Quinton’ SERIES 90 TREADMILL ‘Service Manual and Schematics Package For use with U.S. models onlyOther quality equipment available from Quinton: ECG and Stress Test Monitors ECG Electrodes Diagnostic Electronic Instruments Pulmonary Test Monitors Treadmills and Ergometers for Exercise Stress Testing Biopsy Instruments Catheters, Cannulae, and Accessories for Dialysis, Chemotherapy, and Parenteral Nutrition Home Exercise Equipment Equipment and Accesories for Health and Fitness Facilities Quinton, G-Series, and Series 90 are trademarks of Quinton Instrument Company. Loctite is a registered trademark of Loctite Corporation. Copyright 4994 Quinton Instrument Company All rights reserved ‘Service Manual—Publication No. 000346-830 ‘Text—Part Number 032247-001 (Rev B)Table of Contents SECTION 1. INTRODUCTION ‘SCOPE... DESCRIPTION... ACCESSORIES AND OPTIONS SPECIFICATIONS... SECTION 2 RECEIVING, UNPACKING, AND INSTALLATION INTRODUCTION .. RECEIVING INSPECTION AND UNPACKING... INSTALLATION CHECKOUT PROCEDURE. SECTION 3 THEORY OF OPERATION INTRODUCTION .. OPERATIONAL OVERVIEW... MECHANICAL THEORY OF OPERATION .. Motors, Shafts, Belts, and Pulleys Pinion Shaft and Rack Gears... ELECTRONIC THEORY OF OPERATION Power Supply. Power-up Detect Start Belt. Speed Feedback SPEED LIMITS.. SPEED CONTROL STOP BELT. EMERGENCY OFF SWITCH ... DRIVE MOTOR FAULT. SLOW-SPEED THRESHOLD. RESET SWITCH / HIGH-SPEED DECEL.GRADE CHANGE.. GRADE FEEDBACK.. 3-9 SECTION 4 ASSEMBLY, DISASSEMBLY, AND CALIBRATION PROCE- DURES ii INTRODUCTION .. REMOVING THE TREADMILL HOOD... MOTOR ASSEMBLIES. Drive Motor. Drive Motor Contactor (K1). Speed Change Motor TACHOMETER ASSEMBLY... Optical Sensor Replacement. Beam Chopper Replacement Beam Chopper Wheel Alignment ... REPLACING THE TREADMILL PCB ASSEMBLY INPUT SHAFT ASSEMBLY PROCEDURES .. Input Shaft Assembly and Speed Change Spindle Assembly Removal Input Shaft Assembly Replacement OUTPUT SHAFT ASSEMBLY PROCEDURES .. ‘Output Shaft Assembly Removal Output Shaft Assembly Replacement... Replacing the Variable Speed Belt.. Replacing the Final Drive Belt. Adjusting the Final Drive Belt Tension .. GRADE CHANGE (ELEVATION) SYSTEM. Grade Motor. Grade Potentiometer (Pot) Replacement Removing the Rack Gears Reassembling the Rack Gear. Replacing a Jammed Rack Gear.Replacing the Pinion Shaft WALKING DECK ASSEMBL’ Removing and Replacing the Front (Drive) Roller or the Idler (Rear) Roller 15 Replacing the Walking Belt. Removing the Slider Bed..... WALKING BELT ADJUSTMENT PROCEDURES, Walking Belt Tension Walking Belt Tracking .. Rear Roller Guard Adjustment.. CALIBRATION PROCEDURES .. Grade Potentiometer (Pot) Calibration Grade Feedback Calibration .. Speed Feedback Calibration .. ADJUSTMENT PROCEDURES... V-Belt Adjustment. Torque Limiter Adjustment. REPLACING THE POWER CORD. REPLACING THE RESET SWITCH. CLEANING THE TREADMILL SURFACES. SECTION 5 ‘TROUBLESHOOTING Sel TROUBLESHOOTING BEARING PROBLEMS... SECTION 6 PART NUMBERS AND DRAWINGS Figures 2-1. Unpacking the treadmill. 2-2. Reset switch and connectors... 4-1. Ground wire connection.. 4-2. Reset switch and connectors. 4-3. Drive motor.. iiiiv 4-4, Drive motor contactor. 4-5. Treadmil! PCB assembly... 4-6. Speed change motor and bracket. 4-7. Tachometer optical sensor 4-8, Input shaft assembly 4-9. Loosening the variable speed belt 4-10. "T" stamp shows bearing cap orientation... 4-11. Speed change mechanism 4-12, Output shaft assembly and belts 4-13. End caps and siderail cover .. 4-14. Deck mounting screws and drive pulley Retainer Screws 4-15. Drive pulley cover on bottom of treadmill 4-16. Grade motor. 4:17. Grade pot and pinion shaft. 4:18, Handrail support bracket. 4-19. Walking deck assembly. 4-20, Walking belt replacement (typical). 4-21. Adjusting walking belt tension 4-22. Grade pot and pinion shaft 4-23, Peba, showing switches, jumpers, and pots... 4-24, Drive motor. 4-25. Torque limites adjustment nut and tabs ... 4-26, Reset switch and connectors. Tables J-1. Series 90 Treadmill Specifications 1-2. Power Options and Requirements.. 4-1. Speed Adjustments (mph) 5-1. Troubleshooting Mechanical Component Noises:SECTION 1. INTRODUCTION SCOPE This manual contains the theory of operation, troubleshooting information, installation and maintenance procedures, and the drawing package for the Quinton® Series 90™ medical treadmills listed in Table 1-2 on page 1-3. It is intended for Quinton-trained service personnel. NOTE Do not use this Manual to service the following Q-Series™ treadmills: —Q50 (Quinton p/n 00259 or 000306) —Q55 (p/n 00208 or 00308) —QSSXT (p/n 00264 or 00309) —Q65 (p/n 00221 or 00307) Refer to Quinton Service Manual p/n 000208-830 or 000343-830, as appropriate, for information and schematics for these treadmills. The Manual is divided into five sections: + Section 1 includes a product description, a list of accessories and options, the specifications, and the power requirements for the various treadmills. + Section 2 is the installation instructions for the treadmills. + Section 3 includes a detailed theory of operation for the electronic and mechanical components of the treadmills. This section is prim: intended for reference and training. + Section 4 is the assembly/disassembly, adjustment, and calibration procedures. + Section 5 is the troubleshooting and maintenance guide for the treadmills. It includes a number of tables that contain component and troubleshooting data. + Section 6 is the drawing package. It includes the assembly drawings, parts lists, and schematics for the Series 90 treadmills. DESCRIPTION The Series 90 treadmills are available in a number of models, differing in platform length, belt speed range, and power requirements. The specifications and power options are described in Tables 1-1 and 1-2 on the following pages. Each treadmill requires an external device called the controller for operation. Quinton controllers include: + the Q3000, Q4000, Q4500, and Q5000 Stress Test Monitors. + the 645 Programmable Treadmill Controller. + the 640 Manual Treadmill Controller. Refer to the appropriate Operator Manual to operate the treadmill with each device. (The Model 640 Controller Manual is included with each treadmill. Other manuais are included with each Monitor or Controller.) To order the Operator or Service Manual for any controller, contact your Quinton repre- sentative, or call Quinton Customer Service toll-free at 1-800-426-0347. ACCESSORIES AND OPTIONS The following accessories are shipped with each treadmill + Handrail Assembly (Quinton part number 031569-002) + Hand grip (p/n 013802-001) + Operator Manual (p/n 000346-840) + Service Manual (p/n 000346-830) These additional accessories are available: + Overhead Mask Support (013689-001) + Side Handrail, Short (p/n 13690-001) + Side Handrail, Long (p/n 013691-001) + Handrail OFF Switch (p/n 013675-001) + Catheter Arm Support (p/n 000043-002) 1To order any item, or for more information on any of Quinton’s line of medical and fitness products, contact your Quinton Sales Repre- sentative or call the Quinton Customer Service Department toll-free at 1-800-426-0347, SPECIFICATIONS Table 1-1 lists the performance specifications, physical characteristics, and environmental Tequirements for the Series 90 treadmills. Table 1-2 includes the single-phase power options for each treadmill. Table 1-1. Series 90 Treadmill Specifications Performance Max. Rated Load (Bruce Protocol) 50 275 Ib (125 kg) Q55 360 Ib. (159 kg) 400 Ib (181 kg) 400 ib (181 kg) | Belt Speed Range 0.8 - 8 mph 14-10 mph 1.5- 15 mph 4.5 -15mph (Continuously (1.3 - 13 km/h) (1.6 - 16 km/h) (2.4 - 24 kin) (2.4 ~ 24 km/h) Adjustable)" 0.6 - 6 mph . (0.96 - 9.6 kmn) _ - | Grade Range 0- 25% 0 - 25% 0 - 25% 0 - 25% L (0-14) (0-14) (0- 14") (0-14°) Physical falking Area 20x 50 20 x 55 j 20 x 55 in 20x 65 (Nominal) (81 x 127 om) (51 x 140 om) _(61 x 140 cm) (51 x 165 cm) ‘Walking Belt 115 in. (292.1 cm) | 125 in (317.5cm) | 125 in (317.5cm) 145 in (368.3 cm) Circumference a - - Floor Space 90 x 75 in. | 30 x 80 in. 0 x 80 in. | 30x 90in. Required (7x 191 em) (78 x 203 em) (76 x 203 cm) (76 x 228 om) Walking Surface Height {7.3 in. (48.5 em) 7.3 in. (188 om) 7.3 in, (18.5 cm) 17.3 in. (18.5 cm) | Handrail Height | 47in.(1190m) | 47in.(11Sem) | 47 in, (1190M) AT In. (119 cm) above Floor _ : __ Weight 410 1b. (186 kg) | 430 1b. (198kg) | 430 ib. (195 kg) | 460 Ib. (209 kg) Shipping Weight 560 Ib. (254 kg) ‘580 Ib. (263 kg) 580 Ib. (263 kg) [610 Ib. (277 kg) Power Cord 140 feet (3 m) 10 feet (3 m) 10 feet (3 m) 10 feet {3 m) Length Environment Operating 60 - 98° F 60 - 95° F 60 60 - 95° F. | Temperature | (15- 35°C) (15 - 35°C) (15 -35°C) (15 - 35°C) Storage V0- 120° F T0-120°F 0-120°F 0- 120° F ‘Temperature (-18 - 49° C) [18 -49° 6} | (18 - 49°C) |. (18 - 49° c) Humidity 30 - 90% 30 - 90% 30 = 90% ‘30 = 80% (Non-condensing) *“Typical—Other speed ranges are available.Table 1-2. Power Options and Requirements Model | Part Number | Voltage (VAC) | Frequency | Fullicad | Branch (Hz) Current Circuit (Amps) Amperage (Minimum) ey 345-001 & eae ial 115 60 12 18 345-002 & eed 208/230 60 6 15 345-008 | «100 60 12 15 345-004 100 50 2 6 | 7 345-005 through -009 pen 230 50 6 10 ‘rough -016 346-001 | 208/230 60 12 15 346-002 ise 80 24 30 346-003 | +100 60 2a 30 ass | _346-004 i) 50. 24 | 30 346-005 e through -009 | 230 50 12 13 343-001 208/230 0 16 20 343-002 200 60 16 20 343-008 200 50 16 20 QssxT jo + | 343-004 toug008 230 50 16 16 344-001 208/280 60 16 20 | aaa-o02 & = | = aaoed 200 60 16 20 a | _ 344-003 & aaron 200 50 16 20 344-006 through -010 om em ‘8 a 13SECTION 2 RECEIVING, UNPACKING, AND INSTALLATION INTRODUCTION This section contains instructions for receiving, unpacking, inspecting, and installing the Quin- ton Series 90 Treadmills. RECEIVING Before leaving the factory, the treadmill was thoroughly inspected and tested for proper operation. To minimize shipping damage, careful attention was given to packing, crating, or making the unit ready for padded-van shipment. Quinton’s responsibility for the unit ends upon delivery to the carrier, who assumes. responsibility for safe delivery. When loss or damage to equipment that is shipped FOB Factory is sustained in transit, all claims must ‘be made by the customer and submitted to the cartier. For shipments that are sent FOB Destination, Quinton Instrument Company will file the claim, provided that we are furnished with an acceptable inspection report from the carrier. If the claim is disallowed because the customer failed to obtain the report, repair charges will be billed to customer. INSPECTION AND UNPACKING WARNING The treadmill requires two people to uncrate it, lift it, ard move it into position. The unpacking and removal instructions are inside the box. Please read them after perform- ing Step 2 below, but before removing the tread- mill. Otherwise, you can damage the treadmill. For your convenience, they are reprinted below. Also, note that the operator and service manuals and the front handrail assembly are standard items, although they are not listed on the waypill. 1, Inspect the shipping container for evidence of damage. Damage should be noted on the waybill, which should be signed by the carrier's agent. Failure to describe external evidence: of loss or damage on the waybill can result in the carrier refusing to honor the claim. Use a razor knife to cut the straps that secure the treadmill cover to the pallet, then remove the cover. 3. Remove the empty filler box and discard. 4, Use a razor knife to cut the straps that 10, nN 12, secure the handrail to the treadmill. Remove and discard the plastic bag that encloses the treadmill. Loosen the two hex bolts at the rear of the pallet, then remove and discard the bolts, washers, and rear frame. See Figure 2-1 (page 2-2). Remove the two hex bolts at the center of the pallet. CAUTION Do not remove the bolts at the front of the pallet. Remove the 2 x 4 wood blocking at the rear of the pallet, between the platform and the skid (Figure 2-1). Save the block. Use the wood block removed in Step 8 to pry up the rear of the platform, then lift the treadmill and the platform. Pivot the pallet skids from the rear of the pallet to the left and to the right, then allow the pallet platform to lower to the floor. See Figure 2-1. With help from another person, lift the rear of the treadmill and slowly roll it backwards off the pallet. Roll the treadmill to its final location and set it down, 21PIVOT SKID ON FRONT BOLT REMOVE THESE BOLTS FROM BOTH SIDES 2X4 BLOCKING PALLET Figure 2-1. Unpacking the Treadmillconnector Controller: ‘sonnactor Figure 2-2. Reset switch and connectors INSTALLATION CHECKOUT PROCEDURE Use this procedure to verify proper operation, 1. Verify that the service outlet voltage matches the voltage on the nameplate. CAUTIONS Do not use an autotransformer to increase 115 VAC 10 230 VAC to run the treadmill. Consult a licensed electrician to correct the voltage at your facility, If you are using a Stress Test Monitor as a coniroller, verify that the monitor and the treadmill are each on a separate branch circuit. 2. Plug the treadmill power cord into the wall outlet. WARNINGS + Excessive risk current (leakage) ‘may result if this equipment is connected to other than a single phase grounded center tap supply. + Do not start the walking belt or ress the RESET switch when someone is on the treadmill. The belt starts moving immediately, and the sudden start and subsequent loss of balance could cause serious personal injury. Inspect the controller connector for damage. It is located near the power cord (Figure 2-2). If it is not damaged, connect the control cable to the tread- mill. Connect the control cable to the controller. Ensure that nobody is on the treadmill walking belt, then press the red tread- mill RESET Switch above the tread- mill connector (Figure 2-2). The belt should start momentarily, then stop automatically. Perform the treadmil\ checkout proce- dure described in the Operator Manual for your controller. Perform the following checks on the Model 640 controller (if applicable): a. Verify that the DISCONNECTED CABLE LED is off. b. Press POWER to turn the controller on. c. Press START BELT to start the treadmill. d. Use the SPEED INCREASE and SPEED DECREASE pushbuttons to verify proper operation throughout the treadmills complete speed range: + Q50: 0.8-8 mph (1.3-13 km/h) + Q55: 1-10 mph (1.6-16 km/h) + QSSXT, Q65: 1.5-15 mph (2.4-24 xernfh), e. Use the GRADE INCREASE and GRADE DECREASE pushbuttons to verify proper operation throughout its grade range of 0 to 25% (0-14"). f. Retum treadmill to 0° elevation (horizontal). 8. Press STOP BELT and verify that the treadmill stops. 23SECTION 3 THEORY OF OPERATION INTRODUCTION This Section, which is primarily intended for reference and advanced training, describes the mechanical and electronic theory of operation of the treadmills. It is divided into three subsections: + an overview of treadmill operation, + the mechanical theory of operation, including the motors, gearing, etc. + the electronic theory of operation, including a functional description of the PCB Assembly and the power supply. OPERATIONAL OVERVIEW The Series 90 treadmills include the: 1. Q50 treadmill, with a 50-inch walking platform. 2. QSS treadmill, with a $5-inch platform, 3. QSSXT treadmill, with a 55-inch platform and a higher maximum speed than the Q55. 4, Q65 treadmill, with a 65-inch walking. platform and the same speed range as. the Q5SXT. The treadmills are functionally and operational- ly identical, and employ identical cable inter- faces to the various controllers such as the 640 ‘or the Q4500, The Series 90 treadmills include the following primary assemblies: + Three motors: — drive motor, which drives the walking belt — speed change motor, which changes the beit speed. — grade motor, which changes the ‘treadmill grade. + input and output shafts, belts, and pulleys, which transfer mechanical energy from the motors to operate the walking belt and change the grade. + speed change motor assembly (2A2). + tachometer assembly (243). + pinion shaft and rack gears. + grade potentiometer (2R1). + drive motor relay, or contactor (K1). + treadmill control PCB assembly (21), which includes all the controlling electronics and the power supply. A complete set of schematic diagrams and assembly drawings are included at the end of this Manual. A list of drawings appears on Page 6-1. MECHANICAL THEORY OF OPERATION Motors All treadmill motors are continuous duty, single phase with internal overload protection. Draw- ing 031474, which shows the treadmill with the hood removed, illustrates the layout of the operational components described below. Drive Motor The drive motor provides the force te turn the treadmill drive pulley and move the walking belt. An arrangement of shafts, belts, and pulleys allows a movable sheave on the input shaft to change the output shaft’s rate of rota tion, which varies the speed of the walking belt. Speed Change Motor Assembly ‘The speed change motor assembly consist.. of a reversible, variable speed DC gear motor, linked by a chain and sprockets to the speed change spindle assembly. The motor moves the speed change spindle assembly and :novable sheave laterally along the inpwt shaft to change the speed of the walking belt. A tachometer linked to the output shaft monitors the speed of the walking belt. The speed change motor cannot be operated unless the drive motor is on. 31Grade Motor The grade motor is a right angle gear motor. ‘The motor shaft is linked to a pinion shaft by a chain and sprockets. The chain turns a sprocket on the pinion shaft to raise and lower the headframe of the treadmill on two parallel rack gears, A grade potentiometer linked (0 the pinion shaft by a chain and sprockets monitors elevation. Shafts, Belts, and Pulleys An input shaft, an output shaft, belts, and pulleys function as a transmission for the treadmill Input Shaft The input shaft includes a machined pulley, the fixed and movable sheaves that comprise the input pulley, and the speed change spindle assembly. A V-belt links the drive motor output shaft with the input shaft, which turns at a constant speed. The speed change spindle assembly consists of a fork, a speed change spindle, and a yoke. As the speed change motor turns the spindle, the fork moves laterally on the input shaft, control- ling the movable sheave. The speed change spindle assembly positions the movable sheave on the input shaft. Output Shaft ‘The output shaft includes a spring, the movable and fixed sheaves that comprise the output pul- ley, and a timing pulley. The output shaft tums ata variable speed that depends on the pitch diameter of the output pulley. Variable Speed Belt A variable speed belt links the input pulley and the output pulley. The four sheaves are angled, so the variable-speed belt is forced in or out be- tween pairs of sheaves, and therefore increases or decreases pitch diameter. Spring tension against the movable sheave on the output shaft forces the belt outward, increasing the pitch diameter of the output pulley. When the speed change fork moves the movable sheave on the input shaft inward, the pitch diameter of the input pulley increases, 3-2 causing a simultaneous decrease in the pitch diameter of the output pulley. Treadmill Drive and Idler Pulleys The timing pulley on the output shaft drives the treadmill drive pulley. The drive pulley drives the walking belt and the treadmill idler pulley. Pinion Shaft and Rack Gears The pinion shaft and rack gears allow the entire headirame assembly to tilt for grade changes. The pinion shaft has machined teeth at both ends to move a parallel pair of rack gears up and down, Factory-set limits establish the 0-25% grade range. Mechanical stops at the top and bottom of the rack gears prevent upward and downward overtravel. The pinion shaft has ‘a torque limiting device to prevent damage to the grade motor if it continues t0 turn at the upper or lower limits of travel. ELECTRONIC THEORY OF OPERATION The treadmill electronics is included on the treadmill control PCB assembly, which is located under the treadmill hood. The following paragraphs detail the circuitry and operation of the functional components on the PCB Assembly, including: + power supply. + power-up detect, + start belt, + speed feedback. + speed limits. + speed control. + stop belt, + EMERGENCY OFF switch. + drive motor fault, + slow-speed threshold. + RESET switcivhigh-speed deceleration. + grade change. + grade feedback