMBER FOR ROLLER ROLLER SCREW 1/4-20 X 2 GRD5 ZINC 70157400 REAR ROLLER 70162110 STRADDLE COVER/ALUM. 54 1/2" 70343700 70334000 70334100 500ZT STRAD. CVRS. RT.<. 500ZT STRAD CVR FRONT CAP Rt (Bullet 500ZT STRAD CVR FRONT CAP LT (Bullet LLS ELEVATION RACK POWER CORD ER CORD ON / OFF SWITCH CIRCUIT BREAKER TREADBELT (ZT) DECK (ZT) FRONT ROLLER REAR ROLLER STRADDLE COVERS (ZT) (ZT) Page 49 lt (Bullet RT(bullet) 70030900 DBL SIDE STICK TAPE 3/8 X 1/16 X 108FT 70243400 BLUE TAPE-STR. CVR. 1/2 X 150FT. ROLL 70086700 6X1 SRADDLE COVER SCREW 70330800 70330900 LEFT RAM RAIL RIGHT RAM RAIL 70325000 PEDESTAL- WELDMENT/ROUNDED 70336900 70304200 70156900 500ZT PEDESTAL WELMENT pedestal screw for zt RUBBER WEAR STRIP FOR BASE-PED. 70262401 FRAME WELDMENT/RND. ADJ. ROLLER 70322800 500ZT FRAME WLD/RND. ADJ. FR. ROLL 70155200 BUMPER FEET 70348900 70349000 LUBE STICK SILICONE PACKET (1 APPLICATION) RAMRAILS PEDESTAL (ZT) FRAME (ZT) LUBRICATION Page 50 540P, HRC, CI (NON Z) PARTS LIST CONTROL PANEL PART # 70237419 70237421 70237420 70237614 DESCRIPTION 540 NON CONTROL BOARD 540 P CONTROL BOARD 540 HRC CONTROL BOARD 540 CI CONTROL BOARD 70290110 70289310 70289410 70290310 540non overlay 540p overlay 540hrc overlay 540ci overlay 70177400 70150000 SAFETY KEY ASSY. SAFETY SWITCH 70132500 MOTOR CONTROLLER (PWM) 70013500 SCREW, 10-32x3/8 PPH TFS Bo 70243200 70243300 SPEED SENSOR SCREW 4-40x1/4 PPH SELF TAPPING 70337900 70337800 70337700 540NON, P DATA CABLE 540 HRC DATA CABLE 540 CI DATA CABLE 70104000 SCREW #10x1/2 PPH 70325500 70125700 70155200 70176000 70013500 70125500 70115200 70125600 3HP. DRIVE MOTOR SCREW 10-32x1/4 PPH TFS Bo BUMPER FEET 1 1/8 x1 1/2 3/8 Dbl Coated foam tape Tesa -49 SCREW10-32x1/4 PPH TFS Bo 5/16-18 NYLOC NUT WASHER 3/8 1Dx7/8odx.083F 5/16-18x2 CARRIAGE BOLT 70006300 POLY-V-BELT DRIVE BELT PWM SPEED SENSOR DATA CABLE DRIVE MOTOR DRV BELT Page 51 ELEVATION MTR 70113200 ELEVATION MOTOR 70115500 70116700 70013500 70118900 CLEVIS PIN 3/8x1 1/2 COTTER PIN 1/16 Dia x 1 5/16 SCREW 10-32 x 3/8 PPH TFSBO TORQUE ARM SWIVEL PIN 70121000 70125700 70120500 LLS SCREW - 10-32x 1/4 PPH TFS BO LLS WIRE ASSY. To PWM 70281003 70154600 70122800 70183200 70013500 ELEV. RISER ASSY. ELEV. BLOCK ASSY. SOCKET HD. CAP SCREWS 1/4-20x1 INCLINE START CAPACITOR SCREW FOR CAP./10-32x3/8 70253100 70125700 POWER CORD 12* 14/3 SJTW BLACK STRT SCREW 10-32x1/4 PPH TFS Bo 70251100 ROCKER ON/OFF SWITCH 70017200 15 AMP CIRCUIT BREAKER 70290000 BELT 22x119 3/4 ST E5 2Ply-Lo 70289900 540 ORTHO TREADBELT 70288900 70020200 70158600 70019300 FLEX DECK SCREW 10/32 x 1 1/4 PPH "F" BELT GUIDE SCREW 10x3/4 70275200 70157000 70185300 70190900 70256800 ADJ. FRONT ROLLER WASHER INTERNAL TOOTH STAR 1/4 id NYLOC NUT 1/4-10 2 nc HEX BOLT-TAP1/4-20x2 Grd 5/21NC FLAT WASHER .50x.26x.09 2n Pltd. 70275500 70159000 70158900 REAR ROLLER ASSY. INTERNAL TOOTH WASHER 5/16 BOLT HEX HEAD TAP, Grd 5-5/16 70263900 Straddle cover / Plastic LLS ELEVATION RACK POWER CORD ON / OFF SWITCH CIRCUIT BREAKER TREADBELT DECK FRONT ROLLER REAR ROLLER Page 52 STRADDLE COVERS 70030900 70243400 70086700 TAPE, 3/8x1/16x108ft. DBL stick-49 BLUE TAPE -STR. CVR. 1/2x150ft roll 6X1 DRYWALL SCREW 70274105 70210600 70280600 CHR RAM RAIL #10x3/4 PPH TEK Screw-bo NON CNR RAILS(RAM) 70288600 70156900 PEDESTAL- WELDMENT/ROUNDED RUBBER WEAR STRIPS 70289700 70155200 70020200 70019300 70086700 FRAME WELDMENT/RND. ADJ. FRONT BUMPER FEET SCREW 10/32x1 1/4 SCREW 10x3/4 PPHSMBO 6x1 DRYWALL SCREW 70280800 70019300 AUTO WAXER SCREW 10x3/4 