This description references schematic drawing 030626-201, located in the drawing package following Section 6 a! the end of this Manual. In general, the first paragraph is a functionaldescription of the component, while the follow- ing paragraphs provide a detailed circuit-level discussion, NOTE ‘When components and pinouts are specified, the component type and number are given first, followed by a hyphen and the pin number. If several pins are referenced, they are separated by commas. For example, “J1-3 refers to "Jack 1, pin 3", and “P7- 4,13" refers to "Plug 7, pins 4 and 13." Power Supply The line voltage is stepped down to approx- imately 25 VAC by an external transformer. The 25 VAC is rectified and used to generate: + +28 VDC for the speed-change motor. + 423 VDC for relay coils. + +12 V for analog signals and most logic, and + +45 VDC for speed change-motor driver logic. (Refer to dwg 030626-201, sheet 2.) Line voltage is sent to an off-board step-down transformer via an off-board terminal block. The transformer is configured so that approx- imately 25 VAC is retuned to the PCBA on J1-2,4. CR3, C8 and C6 rectify and filter the ‘AC voltage to provide the input for switching regulator U1. The switching frequency, approx- imately 100 KHz, is determined by R4 and C2. The input voltage is switched to the output at the switching frequency with a pulse width varied so that the feedback voltage (U1-10) stays at 5 V. For U1-10 to be at 5 V, R6 and R7 cause the output voltage (after filter L1/C9) to be at 28 V. The 28 V provides the input for regulator VR (Sheet 1). The output of VR1 is such that a 1.25 V difference between pins 3 and 1. Disregarding the negligible current into pin 1, R2 and R3 cause the output to be approx- imately 23 V. This provides the input for the 12 V regulator VR2, which, in turn, provides the input voltage for the 5 V regulator VR6. J1-284 is also rectified by CR1&2 (Sht 2) and filtered by R1 and C25. R29 is used to adjust this voltage so that a “low-line” condition causes the voltage at U6-11 to drop below +12 V. This causes U6-13 to go low, and R46/C30 ensure that once low, the signal stays low for at least one second. The low causes J11-21, LO-LINE/, to go low, sending the error indication to the controller. Power-up Detect. (Refer to Sheet 5.) Since a loss of power during treadmill use could cause the walking belt to stop with the mechanical transmission set above the acceptable slow-speed threshold, the return of power is detected to prevent a subsequent user from starting the belt until a slow-speed setting of the transmission is verified. ‘When the +23 V buss increases in voltage by more than 12 V (as in a power-up condition) C36, R60, and R58 combine to set latch U14- 10 high. This is the same condition which ‘occurs when the belt is stopped due to an Emer- gency Off or a drive motor overload. (These conditions stop the belt without allowing for a HI SPEED DECEL.) The high from U14-10 ‘goes to three places + to U8-13, forcing it to go high, which causes U11-10 to go high, holding U11 in reset. + to U7-2 via CR33, thereby removing the base drive from Q3 and preventing the user from starting the belt. + to the Reset Switch LED via U7-4 and U7-13. The low at U7-13 is also sent to US-9 via CR23 (see sheet 4). This inhibits any grade change command from the controller by shunting the signal across R23. Start Belt (Refer to Sheets 5 and 6.) Quinton treadmill controllers complete a current path from STOP (I11-1,18) , Sht 5, to START/STOP (J11-2), Sht 6, when START BELT on the controller is pressed. This current causes the off-board contactor to close, thereby sending power to the drive motor. The current path can be broken by Q3 on the circuit board if appropriate.When the treadmill user presses START BELT, STOP, J11-1,18, is pulled low. This low pulls 2-4 (Sheet 6), CONTACTOR COIL, low, activating the drive motor relay. It also tums on QU through Rit and CRIS. This sends +23 V through R13, CR18, and R14 to switch on Q2, which pulls J11-2, START/STOP, low. Control- lets are configured so that when J11-2 is low J11-1,18 is pulled low. Thus, when J11-1,18 is pulled low by pressing START BELT, 311-2 must be pulled low through Q2 before the tread- mill user releases the START BELT button to latch the drive motor contactor on. A key element of the Slow-Start circuit is that Q3 can disable the normal START BELT function by not allowing the low at 111-1,18 to pass to the contactor at J10-4 nor to Q1, which would otherwise complete the latch at Q2. One other condition will start the belt: when flip-flop U1) (Sheet 5) is in the Hi SPEED DECEL mode, or set. The high at U11-13 causes U7-14 to go low, which pulls the contactor low at J10-4. The high at U11-13 also goes to U7-2 through CR32, pulling U7-15 low. The low at U7-15 removes the base drive from Q3 via CR28 and R33 and it removes the base drive from Q2 via CR27, CR18 and R14, This disables the START BELT function of the controller. Speed Feedback (Refer to Sheet 2.) Rotation of the treadmill output shaft causes an optical interrupter to send pulses to the circuit board which have a frequency directly related to the speed of the walking belt. A frequency-to-voltage conver- sion provides a voltage which is inversely proportional to the speed. (ie. the voltage is at +12 V when the belt is stopped and decreases linearly toward 0 V as the treadmill belt speed increases.) This voltage is used to trigger the electronic speed limits (see next section) and to determine the rate of speed change during a SPEED INCREASE or SPEED DECREASE (see SPEED CONTROL section). This voltage is also converted to a current which is directly proportional to the treadmill helt speed (ImA = 1 MPH). This current is sent to the treadmill controller via 311-12, 34 Speed feedback is provided by pulses from an optical tachometer located on the output shaft assembly, R107 completes the current path for the optical tach LED. The output of the tach (J7-1) should swing between +12 V and ground when the belt is moving. These pulses are seen at the inverting input of comparator U18 after noise filter R96/C53. The reference on the non- inverting input is approximately 2/3 the peak pulse voltage, created by the R77/R78 split of UI3-2, CR43 prevents the reference voltage from dropping below approximately 2 V. Positive transitions at the output of U18 are converted to 0.3 ms pulses by R#22/C60 and negative transitions are converted to 0.3 ms pulses by R118/C61. R116 and R117 scale the pulses which are then filtered by R123/C63 and RI24/C62, R128, R129, QS and U20 convert the filtered pulses to a feedback current which is inversely proportional to the time between the pulses. R128 is used to calibrate the output current so that 1 mA corresponds to 1 MPH. ‘The peak tach voltage is held by CR42/R76/C52. U13 buffers this voltage to provide the tach reference described above. U18 compares this voltage to approximately 7 V, generated by R94/R95. 7 V was chosen to allow for the CR42 diode drop as well as the sagging of CS2/R76 during the negative portion of the tach pulse, Before the belt is started R99 and C55 hold flip-flop U19 set (i.e. U19-13 is high). When the belt is started, this RC network allows the peak tach voltage to reach a stable state prior to enabling the error condition, If the peak tach voltage is not at an acceptable level (approximately +8 V) or degenerates to an unacceptable level during use, U18-13 goes high, clearing flip-flop U19, causing UI9-13 to go low. This low is sent to the speed feedback Circuit via CR5O after scaling by R125 and R126. This causes the treadmill controller (such as the 645) to be given feedback indicating a high rate of speed, This, in turn, causes the controller to drive the speed down until it realizes it cannot change the feedback. At this time the controller will go into a Speed-Control Error mode. When the treadmill belt is stopped by the user, the error condition is reset by the high on 119-8,SPEED LIMITS (Refer to Sheet 3.) The voltage generated from the tach pulse frequency-to-voltage conversion discussed in the preceding section is adjusted by R85 to provide a voltage which varies from approximately +10 V to +12 V as the treadmill belt speed varies from its maximum rated speed to 0 MPH (stopped). This voltage is compared to two reference voltages which create a speed window for the allowable speed range. At- tempts to drive the treadmill speed outside this window cause the appropriate speed-change signal from the controller (SPEED INCREASE or SPEED DECREASE) to be ignored. R85 is used to adjust the SPEED FEEDBACK so that the maximum rated speed of the tread- mill provides a voltage at JP3-2 which is slight- ly less than the voltage at JP3-3 (10.1 V). R80 and R81 combine to create the limit reference voltage at JP3-3, R30 is used to adjust the lower limit voltage at JP3-1 so that itis slightly Tess than the voltage at JP3-2 when the tread- mill is at the minimum rated speed. These two adjustments define the speed-range window. ‘When the voltage at JP3-2 falls below the voltage at JP3-1, the low-speed limit is reached. ‘This causes U15-1 to go low, shorting out any SPEED DEC command across R48. Also, via US -1 & 2 and U4-5 & 12, it lights DSS to indicate the low speed limit has been reached. When the voltage at JP3-2 goes above the voltage at JP3-3, the high-speed limit is reached. This causes U15-7 to go low, shorting out any SPEED INC command across R42. Also, via U12 -5 & 6 and U7-1 & 16, it lights DS1 to indicate the high speed limit has been reached. Note that when the beit is stopped U16-1 is at +12 V. Regardless of how R85 is set, the feed- back of R68/R70 will not allow U16-7 to fall below approximately +5 V. Thus, for testing purposes the electronic low-speed-limit can be disabled by shorting JP3-1 to ground using switch SWI-1 & 8. As noted above, R85 adjusts the speed feedback so that approximately 10.0 V is present at JP3-2 4( the treadmill’s maximum rated speed. This occurs when R85-2 is at approximately 10.0 V. Thus from 0 MPH to the treadmills maximum rated speed, R85-2 varies from +12 V to +10 V. If the treadmill could attain four times its rated speed (it will be mechanically limited Jong before then) R85-2 would drop to +6 V. This would cause U16-7 to rise to approximate ly +20 V. Therefore, by pulling JP3-3 to +23 V using switch SW1-3 & 6, the electronic high- speed-limit does not function until the treadmill speed is over four times greater than the maxi- mum speed setting of R85. Thus, if on a 1.5-15 MPH treadmill R85 was set so that the speed limited at 5 MPH, shorting JP3-3 to +23 V will allow the speed to increase to over 20 MPH. NOTE It would be necessary to set JP3-1 to +5 V using switch SW1-4 & 5 (Sheet 6) to provide adequate torque in the situation described above. It is important that switch SW1-4 & 5 are ‘open for normal use. CAUTION The SWI switches are intended for use solely during final calibration of the treadmill control board. Do not alter the post-calibration setting, SPEED CONTROL When a the controller PCBA receives a SPEED INCREASE or SPEED DECREASE command from a treadmill controller such as the Model 645, pulse-width modulated 28 V pulses drive an off-board DC motor, which tums to change the mechanical transmission appropriately to increase or decrease the treadmill beit speed (Refer to Sheet 3.) Speed control is obtained by varying the puise width of the SPEED ENABLE signal. When SPEED ENABLE is high and either SPEED INC or SPEED DEC is high, 28 V is routed to the speed change motor. ‘The current path for a SPEED INC is +28 V from U2-4 to U2-3, through K4 to the speed change motor via J5-3, back from the motor via 35-5, through K4 to U2-2, from U2-2 to U2-1, and through current-sense resistor R8 to ground, SPEED DEC is similar, with the signals at U2-2 and U2-3 reversed. 3-5(Refer to Sheet 6.) The frequency of the SPEED ENABLE pulses are determined as follows: R50, R51, R52, CR31, and R49 com- bine to place approximately 10.17 V at U6-7 when U6-1 is high and 2.78 V at U6-7 when U6-1 is low. When U6-1 is high, R26 and R27 charge C24 from 2.78 V to 10.17 V exponential- ly. This takes approximately 163 us. When U6- is low, CR25 and R45 discharge C24 from 10.17 V'to 2.78 V in approximately 2.21 ps. Thus the output of U6-1 is high for 163 us and pulses low for 2 1s; the input to U6-9 varies exponentially from 2.78 V to 10.17 V in 163 Hs and drops back to 2.78 V in 2 ps. With JP2-1 connected to +5 V by using switch SW1-4 & 5, speed feedback does not affect the circuit and R61 can be adjusted to provide the proper speed change motor torque (i.e. the duty cycle of the 6KHz SPEED ENABLE pulses). The highest torque requirement occurs when increasing the speed at the top of the speed range (e.g. 9.5-10.0 MPH on a 1-10 MPH treadmill). At this time the speed-change motor cosrent wil] be at a maximum. A typical SPEED MOTOR CURRENT value at this time will be 0.2 V; the motor's rated current would produce a voltage of 0.2856 V. Suppose R61 is set at 50.0 KQ. At full-load current, this causes 14.57 V to be present at U10-7. Since we have $V at Ul0-3, the 14.57 V at U10-7 causes 2.75 V to be at Ul0-1 and U6-8. Since U6-9 is going between 10.17 V and 2.78 V, the U6-14 output is always high, giving a 100% duty cycle. Using a typical value of 2 V at U10-5 and the same R61 setting, 50.0 KO, the voltage at U10-7 is 10.2 V, and the voltage at U10-1 is 3.778 V. U6-9 will rise from 2.78 V to 3.778 V in approximately 12.7 ts. Since the period of the reference waveform is 165 ls, this causes a 92% duty cycle. Thus, as the speed-change ‘motor current increases, so does the duty cycle of the SPEED ENABLE 6 KHz pulses. R61 is set so that "hunting” will not occur at the upper speed ranges when using a programmable con- troller such as a 645 or Q-series monitor. This duty cycle is likely to be in the 75% range which occurs when JP2-2 is at 5.67 V, or U10- 7 at 2.13 V. Given the same typical motor cur- rent, R61 is set at 9.65 KQ. The SPEED MOTOR CURRENT signal is also routed to U6-5. On a pulse by pulse basis the current is compared to the voltage threshold determined by R24 and R25. If that voltage is exceeded, U6-2 goes high, resetting U14, there- by turning off the SPEED ENABLE pulse until the next cycle begins (i. when U6-1 goes low, is inverted by US, and sets the U14 latch). When the treadmill goes from minimum to maximum rated speed, SPEED FEEDBACK varies from approximately 5.4 V to 10 V. This is halved by R69 and R65 to provide a voltage swing of 2.7 V to 5 V at U10-3. Neglecting the contribution of the torque circuitry (je. U10- 0 V), U10-1 varies from 3.3 V to 6.2 V. This in- creasing voltage causes a decreasing pulse width at SPEED ENABLE (U6-14) as the tread- mill increases in speed. This causes the speed change motor to move much faster during speed changes at low speed than it does during speed changes at high speed, Note that U7-11 pulls SPEED ENABLE low when the belt is stopped. This inhibits activa- tion of the Speed-Change motor. STOP BELT (Refer to Sht 5 and 6,) The treadmill belt is stopped by interrupting the current path which comes from the contactor coil at 110-4, through Q3, out to the controller at STOP (J11-3,18), back from the controller at START/STOP (J11-2), and through Q2 to ground. The treadmill user normally stops the belt by interrupting the connection between J11-1,18 and J11-2. When J11-1,18 cannot conduct current and U7-[4 is high (open-coilector), the contactor coil is released. 310-4 is pulled high by the contactor coil, which turns off QI via RIL and CRIS, removing the base drive for Q2. The +23 V also goes to U7-6 via R55 which causes U7-11 to go low, inhibiting any normal speed change. U17-3 is also connected to 10-4 via R115, When 110-4 goes high, U17 causes ULI-11 to be clocked. U11 determines whether the treadmitf shiould decelerate from above the "threshold" speed. See the description of HI SPEED DECEL on page 3-8.EMERGENCY OFF SWITCH (Refer to Sheet 5.) Pressing the Emergency Off switch stops the belt without a high-speed deceleration by breaking the current path at Q3, as discussed in the preceding section. In doing 50, it also inhibits further operation of the START BELT, GRADE INCREASE, or GRADE DECREASE switches on the treadmill controller until after the Treadmill Reset switch located on the side of the treadmill is pressed. If an Emergency Off switch is installed, press- ing it causes J10-5 to be pulled low through 310-3. This low causes U12-4 to go high, set- ting U14-10 high through CR35. The high at U14-10 causes the belt to stop by turning off Q3 via CR33 and U7-2,15. It also tums on the Reset Switch LED via U7-4,13. The low at U7-13 is sent to US-9 (Sheet 4) via CR23. This inhibits any grade change command from the controller by shunting the signal across R23. DRIVE MOTOR FAULT (Refer to Sheet 6.) A protection device in the drive motor causes the motor to shut down when it becomes over-heated. When this occurs it is sensed by the circuit board. The START BELT current path discussed in preceding sections is then interrupted at Q3. Also, DS4 on the PCBA is illuminated and a MOTOR FAULT indication is sent to the treadmill con- troller via J11-19. Operation of the controller's START BELT switch is inhibited until the Treadmill Reset switch on the side of the tread- mill is pressed after the drive motor has cooled down, This will also clear the MOTOR FAULT indication. Note If the Treadmill Reset switch does not clear the MOTOR FAULT indication, the drive motor has not had enough time to cool down sufficiently. A thermal switch in the drive motor, under normal conditions, shorts J6-3 to J6-5. When an overload condition occurs, this switch heats up and opens, causing line voltage to appear across 36-35. This causes U3 to pulse on, pulling pin 5 low. The low at U3-5 is latched by U9-11,10 and U9-9,8. The low at U9-11 is inverted at pin 10 and sent to U4-4. This lights DS4 and sends a Motor Fault error indication to the controller. The high at U9-10 is inverted by U9-9,8, sending a low to U8-2 (Sht 5 of 6). At this time, U14-10 is low, so U8-1 is low. The lows at U8-1 and U8-2 cause UB-3 to go high, setting U14-10 high through CR37. After the R39/C27 delay, U8-1 goes high, removing the set from U14-12. (Note that U14-10 stays latched high.) As with the Emergency-Off condition described previously, the high at U14-10 inhibits START BELT and turns on the Reset Switch LED. As long as the thermal switch is open (ie. in the overload state), pressing the Reset Switch resets U14-10 low, which causes the contactor to close. This again sends line voltage across 16-3,5, pulling U3-S low. As described above, this sets U14-10 high, opens the contactor, and lights the Reset Switch LED. When the thermal switch has cooled sufficiently to close, normal operation of the Reset Switch resumes as described below. SLOW-SPEED THRESHOLD (Refer to Sheet 5.) As part of the tach pulse frequency-to-voltage conversion referred to in the SPEED FEEDBACK section, above, each edge of the pulses (leading and trailing) generates a 0,3 ms pulse. The time between these pulses provides an immediate indication of the treadmill belt speed. By discharging a capacitor with each pulse and allowing the capacitor to be charged through a resistor between pulses, a larger peak voltage on the capacitor indicates a slower speed. R88 is used to set a reference voltage which, when exceeded by the peak capacitor voltage, provides an indication that the treadmill belt speed is below the slow-speed threshold. This method is used because the normal speed feed- back signals react too slowly to a rapid speed change, which occurs when the treadmill is in a Hi-Speed-Decel mode (see next section). With this method the Hi-Speed-Decel mode is exited 37within milliseconds of reaching the Slow-Speed Threshold. TACH PULSES goes low for 300 pis and high for a time determined by the treadmill speed; the slower the speed, the fonger the duration, When low, TACH PULSES discharges C48 through CR45; when high, C48 charges through R89, R88 is adjusted to an appropriate refer- cence voltage for the slow-speed threshold desired. (the higher the voltage, the lower the threshold speed). When the treadmill speed is above the threshold, C48 does not charge above the reference voltage at U17-5 before the next low from TACH PULSES discharges C48. This keeps UI7-7 high and U11-5 low. The low to high transition of TACH PULSES clocks through the U11-5 signal and inverts it at UI1-2. Thus, when the treadmill speed is above the slow-speed threshold, U11-2 is high. The high at U11-2 lights DS3 via U7-7,10 to indicate an "above-threshold” speed. ‘When the treadmill speed is below the slow- Speed threshold, C48 will charge above the reference voltage at U17-5 before the next low from TACH PULSES discharges it. This causes UIT7-7 to pulse low, discharging C35 through CR34, When TACH PULSES goes low, C35 will begin charging through R57 and R91. In the 300 [is that TACH PULSES signal is low, the voltage at C35 will increase by a maximum of 50m V. Therefore, when TACH PULSES goes high, a high is still present at ULL-5, causing U11-2 to be clocked low. Note that closing switch SW1-7 and -2 will keep the open-collector output of UI7-7 low. This provides a "below-threshold" indication regardless of treadmill speed or the setting of RR2. This switch should only be used during calibration or troubleshooting RESET SWITCH / HIGH-SPEED DECEL (Refer to Sheet 5.) The Treadmill Reset switch is inactive (i.e. pushing it has no effect) unless the Reset Switch LED under the switch cap is illuminated. This LED will be illuminated after any of the following conditions: 1, Return of power to the treadmill. For example, the treadmill line cord could be unplugged and then plugged back in, wall outlet circuit breaker cycled, or 38 momentary power interruption from the power utility. 2. Use of the treadmill Emergency-Off switch, 3. Occurrence of a drive motor overload condition. (A MOTOR FAULT indication should be present on the controller.) 4. A High-Speed-Decel time-out. (i.e. the treadmill has been stopped above the Slow-Speed Threshold, but was unable to decelerate to the threshold speed within the time-out period, 8 seconds, typically.) If the Treadmill Reset Switch is illuminated, pressing it will turn off the LED and immedi- ately start the treadmill belt. The belt speed will be checked automatically and a high-speed deceleration will occur, if necessary. The tread- mill belt will then stop and normal treadmill operation is enabled. A high-speed deceleration will also occur if a normal STOP BELT is performed while the treadmill belt speed is above the Slow-Speed Threshold, A High-Speed Decel is performed by rectifying 110 VAC and routing it to the Speed-Change motor with the polarity such that a deceleration occurs. During a High-Speed Decel the treadmil! belt speed can decelerate from its maximum rated speed to its Slow- Speed Threshold in approximately 4 seconds. When U14-10 is high, U12-2 is low, enabling the Reset Switch at J8-1 and 18-2. When the Reset Switch is pressed, J8-1 shorts to J8-2, C41 discharges through CR40, and U8-6 pulses low. causing U14-10 to be latched low. This low causes 4 high transition at UI2-2, which puises through C43 to set Ul 1. Note that this is the same condition which exists when the BELT STOPPED signal from U17-1 clocks U11 while the ABOVE THRESHOLD signai from Ul-2 is high. The only difference is that only the Reset switch discharges C41, ‘When U11 is set, the treadmill is in the High- Speed Deceleration mode. The high at U1 1-23 inhibits the user from starting the belt via CR32 and U7-2,15 and it also starts the belt by pull- ing the contactor low via U7-3,14. The low from U11-12 is inverted by U12-11,10 and sentto U12-13 via R73. If U11 was set via the Reset Switch, C41 is discharged, and U12-12 will not go low until C41 charges through R72 and R73. This delay allows the ABOVE THRESHOLD signal from U11-2 to reach a valid state prior to the decision of whether or not to activate the MAX SPEED CHANGE/ signal. If U1 was set by stopping the belt above the “threshold” speed the low transition at U12-12 is not delayed. The low at U12-12 activates the MAX SPEED CHANGE/ signal via U9-3,4 and U7-5,12. This causes relay K4 (Sheet 2 of 6) to be activated, sending rectified 110 VAC to the Speed Motor with the polarity such that the treadmill belt speed will rapidly decelerate. The low from UI12-12 (Sht 5 of 6) also goes to U8-9. As noted above, U14-10 is low and this low goes to U8-13. With U8-9 and U8-13 low, the ABOVE THRESHOLD signal from U11-2 can reset U11-10 whenever it goes low (indicating a speed below the threshold) This resets the Hi-Speed Deceleration mode, enabling the treadmill user to start the belt. Note that when U12-12 goes low, C20 begins discharging through R40. If the ABOVE THRESHOLD signal from U11-2 does not go low before C20 discharges below the U12-9 threshold, U12-8 goes high and U14-10 is latched high. This high: + resets U11-10 through U8-13,11 and U9-1,2 + inhibits the user from starting the belt via CR32 and U7-2,15, and + turns on the Reset Switch LED via U7-4,13. If the treadmill is functioning properly, the treadmill should be able to decelerate from maximum speed to minimum speed in a few seconds. The circuitry described above ensures that when too much time has elapsed in the High-Speed Deceleration mode, the treadmill returns to the Reset Required mode. GRADE CHANGE (Refer to Sheet 4.) A GRADE CHANGE com- mand from the treadmill controller causes line power to be routed to the elevation motor. If at this time the Grade Direction command from the controller is active (high) the elevation ‘motor will turn to cause the grade to increase, otherwise it will tum to decrease the grade. A mechanical torque-limiter and mechanical stops provide grade limits. A grade change occurs when J11-4 is driven high. If J11-3 is driven high at this time, the grade increases. Otherwise, the grade decreases. J11-3 activates KI & K2 via U4-2,15. K1 and K2 configure the grade motor for the proper direction. K3 routes power to the grade motor via K1 and K2. K3 js activated by J11-4 after a 0.2 second delay (approximately) caused by R23/C23. This delay allows K2 to reach the proper state prior to routing power through it. When a grade change becomes inactive, C23 rapidly discharges through CR22 and R22 while C21 discharges through the approximate- ly 10 KQ input resistance at U4-2. This main- ‘tains the direction configuration of K1 and K2 in place until after power has been removed by 3. GRADE FEEDBACK (Refer to Sheet 2.) A linear potentiometer is ‘mechanically connected to the elevation shaft. As the elevation changes the potentiometer tums. This provides a voltage to the circuit board (J9-3) which varies inversely with the grade. This voltage is converted to a current and routed to the treadmill controller via J11-10. This current is calibrated so that 1 mA = 2% grade. A5 KQ linear pot is connected to J9, As the treadmill grade increases, the voltage at J9-3 decreases. This voltage is scaled by R101 and R102 to provide an appropriate voltage at U20- 5 (after the R100/C56 noise filter). R86, R87, R105, R106, and Q4 convert this scaled voltage to an appropriate current (1 mA = 2% grade). R87 is used to adjust the Grade Feedback to ‘OmA when the treadmill is level. This pot is set with R105 tumed fully clockwise. Note that at this time the R87-2 voltage exceeds the U20-5 feedback voltage by the emitter-base voltage of Q4, When R87 is set, R105 can be set by raising the treadmill to 25.2% grade (14°) and turning R105 counterclockwise to provide a 12.6 mA current at J11-10.SECTION 4 ASSEMBLY, DISASSEMBLY, AND CALIBRATION PROCEDURES INTRODUCTION REMOYING THE TREADMILL HOOD This section contains the following maintenance 1. Unplug the treadmill power cord from procedures: the wall socket. + Repair, replacement, disassembly and 2. Use a Phillips screwdriver to disconnect reassembly, the pane wires from the handrail at . it Hi ii the front of the treadmill. See Figure Mechanical adjustment and alignment Fr + Calibration connected to the hood. Oe 3. Loosen the thumbscrews to disconnect Since the treadmill PCB Assembly is a field- the controller cable from the treadmill replaceable module, no procedures are included (Figure 4-2) for component-level repair. 4, Pull up on the handrail and remove it. 5. Remove the four Phillips screws that WARNING attach the hood to the headframe. ‘There are two screws at the front and Ob: the following tion i serve the following precautions one on each side. when servicing the treadmill: * Do not start the walking belt or 6. Lift the hood straight up and off of the press the RESET switch when treadmill. someone is on the treadmill. The 7. To replace the hood, perform Steps 1-6 belt starts moving immediately, and ERE ec a ee the sudden start and subsequent loss of balance could cause serious MOTOR ASSEMBLIES personal injury. Grade motor removal and replacement are + Do not wear loose clothing around described under elevation system maintenance rotating machinery. (page 4-10). + High voltage is present when the , treadmill hood is removed and Deve taotee treadmill is plugged in, Unplug the Replace the drive motor when: cord time 5 poverear ory tmesoeremare tn et nd pt il electrical shock. + The motor start switch (centrifugal + Keep fingers away from chains and switch) fails. rotating parts, + The motor burns out. 1, Remove the treadmill hood (page 4-1). NOTE 2. Remove the cable ties that secure the motor wires, All instructions are oriented as if you , . were exercising on the treadmill 3. Disconnect the wires from the drive motor contactor. Figure 4-3 on page 41Emergency Stop O connector Reset switch Controtier connector AC power oe Figure 4-1. Ground Wire Connection Figure 4-2. Reset switch and connectors eee coe Shifting fork Optica NANG assembly Contactor ote tach ion shaft assy Output shaft ass'y Figure 4-3. Drive Motor Figure 4-4. Drive Motor ContactorBracket Speed change EMI fiter Fuses on other side motor of PCBA Figure 4-5. Treadmill PCB Assembly Figure 4-6. Speed Change Motor and Bracket 4-2 shows the drive motor, while cc. Two wires to connector J10 on the Figure 4-4 shows the contactor treadmill PCB Assembly. 4. Unplug motor connection wire J6 to the 4. Three wires to connector J3 on the treadmill PCB Assembly. PCB Assembly. 3. Replace the contactor with a new one, then reconnect the color-coded wires you removed in Step 2. a. For the Q50 and Q55, Quinton 5. Remove one clamp on each side of the drive motor. These two clamps secure it to the motor base plate. 6. Slip the V-belt off the motor pulley, then drawings 031475 and 031554 lift the drive motor off the base plate. shows the connection points. 7. Install a new drive motor following b. For the Q5SXT and Q65, refer to Steps 5-6 in reverse order. * drawings 031474 and 031 8. Attach the electrical connectors and eee reassemble the treadmill following 5. Restore power and test the treadmill Steps 2-4 in reverse order. The wires are color-coded, Speed Change Motor 9. Replace the hood. Replace the speed change motor if the gears break or if the motor burns out. Drive Motor Contactor (K1. ai ontactor (K1) 1. Remove the treadmit! hood (page 4-1), 1. Remove the treadmill hood as described Inph ch k di fi ee 2. Unplug the quick disconnects from the EMI filter to the motor (Figure 4-6 ). Remove the wires to the contactor Meee ea 3. Loosen the four screws and washers that (Figure 4-4): hold the speed change motor to the a, Two wires to the motor: bracket Two to the cord, ee Lied 4. Slip the chain off the sprocket, then remove the sprocket from the motor.chopper whee! Optical sensor assembly ‘Optical sensor bracket screws (2) ~ assembly bearing cap Figure 4-7. Tachometer Optical Sensor 6. Remove the four screws you loosened in Step 3, then remove the speed change motor. Replace with a new speed change motor, following Steps 3-5 in reverse order. Attach the electrical connectors and reassemble the treadmill following Steps 2-4 in reverse order. The wires are color-coded NOTE Be sure to take the slack out of the ‘motor chain when you replace it. Replace the treadmill hood. Restore power to the treadmill and test the speed limits. TACHOMETER ASSEMBLY Optical Sensor Replacement i Remove the treadmill hood as described on page 4-1 Remove the cable ties to tachometer con- nector J7 at the PCB Assembly, then unplug it. See Figure 4-5 on page 4-3 9. CAUTION To prevent damage to the beam chopper, lift the tachometer bracket straight up to remove it. Verify that the tachometer optical sensor is securely mounted before operating the treadmill. Remove two screws on the top of the tachometer optical sensor bracket, then lift the bracket straight up (Figure 4-7) Remove and save the two screws and spacers that hold the small circuit board in place on the bracket, then remove and discard the old board. Install a new small circuit board using the screws and spacers from Step 4. Reinstall the tach bracket onto the top of the bearing cap. Align the tachometer beam chopper per the procedure on this page. Reconnect connector J7. Tie down the wire hamess with cable ties. Beam Chopper Replacement 1. 2, Remove the hood (page 4-1.) Remove the two screws that hold the tachometer optical sensor in place, then move the sensor out of the way. See Figure 4-7. Remove the beam chopper, Use a 1/8" Allen wrench to remove the screw and the chopper wheel from the end of the output shaft. Replace with a new beam chopper. Replace the tachometer optical sensor on the bearing cap. Align the beam chopper wheel per the procedure in the following paragraph Beam Chopper Wheel Alignment If required, unplug the treadmill and remove the hood (page 4-1)Speed change Input shatt tom assembly Figure 4-8. Input Shaft Assembly ‘Center the beam chopper wheel by sliding it along shaft with a screw- driver and checking its relationship to the tachometer LED. s in the 3. Move the beam chopper until i exact center of the gap. REPLACING THE TREADMILL PCB ASSEMBLY 1, Remove the power cord from the wall socket. 2. Remove the hood (page 4-1) Unplug ail connectors from the Assembly (Figure 4-5 on page 4-3 ). 4. Remove the twelve hex nuts attaching the PCB Assembly to the PCB mount- ing bracket. 5. Remove the PCB Assembly. 6. Replace with a new Assembly following Steps 1-5 in reverse order. 7. Calibrate the grade feedback and the speed feedback as described on page 4-20 and 4-21 INPUT SHAFT A‘ Figure 4-9. Loosening the Variable ‘Speed Belt MBLY PROCEDURES Input Shaft Assembly and Speed Change Spindle Assembly Removal NOTE Special adhesives and a ratchet wrench with a long extension are required to remove and install a new assembly. Read all removal and replacement instructions before continuing. . Remove the treadmill hoad as described on page 4-1. Figure 4-8 shows the input shaft assembly. CAUTION Be careful not to damage the bear- ings and caps on the input shaft. If the shaft is scarred or if the movable sheave is frozen on the input shafi, the entire shaft assembly must be replaced. . Place a rope of flexible belt around the variable speed belt, then pull straight up to loosen belt. See Figure 4-9,"T* stamp on bearing, cap Input bearing cap bolt Figure 4-10, "T" Stamp Shows Bearing 3, 10, Cap Orientation Remove the V-belt from the machined input shaft pulley Unplug the quick disconnects from the two speed change motor leads at the EMI filter. See Figure 4-6 on page 4-3. Loosen, but do not remove, the four screws that hotd the speed change motor to the bracket (Figure 4-6). Slacken the chain and disconnect the master link (if required), then remove the chain from the sprocket Use a ratchet wrench with a long extension to remove the four screws that hold the bearing caps in place (Figure 4-10). Carefully remove the speed change motor and bracket, saving the hardware. Lift the entire input shaft assembly straight up and back towards the walking deck, then slip the sheave out of the transmission belt. To remove the speed change spindle assembly a. Remove the retaining ring on the right end of the spindle. b. Pull the speed change fork to the left until the spindle bearing is clear of the headframe, input shaft assembly Moveable sheave bearing cap (front end) Speed change fork Figure 4-11. Speed Change Mechanism c. Lift the spindle assembly out of the headfrarne (Figure 4-11) Input Shaft Assembly Replacement CAUTION Read these instructions completely before starting this procedure! Loctite™ Primer T, Loctite 660, and Loctite RC 680 are required to install @ new shaft assembly. The input shaft bearing caps and pulley must be bonded to the shaft assembly before use, and the adhesive requires & mini- sum cure time of six hours before operating the treadmill 1, Remove the speed change motor, bracket, and input shaft assembly from the treadmill following the procedure described on pages 4-3 and 4-5. 2. Align the speed change fork with the pin on the base of the headframe, then insert the spindle bearing into the bore provided in the headframe (Figure 4-11). Refer to section view R-R of drawing 31474 or 31475, notes 3 & 4 or 4 & 5 at the end of this manual 3. Install the retaining ring onto the right side of the spindle.4. Pull the transmission belt to the bottom of the transmission output pulley as- sembly and spread the output assembly sheaves apart to create slack in the belt. NOTE Perform the following step only if you are installing a new input shaft assembly. Otherwise, go to Step 6. . Refer to the headfeame assembly drawing (p/n 031474 or 031475). If you are installing a new shaft assemb- ly, prepare the bearing caps and the input assembly following these prepara- tion and gluing procedures: a. Prime the outer diameter of the bearing on the output shaft assembly and the inside diameter of the bearing caps (p/n 013705- 001/003) using Loctite Primer T (p/n 014900-001). b. Coat the outside of the bearings and the inside of the cap with’ Loctite 680 retaining compound (p/n 012465-002). cc. Assemble the cap over the bearing. }. Install the V-belt pulley on the shaft. a. Clean the input shaft in the Keyway area and the V-belt pulley bore, then prime with Loctite Primer T. b. Apply Loctite 660 to the keyways in the input shaft and to the pulley, then position the key in the shaft keyway. Lightly tap the key in the keyway if required. c. Apply Loctite 680 to the shaft from the end of the shaft to the end of the keyway. 4. Install the pulley on the shaft with the hub facing the bearing cap, then slide the pulley and key until the face is 4” from the end of the shaft. ce. Install and torque the two pulley set screws using Loctite 242. £ Wipe the excess adhesives from the shaft and pulley. . Immediately mount the shaft assembly to the headframe: 10. 11 12, 13. a. Put the end of the input shaft assembly through the slack in the transmission belt, then b. Insert the movable sheave’s bear ing cap into the fork on the speed change spindle assembly. The rounded end of the cap faces up (Figure 4-11). NOTE Verify that the “I” stamp on each bearing cap faces up. See Figure 4-10 on page 4-6. stall the speed change motor and bracket by reversing Steps 4-5 in the previous paragraph ("Input Shaft As- sembly and Speed Change Assembly Removal"). Insert the mounting screws through the bearing caps, and rotate the shaft assembly by hand before tightening the screws. The bearing on the fixed sheave end of the shaft assembly must be seated in the bearing cap. If you installed a new assembly, wait six hours for the adhesive to cure before testing the treadmill, It may be more convenient to let the treadmill sit overnight before reassembling and test- ing the treadmil\. CAUTION Do not test or use the treadmill for at least six hours after using adhesive to assemble a new input shaft. Install the V-belt berween the motor pulley and transmission pulley. Verify that the alignment is correct, then tighten the set screws on the input pulley, Attach the electrical connectors and reassemble the treadmill as required. The wires are color-coded. After the adhesive has cured (Step 10), replace the hood, restore power to the ‘treadmill, and test the operation of the ‘new input shaft. Verify that the treadmill operates through its full speed range. 4-7Output shatt Variable assembly speed belt Tach assembly, Figure 4-12, Output Shaft Assembly and Belts OUTPUT SHAFT ASSEMBLY PROCEDURES Output Shaft Assembly Removal ratchet wrench with a Jong extension are required to remove and replace the assembly. Read all removal and replacement instructions before continuing, CAUTION Be careful not to damage the bear- ings and caps on the output shaft. If the shaft is scarred or if the movable sheave is frozen on the shaft, the en- tire shaft assembly must be replaced. 1. Remove the treadmill hood (page 4-1). Figure 4-12 shows the output shaft assembly. 