PPHSMS Bo 70348900 70349000 LUBE STICK SILICONE PACKET (1 APPLICATION) RAMRAILS PEDESTAL FRAME AUTO WAXER LUBRICATION Page 53 540Z, ZT, P, HRC, CI PARTS LIST CONTROL PANEL (540Z's) Overlay only PART # 70292410 (540ZT's)Overlays only 70327510 70327511 (540ZT'S)BOARDS ONLY 540ZT EX'S BOARDS ONLY International ALL 540ZT PANEL ARE THE SAME AS THE REG, 540Z DESCRIPTION 540Z CI Overlay only 540ZT P Overlay Only 540ZT HRC Overlay Only 70328013 70328012 70298612 70328053 70328052 540ZT P CONTROL BOARD ONLY 540ZT HRC CONTROL BOARD ONLY 540 Z CI CONTROL BOARD 540ZT PEX CONTROL BOARD ONLY 540ZT HRCEX CONTROL BOARD ONLY 70328102 70328201 70299201 540Z,ZT P PANEL 540Z,ZT HRC PANEL 540Z,ZT CI PANEL 70298900 70331000 70290602 PANEL SCREW MAGNET SAFETY KEY Panel Back Cover 70132500 PWM MOTOR CONTROLLER 70342900 70013500 540 ZT MOTOR CONTROLLER PWM SCREW 70243200 CIRCUIT BOARD SPEED SENSOR 70243300 SPEED SENSOR SCREW 70341300 70337900 70337800 70337700 540ZT 20 pin Data Cable (Most ZT's) 540Z,ZT P DATA CABLE 540Z,ZT HRC DATA CABLE 6pin & 8pin 540Z,ZT CI DATA CABLE 2 pin & 8 pin 70325500 3HP. DRIVE MOTOR 70341500 540ZT DRIVE MOTOR 70125700 70155200 70176000 Screw 10-32x1/4 PPH TFS Bo BUMPER FEET 1 1/18 X 1 1/2 3/8 DBL. COATED FOAM TAPE OVERLAY PWM 540 ZT SERIES SPEED SENSOR DATA CABLE ALSO FOR 540ZT DRIVE MOTOR Page 54 70013500 70125500 70115200 70125600 Screw 10-32x1/4 PPH TFS Bo 5/16-18 NYLOC NUT WASHER 3/8 ID X 7/8 OD 5/16-18X2 CARRIAGE BOLT 70006300 210J10 DRIVE BELT 70113200 ELEVATION MOTOR 70115500 70116700 70013500 70118900 3/8 X 1 1/2 CLEVIS PIN COTTER PIN Screw 10-32 x 3/8 PPH TFSBO TORQUE ARM SWIVEL PIN 70121000 LLS 70120500 LOWER LIMIT SWITCH WIRE 70281003 540ZT ELEVATION RISER ASSY. 70154600 ELEVATION BLOCK ASSY. 70253100 POWER CORD 9FT. 70251100 ROCKER ON/OFF SWITCH 70017200 15 AMP CIRCUIT BREAKER 70290000 540Z TREADBELT-22 X 108 3/4 70289900 540Z TREADBELT-22 X 108 3/4 Ortho (ZT) 70321800 540ZT-22"X112 1/4" TREADBELT zt DECK 70321900 540ZT ORTHO BELT 70288900 540Z FLEX DECK 70324400 540ZT FLEX DECK 70275200 70352400 ADJ. FRONT ROLLER NEW NUMBER ADJ. FRONT ROLLER DRV BELT ELEVATION MTR LLS ELEVATION RACK (ZT) POWER CORD ON / OFF SWITCH CIRCUIT BREAKER TREADBELT (ZT) FRONT ROLLER Page 55 REAR ROLLER 70275500 REAR ROLLER 70263900 STRADDLE COVER/ALUM. 54 1/2" 55 70343700 70327002 70343901 70030900 540ZT PLASTIC STRAD. CVRS. Plastic Insert 540ZT Alum Side Covers 3/8X1/16X108FT ROLL DBL. SIDE STICK T 70243400 70329600 70086700 BLUE TAPE - STR. CVR. 1/2X150FT. ROLL SILVER sst tape STRADDLE COVER SCREW 70330800 70330900 LEFT RAM RAIL RIGHT RAM RAIL 70325100 PEDESTAL-WELDMENT/ROUNDED 70337000 540ZT PEDESTAL WELDMENT 70289701 FRAME WELDMENT/ROUNDED ADJ. RO 70322900 540ZT FRAME WELDMENT/RND. 70155200 BUMPER FEET 70348900 70349000 LUBE STICK SILICONE PACKET STRADDLE COVERS (ZT) RAMRAILS PEDESTAL (ZT) FRAME (ZT) LUBRICATION Page 56 PART # CONTROL PANEL 550 Board Only DESCRIPTION 70237519 70237518 70237610 550P Board Only 550HRC Board Only 550CI Board Only 70279200 70279100 70279000 550OP/ P DOT/ PANEL 550HRC DOT/PANEL 550CI DOT/PANEL 70279201 70279101 70150000 70279001 70132500 70183500 550OP/ P DOT/OVERLAY 550HRC DOT/ OVERLAY Safety Switch Assembly 550CI OVERLAY MOTOR CONTROLLER 550ci pwm 70243200 CIRCUIT BOARD SPEED SENSOR 70337900 70337800 70337700 550 P INTERFACE CABLE 550 HRC INTERFACE CABLE 550 CI INTERFACE CABLE 70325500 3HP DRIVE MOTOR 70006300 210J10 POLY-V-BELT 70113200 ELEVATION MOTOR 70121000 LOWER LIMIT SWITCH 70281003 ELEVATION RISER ASSY. 70253100 9FT. POWER CORD 70008200 STRAIN RELIEF BUSHING 70251100 ON/OFF ROCKER SWITCH 70017200 15 AMP CIRCUIT BREAKER 70276800 70276900 22X119 3/4" 2PLY TREADBELT 22x119 3/4" 2PLY TREADBELT ORTHO 70276700 FLEX DECK 70352400 ADJ. FRONT ROLLER 550P, HRC PARTS LIST OVERLAY PWM SPEED SENSOR DATA CABLE DRV MTR DRV BELT ELEVATION MTR LLS ELEVATION RACK POWER CORD ON/OFF SWITCH CIRCUIT BREAKER TREADBELT 550CI BELT DECK FRONT ROLLER REAR ROLLER Page 57 70352000 REAR ROLLER 70162109 LT. AND RT.ALUM. STRADDLE COVER 70277600 PEDESTAL-WELDMENT/ROUNDED 70276000 ADJ. FR. ROLLER FRAME/WELDMENT 70348900 70349000 LUBE STICK SILICONE PACKET (1 APPLICATION) STRADDLE COVERS PEDESTAL FRAME LUBRICATION Page 58 550Z, P, HRC, CI PARTS LIST PART # CONTROL PANEL BOARD ONLY 550Z ONLY DESCRIPTION 70298217 70298218 70298613 550Z P BOARD ONLY 550Z HRC BOARD ONLY 550Z CI BOARD ONLY 70292415 550Z P OVERLAY 70334400 70334500 70329900 550Z P PANEL 550Z HRC PANEL 550Z CI PANEL 70331000 MAGNET SAFETY KEY 70132500 PWM MOTOR CONTROLLER 70013500 PWM SCREW 70243200 CIRCUIT BOARD SPEED SENSOR 70243300 SPEED SENSOR SCREW 70337900 70337800 70337700 550Z P DATA CABLE 550Z HRC DATA CABLE 550Z CI DATA CABLE 70325500 3HP DRIVE MOTOR 70006300 210J10 DRIVE BELT 70113200 ELEVATION MOTOR 70183200 70115500 70116700 70013500 70118900 ELEV. MTR. START CAPACITOR 3/8 X 1 1/2 CLEVIS PIN 1/16 DIA X 1 5/16 COTTER PIN Screw 10-32 x 3/8 PPH TFSBO TORQUE ARM SWIVEL PIN 70121000 LLS 70120500 LOWER LIMIT SWITCH WIRE 70281003 70154600 ELEVATION RISER ASSY. ELEVATION BLOCK ASSY. PWM SPEED SENSOR DATA CABLE DRIVE MOTOR DRV BELT ELEVATION MTR LLS ELEVATION RACK Page 59 POWER CORD 70253100 POWER CORD 9FT. 70251100 ROCKER ON/OFF SWITCH 70017200 15 AMP CIRCUIT BREAKER 70276800 70276900 22X119 3/4 2PLY TREADBELT Belt Seig 22x119 3/4 550 Ortho 70276700 FLEX DECK 70352400 ADJ. FRONT ROLLER 70352000 REAR ROLLER 70162110 STRADDLE CVR/ALUM 54 1/2" 70030900 3/8X1/16X108FT. DBL. STICK TAPE 70243400 1/2X150FT ROLL BLUE TAPE 70086700 6X1 STRADDLE COVER SCREW 70330800 70330900 LEFT RAM RAIL RIGHT RAM RAIL ON / OFF SWITCH CIRCUIT BREAKER TREADBELT DECK FRONT ROLLER REAR ROLLER STRADDLE COVERS RAMRAILS CARRIAGE ASSY. 550Z CI 70240900 70241100 70239200 70250700 70249900 70280000 70280400 70252300 ADJ. MOTOR ASSY 550Z CI COVER PAN-WELDMENT SHAFT LIMIT SWITCH ASSY.-STOP 550CI S.O.F.T. SELECT POWER CABLE INTERFACE CABLE-ASSY.550Z CI ADJ. CARRIAGE ASSY. 550Z CI CIRCUIT BOARD INTERFACE 550Z CI PEDESTAL 70325104 70325105 PED-WELDMENT/ROUNDED HRC PED-WELDMENT/ROUNDED P 70276000 FRAME WELDMENT/RND-ADJ ROLLER 70155200 BUMPER FEET 70348900 70349000 LUBE STICK SILICONE PACKET (1 APPLICATION) FRAME Page 60 LUBRICATION 550 ZTX, P, HRC, CI PARTS LIST PART # CONTROL PANEL (550ZTX's) Overlay only DESCRIPTION 70292415 70292413 70292414 550ZTX P Overlay only 550ZTX HRC Overlay only 550ZTX CI Overlay Only Control Board Only 70298216 70298215 70298611 550ZTX P CONTROL Board Only 550ZTX HRC CONTROL Board Only 550ZTX CI CONTROL Board Only International Version 70298256 70298255 70298651 550ZTX PEX CONTROL Board Only 550ZTX HRCEX CONTROL Board Only 550ZTX CIEX CONTROL Board Only Panel Assy. 70299007 70298707 70329900 550ZTX P CONTROL PANEL 550ZTX HRC CONTROL PANEL 550ZTX CI CONTROL PANEL 70342900 MOTOR CONTROLLER 70243200 Speed Sensor 70341300 DATA CABLE 70341500 3HP 10 MPH DRIVE MOTOR 70293002 MOTOR COVER 70006300 210J10 POLY-V-BELT 70330100 INCLINE MOTOR ASSY 70309401 LOWER LIMIT SWITCH 70120501 LOWER LIMIT SWITCH WIRE TO PWM 70329300 INCLINE RACK ASSY 70253100 9FT POWER CORD 70008200 STRAIN RELIEF BUSHING 70017200 15 AMP CIRCUIT BREAKER PWM Speed Sensor DATA CABLE 500zt HRC DRV MTR DRV BELT ELEVATION MTR LLS ELEVATION RACK POWER CORD CIRCUIT BREAKER Page 61 TREADBELT 70322000 22"X124" TREADBELT 70322100 ORTHO BELT FOR THE 550ZTX CI AND O 70324500 70232700 FLEX DECK Bumper 70352400 ADJ. FRONT ROLLER 70352000 REAR ROLLER 70343800 ALUM. STRADDLE COVER RH & LH 70330800 70330900 LH RAM RAIL RH RAM RAIL 70347500 INTERCHANGABLE RAM RAILS RT.