2. Remove the two screws that secure the tachometer optical sensor bracket, then lift the sensor and bracket straight up to remove it from the bearing cap. Lifting it straight up will avoid damage to the beam chopper. See Figure 4-7 on page 4-4, 48 Use a 1/8" Allen wrench to remove the tachometer beam chopper. Use a ratchet wrench with a fong exten- sion to remove the four screws that frold the bearing caps in place Slip the output shaft assembly out of the variable speed belt and the final drive belt, then remove it. Output Shaft Assembly Replacement CAUTION Read these instructions completely before starting this procedure! Loctite Primer T, Loctite 660, and Loctite RC 680 are required to install a new shaft assembly. The output shaft bearing caps must be bonded to the shaft assembly before use, and the ad- hesive requires a minimum cure time of six hours before operating the treadmill. Remove the output shaft assembly’ as described in the previous paragraph, NOTE Perform the following step only i you are installing a new output shaft assembly. Otherwise, go to Step 3. Refer to the headframe assembly drawing (p/n 031474 or 031475) If you are installing a new shaft assembly, prepare the bearing caps and the input assembly following these preparation and gluing procedures a. Prime the outer diameter of the bearing on the output shaft assembly and the inside diameter of the bearing caps (p/n 013705- 001/003) using Loctite Primer T (pln 014900-001), b. Coat the outside of the bearings and the inside of the cap with Loctite 680 retaining compound (p/n 012465-002) ¢. Assemble the cap over the bearing. Immediately put the end of the output shaft assembly through the slack in the variable speed belt (Figure 4-4. Slip the final drive belt over the timing sprocket on the shaft assembly. 5. Spread the pulley sheaves apart slightly to seat the Variable speed belt in the sheaves, then install the output shaft by placing the bearing caps on the head frame mounting pads. NOTE Be sure that the bearing cap with the threaded holes on top is installed on the left side of the shaft assembly. The holes are used for mounting the optical tach assembly. 6, Verify that the “I” stamp on each bearing cap faces up, then use a ratchet wrench with a long extension to lighten the screws, See Figure 4-10 on page 4-6. 7. Install the tachometer beam chopper Replace the tachometer optical sensor on top of the bearing cap, then verify that the beam chopper is aligned (page 4-5). 9. If you installed a new assembly, wait six hours for the adhesive to cure before testing the treadmill. It may be more convenient to let the treadmill sit overnight before reassembling and testing the treadmill. CAUTION Do not test oF use the treadmill for at least six hours after using adhesive t0 assemble a new output shaft. 10. After the adhesive has cured (Step 9), install the hood, restore power to the treadmill and test the operation of the new output shaft. Verify that the treadmill operates through its full speed range. Replacing the Variable Speed Belt 1. Remove the input shaft assembly as described on page 4-5. 2. Remove the output shaft assembly (page 48), Siderail cover End cap Trim step’ (removed) (removed from siderail cover) Figure 4-13. End Caps and Siderail Cover Remove the variable speed belt. (Figure 4-12 on page 4-8), 4. Replace the variable speed belt. 5. Replace the output shaft assembly. 6. Replace the input shaft assembly. Replacing the Final Drive Belt 1. Remove the hood (page 4-1). 2. Loosen the four screws (two on each side) which secure the rear roller ‘guards at the rear of the treadmill, then slide the roller guards toward the front ‘of the treadmill. You may need to hold the wingnuts on the underside of the treadmill deck when you loosen the screws 3. Use a 1/2" socket wrench to remove both end caps, located on either side of the belt at the rear of the walking platform, See Figure 4-13 4, Remove the trim strips from the siderail cov 5. Remove the four 1/2” hex screws and nuts (two on each side) that secure the two front drive roller retainers to the frame siderail, One retainer is onDeck mounting screws (2 per side) [28-36 bolt: Use 9/16" socket] screws (2 per side) Side bumper [5/16-20 bolt: Use Trim strip 1/2" socket] (removed) Figure 4-14. Deck Mounting Screws and Drive Pulley Retainer Screws each side of the drive roller assembly (Figure 4-14 on page 4-10). 6. Slide the drive roller assembly to the lefi, then remove the final drive belt from the right side of the roller. 7. Remove the four serews that fasten the output shaft bearing caps, but do not remove the shaft assembly. 8. Slip the final drive belt under the output shaft assembly bearing cap. 9. Replace with a new belt, then remount the front drive roller assembly and output shaft assembly, 10. Reassemble the treadmill following Steps 1-7 in reverse order. 11. Adjust the walking belt tension follow- ing the procedure on page 4-17 12. Adjust the walking belt tracking using the procedure on page 4-18. 13. Check and adjust the final drive belt tension following the procedure in the next paragraph. Adjusting the Final Drive Belt Tension 4-10 Drive pulley cover, Figure 4-15. Drive pulley cover on bottom of treadmill Perform this procedure as required afier install- ing a new timing belt, or after removing and replacing the deck assembly. 1. Remove the hood (page 4-1). 2. Use a 5/32" hex socket wrench to remove the two screws which secure the treadmill side bumpers to the siderail, then remove the bumpers. 3. Use a 9/16" socket wrench to loosen the four hex-head screws which fasten the deck assembly to the headframe, but do not remove the screws. (Figure 4-14) 4. Loosen, but do not remove, the four 7/16" hex-head screws. Two screws fasten the front of the drive roller cover to the treadmill headframe, and the other two secure the motor mount plate. They are located beneath tie treadmill (Figure 4-15) Set the belt tension so that an 0.11" deflection can be measured at midspan when a 3.75 Ib 0.25 Ib load is applied perpendicular to the belt at midspan. a. To loosen the belt, move the headframe towards the deck assembly,Grade Elevation motor chain \ potchain Torque Set ia collars (2) a Figure 4-16. Grade Motor b. To tighten the belt, move the headframe away from the deck assembly. 6. Reassemble the treadmill following Steps 1-4 in reverse order GRADE CHANGE (ELEVATION) SYSTEM Grade Motor 1. Block the treadmilt headframe seeurely with 8-inch wooden blocks to ensure that the treadmill will not drop: when you remove the grade motor or chain. 2. Remove the hood (page 4-1). However, do not elevate the treadmill. 3. Remove the cable ties that secure the grade motor wires, then disconnect the wires from the PCBA. Figure 4-16 shows the grade motor. 4, Unplug all connections to the treadmill PCB Assembly. 5, Use an {/32" nut driver to remove the 12 hex nuts that attaches the PCBA to the mounting bracket, then remove the PCBA. 6. Remove the four screws that attach the PCBA mounting bracket to the elevation motor. Note the stackup of the isolation washers. Grade pot pinion, shaft sprocket Figure 4-17. Grade Pot and Pinion Shatt 1, 8, Remove the four 7/16" hex head screws that secure the elevation matar fo the headframe, then remove the motor. Note the stackup of the isolation hardware on the screws, Replace with a new grade change motor, following Steps 3-7 in reverse order. ‘The PCB connectors are keyed. WARNINGS * Do not wear loose clothing around rotating machinery. + Keep fingers away from chains and rotating parts. * High voltage is present when the treadmill is plugged in, Restore power to the treadmill and test the new grade motor. Test the treadmill elevation. Verify that a. it operates aver the full range of 0.25%. b. there is no binding when it moves up or down. c. the elevation pot chain is afigned correctly. d._ the grade motor chain is also aligned correctly. A “poppin8. Replace with a new grade change motor, following Steps 3-7 in reverse order. The PCB connectors are keyed. WARNINGS + Do not wear loose clothing around rotating machinery, + Keep fingers away from chains and rotating parts. + High voltage is present when the treadmill is plugged in. 9. Restore power to the treadmill and test the new grade motor. 10. Test the treadmill elevation. Verify that: a, it operates over the full range of 0-25%. b. there is no binding when it moves up or down. ¢. the elevation pot chain is aligned correctly. . the grade motor chain is also aligned correctly. A “popping” sound in the chain indicates that it is misaligned. 11. Turn the treadmill power off, remove the power cable from the outlet, then reinstall the hood. Grade Potentiometer (Pot) Replacement Read the warnings on this page before replacing the pot. 1. Remove the treadmill hood as described on page 4-1. 2. With the hood removed, restore power f0 the treadmill and turn the grade motor ‘on until the set screw on the grade pot bat shaft sprocket is visible (Figure 3. Unplug the treadmill. 4, Release the set screw. 5. Hand-turn the grade pot until the steel set screw on the potentiometer sprocket is visible. 6. Release the steel set screw. 412 10. a. Push the whole sprocket-and-chain assembly away from the grade pot. Remove the 1/2" brass nut and the cable tie. The pot will come off. Cut the cable ties and remove connector J9 from the PCB Assembly. Replace with a new potentiometer, then reassemble following Steps 3-9 in reverse order. When the grade pot, wires, and set screws are in place, calibrate the pot by following the procedure on page 4-20. ‘Removing the Rack Gears a If the treadmill will change grade, take the treadmill to approximately 12% 7). Lower the front of the headframe onto 8-inch wooden blocks to take the weight off the wheels. Unplug the treadmill, then remove the hood (page 4-1). If the rack gear is completely jammed, replace as described on page 4-13. WARNINGS + Do not wear loose clothing around rotating machinery. + Keep fingers away from chains and rotating parts. + High voltage is present when the treadmill is plugged in. Restore power to the treadmill and decrease grade until wheels raise about 1/2" off the floor. Remove the two 9-16" hex-head screws holding the wheels to the rack gears. Note the arrangement of washers used as spacers. Remove the two hex screws located above the wheels. (These screws are the rack gear stops.) Note the arrange- ment of washers used as spacers. Loosen the set screw that secures the grade pot pinion shaft sprocket, thenInstall new rack gears simuftaneously so that they will be parallel. Restore power to the treadmill, Loosen the set screw that secures the grade pot pinion s : not already loose. then verify that the sprocket turns easily on the shaft. This will avoid damage to the pot. See Figure 4-17 on page 4-11 NOTE If the treadmill is connected to a programmable controller such as a 645 or Q4000, it may be necessary to place the controller in open loop mode before performing Step 5. Refer to the Operator Manual for the controller. Decrease the grade until the gears bounce two or three times, then in- crease the grade. This should cause both rack gears to mesh in exactly the same place. NOTE When performing the next step. it may be necessary to turn the grade pot slightly to keep the elevation motor running Run the rack gears down past the bottom of the headframe. Check under the bottom of the headframe to verify that the rack gears are meshing properly. The gears yuld protrude an equal distance. Run the rack gears down until there is enough room to replace wheels. Replace the two screws that hold the wheels to the rack gears. Be sure to: a, replace washers used as spacers in the correct arrangement. 'b. torque the screws tightly 1 46 filb 44 ft-lb. Replace the two screws and washers removed in Step 7 under “Removing the Rack Gears” (page 4-12). These are the rack gear stops. Torque them to 46 fr-lb 24 fib. Rack gear, Shifting fork assembly bearings and Handrail hardware ‘support bracket 4 screws, (2 hidden) Figure 4-18. Handrail Support Bracket and Rack Gear H1. Increase the grace until the wheels touch, the floor. 13, Remove the blocks that support the hheadirame, 14, Calibrate the grade potentiometer by following the procedure on page 4-20. 15, Turn the treadmill power off, remove the power cable from the outlet, then reinstall the hood. Replacing a Jammed Rack Gear 1, If the rack gear is not completely jammed, follow the instructions in the ‘previous paragraph to replace it 2. Unplug treadmill 3. Remove the hood (page 4-1). 4, Securely block the front and rear of the headframe with 8-inch wooden blocks to take the weight off the wheels, then raise the wheels 1/4" to 1/2" off the floor. 5. Shake each gear lightly at the top to determine which rack gear is jammed. 41310. ll 12, 13. 14, 15. 16. . Shake each gear lightly at the top to determine which rack gear is jammed If there is no play in a rack gear, itis jammed, Remove the wheel and the rack gear stop above the whee! from the jammed rack gear. Remove the two hex socket head screws Which secure the side bumper. Remove the four screws that hold the handrail support bracket in place, then remove the bracket (Figure 4-18 on page 4-13), Slide the rack gear out sideways and remove it. Inspect the gear on the pinion shaft. If it is damaged, replace both the rack gear and the pinion shaft (as described on the following page.) Screw the handrail support bracket back into place. Loosen the set screw that secures the grade potentiometer (pot) pinion shaft sprocket, if necessary, then verify that the sprocket turns easily on the shaft, This will avoid damage to the pot. See Figure 4-17 on page 4-11. WARNINGS + Do not wear loose clothing around rotating machinery. + Keep fingers away from chains and rotating parts. + High voltage is present when the treadmill is plugged in. Restore power and decrease the grade to run the other rack gear out the top. Reassemble the rack gear as described in the previous paragraph. Calibrate the grade potentiometer as described on page 4-20. Test the treadmill elevation, Verify that: a. it operates over the ful) range of 08-25%. . there is no binding when it moves up or down. 17. 18, ¢, the elevation pot chain is aligned correctly. d. the grade motor chain is also aligned correctly. A “popping” sound in the chain indicates that it is misaligned. Tum the treadmill off and unplug it. Replace the hood. Replacing the Pinion Shaft L Remove the rack gear as described on page 4-12. Remove the two hex socket head screws, which secure the right side bumper to the treadmill siderail, then remove the bumper. WARNINGS + Do not wear loose clothing around rotating machinery. + Keep fingers away from chains and rotating parts, + High voltage is present when the treadmill is plugged in, Restore power to the treadmill, then use the grade motor to turn the shaft unt? the set screw on the grade pot sprocket is visible (Figure 4-17 on page 4-11.) Loosen, but do not remove, the set screws from: a. the torque limiter b. the grade potentiometer pinion sprocket ¢. the two pinion shaft set collars. ‘The set screws are on the pinion shaft. Unplug the treadmill. Remove the handrail support bracket on the right side. 7. Slide the pinion shaft out. While sliding a new pinion shaft in, place the elevation sprocket, the set Collars, and the grade potentiometer sprocket on the shaft. Replace the handrait support bracket you removed in Step 8.Figure 4-19. Walking Deck Assembly 10. 12. 13, 15. Roller guards (2) UEJIMEE Poter guard mounting screws (4) [4 wing nuts hidden} 1/2" socket wrench Before performing Step 11, verify that neither end of the pinion shaft touches the handrail support brackets. Tighten the set screws on the set collars. NOTE Do not force the set collars tightly against the headframe. Verify that the pinion shaft will tum freely when the set collars are in place. Align the grade potentiometer sprocket, then tighten its set screw. Align the torque limiter and geade motor sprocket, then tighten the set screw on the torque limiter. Reassemble the rack gear as described on page 4-12. Replace the side bumper removed in Step 2 Walking belt Deck mounting screws (10 or 12) Slider bed 16. My. 18. ‘Siderail cover ‘Side bumper \ (location) ee stein (removed) Calibrate the grade potentiometer as described on page 4-20. ‘Test the treadmill elevation. Verify that: a. it operates over the full range of 0.25%. b. there is no binding when it moves up or dows. €. the elevation pot chain is aligned correctly. d. the grade motor chain is also aligned correctly. A “popping” sound in the chain indicates that it is misaligned. ‘Unplug the treadmill and replace the hood. WALKING DECK ASSEMBLY Figure 4-19 is an overview of the walking deck assembly, NOTE Do not lubricate the walking deck (lider bed). It is not required. 415NEW WALKING BELT (Position splice overlap as shown) Belt travel direction Front roller Splice Sverap NOT TO SCALE Walking belt Splice (inside) overlap —————— ‘Walking belt (outside) —_—— Bett travel direction Removing and Replacing the Front (Drive) Roller or the Idler (Rear) Roller 1, Remove the hood (page 4-1). 2. Remove the four Phillips screws that secure the rear roller guards, then remove the guards. Four wing nuts hold the screws in place on the under- side of the treadmill, as indicated ia Figure 4-19 on page 4-15. 3. Remove both end caps, located on cither side of the belt at the rear of the walking platform. 4, Remove the trim strips from the siderail covers, then loosen the six set screws (three per side) that secure the plastic siderail covers to the siderails. 5, Slide the siderail covers back off the treadmill. 6, Remove the four 1/2" hex screws and nuts (two on each side) that secure the ‘two front drive roller retainers to the frame siderail. One retainer is on each side of the drive roller assembly. 7. Slide the drive roller assembly to the left, then remove the timing belt from the right side of the roller. 8. Lift the roller assembly out from under the walking belt. 9. Puli the walking belt towards the rear of the deck, then slide the rear roller assembly out from between the side- rails toward the rear of the treadmill. 416 jure 4-20. Walking Belt Splice Overlap Placement 10. Replace the rollers and reassemble the treadmill following Steps 1-8 in reverse order. 11, Adjust the walking belt tension follow- ing the procedure on page 4-17. 12. Adjust the walking belt tracking follow- ing the procedure on page 4-18, 13. Verify that the gap between the rear roller guards and the rear roller is no more than 94", Adjust if necessary following the procedure on page 4-19. Replacing the Walking Belt NOTES + All orientations are given as if you were walking on the treadmill. + A new slider bed is recommended when you install a new walking belt. 1. Unplug the treadmill and remove the treadmitt thood (page 4-1). 2, Remove the two hex socket head screws which secure the right side bumper to the treadmill siderail, chen remove the bumper. 3. Remove the left bumper as in Step 2. 4. Remove the front and rear roller assemblies as described on this page. 5. Place blocks to the right of the headframe and deck to prevent damage. 6. Carefully place the treadmill on its right side on the blocks.10. uM. 12. Remove the drive pulley bottom cover: a. Loosen, but do not remove, the four screws which mount the cover to the headframe. Two serews secure the motor, and two are in the head frame. b. Remove the two hex nuts which secure the cover to the deck frame. c. Remove the cover. Use a 9/16” wrench to remove the two screws holding the walking deck frame to the left side of the headframe (Figure 4-19). Slide the walking belt off by working the belt between the walking deck frame and the headframe. NOTE When you install a new belt, verify that the closed end of the splice on the walking belt hits the roller first as the belt rotates. See Figure 4-20 on page 4-16. Install a new belt and reassemble the treadmill following Steps 1-9 in reverse order. Tension the belt as described on this page. Adjust belt tracking following the procedure on page 4-18. Removing the Slider Bed 3 Remove the front and rear roller assemblies as described on page 4-16. Remove the cight or 10 Phillips screws securing the slider bed, then slide the slider bed from underneath the walking belt to remove it. NOTE The two front screws also attach the drive pulley cover underneath the treadmill. To replace the slider bed, follow Steps 1-2 in reverse order. Tension the belt following the procedure ‘on this page. Adjust the belt tracking following the procedure on page 4-18. Verify that the gap between the rear roller guards and the rear roller is no more than 3". Adjust if necessary. WALKING BELT ADJUSTMENT PROCEDURES Walking Belt Tension Adjust the walking belt tension: whenever the belt slips or moves unsteadily during operation. after installing a new walking belt. each time you remove or replace the walking belt. shenever specified in the procedures in Section. Two adjustment methods are specified. Method 1 is preferred, but two belt tension calipers (Quinton p/n 030113-001) are required. NOTE Both adjustment screws must be completely slack before starting this, procedure. Method 1 (Calipers available) Press POWER to turn the treadmill off, then disconnect the treadmill power cord from the outlet. Thread both tension adjustment screws in until most of the slack is removed from the walking belt (Figure 4-21). NOTE Do not stretch the belt at this point, Position one caliper on each side of the belt, approximately 18" from the rear roller assembly. Grasp the belt with one caliper clamp. 