<. 70325302 PEDESTAL WELDMENT - ARCHED 70337100 FRAME WELDMENT 70348900 70349000 LUBE STICK SILICONE PACKET (1 APPLICATION) DECK FRONT ROLLER REAR ROLLER STRADDLE COVERS RAMRAILS PEDESTAL FRAME LUBRICATION Page 62 550ztx hrc Model 600-750 Parts List 600, P, HRC Page 64 600Z / 700Z, P, HRC Page 67 700, P, HRC Page 70 700A, P, HRC Page 73 725 P, HRC Page 76 750, P, HRC, CI Page 79 (SS100-SS90) Page 63 600P, HRC PARTS LIST PART # CONTROL PANEL (600) Board Only DESCRIPTION 70237412 70237411 70237410 600NON Board Only 600P Board Only 600HRC Board Only 70269900 70269901 70150000 70182800 600NON DOT PANEL 00-PRESENT 600P DOT PANEL 00-PRESENT SAFETY SWITCH ASSY. SAFETY KEY ASSY. 70269910 70269911 70265011 600NON DOT OVERLAY 00-PRESENT 600P DOT OVERLAY 00-PRESENT 600HRC DOT OVERLAY 00-PRESENT 70219200 70219201 70013500 MOTOR CONTROLLER SS-92 DCI MOTOR CONTROLLER 02-PRESENT PWM SCREW 70243200 70243300 CIRCUIT BOARD SPEED SENSOR SPEED SENSOR SCREW 70337900 70337800 NON HRC DATA CABLE P DATA CABLE 70325500 70282700 70125500 70125600 3HP DRIVE MOTOR MOTOR CHOKE ASSY. NYLOCK NUT- 5/16-18 DRIVE MTR. CARRIAGE BOLT -5/16-18 X 2 3/4 70006300 210J10 POLY-V-BELT 70113200 70115500 70118900 70116700 70183200 70013500 ELEVATION MOTOR CLEVIS PIN 3/8 X 1 1/2 TORQUE ARM SWIVEL PIN COTTER PIN 1/16 DIA. X1 5/16 ELEVATION START CAPACITOR CAPACITOR SCREW 10-32 3/8 PPH 70121000 LOWER LIMIT SWITCH OVERLAY PWM SPEED SENSOR DATA CABLE DRV MTR DRV BELT ELEVATION MTR Page 64 LLS 70125700 70120500 10-32 X 1/4 PPH SCREW LOWER LIMIT SWITCH WIRE TO PWM 70281002 70154600 70122800 ELEVATION RISER ASSY. ELEVATION BLOCK ASSY. 1/4-20 X 1 SOCKET HD. CAP SCREW 70282900 70303700 12 FT. POWER CORD NEMA PLUG 70251100 ROCKER ON/OFF SWITCH 70017200 15 AMP CIRCUIT BREAKER 70159400 20" X 108" 2 PLY SEIGLING TREADBELT 70157900 70020200 FLEX DECK DECK SCREW 10/32 X 1 1/4 70155200 70020200 70232700 70086700 BUMPER FEET 10/32 X 1 1/4 PPH SCREW FLEX BUMPER BUMPER SCREW 6 X 1 70255400 70188500 70185300 70256800 70190900 ADJ. FRONT ROLLER BOLT - ADJ. FR. NYLOCK NUT - ADJ. FR. FLAT WASHER BOLT - FR. SOLID MOUNT END / ADJ. FR 70157400 70158900 70159000 REAR ROLLER REAR ROLLER BOLT INTERNAL TOOTH WASHER 5/16 70162101 70086700 70030900 70243400 STRADDLE COVERS RT. & LT. ALUM. 6 X 1 DRYWALL SCREW DBL. STICK TAPE 3/8 X 1/16 X 108FT. BLUE TAPE 1/2 X 150FT. ELEVATION RACK POWER CORD ON / OFF SWITCH CIRCUIT BREAKER TREADBELT DECK BUMPER KIT FRONT ROLLER (ADJUSTABLE) REAR ROLLER STRADDLE COVERS Page 65 RAMRAILS 70274101 70210600 HANDLEBAR ASSY./ RAM - CHR #10 X 3/4 PPH TEK SCREW REHAB RAILS 70274401 REHAB HANDRAIL ASSY. - CHR 70157000 70013500 70104000 70122800 70064500 WASHER - INTERNAL STAR SCREW 10-32 X 38 PPH SCREW # 10 X 1/2 PPH TEK SCREW 1/4-20 X 1 SOCKET HEAD CAP PLASTIC PLUG 70264600 70155900 70157000 70269800 70019300 WELDED PEDESTAL 600 NON-CI SCREW PED / 1/4-20 X 5/8 INTERNAL TOOTH STAR WASHER / PED BOTTLE HOLDER / MOLDED PLASTIC SCREW - BOTTLE HOLDER 70262401 FRAME WELDMENT/ROUNDED ADJ. RO 70280800 70019300 70239800 600 AUTO WAXER ASSY. 10 X 3/4 PPHSMS SCREW REPLACEMENT WAX CHANNEL ASSY. 70348900 70349000 LUBE STICK SILICONE PACKET (1 APPLICATION) REHAB HARDWARE PEDESTAL FRAME AUTO WAXER LUBRICATION Page 66 600Z/ 700Z, P, HRC PARTS LIST PART # CONTROL PANEL (600Z's) Overlays only 70327510 70327511 70328011 Board Only 600Z 70328010 International 70328051 (700Z's) Overlays only 70292412 70292411 70292413 DESCRIPTION 600Z NON/P Overlay Only 600Z HRCEX OVERLAY 600Z NON Control Board Only 600Z P 600Z HRCEX Control Board Only 700Z Overlay only 700Z P Overlay only 700Z HRC Overlay only Board Only 700Z 70298412 70298214 70298213 700Z NON Control Board Only 700Z P Control Board Only 700Z HRC Control Board Only International 70298452 70298254 70298253 700Z NONEX Control Board Only 700Z PEX Control Board Only 700Z HRCEX Control Board Only 70290601 70294301 70294302 PANEL,BOTTOM CONSOLE PANEL LF. HANDLEGRIP LOWER PANEL RT. HANDLEGRIP LOWER 70343000 70342900 220 VOLT PWM MOTOR CONTROLLER 70243200 CIRCUIT BOARD SPEED SENSOR 70341300 20 PIN DATA CABLE 70260800 70341500 220 MOTOR 3HP 115V DRIVE MOTOR 70006300 210J10 POLY-V-BELT 70260800 70113200 220 ELEVATION MOTOR ELEVATION MOTOR PWM SPEED SENSOR DATA CABLE DRV MTR DRV BELT ELEVATION MTR Page 67 LLS 70121000 LOWER LIMIT SWITCH 70281002 600Z ELEVATION RISER ASSY. 70281003 700Z ELEVATION RISER ASSY. 70303700 12' POWER CORD 70251100 ON/OFF ROCKER SWITCH 70017200 15 AMP CIRCUIT BREAKER 70317300 600Z 20"X108" TREADBELT 70317400 700Z 22"X119 3/4" TREADBELT 70157900 600Z FLEX DECK 70276700 700Z FLEX DECK 70352200 600Z ADJ. FRONT ROLLER 70352400 700Z ADJ. FRONT ROLLER 70351800 600Z REAR ROLLER 70352000 700Z REAR ROLLER 70162111 600Z ALUM.STRADDLE CVRS. 70162110 700Z ALUM. STRADDLE COVERS 70330800 70330900 LH RAM RAILS RH RAM RAILS ELEVATION RACK POWER CORD ON / OFF SWITCH CIRCUIT BREAKER TREADBELT DECK FRONT ROLLER REAR ROLLER STRADDLE COVERS RAMRAILS Page 68 PEDESTAL 70325100 PEDESTAL WELDMENT 70262405 600Z WLD/RND ADJ. ROLLER FRAME 70276003 700Z FRAME W/ ADJ. FR. ROLLER 70280800 AUTOWAXER 70348900 70349000 LUBE STICK SILICONE PACKET (1 APPLICATION) FRAME AUTO WAXER LUBRICATION Replacement Pedestal 70325103! Page 69 700P, HRC (SS100-SS90) PARTS LIST PART # CONTROL PANEL (SS100) 70119300 70119900 70179700 700NON SS100 PANEL 95-96 700P SS100 PANEL 95-96 700HRC SS100 PANEL 95-95 (97-98 STYLE) Board Only 70132412 70132411 70132410 700NON SS90 Control Board Only 97-98 700P SS90 Control Board Only 97-98 700HRC SS90 Control Board Only 97-98 (99-PRESENT) (DOT Control Board) 70237515 70237514 70237513 700NON 15% DOT Control Board Only 99-Z 700P 15% DOT Control Board Only 99-Z 700HRC 15% DOT Control Board Only 99-Z 70185400 70138500 70273800 70182800 70209700 HEART RATE RECEIVER POLAR CHEST STRAP-HEART RATE CONTACT H R TRANSMITTER SAFETY SWITCH ASSY. 700 PUSH BUTTON SAFETY SWITCH SS90 TON SAFETY SWITCH SS90 70119301 70119901 70179701 700NON SS100 OVERLAY 95-96 700P SS100 OVERLAY 95-96 700HRC SS100 OVERLAY 95-96 (97-98 STYLE) 70160815 70160816 70160814 700NON SS90 OVERLAY 97-98 700P SS90 OVERLAY 97-98 700HRC SS90 OVERLAY 97-98 (99-PRESENT) 70242310 70242311 70242312 700NON DOT OVERLAY 99-PRESENT 700P DOT OVERLAY 99-PRESENT 700HRC DOT OVERLAY 99-PRESENT 70113900 (SS100) MOTOR CONTROLLER 70219200 PWM MOTOR CONTROLLER 70162402 SPEED SENSOR SS90 OVERLAY (SS100 STYLE) PWM (SS100) Page 70 DESCRIPTION (96-800000-) (PRESENT) SPEED SENSOR (SS90 STYLE-98-) (99-PRESENT) 70243201 SPEED SENSOR 700, P, HRC 70337900 70337800 700, P