5. Pull the slack between the clamps out of the belt with your fingers, then grasp the belt with the second clamp. 417Tension adjustment © Figure 4-21. Adjusting Walking Belt Tension 6. Repeat Steps 4 and 5 on the other side of the belt using the other caliper 7. Zero out the dials of both calipers 8. Alternately tighten each tension adjustment screw in 0.1% increments until both sides read 0.4%. Ensure that the pointer reads exactly on the line increment of the dial for each setting. CAUTION Do not overtighten the adjustment screws. Overtightening may damage the walking belt and roller assemblies. Remove both gauge 10. Adjust the walking belt tracking follow- ing the procedure on this page. Method 2 (Calipers not available) NOTE Both adjustment screws must be completely slack before starting this procedure 418 Use this method only if two belt adjustment calipers are not available. However, an accurate measuring device is required. 1, Bress POWER to turn the treadmill off, then discomrect the treadmill power cord from the outlet. ‘Thread both tension adjustment screws in until most of the slack is removed from the belt. Figure 4-21 shows where the screws are located. NOTE Do not stretch the walking belt at this point. 3. Place two pieces of masking tape or two light pencil marks on the right edge of the belt exactly 50,000" apart 4, Repeat Step 3 on the left edge of the belt, 5. Alternately turn the left and right adjust- ment screws one-half turn each time until the distance between the tape (or pencil marks) is 50.203" +0.016" on both sides. CAUTION Do not overtighten the adjustment screws. Overtightening may damage the walking belt and roller assemblies. 6. Remove the tape, if used in Step 3. Adjust the walking belt tracking follow- ing the procedures described below. Walking Belt Tracking Perform this procedure: + whenever the belt moves to one side or the other, + after instaifing a new walking belt + each time you remove or replace the walking belt. + each time you adjust the walking belt tension, + whenever specified in the procedures in this Section.Stay off the belt when adjusting the tracking. 1. Tension the walking belt using either Method | or Method 2 in the previous paragraph. WARNING Do not start the treadmill when some- one is on the walking belt. The belt starts moving immediately, and the sudden start and subsequent loss of balance could cause serious personal injury. 2. Start the treadmill and tet it run for at least one minute at minimum speed and grade. 3. Make the following adjustment to the right adjustment screw only a, If the belt moves to the right, turn the screw 1/4 turn clockwise. b. If the belt moves to the left, turn the screw 1/4 turn counterclock- wise, Figure 4-21 shows the location of the adjustment screws. 4, After making an initial adjustment, run the treadmill for at least one minute to observe how the belt tracks. Adjust ments to belt tracking take some time to become apparent. 5. Repeat Steps 3 and 4 as required, CAUTION Do not overtighten the adjustment screw. Overtightening may damage the walking belt and assemblies. 6. Increase the speed to 8 mph, then repeat Steps 3 and 4 as required. 7. Press STOP BELT to stop the treadmill, then press POWER to turn it off. 8. Disconnect the treadmill power cord from the outlet. 9. Check the gap between the rear roller guards and the rear roller following the rear roller guard adjustment procedure described on this page. Grade pot pinion shaft sprocket Pinion shatt § sprocket Figure 4-22. Grade Pot and Pinion Shaft Rear Roller Guard Adjustment WARNING Disconnect the power cord from the AC power source before performing this procedure. Check the position of the rear roller guards each time you adjust the beh tracking or belt tension. The roller guards are located at the rear of the treadmill between the rear roller and the slider bed (Figure 4-19). The gap should be no more than 3/8" 1. Verify that the power cord is discon- nected from the wall socket. Measure the gap between the roller guards and the rear roller. a. Ifitis 3/8" or less, no adjustment is required. b. If itis greater than 3/8", go to Step 3 to adjust it 3. Loosen, but do not remove, the two serews attaching the rear roller guard to the treadmill deck. Hold the nuts on the underside so they do not fall off. 4. Slide the rear roller guard toward the rear roller until the gap between the two is approximately 1/8" inch. 5. ‘Tighten the screws loosened in Step 3. 419CALIBRATION PROCEDURES Grade Potentiometer (Pot) Calibration Calibrate the grade pot whenever specified in the procedures in this Section. Figure 4-22 on page 4-20 shows the location of the pot. 1. Remove the hood (page 4-1). WARNINGS + Do not wear loose clothing around rotating machinery. + Keep fingers away from chains and rotating parts. + High voltage is present when the treadmill is plugged in, 2. Restore power to the treadmill. 3. Lower the elevation until the torque limiter spins against the lower mechani- cal stop without changing the grade. This is the minimum grade. 4, Kneel in front of the treadmill, then loosen the set screw which secures the grade pot sprocket to the pinion shaft (Figure 4-22). 5. Rotate the sprocket away from you until it stops, then rotate it back ¥2 turn towards you. 6. Tighten the set screw you loosened in Step 4. 7. Elevate the treadmill until it reaches maximum grade. Make sure that the grade pot spins freely during elevation. There should be no evidence of mechanical binding throughout the grade change. 8. Calibrate the grade feedback following the procedure in the next paragraph. Grade Feedback Calibration Calibrate the grade feedback when you: + replace the treadmill PCB Assembly, or + calibrate the grade pot. 1. If necessary, remove the hood (page 4-1). 4-20 10. WARNINGS: + Do not wear loose clothing around rotating machinery. + Keep fingers away from chains and rotating parts. + High voltage is present when the treadmill is plugged in. Restore power to the treadmill, If a programmable controller such as a 645 or Q4000 is used, place it in open loop mode before continuing. Refer to the Manual for the specific controller. (On the 645 Controller, the CAL LED should be illuminated.) Decrease the treadmill grade to the lower mechanical stop, then raise the treadmill grade 4". Adjust potentiometer R87 on the PCBA until the grade (elevation) display on the controller reads 0.2. Lower the treadmill to the mechanical stop and verify that 0.0 appears on the grade display. Raise the grade to the upper mechanical stop. Adjust R105 on the PCBA until the grade display reads 25.2. Lower the treadmill to the mechanical stop and verify that 0.0 appears on the grade display. Adjust R87 if neces- sary. If you have replaced the PCB Assembly, perform the speed feedback calibration in the next paragraph. Otherwise, remove power to the treadmill and replace the hood. Speed Feedback Calibration ‘When a new PCB Assembly is installed, you must: determine walking belt speed. calibrate the speed display. set the threshold speed. set the maximum and minimum speed.‘When the user presses STOP BELT when the belt is traveling above the threshold speed, the speed change motor performs a high speed deceleration to slow the treadmill down to the threshold speed, then stops. Below the threshold speed, the treadmill stops without the high speed deceleration, Read the warnings on this page before calculating belt speed or calibrating speed ‘feedback. Measuring Walking Belt Speed To determine the belt speed, use one of the following methods: Method 1. Attach the positive lead of a frequency counter to JPS-1, and the negative lead to TP4 (ground). Their locations are shown in Figure 4-23 on page 4-22. This reads the pulse counts from the treadmill’s tachometer, which increases linearly with belt speed. (Remove the counter when you have determined the speed.) 69.67 Hz corresponds to 1 mph. Method 2. Hold a tachometer against the exposed (right) end of the output shaft. The treadmill speed is: ‘Speed (mph) = Tachometer RPM / 209. Method 3, Hold a tachometer with a 6-inch circumference roller against the walk- ing belt. Speed (mph) = Tachometer RPM / 176. Method 4. Measure the belt circumference and count the belt revolutions in one minute. This is the least accurate method, but no tachometer is required. The treadmill should be running at a moderate speed while you are counting the revolutions. Note that measure- ment, timing, and counting errors will all be reflected in the calculated speed. Speed (mph) = C X RPM / 1056 where C = walking belt circumference in inches. + For the Q50, C = 115” (approximately) + For the Q55 or Q5SXT, C = 125" + For the Q65, C = 145" Calibrating the Speed This procedure is easier to perform from the left side of the headframe. The hood should be removed and there should be power to the treadmill. Read the warnings on page 4-20 before continuing this procedure. NOTES 1) If you are using an automatic treadmill controller such as the Quinton Model 645 or the Q4000, you must place it in the open loop ‘mode for this procedure. Refer to the manual for your controller. 2) The 640 controller, which does not have an open loop mode, will not update the speed display when you adjust R128 (in step 4) until you tap the Speed Increase or Speed Decrease button. Tap either key quickly to update the display after you have adjusted R128, and be sure to verify the treadmill speed before making the final adjustment to R128, 1. Locate switch SW! on the PCBA, then set SW1-1, SW1-3, and SW1-4 to the ON position (Figure 4-23 on page 4-22), To calibrate the speed display: 2. Increase the speed to 6.0 mph or above. 3. Determine the belt speed using one of the methods descibed on this page. 4, Adjust pot R128 on the PCBA until the speed display is correct according to your calculations. Turn the pot coiinter-clockwise to increase the value on the display. 5. Use the calibrated display speed for the remainder of this procedure. To set the threshold speed: 6. Decrease the treadmill speed to the threshold speed for the treadmill. Refer to column 2 in Table 4-1 on page 4-23. 7. Adjust potentiometer R88 counter-clock- wise until LED DS3 illuminates fully. 421R30 ‘Switch settings shown above are for calibration ONLY. Step 9 on page 4-21 specifies the normal operational settings. amayes F bs eat Cc en waa O Peet ter _conciafty oF TP4 L / R128 Figure 4-23. PCBA, showing Switches, Jumpers, and Pots 4.22Table 4-1. Speed Adjustments (mph) ‘Speed Range | Threshold Speed | Maximum Spred | Minimum Speed Speed Window (rmph) (mph) Setpoint (mph) | _ Setpoint (mph) (mph) 0.660 08 62 os 05-65 0.8-8.0 1.0 82 or 07-85 1.0100 14 10.2 oy as105 4.2:42.0 16 12.2 14 1AA25 15-18.0 20 15.2 13 13-155 8, Adjust R88 clockwise until DS3 is 17. If the display changes too rapidly or if completely extinguished. 9. Reset SW1-1, SW1-3, and SW1-4 on switch SW1 to the OFF position. To set the maximum speed: 10, Increase the speed to the value fisted in Table 4-1, column 3. If the treadmill will not reach this speed, adjust pot R85 clockwise until it does. 11, Adjust R85 until LED DS1 just illuminates. This sets the maximum electronic speed limit. 12. Verify that the speed is limited electroni- cally at the maximum rated speed. To set the minimum speed: 13. Decrease the speed to the value tisted in Table 4-1, column 4. If the treadmill will not reach this speed, adjust pot R30 1-2 turns clockwise until it does. 14, Adjust R30 counter-clockwise until LED DSS just illuminates. This sets the minimum electronic speed limit. 15. Verify that the speed is limited electroni- cally at the minimum rated speed. 16. Watch the speed display while you increase the speed to the electronic maximum, The displayed speed should not change more than 0.2 mph at a time. (If the speed approaches the limit too rapidly, it may overshoot the electronic limit because of the inherent delay in the feedback circuitry.) 18. 20, 2. the treadmill overshoots its maximum rated speed, adjust pot R61 counter- clockwise, then repeat step 16. Verify that the treadmill does not overshoot its maximum speed rating. NOTE The adjustment in Step 17 prevents “hunting” for the speed setpoint (ie. the displayed speed). If R61 is not adjusted correctly, the speed may increase and decrease continuously around the setpoint during use, particularly at high speeds. Verify that the treadmill speed range is as specified in Table 4-1, column I: a. Increase the treadmill to maximum speed, b. Decrease it to minimum speed. Verify that the speed range falls within the speed window in Table 4-1, column 5. . Increase the treadmill speed above the threshold speed in Table 4-1, column 2, then press STOP BELT. Verify that a high-speed deceleration occurs before the treadmill shuts off. Press START BELT and verify that the walking belt starts at or below the appropriate threshold speed (Table 4 column 2). Press STOP BELT, then remove power from the treadmill 423ADJUSTMENT PROCEDURE: V-Belt Adjustment ‘The V-belt connects the drive motor to the. input shaft assembly (Figure 4-24). Perform this adjustment procedure: + each time you replace the V-belt with a new one. + if the V-belt squeaks during treadmill operation. NOTE Place a clean sheet of cardboard or a clean rag on the treadmill deck before starting this procedure. 1. Remove the hood (page 4-1). 2. Remove cable ties that secure the drive motor Wires. 3. Remove one clamp from either side of the drive motor that secure it to the motor base plate. 4, Slip the V-belt off the motor pulley, then. lift the drive motor off the base plate Set it down carefully on the walking deck, 6. Use a pencil to scribe a line along the edge of the motor base place which is closest to you. The angle between the line and the edge of the headframe casting must be maintained for correct belt alignment. 7. Loosen, but do not remove, the four 7/16" hex-head screws which secure the motor mounting base to the headframe location, NOTE In the following step, move the base in 1/8" increments, and maintain the angle described in’Step 6. 8. Adjust the belt in 1/8" increments as follows: 424 4 motor mount screws (2 hidden) Motor clamps (2) Figure 4-24. Drive Motor ‘&. To Joosen the belt, move the motor mounting base towards the front of the treadmill b. To tighten the belt, move the motor mounting base avvay from the from of the treadmill 9. Tighten all four screws. 10. Place the drive motor on the motor base, then loop the V-belt over the motor pulley and the input shaft pulley. 11, Install the motor clamps, then tighten securely. 12. Cheek the belt alignment to verify that the motor base is fastened correctly. Adjust if necessary. 13. Replace the treadmill hood (Page 4-1). Torque Limiter Adjustment ‘The torque limiter adjustment nut clamps the torque limiter friction pads to the elevation sprocket, which is connected to the grade motor. If the pads are worn, the nut may need to be tightened, 1. Remove the hood (page 4-1).Pinion Shaft nut Locking’tabs alongside nut limiter Torque Figure 4-25. Torque Limiter, Adjustment Nut, and Tabs WARNINGS * Do not wear loose clothing around rotating machinery. + Keep fingers away from chains and rotating parts. + High voltage is present when the treadmill is plugged in. 2. Restore power to the treadmill. 3. Ifa programmable controller such as a 645 or Q4000 is used, place it in open Joop mode before continuing. Refer to the Manual for the specific controller. (On the 645 Controller, the CAL LED should be illuminated.) 4. Bend the locking tabs away from the torque limiter adjustment nut. lt may be necessary to operate the grade motor in order to access all tabs (Figure 4-25), 5. Run the treadmill elevation down to the lower stop. 6. Press the grade down to run the elevation against the lower stop, then release. Emergency stop >) connector Reset / switch, ; Controller connector AC cord Figure 4-26, Reset switch and connectors WARNING The treadmill must be at 0% grade when you loosen the torque limiter adjustment nut. Loosening the nut when the treadmill is elevated can cause the treadmill to drop suddenly, which may result in serious injury. 7. Use locking pliers to tighten the torque limiter adjustment nut until the motor hesitates when it is started while the treadmill is against the lower stop. 1/8 turn is generally sufficient. Do not overtighten the nut! 8. Loosen the nut until the motor just stops hesitating when it is started 9. Stand on the walking deck and elevate the treadmill to verify that it will reach its upper limit (25%). If possible, two people should stand on the deck 10. Lower the elevation to 0%, then bend at Jeast 3 locking tabs on three different surfaces over the adjustment nut (Figure 4- 11. Remove power to the treadmill, then reinstall the hood (page 4-1), 4.25REPLACING THE POWER CORD Figure 4-26 on page 4-25 shows the location of the power cord and reset switch. Unplug the treadmill from the power source. Remove the hood (page 4-1). Disconnect the power cord ground wire from the headframe. Note the order in which the washers stack up. Disconnect the power cord leads from the terminal block. Note the connection point Cut the cable ties that secure the power cord leads to the wire harness. Use pliers to squeeze the strain relief that holds the power cord to the mounting plate, then remove the cord. Install a new power cord and strain relief following Steps 1-6 in reverse order. Be sure that the cord has the correct voltage and amperage rating. REPLACING THE RESET SWITCH 1 2 4.26 Unplug the treadmill from the power source, Remove the hood (page 4-1). 1. (CLEANING THE TREADMILL SURFACES. les Disconnect the reset switch wires from connector J8 on the PCB Assembly, then cut the cable ties securing them to the wire harness. Push the reset switch out from the back of the mounting plate. The switch fits tightly, so you may need to rock it up and down to loosen it. Push the new switch straight into the hole until it is firmly seated. Plug the connector into J8 on the PCB Assembly, then use cable ties to secure the wires to the harness. Install the treadmill hood. -an the treadmill after servicing or as needed: Clean the treadmill exterior with a damp sponge. Do not use detergents or cleaning agents. Clean the control panel with a mild non-abrasive liquid cleaner, then rinse it with a damp (not wet) cloth. NOTE Do not lubricate the surface of the treadmill deck (slider bed).SECTION 5 TROUBLESHOOTING This Section consists of several tables that isolate most problems that could occur during treadmil] operation, and provide a variety of suggestions for onsite repair. The tables include: L 2. 3. 4. 8. 9. 