DATA CABLE 700 HRC DATA CABLE 70325600 DRIVE MOTOR 3HP W/FLYWHEEL 70263500 220V DRIVE MOTOR 70155300 70146500 DRIVE PULLEY 1 11/16" DIA. DRIVE PULLEY 12MPH 70127600 DRIVE BELT 260J10 POLY-V-BELT 70171500 70126200 70118900 70115500 70116700 70022600 ELEVATION MOTOR 115V 700, P, HRC INCLINE BEARING (FLANGED) SWIVEL PIN/TORQUE ARM CLEVIS PIN 3/8 DIA. 1 1/2 IN. LONG HAIR COTTER PIN .062 DIA. SET SCREW, INCLINE, CONE POINT 70121000 70018100 70120500 LOWER LIMIT SWITCH CHERRY SWITCH LOWER LIMIT SWITCH WIRE 70176700 70003100 MOLDED WHEEL 3/8 BEF.AUG.99 WHEEL BOLT 3/8 BEFORE AUG, 99 70176701 70174300 MOLDED WHEEL 2 1/4 AFT.AUG, 99 WHEEL BOLT 1/2" AFTER AUG., 99 70282900 70008200 POWER CORD 12 FT. STRAIN RELIEF BUSHING 70251100 ON/OFF SWITCH 70017200 15 AMP CIRCUIT BREAKER 70214300 TREADBELT 700, P, HRC DATA CABLE DRV MTR DRV BELT ELEVATION MTR (HARDWARE) LLS ELEVATION RACK (BEFORE AUG99) AFTER AUG., 99) POWER CORD ON / OFF SWITCH CIRCUIT BREAKER TREADBELT Page 71 DECK 70158000 70086700 70020200 DECK DECK SUSP. BLOCK SCREW6X1 DECK SCREWS 10/32X1 1/4" 70150800 FRONT ROLLER ASSY, 700 W/SS100 (NON-ADJ.) 70164700 FRONT ROLLER 8 MAGNET/NON ADJ (ADJ. NOV.-00) 70265300 FRONT ROLLER ADJ.-NOV.2000 70005600 70005500 ROLLER SCREW 3/8-16X3/4 ROLLER BOLT 3/8X16X3 HX HD. BOLT 70186000 70005600 70005500 70073900 REAR ROLLER SS90 ROLLER SCREW 3/8-16X3/4 ROLLER BOLT 3/8X16X3 HX HD. BOLT OLD STYLE 70162107 70030901 STRADDLE COVER-ALUM.-46 13/16" 3/8 X1/16 X 36YD. DBLE STK TAPE 16' 70204200 70104000 RAMRAIL HANDLE BAR RAIL SCREWS #10-32X3/8 70233500 70207800 PEDESTAL-99-00 700,700P,700HRC BOLT - PED 3/8" - 16 X 3/4" 70167000 70239800 70342000 AUTOWAXER - ASSY WAX CHANNEL (ONLY) GRND. WIRE FOR WAXER 70348900 70349000 LUBE STICK SILICONE PACKET (1 APPLICATION) FRONT ROLLER REAR ROLLER STRADDLE COVERS RAMRAILS PEDESTAL AUTO WAXER LUBRICATION Page 72 700A, P, HRC PARTS LIST WEIGHT PART # 3lbs. 1lbs. 44lbs. DESCRIPTION 70298413 70237517 70237516 700A NON Board Only 700A P Board Only 700A HRC Board Only 70311700 70312100 70312000 700A DOT PANEL ASSY. 700A P DOT PANEL ASSY. 700A HRC DOT PANEL ASSY. 70240505 70020300 70182800 EXTRUSION PANEL CLIP28 3/4" LG SCREW 6-32x3/8 PPHMS BLK OX SAFETY SWITCH 70242313 70279201 70279101 700A DOT /OVERLAY 700A P DOT/OVERLAY 700A HRC DOT/OVERLAY 70219200 70219201 MOTOR CONTROLLER 5592/DCI (Green) MOTOR CONTROLLER (02) 70013500 70282700 SCREW, 10-32x3/8 PPH TFS Bo CHOKE ASSY. 70243200 70243300 SPEED SENSOR SCREW 4-40x1/4 PPH SELF TAPPING 70337900 70337800 NON HRC DATA CABLE AP, HRC 70325500 3HP. DRIVE MOTOR 70125700 70176000 70013500 70125500 70115200 70125600 SCREW 10-32x1/4 PPH TFS Bo 3/8 DBL. COATED FOAM TAPE TESA -49 SCREW 10-32x1/4 PPH TFS Bo 5/16-18 NYLOC NUT WASHER 3/8 1Dx7/8odx.083F 5/16-18x2 CARRIAGE BOLT Page 73 70006300 DRIVE BELT 70113200 ELEVATION MOTOR 70183200 70013500 70115500 70116700 70013500 70118900 INCLINE START CAPACITOR SCREW FOR CAP. /10-32x3/8 CLEVIS PIN 3/8x1 1/2 COTTER PIN 1/16 Diaz x 1 5/16 SCREW 10-32 x 3/8 PPH TFSBO TORQUE ARM SWIVEL PIN 70121000 70125700 70120500 LLS SCREW - 10-32x 1/4 PPH TFS BO LLS WIRE ASSY. To PWM 70281003 70122800 ELEV. RISER ASSY. SOCKET HD. CAP SCREW 1/4-20x1 70303700 70125700 70013500 POWER CORD 12* 14/3 SJTW Black STRT SCREW 10-32x1/4 PPH TFS Bo SCREW 10-32x3/8 PPH TFS Bo 70251100 ROCKER ON/OFF SWITCH 70017200 15 AMP CIRCUIT BREAKER 9lbs. 70317400 BELT 22x119 3/4 ST E5 2Ply-Lo 60lbs. 70276700 70020200 70158600 70019300 FLEX DECK SCREW 10/32 x 1 1/4 PPH "F" z1 BELT GUIDE SCREW 10x3/4 9lbs. 70275200 70352400 ADJ. FRONT ROLLER NEW NUMBER ADJ. FRONT ROLLER 70157000 70185300 70256800 INTERNAL TOOTH STAR WASHER 1/4 id NYLOC NUT 1/4-10 2 no FLAT WASHER .50x.26x.09 2n Plod. 70275500 70159000 REAR ROLLER ASSY. INTERNAL TOOTH WASHER 5/16 10lbs. 26lbs. Page 74 13lbs. 1lbs. 70158900 BOLT HEX HEAD TAP, Gird 5-5/16 70162109 70031200 70030900 70243400 70086700 STRADDLE COVER/ALUM. 54 1/2" 55 TAPE 1/2"x18yd. Adhesive TAPE, 3/8x1/16x108ft. DBL stick-49 BLUE TAPE -STR. CVR. 1/2x150ft roll 6x1 DRYWALL SCREW 70274105 70280600 CHR RAM RAIL NON CHR RAIL (ram) 70210600 #10x3/4 PPH TEK Screw-boo 70277601 70156900 PEDESTAL- WELDMENT/ROUNDED RUBBER WEAR STRIPS 70276003 70155200 70020200 70019300 70086700 FRAME WLDMNT. BUMPER FEET SCREW 10/32x1 1/4 SCREW 10x3/4 PPHSMBO 6X1 DRYWALL SCREW 70280800 70019300 AUTO WAXER SCREW 10x3/4 PPHSMS Bo 70348900 70349000 LUBE STICK SILICONE PACKET (1 APPLICATION) Page 75 725P, HRC PARTS LIST PART # CONTROL PANEL (98 STYLE) Board Only (99-00 STYLE) Board Only OVERLAYS (98 STYLE) ( 99- 00 STYLE) DESCRIPTION 70132412 70132411 70132410 725 NON CONTROL Board Only-SS90 (98) 725P CONTROL Board Only-SS90 (98) 725HRC CONTROL Board Only-SS90 (98) 70237512 70237511 70237510 725 NON DOT CONTROL Board Only (99-00) 725P DOT CONTROL Board Only (99-00) 725HRC DOT CONTROL Board Only (99-00) 70182800 70185400 70138500 70239800 70245100 SAFETY KEY ASSY. HEART RATE RECEIVER HEART RATE POLAR CHEST STRAP HEART RATE TRANSMITTER PLASTIC COVER -HR CONTROL 70160815 70160816 70160814 725 NON OVERLAY-SS90 (98) 725P OVERLAY-SS90 (98) 725HRC OVERLAY-SS90 (98) 70242310 70242311 70242312 725 NON DOT/OVERLAY (99-00) 725P DOT/OVERLAY (99-00) 725 HRC DOT/OVERLAY (99-00) 70219200 70219201 70013500 70282700 MOTOR CONTROLLER 5592/DCI(Green) MOTOR CONTROLLER WITH CHOKE (02) SCREW, 10-32x3/8 PPH TFS Bo CHOKE ASSY. 70243201 70243300 SPEED SENSOR SCREW 4-40x1/4 PPH SELF TAPPING 70337900 70337800 725, P DATA CABLE 725 HRC DATA CABLE 70325800 MED. MOTOR PWM SPEED SENSOR DATA CABLE Page 76 DRV MTR 70325600 70125700 70125600 70125500 70115200 70219601 DRIVE MOTOR 3 HP. MOTOR SCREW CARRIAGE BOLT 5/16-18X2" NYLOC NUT-5/16-18 WASHER-3/8 ID. X 7/8 OD. MOTOR ISOLATION KIT (725) 70127600 DRIVE BELT 260J10 70171500 70183600 70118900 70183200 70013500 INCLINE MOTOR (HUBBLE) CLEVIS PIN 3/8 X 1 3/4 SWIVEL PIN - TORQUE ARM START CAPACITOR CAPACITOR SCREW 10-32X3/8 70121000 70125700 70120500 LOWER LIMIT SWITCH LOWER LIMIT SWITCH SCREW LOWER LIMIT TO PWM WIRE 70281002 70122800 70116900 70176700 70003100 70176701 70174300 ELEVATION RACK ELEV. SCREW 1/4-20X1 SOCKET HEAD LOCK NUT 1/4-20 ZINC/COURSE-THREAD MOLDED WHEEL 3/8 BEF. AUG., 99 MOLDED WHEEL BOLT BEF. AUG., 99 MOLDED WHEEL 1/2 AFTER AUG., 99 MOLDED WHEEL BOLT AFTER AUG., 99 70282900 12 FT. POWER CORD 70251100 ON/OFF SWITCH 70017200 70213100 CIRCUIT BREAKER 15 AMP CIRCUIT BREAKER 10 AMP DUAL POLE 70214400 SEIGLING TREADBELT E5X20X129 70159100 70020200 70155200 FLEX DECK DECK AND BUMPER FEET SCREW DECK BUMPER FEET 70164700 FRONT ROLLER BEFORE NOV.,00 DRV BELT ELEVATION MTR (HARDWARE) LLS ELEVATION RACK POWER CORD ON / OFF SWITCH CIRCUIT BREAKER TREADBELT DECK FRONT ROLLER (BEFORE NOV.00) Page 77 (AFTER NOV.00) 70265300 FRONT ROLLER AFTER NOV.,00-ADJ. 70207800 70283700 70115200 70253700 ROLLER SCREW 3/8-16X3/4 ROLLER BOLT 3/8-16X3 LG. ROLLER WASHER 3/8 IDX7/8 OD 3/8 NYLOC NUT 70186000 70188600 REAR ROLLER REAR ROLLER BOLT 70162106 STRADDLE COVER 70086700 70030900 70243400 STRADDLE COVER SCREW STRADDLE COVER