10. ML. mechanical noises. . LED codes for the 640 controller. fuses on the PCB Assembly. . LEDs, jumper points, and test points on the PCB Assembly. connectors and jumper points. power-up problems. speed change problems and belt not moving. elevation problems. speed and grade feedback problems. walking belt not tracking correctly. belt slippages. In addition, this Section includes a discussion of troubleshooting techniques for bearing problems, TROUBLESHOOTING BEARING PROBLEMS WARNING Observe the following precautions when servicing the treadmill: + Do not start the walking belt when someone is on the treadmill. The belt starts moving immedi- ately, and the sudden start and subsequent loss of balance could cause Serious personal injury. High voltage is present when the treadmill hood is removed and the treadmill is plugged in. + Do not wear loose clothing around rotating machinery, Never place your fingers near rotating parts. All bearings are sealed and permanently lubricated, so maintenance is not required. The following information is provided to assist in diagnosing and trouble-shooting bearing failures. ‘Most failures cause clicking or knocking noises that are heard during treadmill operation. Determining the type and the rate of bearing noise can help establish which bearing is at fault. Table 5-1 on page 5-2 is a diagnostic summary of bearing noises, along with other noises that may indicate problems. + Transmission bearings generally click when they fail. — The input shaft assembly rotates at a constant speed, so the rate of the bearing noise (i.e. the number of clicks per minute) remains constant regardless of the walking beit speed. — The speed of the output shaft assembly varies with the treadmill speed, so the rate of the bearing noise (i.e. the number of clicks per minute) increases or decreases along with the walking belt speed. + Front and rear roller assembly bearings tend to knock when they fail. (There are exceptions, however.) Also, the rate of the bearing noise (number of knocks per minute) varies with treadmill speed, because the roller speeds increase or decrease as belt speed changes. A stethoscope with an open or tube end, or a piece of hose about two feet long, is useful for isolating bearing problems. (Hold one end of the hose near the suspected bearing, and the other end near your ear.) Compare several bearings to determine the sound of a faulty one. Read the warning on this page first before attempting this! 51Table 5-1. Troubleshooting Mechanical Component Noises NOISE PROBABLE FAULTY ‘ACTION ‘COMPONENT Clicking (Constant speed) Input shaft assembly Isolate bearing, then replace | transmission bearing input shaft assembly (page 4-6) Clicking (Rate increases/ Output shaft assembly Isolate bearing, then replace decreases with walking belt transmission bearing ‘output shatt assembly (page speed) 4-8) Knocking or thumping (Rate increases/decreases with walking belt speed) Front or rear roller (pulley) assembly bearings \solate and replace roller [pulley] (page 4-16) |” High-pitched “singing” Final drive belt too loose or too tight ‘Adjust belt tension (page 4-10) ‘Squealing (like loose automobile fan bett) Motor belt (V-belt) ioose ‘Adjust belt tension (page 4-24). Replace belt if necessary. Popping (during grade increase or decrease) Faulty elevation chain alignment ‘Adjust alignment of sprockets Table 5-2. LED Codes for the Model 640 Controtier MOTOR OVERLOAD | ILLUMINATED (ON) LED FAULT INDICATION ACTION ‘ADJUST BELT | (Not used) TRACKING ‘Motor overload when | 1. Press STOP, followed by RUN to tum off LED, or cycle AC power at the treadmill circuit breaker. 2. IFL1 remains lit, check the walking belt amd deck surface for excessive wear. Replace if necessary. Low power when Indicates that AC line voltage has dropped 15% or ILLUMINATED (ON) Conca! ILLUMINATED (ON) more below nominal. Check line voltage at AC outlet. Cable partially Indicates that the cable between the treadmill and the Disconnecten | Gab peretvnen | Mose 0 conter's mpropery comes Verity connection and reattach or replace as required. 5-2Table 5-3. Fuses for 208/230 Volt Treadmitis FUSE RATING FUNCTION | Ft & Fa" ‘32 Amp, 250 V Slow-biow | Grade motor F3& Fa" 0.7 Amp, 250V Slow-blow | High-speed deceleration circuitry | | for speed change motor | F586 0.5 Amp, 250V Slow-blow | Transformer Fuses for 115 Volt Treadmills RATING FUNCTION Fi & Fo" 6.25 Amp, 250 V Slow-blow | Grade motor : ‘ High-speed deceleration circuitry Fa 8 Fa 0.7 Amp, 250V Siow-blow | {QP eneed change motor 58 Fe" 1.9 Amp, 250 V Slow-blow | Transformer WARNING: High voltage may be present on fuses. Unplug treadmill before replacing any fuse. *NOTE: If one fuse of a pair is biown, replace both fuses. Table 5-4. LEDs on Treadmill PCB Assembly tcp | FUNCTION SST DS2___| Lights when a “low-line" voltage condition is detected a DS3 | Lights when teacmil speed is above he high-speed deceleration threshold | D4 Lighs when a “ive motr overload” condton has occured DSS__Lights when lower speed limit i reached [086 | Ligts when the RESET switch neods io be pressed [ps7 | tists wena controler suchas the 640i connected to he Weadhnil 53Table 5-5. Connectors and Jumper Pins CONNECTOR PIN(S) FUNCTION JPt ‘Normal speed-change motor vollages Pulse-width modulated +28 V when Speed Decrease is active JP2 Voltage proportional to the speed change motor current WV= 051 x!) Pulse-width modulated +28 V when Speed Increase is active ‘Speed change contour circultry ‘Speed contour input Contour output Torque contour input Electronic speed limits Low-speed limit voltage (approx +5.4 V) ‘Speed feedback voltage ee High-speed limit voltage (approx +10.1 V) ‘Speed-change commands High (+12 V) when the controller sends a Speed Decrease command whila the walking belt speed is faster than the low-speed limit. ‘UPS: High (+12 V) when the controller sends a Speed Increase command hilo the walking belt speed is slower than the high-speed limit. ‘Tachometer pulses “+12 V and OV (pulsed). Frequency is proportional to walking belt speed. Ground (0 V) PE Emergency-off switch jumper 1-2 Normal operation: the walking belt stops without a high-speed deceleration when the user presses the Emergency Off switch (This also causes the RESET switch to light up.) 23 Undefined operation: Normal stop occurs (including high-speed deceleration) when the user presses the Emergency Off switch. 5-4Table 5-6. Voltage Test Points on PCB Assembly TEST EXPECTED FUNCTION POINT VOLTAGE* Pt +28V +28 V power supply TP2 Hav +12 V power supply TP3 ov Power ground (0 V) TPs ov Signal ground (0 V) TPS +23 323 V power supply Te | +5V +5 V power supply Tach pulses: negative-going 0.3 msec pulses 17 + 7A Nueea) | With a frequency proportional to the speed of the (pulsed) walking belt. aoa +05V at 25% | Grade: DC voltage inversely proportional to the +115 Vato% | treadmill grade. DC voltage inversely proprortional to the walking tea | *86\ at 1S meh | belt speed. [Derived from fitered and scaled 7 mph | tachometer pulses.) *All voltages DC unless otherwise indicated. 5-5Table 5-7. Treadmit! Does Not Power Up POSSIBLE PROBLEM ‘ACTION ‘Treadmill not plugged in _ Plug power cord into an appropriate outlet. ‘AC Main (building) circuit breaker tipped Contact building maintenance to reset breaker If breaker trips again: 41) Verity that treadmill is on a dedicated line. 2) Check voltage at outlet. I necessary, verity that rated power at outlet and at breaker is sufficient to operate treadmill 3)_ Verity that power cord is not caught in rack gear. Power cord cut or damaged Remove cord from outlet and replace. Fuse in treadmill blown Remove power cord from wall outlet and replace fuse (Table 5-3) It fuse blows again, isolate mechanical assembly and ensure thal no parts are jammed (e.g. rack gear in grade change assembly.) | Control cable between treadmill and controller ‘Check both plugs and connectors. Reconnect and disconnected at either end. tighten screws as required. Control cable (including connector pins) between Check for bent or broken pins. Replace control ‘treadmill and controller faulty cable. | Treadmil PCB Assembly faire -—=—~~S~S~S*S:Che ce power supply power at test pons Table 5-6). If power is incorrect, replace PCB Assembly. Repair or replace controller as required a ——+ | Controller problem Table 5-8. Treadmill Does Not Change Speed POSSIBLE PROBLEM | ACTION ‘Speed change relays on PGBA not operational | ‘Replace treadmill PCBA ‘Speed change motor burrted out or not operational | 1) Verify that motor can rotate (Le. is not jammed) 2). Test voltage from fitter to motor. It should range from 0-28 V (maximum) during normal speed change. Replace motor if required. Wires poorly connected to (or disconnected from) | Crimp terminals and reconnect wires as required. speed change motor terminals Speed change motor brushes worn Check brushes. Replace as required. ‘Speed change spindle jammed Remove and replace spindle assembly (Refer to Input Shatt Removal, Section 3) Input shaft assembly moveable sheave jammed Remove and replace input shait assembly ‘Output shaft assembly moveable sheave jammed | Remove and replace output shaft assembly 5-6Table 5-9. No High-Speed Deceleration POSSIBLE PROBLEM ACTION Fuse F3 or F4 blown. Loose connection to Isolation transtormer. Isolate problem, then replace fuse(s) with one of same rating. ‘Check all connections and tighten as required. Table 5-10. Treadmill Powers Up, but Belt Does Not Move POSSIBLE PROBLEM ACTION RESET button (on hood) lt. Contactor not operational Ensure nobody is on walking bel, then press RESET button. Verity that wires are connected, then check power supply voltages). Replace contactor as required. Drive motor overheated or not operational. ‘Check voltage trom contactor to motor. Replace motor if required, Wires to motor disconnected. Reconnect wires as required. Motor noise audible, but walking belt not moving. RESET button illuminated, but: 1) stays lit when pressed, and 2) _belt does nat move Replace broken motor belt. ‘Short in Emergency Off switch. 1) Remove switch and verify correct operation. 2) Replace Emergency Off switch as required. Table 5-11. Treadmill will not change grade POSSIBLE PROBLEM ACTION Grade changa motor bumed out or not operational Test motor. Replace if required. Wires poorly connected to (or disconnected from) terminals Crimp terminals and reconnect wires as required. Rack gear jammed Check and free gear (page 4-13) Torque limiter toc ioose Readjust limiter and tighten nut (page 4-24) Fuse Ft or F2 blown Isolate problem, then replace fuse(s) with one of same rating.Table 5-12, Grade Feedbac! ‘SYMPTOMS k Problem: Display Varies from Actual Grade POSSIBLE PROBLEM ACTION Grade does not change from 0% 14) Reconnect u9 1) J9 disconnected 2) Replace grade pot 2) Detective grade pot Display does not change from a value other than 0%. Minimum grade reading not 0% OR Maximum grade reading not 25.2% Table 5-13. Speed Feedback Problem: Defective grade pot | Replace grade pot Calibrate grade as described in Feedback out of adjustment Section 4, page 4-20 isplay Varies from Actual Speed SYMPTOMS Display indicates speed greater than 20 mph when belt is started. ACTION 1) Reconnect J7 2) Replace tach assembly POSSIBLE PROBLEM 4). J7 disconnected 2) Defective tach assembly Display suddenly indicates speed greater than 20 mph when treadmil is in use. Defective tach assembly | Replace tach assembly ‘Speed readings tao high or too low Calibrate speed as described in Feedback out of adjustment Section 4, page 4.21Table 5-14. Walking Belt Slipping or Not Tracking POSSIBLE PROBLEM ACTION Walking belt slipping ‘Adjust belt tension (page 4-18) NOTE: Do not lubricate the surface of the treadmill deck {slider bed), Belt not tracking: Tracking adjusted incorrectly ‘Adjust tracking (page 4-19) Walking belt worn out Replace belt (page 4-17) Walking deck (slider bed) worn out Replace deck (page 4-18) Table 5-15. Internal Belt Slippages SYMPTOMS POSSIBLE PROBLEM ACTION 1) Squealing sound like automobile fan belt, and 2) Walking belt slows down as user's foot strikes the deck Motor drive belt (V-belt) slipping ‘Adjust belt Tension or replace belt as necessary (page 423) Walking belt sows as users foot strikes the deck. Transmission belt sipping Check pulley sheaves for grease or oil. Clean as required.SECTION 6 PART NUMBERS AND DRAWINGS Table 6-1 on pages 6-1 and 6-2 lists the assemb- ly drawings and schematics that are included in this Section. (The drawings appear in numerical order.) Refer to the assembly drawings for a complete list of treadmill parts. Table 6-2 on page 6-3 lists the most commonly referenced part numbers for the treadmill and the Model 640 controller. Table 6-1. Series 90 Drawing List DRAWING NUMBER DRAWING TITLE NOTE Table 6-: for information only. Refer to the drawings included with this manual for specific part numbers when ordering replacement parts. (000843, Final Assembly, Q5SXTddd 00344 Final Assembly, Q65 (000845, Final Assembly, Q50 000346 Final Assembly, O55 01307 ‘Tachometer Pickup Assembly 013089 Grade Pot Assembly 015273, Input Shatt Assembly 015313, Output Shaft Assembly 018351 Pulley (Roller) Assembly, Drive 018382 Pulley (Roller) Assembly, Rear 18533 PCBA, Model 640 Controller (018533-201 ‘Schematic, Model 640 Controller PCBA 019089 Reset Switch Assembly 019130 ‘Speed Change Motor Assembly 030262 Spindle Assembly, Speed Change 030626 PGB Assembly, Treadmill (030626-201 ‘Schematic, PCB Assembly, Treadmill 030656 Drive Motor Assembly (Q55) 030657 Drive Motor Assembly, 200 V (QS5XT & Q65) 030658 Drive Motor Assembly, 230 V (QS5XT & Q65) 030665 Drive Motor Assembly, Q50 030869 Drive Motor Assembly, Q50 030736 Cordset, Power (Intemational) 031193, Hood Assembly 6-1Table 6-1. (Continued) 6-2 DRAWING NUMBER DRAWING TITLE 031447 Tnput Shaft Assembly Spares Kit, O55/Q50, ‘eee | Input Shaft Astembly Spares Ki, GBS/OSSXT 031464 Power Relay 031474 Headirame Assembly (Q55XT, 065) 031475 Headframe Assembly (050, G55) 031476 Deck Assembly, Q50 & Q55 031477 Deck Assembly, O65 031493 Transformer Assembly 031496 Mechanical Assembly (050) [_oats11 Contactor 031517 Mechanical Assembly (Q55XT) P 031518 ‘Grade Change Motor Assembly 031825 Mechanical Assembly (55) 031830 Mechanical Assembly (G65) - 031541 Strain Relief Plate Assembly (Domestic) 031554 PCBA Bracket Assembly (International) (031870 Cable Assembly, Interface oats71 Strain Relief Plate Assembly (International) 031602 Power Cord (Domestic) 031701 640 Controller, Top AssemblyTable 6-2. Commonly Referenced Part Numbers NAME PART NUMBERS APPLICATION Beam chopper (006875-001 All models Transmission to front Belt, HTD 031 107-004 Tage (aPEER) Circuit breaker, 2-pole (031396-003 European treadmills only (031464-001 All models Contactor, AC power Drive motor assembly 030661, 030664-65, 030669 Refer to drawings for specific part number for each model 081519-001 208/290 V, 60 Hz Grade motor assembly 031519-002 100/120 V, 60 Hz 031519-003 290/240 V, 6012 (031519-004 100/120 V, 50 Hz Grade pot assembly 031089-002 ‘All models PCB assembly, treadmill 030626-001 All models Gowei cod fd ‘Pat arbor for ach oael Pulley assembly, dive 016351-001 All models Pulley assembly, ear 018952.002 All models Reset switch 019089-001 All models 032245-001 O55 Slider bed (boxed for shipping) 032245-002 Q65 032245-003 ‘as0 ‘Speed change motor, 90 V ossten ee) UsA/Japan (019130-003 European ‘Speed change spindle assembly 030263-001 Replacement kit “Tacometer pickup assembiy 013077-001 All models Transmission input 031447" Replacement kit, Q50/Q55* shaft assembly" 31449 Replacement kt, OSSXT/Q65" Trangmission output 018313-001 All models \V-Belt, motor to transmission o1sae1 Rte to drawings for speciis Variable speed belt (019062001 ‘Al models 018818-001 55 ‘Walking belt 018818-002 65 018818003 ‘as0 interlace cable, Model 640 091870-001 (2 m) length Replacement assembly, (031701-002 USA Model 640 031701-004 International *Refer to the dra gs in this Manual for the specific part and dash number. 63TNITIAL_APPLICATION REVISIONS Gasn wo] next assy. | nei TESCRPTON wrenoveo | pate 001 ADEN: 27859 FRAMIREZ [92193 THRU | STDS. STDS f ioe 014 | E UPDATED DRAWING AM Asha ie: ACTION CODE: H1 | MOD: 9-20-93 ONLY THE ITEM DESCRIBED ON THIS. DRAWING. WHEN PROCURED FROM THE 1.0 DESCRIPTION: POWER CORDSETS VENOOR(S) LISTED. HEREON SapenoveD er THE FOR INTERNATIONAL APPLICATIONS QUINTON DESIGN ENGINEERING OEPARTMENT INTHE. APPLICATIONS SPECIFIED BY THIS DOCUMENT NUMBER. Sbastirute irews SHALL NOT BE USEO UNIT OF MEASURE: EACH ALU DIMENSIONS. ARE IN’ MILLIMETERS AND ARE. NOMINAL ONCESS OTHERWISE. SPECIFIED, TABLE 1 PARTS UST SOURCE CONTROL DRAWING SEATILE, WA Ve IN TLZZ 206/223-7373 oRAWN | F.RAMIREZ |* TITLE, cHecKeo| CMATHIS _|°275,] CORDSET, PANEL COMPONENTS] ence. | A.NELSEN _|!305, INTERNATIONAL POWER roe 7 WG. NO. meV G)SANTA ROSA CA[MFS. | A.BELLAMY [7 tool SE TO Brace 7 verroves sources) f24 | Caonoan [7 nL A oF SUPPLY PuRCH ScaLe NONE | sounce: acd |snee> * oF ta2.0 TABLE 1: MFG P/N. DASH MFG NO. 1 | | No. (PANEL COMPONENTS) | -001 86511052 T 1 002 86516034 86516060 | ! -003 86552007 i -004 86536041 | | -005 86559011 -006 86558011 I -007 86531031 008 86589010 -009 86610300 010 86515050 -011 98010801.10074.2 -012 98010721.10074.2 =013 98010871.10074.2 -014 98010801.10074.1 1030736 SHEET 2 oF 1431 3.2 3.3 ‘SPECIFICATIONS: ELECTRICAL: CURRENT RATING: -008 (JAPAN) = 15 AMPS 011 & -014 (CONT. EUROPE) 012 (UK) = 13 AMPS -013 (ITALY) = 16 AMPS ALL OTHERS = 10 AMPS VOLTAGE RATING: -008 (JAPAN) = 125 VAC =009 (NORTH AMERICA) = 125 VAC “ALL OTHERS = 250 VAC 16 AMPS MECHANICAL: PLUG CONFIGURATION: PER TABLE 2. END TERMINATION: PER TABLE 2. NOMINAL CORD LENGTH: PER TABLE 2. NOMINAL CORD DIAMETER: -008 (JAPAN) = 8.5mm -009 (NORTH AMERICA) = .33_ INCH -001 THRU -007 & -010 = 7.0mm -011 THRU ~014 = 8.0 TO 9.8mm CONDUCTORS: -008 (JAPAN) = 3 X 2mm =009 (NORTH AMERICA) = 3 X 18AWG -001 THRU -007 & -010 = 3X Imm -011 THRU -014 = 3X 1.5mm CONDUCTOR COLOR CODE! INTERNATIONAL: NOTE: -009 (NORTH AMERICA) MAY BE. BROWN = LINE BLACK = LINE BLUE = NEUTRAL WHITE = NEUTRAL GREEN/YELLOW = GROUND GREEN = GROUND34 VV AGENCY APPROVALS: TABLE 2 END DASH APPROVALS. LENGTH) PLUG | TERM no. | COUNTRY | “CouNTRY | AGENCY (Fis) | F6) 7001 | CONTINENTAL | AUSTRIA love 25m] 4 W EUROPE BELGIUM CEBEC | FINLAND set ' ' | FRANCE UTE i ' GERMANY VDE | NETHERLANDS kKEMA | NORWAY NEMCO SWEDEN SEMCO =002 | AUSTRALIA/ AUSTRALIA SEcv 3.0m] 2A "1 NEW ZEALAND | 28 =003 | U.K./IRELAND | UNITED KINGDOM | ASTA | 2.5m| 3 n =004 | DENMARK DENMARK DEMco | 2.5m 4 un =005 | INDIA UNITED KINGDOM | BSI 2.5m] 5 "1 =006 | ISRAEL [ISRAEL sil | 2.5m] 6 W =007 | \raty ITALY {ima 2.5m 7 " =008 | JAPAN JAPAN JIS/DENTOR:| 2.4m | 8 u =009 | NORTH AMERICA US/CANADA UL/CSA tof | 9 u =010 | SWITZERLAND SWITZERLAND SEV [2.5m | 10 MW | -011 [CONTINENTAL | AUSTRIA Ove 1OFT | 12 15 EUROPE FINLAND SETI GERMANY VDE | NETHERLANDS KEMA NORWAY NEMCO | | SWEDEN | seco} -012 | UK VT vort | 13 “5 =015 | ITALY ITALY IMO TOFT | 14 7 [S014 [CONTINENTAL | AUSTRIA ove TORT | 12 “6 EUROPE FINLAND SETI | | i | GERMANY VDE | | | | NETHERLANDS | KEMA | ; me roel | SWEDEN |__sewco MEDICAL/HOSPITAL GRADE — CLEAR PLUG. COMES WITH 13A FUSE 7 Quinton xe NO 030736 SHEET + OF 144.0 DIMENSIONAL DATA: -001 FIGURE 1: CONTINENTAL EUROPE LINE —/--—— NEUTRAL -002 POLARIZATION FIGURE 2A: AUSTRALIA/NEW ZEALAND T owe HO 030736 SCALE: NONE ‘ACAD SHEET = OF 14 Quinton//— GROUND -002 FIGURE 2B: AUSTRALIA/NEW ZEALAND POLARIZATIONae =o 6352013 el RS La VY \ ‘ - 048 13 20.3 | ! 1 T “ie T 6 +0. a 19 FiguRE « \e \ he] ~ Z SN eureat vine (ewe) (BROWN, FUSED) POLARIZATION -003 FIGURE 3: UNTED KINGDOM /IRELAND 0385-4 ie pe Hy —. UNE NEUTRAL £ (erowny (BLUE) GROUND (YELLOW/GREEN) POLARIZATION -004 DENMARK, Owe (030736 SHEET ~ OF 14ee Hh —ti | wie) na pl | lof — —L ls ma -005 FouRE 5: mow re i 73) une — — NEUTRAL —006 FIGURE 6: ISRAEL —— crouno POLARIZATIONte POLARIZATION NTALIAN MAINS IS NOT POLARIZED —007 FIGURE 7: ITALY > 56.3 —— NEUTRAL Uwe POLARIZATION —008 FIGURE 8: JAPAN ‘SCALE: NONE9327-5 mes | pallieeg ee ren a re” ST (nn weve, SC ne POLARIZATION —009 FIGURE 9: NORTH AMERICA _-— ROUND NEUTRAL — POLARIZATION -010 FIGURE 10: SWITZERLAND "030736 Scat: none CS™”™SCO™~™~i~ TT40.3 23 #93 —— GROUND (GREEN/YELLOW) jp 7 208 1 \ | ee) TS Z ' 7 ON i se “4 15.8 709 ay Hd ties aU ein oro re Os pf oe Fees ume Oe astm 25235 (Blue) POLARIZATION TYPICAL CONFIGURATION rioure 11 ENO TERMINATIONO11 14 FIGURE 12: CONTINENTAL EUROPE 16 AMPS Dac 030736 SOURCE: nem SHEET 120F 146 TT ae 2 & _ = Shem =x a Sin 13 FIGURE 14: ITALY 18 AMPS FIGURE SHEET 7 SOF 14 ‘SCALE: NONE ‘SOURCE: ACADNOTE: INDIVIDUAL WIRES NOT STRIPPED -014 FIGURE 16: CONTINENTAL EUROPE 16 AMPS. 5.0 MARKING: PACKAGING MEQIA TO BE CLEARLY MARKED WITH MFG NAME OR SYMBOL & PART NO. 6.0 PACKAGING: \TEMS SHALL 8E SUITABLY PACKAGED FOR ACCEPTANCE BY COMMON CARRIER FOR SURFACE TRANSPORTATION, HANDLING AND STORAGE WITHOUT DETRIMENTAL EFFECTS TO THE ITEMS. 030736 ‘SCALE: NONE SOURCE: ACAD SHEET 40F 14INITIAL_APPLICATION END Ie Na, REVISIONS DESCRIPTION next assy. | DASH NO. ‘approveo | pate ONLY THE ITEM pescRiseD ON. THIS DRAWING: WHEN PROGURED FROM THE VENDOR(S) LISTED. HEREON 's APPROVED BY THE QUINTON ESIGN ENGINEERING. DEPARTMENT INTHE. APPLICATIONS Specified ey THIS 1.0 DESCRIPTION: THREE POLE POWER CONTACTOR DOCUMENT NUMBER, SUBSTITUTE ITEMS ec SHALL NO BE USED. UNIT OF MEASURE: EACH ALL DIMENSIONS ARE IN. INCHES AND NOMINAL UNLESS OTHERWISE NOTEO. PRODUCTION T contactor, | : AC POWER ae DESCRIPTION mre cope | wro PART NLMBER PARTS LIST SEATILE, WA, 206/223-7373 @2.0 2a 2.2 2.3 3.0 4.0 SPECIFICATIONS: ELECTRICAL: COIL VOLTAGE HORSEPOWER RATING: tec eeeeeee 3 HP 8230 VAC CONTACT CURRENT RATING: — ———— ———— 20A RESISTIVE 16A INDUCTIVE MECHANICAL: DIMENSIONAL (OUTLINE | 2): uade etree et ete PER FIGURE 1 AGENCY APPROVALS: UL, CSA, NEMKO, SEMKO, SEV & DEMKO. DESIGN DATA: THE FOLLOWING INFORMATION IS FOR USE 8Y THE DRAFTING DEPARTMENT. SUGGESTED MOUNTING PATTERN: — —— PER FIGURE MARKING: DEVICES AND/OR PACKAGING MEDIA WILL BE MARKED WITH THE MANUFACTURER'S NAME OR SYMBOL AND DEVICE TYPE. PACKAGING: TEMS SHALL 8E SUITABLY PACKAGED FOR ACCEPTANCE 8Y COMMON CARRIER FOR SURFACE TRANSPORTATION, HANDLING AND STORAGE WITHOUT DETRIMENTAL EFFECTS TO THE ITEMS. Citi ‘SCALE: NONE ‘SOURCE: ACADan aT gr3 FIGURE 1: PHYSICAL INFORMATION ‘SCALE: NONE ‘SOURCE: ACAD SHEET 3 OF 3INITIAL APPLICATION DASH NO. WeXT ASSY. | geihD, REVISIONS ur DESCRIPTION. approveo | OATE VARIOUS ONLY THE ITEM DESCRIBED ON THIS DRAWING. WHEN PROCURED FROM THE VENDOR(S) LISTED. HEREON IS aPPROVED BY THE QUINTON DESIGN ENGINEERING. DEPARTMENT INTHE APPLICATIONS SPECIFIED BY THIS 1.0 DESCRIPTION: RS-232—C DATA INTERFACE Document Nuuaee Been SUBSTITUTE ITEMS eee SHALL NOT BE USED. UNIT OF MExSURE: EACH ALL DIMENSIONS ARE IN FEET OR METER: AND NOMINAL UNLESS OTHERWISE NOTED. PRODUCTION PER TABLE DASH No. DESCRIPTION weg cope | MFG PaRT NUMBER PARTS LIST SOURCE CONTROL DRAWING Quinton 2121 TERRY & SEATILE, WA, 208/225-7372 CABLE ASSY, INTERFACE @ ‘ASSMANN (PHOENIX, a APPROVED SOURCE OF SUPr 031570 Z SCALE NONE [ source: acan [si2.0 3.0 Ba 3.2 TABLE 1: MANUFACTURER'S PART NUMBERS DASH, MFGHT DESCRIPTION - - NO, _| (ASSMANN) =001 | A-TAI041 __ RS232—C CABLE, 6 FT LONG 002 | A-TA1042_ RS232-C CABLE. 10 FT LONG i SPECIFICATIONS: ELECTRICAL: CABLE: VOLTAGE RATING: CAPACITANCE: — ~~~ - 300v _ 35 pF/FT NOM IMPEDANCE: __ — 50 OHMS NOM CONNECTORS: CONTACT CURRENT RATING: ———————-2 AMPS MIN DIELECTRIC WITHSTANDING VOLTAGE: ——~——I1KV MIN INSULATION RESISTANCE: __._-___-§_.___.___ 5 KMEG OHMS INITIAL CONTACT RESISTANCE: __ ___ _ __10m OHMS MAX (@ 10mV & 10mA) MECHANICAL: OUTLINE DIMENSIONS: — PER FIGURE 1 CONFIGURATION: A SHIELDED 25 CONDUCTOR CABLE TERMINATED PIN 1 TO PM 1, 2 TO 2 STC, TO A 25 POSN D-SUB SOCKET CONNECTOR ON ONE END AND A 25 POSN D-SUB PIN CONNECTOR ON THE OTHER WITH THE SHIELO TERMINATED SHELL TO SHELL. A PLASTIC SHROUD WITH SELF CONTAINED JACK SCREWS AND A CABLE STRAIN RELIEF FEATURE IS TO BE MOLDED ON TO EACH END OF THE CABLE Quinton [°" "931570 ‘SCALE: NONE SOURCE: ACAD SHEET 2 oF 43.3. MATERIALS: CABLE: CONDUCTORS: #26 AWG (7/34) TINNED COPER WITH PVC INSULATION SHIELD: __. AL/POLYESTER FOIL WITH STRANCED TINNED COPPER DRAIN WIRE _ BEIGE PVC, .032 TR CK _. BEIGE UL 94 VO THERMOPLASTIC OUTER JACKET: _ STRAIN RELIEF: CONNECTORS: INSULATOR: — —_—————_____ UL 94 VO THERMOPLASTIC a COPPER AL_OY _- PHOSPHOR BRONZE OR BERYLLIUM COPPER CONTACTS: PINS: ___ SOCKETS: CONTACT PLATING: — _ __ ————15u INCH MIN GOLD ¢¥ER 50u INCH MIN NIC cROUNDING LABEL (2.1, PART NUMBER 016256-001 OR EQUIV.) ‘SCALE: NONE SOURCE: ACAD SHEET = OF 6144,00 4,00 ————_—_+ Pp 9.00 —T oc GRN/YEL — (Blu) L_ 3.00 =} / \ (eRN/veL) | ere i = 136 / = | PreK EL \ CONFIGURATION / (BRN) OPTIONAL WITHIN Lnewa L5-30P LIMITS SHOWN, PLUG FIGURE 2: (~002) 30 AMP, 125 VOLT POWER CORD [> vouste cRIMP QUICK DISCONNECTS FOR NEMA .032 x .250 TAB (2 PLACES). (HOLLINGSWORTH XSO9788 OR EQUIV.) DOUBLE CRIMP RING TERMINAL FOR #10 SCREW. (HOLLINGSWORTH XR5103N OR EQUIV.) [B= 5 « 10 awe svt corDace. [E> GROUNDING LABEL (G.. PART NUMBER 016256-001 OR EQUIV.) eT Quinton 031602 ‘SCALE: NONE ‘SOURCE: ACAD SHEET = OF 6144.00 = 4.00 ———__—___~ 9.09 ——= — (GRN/YEL) i {=> GRN/YEL 01.50 |e CONFIGURATION + 6.00 —~ —(BLU) OPTIONAL WITHIN NEMA 6-i5P, 15A, 250v LIMITS SHOWN HOSPITAL PLUG FIGURE 3: (—003) 15 AMP, 250 VOLT POWER CORD [E> douse cRIMP QUICK DISCONNECTS FOR NEMA .032 x .250 TAB (2 PLACES). (HOLLINGSWORTH X309787 OR EQUIV.) DOUBLE CRIMP RING TERMINAL FOR 210 SCREW. (HOLLINGSWORTH XR1903SN OR EQUIV.) E> GROUNDING LABEL (Q.I. PART NUMBER 016256-001 OR EQUIV.) lon | 031602 | | SOURCE: ACAD SHEET = oF 6~~ — (GRN/YEL) \\ om +l) TN Lo nema 6-20", 20a, 250V ss 144,00 = 4.00 ———— + fs 9.00 —— GRN/YEL, 3.00 / CBRN 4 | / t - : 2 | CONFIGURATION 6.00 —= OPTIONAL WITHIN UMITS SHOWN FIGURE 4: (-004) 20 AMP, 250 VOLT POWER CORD [E> pousie cRIMP QUICK DISCONNECTS FOR NEMA .052 x .250 TAB (2 PLACI ES). (HOLLINGSWORTH XS09787 OR EQUIV.) DOUBLE CRIMP RING TERMINAL FOR #10 SCREW. (HOLLINGSWORTH XR1903SN OR EQUIV.) [E> 5 x 14 awe, 60°, 3oov, SuT CoRDAGE. [> crounoine LABEL (0.1, PART NUMBER 016256-001 OR EQUIV.) 031602 ser 6 osNOTES: uNLess omeRWise APPLY OPTIONS SHOWN, WHEN APPLICABLE, ABEL (PART OF ABPLY LABEL (TEM 8) FOLLOWING ACCEPTANCE 0 PRODUCTION TESTS AND QUALITY ASSURANCE PROCEDURES. o yee ee eee TABLE | NAMEPLATE INFORMATION lwooe. nol ‘a5sxT__| 343-001—Wex ‘sport | 343-002—%xx caseort_ | 343~003—xxx assxt_| 343-006—xxx (a5sxT__| 343-005—¥xx ‘55xT | 343-008—Kxx ‘O55xT ‘55x TABLE I! INDEX OF OPTIONS [=> % AON: 38178 INTERNATIONAL VOLTS [ACTION CODE: 1 DELETED “PHASE” & “CIRCUIT CONDUCTOR’ COLs, ACTION CODE: HT MODIFIER: DATE OF RELEASE ITEM 5 WAS: P/N: 03036-012, AND MATERIAL SPEC: 004, WATERIAL SPEC ACTION CODE: Ht MODFIER: DATE opmion TYPE 073689-001 | Kil, MASK SUPPORT (013756-001 | EMERGENCY OFF SWITCH (000043-002 | ARM SUPPORT KIT (018846-003 | KIT, LONG HANDRAIL (015847~003 | IT, SHORT HANORAL 016242-001 | 1.2-12 MPA, SOHe (016243-001 | 1-10 MPH, SOHz o16244~001 | 1-10 MPH, 6OHe coversa—oor | 12-12 WP, 6ONE EXAMPLE PROTOTYPE (000543~001 NAMEPLATE WARKING, SEE TABLE 1 FOR PARIS UST SEE SH 2 FINAL ASSEMBLY CARDIO EXERCISE TREADMILL, Q55XT “000343 NOTICE: QUINTON CONFIDENTIAL [ert aa PE CSTt D ~ [=] ]- [77 [oe] eooseeme30 [Service wanonl, SEMES 90, OOwEsne | 050, 055. asseT, O65 -{-]a]-[-[-[-[-]17 | oste6s-350 | unpacaing instRUCTONS, FRENCH - SSg0gSSS0R. 20. c =[= [FTE] -]- JH ]inf esrsos-s00 [loreieron watiunt, SERIES 90, StRwan = =[A]= [|= fief osises-sso orcrarom watum, SeRes 90, ORITsH =e ‘co0346—810 | OPERATON WanuAL, SERES 90 ‘ouEST Wt ERP LEEL (030736-077| CORDSET, WTE;WATONAL POWER 6A CONTINENTAL EUROPE i 7 =EII-EFE 030736-0%3 | poRosey, WTEMATONAL POWER 1 TAY 7 PROTOTYPE -[-|- ean (030736-0%4 | CORDSET, INTERNATIONAL POWER 1A, UK. — oe thetelste]-[- "031517=G02 | MECHANICAL ASSY, TREADMEL, GDSxT | 230—240V, SOHe 3 = aire (031817-00¢ | MECHANICAL ASSY, TREADMILL, O5SxT | 200V, SOME ie =r ER ‘051517-003 | MECHANICAL ASS, TREAOWILL, GBA | 200, 6Ohe ei =[-[=I-I- Ie "031517001 | MECHEL ASSr, TREAD, OSSKT | 208/230, GORE ~ ee eae =007 | FINAL ASSY,CARDIO EXERCISE Tw, OB5AT| 230v, SOHe (TALY) Ss prec eeaee 008 | FINAL ASSY.CARDIO EXERCISE TW, O55xT | 230v, SOMe (GERMANY) a —|-y-]- Sane 008 Fm ASSY-CARDIG EXERCISE Tw, a55A1 | 2aQv, SO%2 (UK) -{-{-1-N-[-]- 003 | FNAL ASSY, CARDIO EXERCISE TM GSPORT| zoOv, SOHE SSGGee =|- “002 [Few ASSy, CAROID EXEROSE 1M, OSPORT) Z00v, Gone SEE EEN or cece cine a | a oe alalalel|a|a/al2 a ay AN A i Ram scumcccrgied user sere] p [aon | 000343 [C Eoomtet Stes doMtON settee eo, ha Rone ReaD AOU pone PORT automo [oer 2a 4 3 2 1lpa ¢ il NS PROTOTYPE - (73.8) =001 SHOWN =002 THRU 008 SIMLAR EXCEPT AS NOTED ewe |” 000343 [C ° Te [pel 8c rc00o ee ae RAT Rone | HE aroma [aac Do 4 1\ FPF 0543 fate PROTOTYPE 5 ag Si ol Ely fol8 7 6 5 v 4 | 2 1 - 4 —— — FFE000 SRVATION —] evox erie NOTES: uNLeSs OMERWSE SPECRIED TABLE | NAMEPLATE INFORMATION 7A FETT wane nat [orl wo, |wooes Ne us [AL aus | FRE Borg pedal ee aed aoe OPTIONS LABEL (PART OF OPTIONS KIT) AS. ee eeeeae te teea eae eee vous, [FL AMPS] FREQ oe pa lee Rome SHOWN, WHEN APPLICABLE. = 344-001-) ‘BOHZ SCHON. a ooses-ooifoss | se-oor-ane [200/250 | Te penance ee WHS OPHION APPLIES 10 003, 008 THRU 010. jo00344-002) 065 | 344-002-xxx[ 200 OH Eee PEO EV Der ere looase4=oosfass | s+4~003-xxx | 200 50H2 DELETED "PHASE! & “ciRCUIT PRODUCHON TESTS and QUALITY ASSURANCE PROCEDURES (o00344—004| aSPORERT | 344—004—xxx | 200 oa CONDUCTOR" COLS. TABLE 1 ‘action ‘cooe: 1 (000344=005) esponrxT | 344~005—xxx | 200 Bonz MODMER: DATE OF RELEASE Jooas44—oo8)o6s | S44~008~xxx | 230-240 sone | fe ocx 28361 [00344007] 965 | 344-007—xxx | 230-240. One IEW 8 WAS. ®/1 03036-012 AND MATERIA. SPC" TA, UK joo03e4—vos]ass | 344—008-nxx | 250—240 sone eater ee [oo0344—009|a65 | 344=009—xxx | 230~240 sone SPEC. 230v, 50He (UK) }— }009344-010] 065. 344-010-xxx [230-240] 16 ‘SOHZ GIV PER ASSY WaS: trem 9, ~006. + ITE 8, ~007; NONE TABL INDEX OF OPTIONS [i eae El iN TIONS [> ITEM 8, 008: NONE PARI NO. OPTION TYPE ee porn cou | USED ON MODIFIER: OATE OF RELEASE (013689 00% | rr, MASK SUPPORT AL swona [pari] 013756-007] ewERGENcY OFF swion Laue memorern| > Tl } | (000043~002 | aia SUPPORT KIT AL 015046004] KIT, LONG HANDRAL AL (015847 -008| KIT, SHORT WaNORAL [ALL 016242 -001| 1.212 WPH, Sone (016243 -007| 1-10 MPH, Sore (016244 -001| 1=10 MPH, Gbiiz (16238 ~00r| 12-12 WPH, 60 ‘016384 -001] SHORT DECK aL Gagan ae ee | B SAMPLE, oF 000388-001 NAMEPLATE WARKING, SEE TABLET FOR PARTS UST SEE SH 2 }[eseeen rae PE eae Povo] Quinton | Eh y PROTOTYPE Bu [tee] 5. crome: FINAL ASSEMBLY 08 oT NOTICE: QUINTON CONFIDENTIAL |", trotnen few CARDIO EXERCISE 728 | snaver i Aer comms caer Porat Lae TREADMILL, O65 oat Se Be ramet ee Sa Te a ae x Sen otter inate ih Am ete 10 |b] 000344 |C : ! REET pa [EE 065 SEAT oon PRE owe RT noes Te Toe 8 7 6 5 * 4 3 2 1A © | t = = iE ce) @ cee (| PROTOTYPE can [Se 1 pl [000344 [C8 7 6 L 2 y : 1 _ NOTES: UNLESS otHeMISE SPECIFIED TABLE | NAMEPLATE INFORMATION 7% won: 28176 alee = T TABLE, INTERNATIONAL vouts |* “e"* |82 [E> aneey opmons saat (exer oF oPtoNS KT) AS Part No. [woe nof semat no | vous |r awos| Free were: 230 pA ph SHOWN, WHEN APPLICABLE oooss-00%] aso | s4s-oormx] vis | 12 _peone oe [E> pervs to -c01,-002,-003,-004,-010 AND 01 oases 002] aso | 345-002-xnx | 708/230 | 6 [eon 3 meres D [Eo> Aeruy wages (new 12) FouLOWNG ACCEPTANCE OF ALL aoos4s-ons} aso | s45-o08—xxx| 100 _| 12 | eon c DELETED "PHASE’ & “cRCU PRODUCTION TESTS AND QUALITY ASSURANCE” PROCEDURES. coasasoo4| oso [s46-00r=xax | 100 12 fear pe NOUEIOR COS TBE 1 o09345=005] aso | s4s=005-x0« | 730-240) 6 [sow MODITIER: BATE OF RELEASE 000345008) _as0 | 345-006-x«x | 250-240 | 6 | SOHZ e) eattecan 1000345-007| a50 345-007—Xxx | 230-240 6 ‘SOHZ TEM le ‘SPEC WAS: o00345-00a) aso | s45=o00-n0x | 230-240) 6 | son cto CODE: Hi 00345-0710] 50 345—010-XXX 115 12 6OHZ Senet enone een joos45-o11 aso _| s45-or1—vx | 208/230 | 6 | 6onz aoosas=or2] aso | sas-or2-v0x [230-240 | 6 [son 0545-013) _a50__| 345-013-x0x | 250-240] 8 [50H ooosas=or4] aso [3as~ore-vox 230-240) 6 | SONZ ooos4s=or5] 50 | 345-0r5-n« [230-240 6 | son fooosas—or6] 050 | 345-016~xxx]230-200[ 6 | SOHZ Cc TABLE ll INDEX OF OPTIONS D> ws wo. | option TPE DASH NO USED oN or36ee—o0i] 1, waSk SUPPORT [AL (013756-001| EweRcENcy orF swicH | [2 st .000043-02| aa SUPPORT Kir A 216709-002| Kr, SHORT HANORAL [ALL a 018905-001] .6-6 MPH oH =065 014904-001] -6-6 MPH SOHE 008 E 030808=001] sAPAN CORD ASSEMBLY —_|-Ot1 8 s & (rem 12) EXAUPLE, OF 000345-001 NAMEPLATE a ih, See ABLE TOR PARTS UST SEE HD pL rs ere A estoue Jove! QUIMION | EMEA. wa Bek [ieee] acu 2 5 rome lewnl FINAL. ASSEMBLY A ~o16 NONICE: QUINTON CONFIDENTIAL |” Trotnen omm CARDIO EXERCISE ind | warner | oo0sas pati Seta TREADMILL, Q50 ot SO Be artis ba aaa ore = mara | anreae | oe ae Srivareesm rece! 0 |D| | 000345 |C care pa [HC GROTH ae oe PRT nme ans [sa TZ 8 T 7 T 6 T 5 4 4 3 2 1TEEPEP PEPPERELL Te] wien [ard owe tEEEEEEPEE =[= |= fas] ceseco-200 [vnc nemvctons sae ~t+f-[-[-|-T-[-[[- = |= |-|2«] catec2sso | uneacks wstructions, Taunn | [ER EEEEEEPEELEE [fal sme-ne[umowe srmuaos. ane TPT TEE EFT [| [22 oitcerss0 | onrtnne nsraerane emu TEEPE EEL ED} ppt far sieee-s00 [unot nemctors ous | ooaste ox tebe} FFepat feds fe}=[=]-] =a) estaso-ao [sence wins, stnes oo, om | of0 as, os5 ofp EEE EREEEEIEE DLL [fe] eoshe-sio [seer unin, senes so ose | 0:0 8 asi of PE EEE EER EEE EET [el enseroao [oman utsan. semes 0, crass TET ETT EET I=Te [eI Fl sebe-eeo [orton sons on; miu TEE EEE EIT Ps osnes-t0 feveevon wosua, sens 90, ro SPT TeLTEP TED Fe Tete fief conse s10 Pores wai snes 0, comin === PeP Ye f- FT - ELE EEF |e] estsos-e00 [orezaton want, series 90, eran =t-f-[-]-[)}o[-[-]- a] [a] 1 |is] 000366-e40 | oreRATOR MANUAL, SERIES 90, Bowesnc 7 spefatapafafepeyata tft] tafrz] owor—-v7 | ase, anHeswe kAcKED AL FOR | pwariare TEP DEEEPERPP IEEE [a] cursor [ooaser ercnutow: powcr | cownowas ore =P EEE EERE Telefe [e pel sone-o13 feomser wrematona poren | tea my c FEE ERIE EET {2 [certo [oust erent rover ak ux: Teel Ppt ttf fe led Le eaoe-om cor ss, mai a0 230-206, Sah PEER EEE EEL [onsen cor ss enue 108/230, eon, er =T-TEI-T-I- EEF I-F-EL- FEEL [|e | cstese-006 | wecr assy, 1Reaouit, 050 15, Gore, MPH =EEEEEEPEEPEEEL Df [esnsto Juco assr mou 20-2, Som eh PROTOTYPE TEE EEEEEE EEE [ef [esuss-o cos ass menu 0 1a, Soe ees TT=[ [EESTI ELE e[e Fe eae fentes-a0e faassen ao 100 ee ea == ete = [=F Efe [ef | cexrnemoor | weorass. taoowe a0 208/26, =F EEEEEEEEEEFEL ans [fave 5% OOO BASE TD | 2. SO, cr PD = -l-I-1-I-I-I-I-1-F-I-[-I-F-[- 015 | FNAL ASSY, CARDIO EXEROSE Tm, 080 | 230, SoH, GMPH (TALY) FEN esceaeeicigiasciee are [i AS, Game ORE Tu, 080 | 250, SP (TNE -f-T- -|-T-I-|-|-T-T-1-1-J-]-f- —o13 | rial ASSr, CARDIO EXERCISE Tw, 050 | 230v, Sore, euPH (GERUN) | SEER Sette et = one [ra 554 C0 OEROSE wu. cs0 | ae, Se sur CuK) =e NGL-LEE EEE ELE re =ELEEEEN-FELEEEEEL 010 [ra assy, RDO ERESE 1, so |, ee, ~ IEE EELENEELEEELEE ota [ra as51 ORDO EXHESE Tu, 80 | 2300 20, Bury PAN) =EEEEEELN-EELELECLE eon | fa assy cs OH Tu oso | 290% Se, Ben (TAD ~ SELEEEEEE sft I Saal cc an caer oon fae me ahh EEE Need aot [Faw esr OO EMRESE TW, o80 | 2301, ea (ERMA See ELE NEE ELE ees | Hat Ay ono BEE exo | 201 etme BwPY (OR) =FPEEEELEELELEN-F EE aor | ra S57, of00 EXRCRE TM 50 | 100% sore, SESS Se sacle Nels 03 | ro 1564 CRD GERCET TH, o30 | 100V eve HP -|-1-]-]-]-]-[-[- -|-]-|- -|- 002 | rma ASSY, caRaio CxERCISE TM, O50 | 208/230v, 6OHZ, BMH aoa EE EEEEEEE-ELEENE toi [rv 1557-ext0 OROSE mo | 1v, eve. ture ; y]l= a 5/515] 8] 8] 5] S]ETE1 EY 8] a] sara RTE eS Ta TOT 7 gama casas oe merenetes dO] |” 000345 | C ERE P Ss ania eae) hr nate masa em ove [Ro [oe Do + —— TT TePA -o01 a7) 008 THRU —009 010 on 012 THRU ~016 (22.3) iL (748) ————_ = =001_SHOWN 002 IHU O16 SIMILAR EXCEPT AS. NOIED PROTOTYPE Z Ts Te 1_ses000 7 oF ees PRT asroca [seer Sw 4 1PROTOTYPE d Ic] 4 p= |” 000345TT srs00e 8 7 ! 5 v 4 i 3 L 2 1 Bi AMEPLA ORMATIOI x ae —a NOTES: UNLESS OTHERWISE SPECIFIED TABLE |_ NAMEPLATE INFORMATION ADGR: 78178 ona vo.ns Pe por [T= septy options tase (PART OF OPTIONS KIT) AS PART NO. [MODEL NO} SERIAL NO. | VOLTS JFL AMPS) FREG WEE BO SHOWN, WHEN APPLICABLE. 0346-001 = xX 2 1 Mi ACTION " c00346-00i] ass | 346-001—nx| 2087230 12 fear2| Ac COE D APPLES TO -001 THRU ~O04 aoo346=002] 055 | s46-o02-xxx} 115 _| 24 | eon ores APPLES TO -008 THRD ~009 ooas4e-cos) 056 | s46=003-wxx | 100 | 24 feoha c OELLIED “PHASE” & ‘OCU ns] oss _| 24 _f cote ONaVETOR” OLS IN TABLE 1 al ons | s48-004—0 a APPLY LABEL (few 9) FOLLOWNG ACCEPTANCE OF Att aonsse=coe| oss__[346—o0e—xmx[ “igo_| 34 [sanz FON CODE: 41 Probuchan WSIs ano. QUALITY asSoRanck PROCEDURES. f900546-005] _o85 } 346-005 xxx] 230-240) _12 | S0Ht eee jaoosaé=o06] —a55] s46-006-xxx | 230-740] 12 [son © ben 28388 }00346-007] 955 346-007-xxx [230-240] 12 ‘SOHZ on ane SPEC. WAS: o00s46-00e) a56 | s46 008-vxx]| 230-240] 12 [Sone Foatcooe 4 ooos46-o09} ass | 346-005-0«x | 230-240] 12 [S0Kz MODPIER ATE OF RELEASE I TABLE il INDEX OF OPTIONS = 7 DASH NOWaERS part wo | OPTION TPE SH NOs 013689~001 | i, wASK SUPPORT AL c 015756-001 ] EWERGENCY OFF swiTGn 000045002 | Kir, ARM SUPPORT aL (018646003 | KIT, LONG HaNDRAL [ALL 015847008 | KI, SHORT HaNDRAL [ALL (016245-001 | 6-6MPH, SOM Te 015713-001 | .6-6upri, Gone =061 =002, 005 >| (rew 8) 8 nen A on A atete [Quarto woe. oss fin ae t SYNPLE OF 090346=001 NAMEPLATE rma a a aa “For Panis ust Se SHE AT OR = mA ere | = oe [aoe REE : es + PROTOTYPE 31 T nestoue [ewe] Quinton a ‘ eR |atiet| occ # “FINAL ASSEMBLY ) kestoo NOTICE, QUINTON CONFIDENTIAL [°° CARDIO EXERCISE Tied | wareer | cooses Bees pram =———}—} TREADMILL, 055 ites 2 RE lear wa pS s = z (ee Pp Rta aaa 10 |p|» | 000346 |C nN FINA PEO Qs | wo wrvenr ones [A noe | aot [oa Dore 6 1 7 I I 5 4 4 T 3 2 I 1 r1 - fe f tpata}ifa 3] e3tess-650 | SERVCE MAMLAL, SERIES 90, WH | G50, 055 QS5xT, O65 a bl ‘31841=061 | SHIPPING CRATE iz [ai] —co0ses-w30 050, os6, GR, OS a 051865—350 | UNPACKING INSTRUCTIONS, SPANEH _ aa1962-360 [unmcions wistaucnons, Tan | 031863-360 | UNPAGENG WSTRUCTONS, FRENGH ~ ‘anre6i~360 | UNA _ 1051864-350 | UNPAOKING NSTRUCTIONS, ENGUSH DOMESTIC, UK. a ‘31801840 | OPERATOR MANUAL, SERES 90, SPaNSH PROTOTYPE eis ‘OV001)=117 | LABEL, ADHESME BACKED AL FOL Nae PLATE _ 2 030796-011 | CORDSET, TERNATIONAL POWER Teh, CONNENTAL GLROPE 059525-005 | ME ASSY, TROOMAL, O55 Toe, Som | osrses-oos | ueciy Asse, MREADWLL, O58) “100, Ke MECH ASSy, TRCADMLL, 055 ey, cone “Sa | as taoe Bae a | Bo \° 205 Fike ASS. CARO ERENCE Tw 055 | 230%, sore (MALY ale 0s | at Aor, cA00_ ESE tw, @55 = 000346 |C ole 1«ny -001 SHOWN 002 THRU —009 SMILAR EXCEPT AS NOTED Z To Te 1 svsoooPROTOTYPE[> LABEL wiTH PART NO. AND REV LETTER To WHICH MFG, AND LOT CODE OF OPTICAL INTERRUPTER [> FILE OFF PROTRUSION ON PCB (ITEM 3 OR 9) EDGE, PSBED CDyPONEN TS Ta PCT ALT eet EAbe To PREPROOUCTION: ATEN | WS PART NO o1o8a)- a ary HAS BRemee yalS chat no Soibeb S30 acces tems! " thr, BINME omens DART! 1uiae REV NOTE! ADDED FLAG Ic AObeD ITEMS REL To PROD EFF PTI, DISP!NONE, erry Siete Vincente 2. a Fon [ 2494 cers Deteancen woo zene) [Mile PRODUCTION. T= [SOB OTS = Ce RB FRY, IERRUPIER PAL] =e SOO PRONE TER POLLP SET 1} [a foo1ess - cor [case Tie 2[2| 7 loonea- oor |washen, FLT oa a 2}2|@ |oos4as-or_| wasneR Lock |Fe EXT Star al 22 [= |oo1767 C01 |NUT,wEx Jeo-s2uUNIC 2B z[2[4Jocsz06-a02 |spacee,Flaze S00 x 44g = [1 [3 Jor3075-cor —_|ineaueTer, OPTICAL] AC.8. ASSY.— 11 [2 |orso7e- 001 JarackeT, TACHOMETER —_ Ze] 1 [owse7-24z [SCRE vy, PANHEAD Fax 7516 7 7 =001 TACHOMETER PICKUP _AGSY 10 me O1O]E | gt too oat Pe = VPP || }-“] TACHOMETER PICKUP ASSY 4NOTES: UNLESS OTHERWISE SPECIFIED ©)[r> MLAs noon em MEE SEV cit 4) USN eal SHRIve ae COVER TERIINAL (PART OF MEM 1) AND X END OF WIRE r mage Ser (reat 8 OR ew 12") Using HEAT Sumi er | pf [eRe ose: wine TOBNG (rea°6) PER DEAL A ik ben 2009 FOR ALTERNATE SOURCE POTENTIOMETER, SEE OETAL B. L 7 BRENT e woucten D 19 NOT IMMERSE POT ASSY IN ANY SOLVENT OR CLEANING SOLUTION a Ein ceoe H, Nop" Ste SF natese DETAIL ROTATED Sot Sptacts . x20 = 20 SEE DETAR A \ / OR /8 sae ¢ \ {3 ruces Now cow 5 ) ea | — ag c L700 +80 7179-008 [TENG NEAT SHRINK 250 10 L 350875-001 P ROTENTIOUETER 5k On, 5 TOR 018324-002 | WIRE SET, GRADE POT ~~ 9 | ot6212-002 | PoTENTIOWETER 3 On, 10T © 1[7}e| orasae-oor |wRE Seq, GRADE Por & 7] oeteteD 3 6 | 009175-001 | TUBNG, HEAT SARINK 125 10. \ 5] _peLerED ow oon Ae | ~octereo super $= [id 3] @ia7as-001 [Pave, KEYG TONG NOSE v cow ai i's 2| 012750-005 [CONNECTOR HOUSING, LOCKING | RED, 6 POS., 22 AWG 7 1 | 016212-001 | POTENTIOMETER: 200 OHM, 10 T - 003 | GRADE POT. ASSY. 1 B SCHEMATIC DIAGRAM = (002 | GRADE POT. ASSY. ae sec oem a —/ ETAL a 2 | ubE POT_ASe 3 PLACES, = oul Gr = ARTERIATE POTENTOMETER ~ [ere 7 man wero Te {| Reoeme were Phare [om | 030651 o00336 | AB Jio[ om + brag SEAR _{aevee . 030659 000335 aa eee eeee D.EDWARDS _|s/0/es — | PRODUCTION TRICE: QUINTON CONFIDENTIAL P™ pover erm 0130s. | 000208 ati aka AT a [mame [oe mw SP nist mu Ss a janine 21D 013089 [P. om) sara por [= 56/7) | ae aoa oa [RE aoe [aon es T 7 T 6 5 * 4 T 3 2 1@)-co4 oy : 003 ONLY \ @® - 002 oney -001 ONLY OE ) & 1, BAG OR TAG WITH PART NO © REV. 0) CLIN TENT ION USING [E> To insTaue Beagines iTem 4 EORERSE SHAFT AND BEAR IN EUKFALES WATH ITEI 1c PRES No ITENM TE(LOCTITE 480) bck othe 0 ROFTL wT BEST TEM 1 ,OvER END'S AND FACE KHIGH CONTACTS JOG, 8 ¥ STEM 5 TS, MEMO PRIOF NTEMS, CZ PLACES, © ITEM 7 SNTO ITEM 1 OVER END. ITEM & ONTO TENA 9) UR.TOWHICH MED, B OIL(TEMIS) 52108 TO 1 20S/TION INDICATED. TOMB AND 1b OF HOLES TEM G)-7-409 S| FRAG RAD MES FLEE TC RESIN OUT TBAT, USNs LICTITE PEM) 3 TO PRESSING MMIC VER END A’ TO THE SETOTEM I PRIME EST < PARTS TOSETHER ORGNE (LOcK NUT)iTEM Ho OF THE Lock ALIGNED ZLOT NTQ KEYWAY OF ITEM |. PRESS ITEM ay OF TEM 17) TAEADS, SHER ITEM). eer eae bean NOTE 7 SOU WAS OET LES ay pen low} “am gta een Bee ene, TION Bee ieee [FP fot PRODUC ener ee rere Tees Ce conrenennon SFE PT ©) DSP KEW ASKEMBY D Urine 3) c rem) SECTION A-A 0) © 2001 SHOWN =OOL, 0B 6-004 SHNAR CEPT AS NOTED 7 VO MAK a SISAS= OO] [RILEY RARED GSTS 2 a a oral [oI 2] O12 465 =OOT [COMPOUND RETAINING [Loc TTTE Soy ———| ——] kat Diess-001 —[ABESVE ETE aE it peceTeD a= g 4 S.0633-1as | sent, Se e0-20x.28ue|IZ/E|2} 2 [10/012 500- 007 PIN, BOWEL EDIE. R'7500G——— | i oi@579-G01 | wick,oiL TIT 19 10129 8e= OOF [ROUSING BEARING. TAWA MACHINING] — = [015-400-091 —_| PULLEY, MACHINED ESUCET- GE TIT He [00G853-G01 [BEARING — [Sain D.