TAPE-108FT.DBL.STK. STRADDLE COVER BLUE TAPE150 FT. 70274101 70210600 RAM RAILS CONTACT HEART RATE RAIL SCREW #10X3/4 70233501 70156900 70207800 70269800 70019300 PEDESTAL-WELDED RUBBER WEAR STRIP BOLT - PED. 3/8"-16 X 3/4" BOTTLE HOLDER MOLDED PLASTIC BOTTLE HOLDER SCREW 10X3/4 REAR ROLLER STRADDLE COVERS RAMRAILS PEDESTAL AUTO WAXER 70167000 70019300 70342000 70239800 AUTO WAXER SCREW 10x3/4 PPHSMS BO GROUNDING STRAP ASSY. WAX CHANNEL (ONLY) LUBRICATION 70348900 70349000 Page 78 LUBE STICK SILICONE PACKET (1 APPLICATION) 750P, HRC, CI PARTS LIST PART # DESCRIPTION (99-PRESENT) BOARD ONLY 70237524 70237525 70237613 750 BOARD ONLY 99-PRESENT 750P BOARD ONLY 99-PRESENT 750CI BOARD ONLY 99-PRESENT GRAY MACHINES ONLY! BOARD ONLY 70219310 70176910 750 P Board Only 750CI Board Only 70185400 70245100 70182800 HRC RECEIVER PLASTIC HR COVER SAFETY KEY/SWITCH 70216212 70216211 70177011 750NON OVERLAY 1998 750P OVERLAY 1998 750CI OVERLAY 1998 70242510 70242511 70242610 750NON DOT OVERLAY 99-PRESENT 750P DOT OVERLAY 99-PRESENT 750CI DOT OVERLAY 99-PRESENT 70183500 70183502 70264800 MOTOR CONTROLLER-BEFORE 08/00 PWM WITH CHOKE-AFTER-08/00 MOTOR CONTROLLER- 220V 70013500 10-32X3/8 SCREW (PWM) 70243201 70243300 CIRCUIT BOARD SPEED SENSOR 4-40 X 1/4 SELF TAPPING SCREW 70286700 70337700 70219500 70271700 750, P DATA CABLE BEFORE 08/00 750 CI DATA CABLE 750 non, p data cable '99 750B & PB DATA CABLE '00 70172000 70263400 70169600 70159000 3HP DRIVE MOTOR Core charge added 3HP DRIVE MOTOR EX 220V Core charge added Page 79 DRIVE MOTOR TENSION PLATE 5/16 STAR WASHER OVERLAY (98 STYLE) (99-PRESENT) PWM SPEED SENSOR DATA CABLE Verify config. Verify config. Verify config. DRV MTR 70125700 70219701 10-32X1/4 SCREW MOTOR ISOLATION KIT (750) 70127600 260J10 POLY-V-BELT 70214500 TREADBELT/SIEGLING E5X23X129 70169400 70020200 70183400 DECK 32 1/2 X 56 DECK SCREW 10 X 1 1/4 DECK BUMPER 70171500 70183200 70183600 70118900 70013500 70116700 HUBBLE ELEVATION MOTOR CAPACITOR-LIFT MOTOR 3/8 X 1 3/4 CLEVIS PIN TORQUE ARM SWIVEL PIN 10-32 X 3/8 SCREW 1/16DIA. X 15/16 COTTER PIN 70121000 70125700 70120500 LLS 10- 32 X 1/4 Screw for LLS Bracket LLS TO PWM WIRE 70281004 70154600 70122800 70173900 70174300 ELEVATION RISER ASSY. ELEVATION BLOCK ASSY. 1/4-20 SOCKET HEAD CAP SCREW MACHINED WHEEL 2 1/4" OD. WHEEL BOLT 1/2" X 1 SHOULDER BOLT 70282900 70008200 12 FT. POWER CORD STRAIN RELIEF BUSHING 70251100 ON/OFF ROCKER SWITCH 70017200 15 AMP CIRCUIT BREAKER 70168000 70265400 70207800 NON ADJ. FRONT ROLLER ADJ. FRONT ROLLER SCREW 3/8-16 X 3/4 70168300 70170800 REAR ROLLER 1/2- 13 X 4" TAP BOLT DRV BELT TREADBELT DECK ELEVATION MTR (HARDWARE) LLS ELEVATION RACK POWER CORD ON / OFF SWITCH CIRCUIT BREAKER FRONT ROLLER REAR ROLLER Page 80 70170900 1/2INTERNAL TOOTH STAR WASHER 70171800 70243400 70086700 70030900 RT. AND LT. STRADDLE COVER BLUE TAPE, STR CVR 1/2 X 150 FT ROLL 6 X 1 DRYWALL SCREW DOUBLE STICK TAPE 3/8 X 1/16 X 108 Ft 70165100 70210600 RAM HANDLE BAR #10 X 3/4 SCREW 70233601 70156900 70269800 70019300 ROUNDED PEDESTAL WELDMENT RUBBER WEAR STRIP BOTTLE HOLDER BOTTLE HOLDER SCREW 10X3/4 70227501 70155200 70020200 70164500 FRAME WELDMENT/ROUNDED GRAY BUMPER FEET BUMPER FEET SCREWS BUMPON DECK BUMPER 70167000 70019300 70342000 AUTOWAXER AUTOWAXER SCREW, 10 X 3/4 GROUNDING STRAP ASSY. WAX CHANNEL 70348900 70349000 LUBE STICK SILICONE PACKET (1 APPLICATION) STRADDLE COVERS RAMRAILS PEDESTAL FRAME AUTO WAXER LUBRICATION Page 81
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