¥ oe MMOD. HHT] (OF =| = OOS INBUT SharT assy. [GSO TH Ty [7 {orseee-oor | Sueave ASSY, WUT, = 7 ft |* [1 feforsz3e= cor fwasuer, Lock Tir}r|t}E{oysoes=eo% TED [-~— Fy ibefe ert NUT,LOCK, SPANNER E) teered eas —— | soz [PRIMER 2 [4 |515307 “OO |seRRING BALL MEO aif att oi COMPOUND, RETAINING 1 [O01 100-004 [KEY, SQUARE BT X 150 T | 7 PUT SHAFT ASSY._ 1] 7] O15 362-001] PULLEY MACHINED | 16-3Ux- 4.92 %.e25 1] =f |ote487- Oo [PULLEY MaLRINED: [Tt] 15249 -CoWINPUT SHAFT, Hvy DOTY GisJOrsa tT = 062 JOIL, CYLINDER. SYNTAETIC HYOROCAREON | [AA Cor PUT SHAFT ASSY_[Os's aa ! ] clzant nuwBeR | _DESCAIPTION [MATERIAL srzimexnens aren cecnenon were wecneon ¥ PARTS LIST aaa i = EEMEUERT wen 3 i on Bae i & Soy INPUT SHAFT ASSY, =003 [o13032 [50259 fo fe HEAVY DUTY ee C af oot | Ree aa [ae a ae ra anes assem ra > 15273 aT owt Sct onan Pee Pom ae 6 5 4 3 2 1Focn: 3768, 43584.010 eee ETOP Nowe wooo, fara77| nevoon ve G PRODUCTION SECTION AA SCALE, PIL CONT. ISAT = Goz [OIL ,CYEIMIOER [SYMTRETIC WVORDEMEOH ASSEMBLE ITEM 6 TO ITEM 1OVER ENO'B),UP TO ITEM2. Set soe [On eee ACE ITEMS IN KEY GROOVE OF ITEM1. SIDE ITEM 4 OVER O10157- 003 _| SCREW, SHLDR, Hex SOC [7S 1 OF INC-A PLACE ITEMS IN KEY GROOvE \TeEM1 r 006875-001 | CHOPPER. BEAM END OF ITEMI, FIFTING KEY GROOVE OF ITEM 4 OVER : TEMS, 073049- 001] SPRING.CVL HEL p15682-002 | SHEAVE ASS¥, OUTPUT OAK OI WICK (ITEM 8) IN CYLINDER OIL (ITEM 13) BEFORE oe eo es pe a 13063 -OST TD ISERTING INTO ITEM 8. Pe 051803=004 [KEY, SQUARE. (230 5Q xZ001G. SLIDE ITEMS 6,9 biz QvER END'B OF ITEM |, 18 |O1@579-O57 [WICK OIL 330% 72, O'SBSz-007_ | SPROCKET ASST, TIMING IDE (TEM 1 ONTO sTEM 11 Ano APBLY AONESE TET TO THREADS (015233-001 | ADHESIVE, Loctite 242 | CISS07-CO1 | BEARING BALL ED UMi| San S088 22 aa Bye NOTH PEt PRIOR TO THREADING TEM ITS ENCE GF ITEM Ie aL DELETED ; ee OINSTALL BEARING(S), ITS, 7O SHAFT WITH LESS THAN OS, 51246.5.008 [SETANNG USAIN OCTTE SEOE| [o1S808-O0)_| SHAFT, CoTeUy Remy Out CLEARANCE. CEGREADE Tee SuahT ITEM 1. ANS BEARING, Biaas0-Sor Weave = =o | OUTRT SHAFTASSY, SEAT CTY SEM 3. 15.. PRIME AbT SUR Aces Ath LOCauIc PEIN T, TEM (a ANO'eIT THE Put TOGETHER UNG LOCT ITE C80, PAT noueeS © BSG NOT MOVE PARTS FOR GRD. AFTER ADDY vv vy VV fuaTemia sbec nomenpee vant men enon Toren Sans Bae OR TAS WITH PART NO, AND REN LT. TO WhIGN MED. = po Fae [2 — OUTPUT SHAFT ASO. Me ssieins PO eeeNotes: [E> crey Pes T° (ITEM 12) 0210 TO APPLYING RETAINING COMPOUNDLITEM 7) TO. SURFACES OF SHAFT(ITEM |) ANDO PULLEY (ITEM 4) PRIOR TO WISERTION OF BEARINGS: (r1ems 345) INTO ORIVE PULLEY WELDMENT (ITEM 4) MARE OW TAS WITH PART NO AND REV UTE. TO WHICH MFO. [So> Use ane0e sina (ITEMS 104 14) AS REQUIRED TO ACHIEVE .COS-.OIDEND PLAY GETWEEN ECARING(ITEM 3) AUD RETAILING RINGCTEM 2) nn) 7 6 PRODUCTION =oor_[ois723 [oooz0s DART 12226 REVISED NOTE 3 RELEASED TO PRODUCTION EFF T:7, DISP:Use. — DB aeons | PA ew a B (8) 3eeaD ic i 0 oo pal o]oTaSOO-OOT [eee q =} felis o13399-o13 | Shih ARBOR 375 DESO OS e Relioforss09-o4 [oui ako ESS YISIS OO # ceo 1 9 Jowses-oot [spec ee TNS: 3 |e |oiosse=n2 —fECee w capes SaeeT he — PRR ERTEETS 7 7|oieses-00e _|cowmOUNG RETANING [-OcTITE "CBS 1 ]g]oowss-o15 enc eTARING, ExT 1 T}sforazen-co1—|peatnc,exte SSDe ODT ASTD ATRL ~ Ts foress3-cor webu 0eNe PTET + [3 Joiss59-oo1—[aeanng om SARS COTTE TARE 1] [oors2= cos enc, ce raniING, EXE 1] [oissse-Oo1 | srr cee PULLEY = =201 [PULLEY ASS, DRIVE E a =a 3 sae lt wane ae CO EEO an i ats a Ey A Pg Se pre) mene mals - PULLEY ASSEMBLY, DRIVE ear ta : as 3 as [OIsssi Tk ze Tr [oer ertTeton aL BEDE Seo mov coene = P| Seer eae, SoS EE connec moore KF ess \ es W@ Tee \Sie wores PRODUCTION @ ABELY PRUAER T (\TEM &) POR TO EDELYING CETAINING COMPOUND (ITEM 5) To SURFACE OF TUEE(ITEM) 5 INDICATED PRIOR 10 PRESSING BEARINGS (ITEM 3) INTO ENDS OF ITEM | (O1SSES=00S [SWART REAR PULLEY Maw< OR TAG WITH PART NO. AND REV. LTR. TO WHICH MED. 002 | PULEN ASEM, REAR 014900-001_[PeIvE T (01589-0513 — [ARBORS (SE DALEE OOK Uke ina (TERS C17) AS ceayRcO TO KEMEYE. 005 - OD END PLA. [o1ss93-s13 | Akeoe SAM Lae DxLETS xO wi iG ) INING RING (ITEM 4) = ! a BETWEEN AEARING (ITEM 3) AND RETAI ING (ITE! Jores65-002 | COMPOUND, RETAINING —[LOCTITE =460) ASEEMBLE PER ASSEMBLY PROCEDURE O18252-80 . J00i032-009 — en. BETANING, EXTERNAL] 272 10 + OSOTHE 5is3e9.001 | BEARING, BALL 30 IY 3.19% OREO! [ores58- oor | SHAFT, REAR POCLEY. [o18357-O01 | TUBE, MACninED EAE PCLEY| ~001_ [PULLEY ASSY, REAR Osa fe | 031876 at fof O3aTT ac C317 a aE oa pane HF QSSQGS8 | 7 6 ) > > pe A (a> = - A Ni UNLESS OTHERWISE SPECIFIED Ls ell S. vegn OTES: UNLESS OTF fratos(at ene ls R6, RO. RIO, RIN, RIS, RIP, RZt, R22. R23, R24, R26, RST rr Pt 7 ISP. NONE | La] Hoe 7 D| | woe ate (wa [one THESE COMPONENTS STALED AFTER ATE TESTING tonto "0 concur . POsmON PLASTIC COVER (PART OF Sit) SO THAT THE ViEMNG Conn oe 88 WinbOw 1S OVE OSHON 5 ON Swi Jet" C000 HHO ONE OF RLOSE SPACER (ITEM 62) TO BE SNUG BETWEEN LED AND PCB. a PLACE INSULATOR (EM. 64) BEIVWEEN DEWCE (Q}, a2, 014, OF RI) i) DISCARD MOUVING HARDWARE SUPPLIED WITH SPRING LATCH (EM 65). SERALZE WAH WORK OFOER AND OASH NUMBER (001 THRU —OxK EE BER" QUT ml GO) anh MARK. APPROPRATEREVSION LETTER IN AREA SHOWN MASK THIS HOLE PRIOR TO FLOW SOLDER. 1] 1 [25] oos6z7-00r |es, wr 100 Ons, 1780, R50 = 1] a [ze] cosea7—sis [res wr : 8.1K OHMS, 1/8, 1% Rao FOR SCHEMATIC OIKGRAM SEE 018533~201 REV: NEW, OR SUBSEQUENT. atrtal cones free we SEE — FOR ATE TEST PROGRAM SEE 018533-861. — ~ meee 2a [za] ovzis-rze [reser lees wane | C 081 AND 052 MUST BE FROM THE SANE VENDOR eG 1 om 17, is 0S3 THRU OS6 ARE MOUNTED WITH THE FLAT ORIENTED OPPOSITE OF THE 24? {20} consa7n252 | RES, MF ean FBR Fist Sout SusseeteN 3] 2 fra] oaes-ra res or "00 Oa om ess SOCKETS (ITEM 61) MUST SE SOLOERED PERPENDICULAR TO PCB (TEM 1) 2 [2 [ve] oosezr—ze2 | es. wr 5.366 CUS, 1/80, 1% rane | CAPACITOR 030091-001 MAY BE USED AS A DIRECT REPLACEMENT 242 [1 cosrze-ort | POTENTIONETER — — Pram os0001-008 a [fool crs oc. Om 738 Te 16, R25, R28, RO 2 [2a] eras [ns 750 OS, 7a, maa S| 3]12| o12res-o22 [res, cr 22 OMS. 1/44, 5k RIZR19, 29, R20, R73, RBI, RB2. ae = 2f2 |) erzs-owo [res. or 30 oI 700 3 Ae vefralo | ovzre-aea [ies er ta OS om 8 be 03, 04, 08, 012, a5 3[3 [6] orzes-ox [ees or 100 O03 eine «eon ovo on on ov8 tps z oer m as a ra vr fe | onrer-oo pe. ear cas 6 somes ou os een vfs eteste-aor_ fe. unm. vnce cowewiee ies 5 tLe] 2] -ewstr-201 Je. user or ur rato vw 2, C3, C4, C16, C23. 2[2|3| orasao-o01 ic, unear, a/o Converter wun v2us Le] | cersnacoot|pcs, wan tar conmouth |e 6 8, c13, 622, c25 Pena, =[=[- wa [roar won tenoucommous - IBa'R Hai = NE or rca ee mo common R2-R5, RSO-R6E. -002 a iar sro ersnetal T= — al-|e Pas a ~ ON 002 ASSEMBLES. REMOVE ~001 AND CHANGE TO ~002 ele = cn [oa | Eee A FE PF erossxan | we PCB ASSEMBLY, a PRODUCTION ROUGE QURION-COMEDENTAL Fs cums [um] MANUAL TREADMILL 8003 ee T CONTROLLER ‘00781 Savion hes ett ee en 7 wm Seer oCaaie SbPios aaa acted [ 2 |o| 018533 SO peg PE Gap |e oe ree PT 7 6 4 I 3 2 1J 2 Ll “ 1 ' D 7 [> [eo] osis-on[remwna, War pon cer 2 [2 [sa] overoe-oo1 comecton, wiv mene, rob MoU 3.8 [Joe] ora707-001 Jeomecton, o-sue, verrea wowt [25 F050 2 | + [Jor] oraros-001 Jeomecron, oer, Rent wae [14 Pose a +] ]s5]o1asee-o0r [emer Rote Sore acto on 1] 1 [ss] oras-o2e [ewneron cere oF a ee 2 [2 [se] oissse-001 [omer row 10 wh 250 een 2 [2 [ss] ov7ess-o27 [eamanee, eau OF 2 of 507 coe 2] 2 [22] onoss-o1 |camaror, ccmawe OF ce eeu [+ ]51] _oiz923-019 |aracior, ceraue oF 21 oF, 87 iE c 2 [2 [20] _ctams-o0r [earvaror, ccm OF 100 9 500 caer 3] [e9] _otames-c2s_feamoron, exec om 1 oF 507 Be 3) 5 foe] _cossataoor |camoron, ontnua 7 sf, 360 2 [2 [0] eneas-oa_|cneton comme oF od «| « [oo] _o1szns-o0r [oobe, vent curine reuiew 2] 2 [4s] o%esse-o01 oar, ico ‘ros 1] [+#[orsoss-o1e [oooe, zener s2e2 Net 72]:2 [+3] _oneer-cor Joon. some wae Ee +] fea) conos-oor |i, vane nesaaror ‘rae wa 7 Tf] omtenooe |e vance seouon ro ol q + [1 [oa] arzees-oor | waar, eur, Won PontR wes ae | @ |e [22] _otors-o01 | mason. pur, Low Powe zo? Br ie 2p 2 [se] oxssey-oor [meron Ft, n-wmE aussi war | aif [cnnes=coi exe necTst to cE fe orate temas cea aes Fi es fe | ri] wvzsercoor wat ex ees 2 [2 [36] oraeie-cor [sont nest Fone wae e108 Le el mare fay toe ome oe i LF [est connie fae | oma vm ren a} +fee} ore 162 [ren mown, Paw PPS [eS EA KTR 1 [ [24] crates ora fres, ef 2% OMS, 1/4, fa = [Joe] _anencens Waser oex, REN STAR “ 1 [+ fas] sae6"oo1 [nes ce oh 3 Ga io = [efor] ovoeer-s0; |sonen, wicnne, rvs, Peurs evo em | Sfsfe] omescor [aes oF ~ onus, an, 5 R74 2] 7 |e] o00ses-001 | sence, wx, REED ym ala[s) omen eso 80K Os 1/48 Se 908 =| [es] orare-c01_|uaten, see _ = oe 7 200K Onsen ed «| fee[oraseeceor [asuaron,To-z20 recess an oz ove + | [25] osaiee-oso [mes or 30 O10, 1728, 5 ss [fea] _orrre7-aor ens, 10-220 fom vata, 02 ar [ops [eal ovaear-oi0 Yes, wr 20 Ons 1/0, eo a [efee] otases oor fame, uo se as [far] coaeero2s foes. SSSS=*d os es | ale lerl oveers-c0r eer, mp0 oP Fon 651,082 =r S685 2c ans. 7on 8 sn i a ; a CE ets]: ; 0 A VE . PRODUCTION co a : 2 Ssoal pase zas 1PRODUCTIONNOTES: wcess onesase sri, 9. AST FERENCE eStOQATOR Ses RCD CHER Uy, IC POWER SUPPLY TABLE bE a ; : PREPRODUCTION. "SCHEMATIC, PCB ASSY MANUAL TREADMILL CONTROLLER alle Im rey l= 1 econ 0 NOT SCALE paawina PRINTSMAGE WITH PART HUMBER ALD REV LTE TO soon, Ti EER we WOH MED, AO MARK CONNECTOR (TEM 4) coat Saree 53 OR (-TeMi!) P10. purse aes he CUT AND STRIP WIRES (ITEMS &-9) PER _ ne en 7 i TABLE I. pene PATbotE kaooe ane canons ["aRe Rao peasant es fess SEPT oe new pan Fal. bere ANODE (+) CONDUC OTHER we (REPRODUCTION, OASH, MUMaEnS CATHODE, =ANooe (+) PRODUCTION Lae ea 2B RPO yy cons swt ie ——com Doe | Switcin AS, RESET 2 sve wn NO CLL ses 19935"- 001 | PIN, CONTACT a ee Fe (©10603 = 006 | WIRE, WSULATED, SANDED | ~ GREEN. 2 RWG = 003 RED, 2LAWG. weg ey = 001 BLACK 22 AWG DIOEOS= O10 | WiRE, HEUATED, SIRANDED | WHITE. 22 AWG 19090= OOF | TEMA, FEMALE 1SCOMNECT (O1@5°78~ GO3_| COMECTOL, LOCKIiG HOUSING 22 AWS] 4 CONTACT TABLET 019006: 00! _| LENS, SWITCH, RED SRE (019005-001_| LAMD,LED RED (@19007- OO! | SWITCH, ELECTRONIC COUTROL PUSHBUTTON] WIRE | ITEM LENGTH = C01_| swiTcH 455Y, RESET NO No. -001 | -002 ITEM! wi e525] 30%5 i we 125 3.02.5 mn ws 25 3015) u wa 12525| 3025 u ess onan wee [Yandel aoe mh Pa Boos rea Fe SWiA, ce a5sa65,mae Teneo Terms [oat NOTES: UNLESS OTHERWISE SPECIFIED © ADEN 26846 scones : . REDRAWN ON AUTOCAD ee 1. APPLY ADHESIVE (TEM 11) TO ALL THREADED FASTENERS TERE ai BF BERE 09 hast: - — oeeueeees AboED Stara te O5i47S 10 ‘is p] Boas sr (reH 9 or aerate ov 002 mo ~ots SQo2 NERY ASS NO bal 3. TORQUE THE SET SCREWS (MEM a) TO 304.8 IN-LaS >} action cove: #4 Arie penis UOTE (ew 41 Noomen: 7/15/93 : H ADO: 27569 SJ tons] TABLE 1002: Wi LENGTH WAS 570, we de WS. STA LENGTH was’ 3 Acnow cone: #1 Noomen: 8/27/93 ‘Pow: 27288 ‘ADDED 003 CONFIGURATION t— ACTON CODE: Hs |__| Mooiren bare" OF weveAse c c T]= |= 5] esbe00-o1e | emo, SCoRS, ANS [do va=16 awe >| “4 [4] [1s[ 001162~007 | WASHER, LOCK, EXT STAR Ho =] 1] }r3) eoiaes=o01 |TeRwNAL, DRS, GLE SPUCE 22 |= [12] o3dco0-103 |Yemmnal, S.oms FeAALe a | FewALe, 250, va—16 NS lar|ae}an|11| orca01-00t [amnesne tocmne 222 = |=] ie] 012685001 | Yemuna. Scores wale TAB — {= {ifs {ors307—001 [CABLE ASSY, SPEED CHNG wot | 2] [ze [owass—i44 |Sonew. set Tio=32 x0 B 4 [+ [2] 7| ooties-o03 [wasner, FLAT fio 4) 4) 4) 6] 010827-224 } SCREW, MACH PNH PHIL #10-32 X 625 1] 1] 1] 5 [030449-001 | kit, CHAIN #25 t[+[ 1] | orei90-00r | spRocxer, woo, 24 Tom T+ [a] 3 [eotaae-oor [kev, souaRe Bou x aS Xa t[tfrf2 [ ore00s-o0r [SecKer, SPEED ONG _HOTOR 1[e[ a + [ores72-o0r [wotor, 90 voc =j-|- 003 | MOTOR ASSY, SPEED CHANGE | aa REE] =NEE 20 {MOTOR ASSY. SPEED Ciwce | oo |_| BE =ENE 001 | Wo10R ASSY. SPEED CHANGE osiars | SB884E [nna | oe oa eee oT | SaBHE slats’ 7 oo oor | osva7s | Spgs FS | Rg [ os oes Ps pace [ome AL [rovers o00s13 | AaB Pe oncer have, ores | 880588 _| Ge QUINTON COMTOENTL Ps nomen Toc] MOTOR ASSEMBLY, 81) grasso | | S00380 Began pus cmt, Pe fae LO SPEED CHANGE ‘ | 808388 PRODUCTION See oa otc [F,_DANESHEAR eh ge eee = ae 0 ow ee Beassein ssc 3 #@ |" 019130_|J re seco | Be NOTOR [awa sar oom PRT oe [ET atoco [ower To? aa ; T 7 T 6 ] 5 a 4 T 3 1i | 6 | 5 v 4 5 ' - : —(16.00) + / __ (@00)=003 {77 18.00)-002,-003 @rn cea (= Sn J _. C= B= ¢ is \ A he —001 SHOWN Lae —002 & —003 AS NOTED Edens, ee = exo | wn —002 ENO wae 003 ]_END we no. | uenora | stm | mew [we wo. | unm | sree | ire | wre no. | uence | simp | Tew wi }eoo+so| a] ro | wi |ecoe sol se*&] 13 | wi [ooos.so| oat] 1s w2 | 8oo+.so[ sata] 10 | wa [900e.s0| 41%] 12 | wa [900250]. °8| 12 [ws Teor sofse233[ 10 | ws [sooesol aa) 2 | wa [ooorsol.%| 12 PRODUCTION @ [019130 one [=F awtoeno [ent Do 7 6 T 5 4s 4 7——s | 7 fe tw tz NOTES: UNLESS OTHERWISE SPECIFIED i io APPLY GREASE (TEM 17} TO THREADS OF SPINDLE (TEM 1) APPLY ADHESWE (TEM 12) TO SET SCREWS (TEM 7) AND THREAD > SELOAWESNE SUM SS TREE SEEPS A LE ou, Baki fra oF p Fonte soit Ge Sie iS SMe sonoue ye senOn (oH 8) comnts, oe Se fa 2. gk oF sence cw sngeD one ELUNO, SOs oie 8 B APPLY ADHESI To Fe IDICATED. [Bo> appLy ADHESIVE (eM 12) TO FASTENERS IN “eon fal [E> ASSEMBLE, SPROCKET ((TEM 4, -001)(ITEM 18, -002) TO SPINDLE ‘mevs.on LEVEL Ue Pret} aS FoCLows, e SSR te A NR o. Bienes ARR SP Maca ta c C, INSERT WOODRUFF KEY INTO SPINDLE KEYWAY. APPLY c Sea UNT ASN: Mace gay o> AER Gites Salsa Pi Set Sette gers ‘ASSEMBLY TORQUE: 10 IN-LB 1 |= ]18] 019547—002 [ SPROCKET, MODIFIED 36 TOOTH (STEEL) Be pan rce-co [ake case Fs SD] Ewer apneswe (ew 19) To SET screws woIcArED. ra |an|15] G14g00=170 | PRIMER, *T Locavie ei [E> |_|ae|an|12| 015285001 [aDnEsve LOcTITE #242 ‘| 2 [2 [10] 019872-001 | WASHER, FLAT, NYLON 38510 X 62500 x 230THK e [1] 8 | o10821-202 [ScREW, cap, HEX SCH 6-32 UNC x S00L s B 2) 2) 8] o0r172-008 | SCREW, SHOULDER SCH ‘S1S—18 UNG X_375L 8s 2(2[7 | o10833~205 | SCREW. ser 250-20, FULL DOG _ 1] 1] 6 | 019004—002 | FORK, SPEED CHANGE e if] ctesaoor |me, eacn [i] eosssor [acne ser —— I ae lel ra SEE | Gs UE Topo san oe] uinton. | TBARS om AY 002 | S268l5 | S50833 a attra] se = == GMTZENEWNER Jorr/e A BEE font ||: IE ce Lo | e3aag1 | 000822 NOTICE: QUINTON CONFIDENTIA. ["% SPINDLE ASSEMBLY, t woo | $1383? | 900313 Tie aee gums Sorpeine meparyan (8. TRATHEN ern PEED 018330 | coos wav Gans PR CTI cet & Gamma Penson [OR SI CHANGE Biss [oss ODU BE PSS EET acs lunnl x aoc 7 ie Te Sie ow comin Sieh a wots eG D fou} 030262 Cc SPI TT RED 0 wor scan cewns [AC ann _[" nyrocap | sveel 1 3 |s07] _oevere0 “06 Dw Taso 7 ADON 18800 ‘S.cozan] yin EM_& WAS 019004—-004 sets REVISED FLAGNOTE. 2 Mos. hess ale 7 6 * 4 3 2 1[2nd 2.) 2220EC PRODUCTIONt / Anitem 1) (TEM 11) Ares 2) SECTION ATA, {ITEM 4) -001 (ITEM IB) -002. ((TEMB) 2 ueaD PRODUCTION 292060,UNUSED OEVICES 0 a aPREPRODUCTVeale] toe-seaeo 263 gpee0 wor + resco #15 6 xe woePREPRODUCT LON I st "| — Tt ae —t-> teal ay Beh ) !‘De [” 0s0626-201 | 2 meawie 2-2 x weno 91m nic tl x sevove POW Vo] 108-2500,@ IN lm jon 4 + 0 NOTES: UnLess OTHERWISE SPECIFIED ° OOE0 Has 4 AND 13 raed [>> waterai; 10 BF SUPPLIED BY VENDOR OMY THE ITEUS DESCRIBED ON THS BE) Rees ebay eat se wade l ORAWNG WHEN PROCURED OM 0] | ies tae nae 8 Se D 2, ALL PARTS MUST BE PER DRAWING RECOMMENDATION. THE VENDOR(S) LISTED HEREON REWSED FLAGNOTE & |S APPROVED BY THE QUINTON action cove: 4 IGN ENGINEER i sch [32> Pemwanentey waRK Wirt QUINTON PART NO. DASH NO, REV LETTER Ih ine sPpusATONS SPECIED ark 8/39/08 TO WHCH MFO AND VENDOR IDENT IN APPROX LOCATION. SHOWN By THis DOCUMENT. NUMBER _| _ SuesiTUTE ens Shalt NOT [E> THs component Must BE CERTIFIED By A RECOGNIZED TESTING AGENCY BE useo. TO COMPLY WITH APPROPRIATE CSA AND UL. STANDARDS. — Sew ake [Bo= Motor wires 1, P2, 12-15, 18 SHOULD EXTEND AT LEAST In 4 INCHES FROM WOTOR CASE ere) STRIP WRE PER TERMINAL MANUFACTURER'S. RECOMMENDATIONS PRIOR TO CRMPING 7. INSTALL CONNECTORS PER MANUFACTURERS. RECOMMENOATIONS. [E> we wsuLaTION DANETER SHOULD NOT EXCEED MANUFACTURERS a 002 | woToR ASSY, ORWE 7_]_13888.00 001 | WoTOR ASS. ORWE 1 173866.00 c > WIRE INSULATION DANETER SHOULD NOT EXCEED MANUFACTURERS = met wow we mer c RECOMMENDATION FOR TEM 3 [D> nor stows, SOURCE CONTROL DRAWING [i> wre nsuvaTion DANETER, SHOULD NOT EXCEED MANUFACTURER'S RECOMMENDATIONS FOR TEM TS. [P= ws GecTRICALLY CONNECTS ORECTLY TO MOTOR FRAME WITH LESS PE THAN ONE OHM CONTACT RESISTANCE. >| 6 As serie Poreye es Ths TER, SOLDERLESS, RING FO [ HOLLINGSWORTH, xRI9035N A=" MEASURED FROM THE CABLE CLAMP TO THE END OF THE TERMINAL i WaIA/R| 14] | WIRE, INSULATED, STRANDED 14AWG,600V,UL1015,GRN/YEL| w5 vp hl fo CLP, CABLE REGAL, 6625-3/8 3 wala [1 WRE, INSUATED, STRANDED | 14aWG, 6O0v, ULIOTS, BLU Morel ec enone T_Iwalua oC WIRE, INSULATED, STRANOEO | T4AWG,_600¥. ULIOTS, BRR] S1_|welwel ol [ WIRE, STRANDED BANG, S0D¥, ULTOO7, BLK S1_Iwalval 9 | [ WIRE, STRANDED BANG, S00V, ULI007, 0 B wet MAX FULL LOAD AMPS 16.8/8.4 AMPS bs. fel fe Key D9 x 138 L wea FRAME sen semvee Factor 3.18 scien 4 ne “th SS AED : LUG, KEMNG —_. FLUSH | aw, 6408291 ENCLOSURE OPEN RIP PROOF LocKED ROTOR TORQUE ___ 15.8 B-FT bury exc ___ cont ete FOr REMNe tet SSE] a po ze 1425 @ RATED LOAD LOCKED ROTOR AMPS _ 46.4 AMPS MAK ee eee “ele TeRw, SLDRLS, CE SPLC AP, 35853, Paase sine. BREAKDOWN TORQUE —___ 13.6 \B-#T MIN INSULATION css 81 AED TERNAL, SOLDERLESS Tas, RO2237 4} rcouener 50 ne owen racton aa rotaion —___ ow otron gt a tea0 eNO ‘Tt ®VE MOTOR PER SPEC VOUTAGE —______ 110//280/240 VRS —_EFFIGENCY-FULL LOAD 74% e = cogil MamRTiesveoRNe TATE roles eae woTOR TYPE «op 78% oad —_-- =RE 001 [MOTOR ASSY,_ORVE 1S He, 230/240V, 50 HE VOLTAGE RANGE 100-132/200-264 VRUS 50% LOAD = a nuh caer aun waren | EE, pRorecton auto ctussev a — =e TT] gL ewes onommse orereo ["3. Coroa frm] Quintore [gases aaa m=: oes vem Presenenss | _ te A LY at Jin] ta 2 ey [Beree-coman fies: Fe A SB _|ea]" ce = oe [Pe rset fel 7 NOTICE: QUINTON CONFIDENTIAL FPS. curron [vere ]OTOR ASSEMBLY, oo | o30ss? | 000338 N i sen Rene cot SE PSR Pte aoe ORI ees PRODUCTION SEER ease toe ORME rare [seat mors | 0 orm ne CEE ot SC ra is a ens 3 {D] 030656 __|D Fecenron TO yOTR [ER 085//7 | warant mee PT vee [PRC roo [oe Te 8 q T 6 T 5 a 4 T 3 2 1On LEAD _END7 6 ! 5 yv + 1 E Lu orm 6 4, 1 st WS BLACK Stowe a mes Pm 2 / Qs 100 8 et — = 16 ct SS. en wwe, ova \@)rm : En wt | 45 Tae WS GRN/rEL \Q@ “we ewra a cD) re00 001 _250/240V 50 H2 SCHEMATIC & WIRING DIAGRAM VIEW FROM OUTSIDE OF MOTOR AT SWITCH END, 001 _230/240v, SOHZ 5k ne uestOn 10 EXTEND sa SE 25 INTO CONeTOR MSULATON ws erom Shar (a § Sa ogg em me fs ME pe eI Pw 2 we WOT _¢ py 5 Le P es | Ol al SE Le 2} Pf 3 wa VIO W2_ BLUE 4 a roel <2 ‘ 7 one NO): ecoo o, = Ww aa es * 1 Qs SY @ sane wll I WS_omvret Yo = \@ waa 2 3 Rao —002 110V_ 50 HZ SCHEMATIC & WIRING DIAGRAM Wwto Coneeron nswuanon "OF 28 PRODUCTION om [939020 e |” 030656 [0 7 ene [roe [ae Se 3 5 * 4 1NOTES: ae, ara = Eh ME ey v3 ht thy ONLY THE ITEMS DESCRIBED ON THIS. SEG, S RS Stew UewGIn, 343 Tre WeNoOR(S) UsteD FERN si" 2 ALL PARTS MUST BE PER DRAWING RECOMMENDATION. 1S APPROVED BY THE QUINTON. Hag Ones UREICATONS:, VOLTAGE. D ESIGN ENGINEERING DEPARTMENT aoe | TAS dee MS, t00eD voLTAcE ance E> PERMANENTLY MARK WITH QUINTON PART ND., DASH NO. REV LETTER IN THE APPLICATIONS SPECIFIED ction cone 11, Mob 6/19/98 By "THis DOCUMENT. NUMBER, SUBSTITUTE TEMS. SHALL NOT BE USED. TO WHICH MFD AND VENOOR IDENT IN-APPROX LOCATION SHOWN, = TWS COMPONENT MUST BE GERTIFED BY A RECOGNIZED TESTING AGENCY TO COMPLY WITH APPROPRIATE CSA AND UL STANDARDS. [si se coe ~WOTOR WIRES 1, P2, T4, T& SHOULD EXTEND AT LEAST INCHES FROM MOTOR CASE [ES=SIR we eR TERMNAL MANUFACTURERS RECOMMENDATIONS E> iid cmH 7, INSTALL CONNECTORS PER MANUFACTU S RECOMMENDATIONS, PRODUCTION [E> wie mnsuLATiON ouWETER SHOULD NOT EXCEED MANUFACTURERS RECOMMENDATION FOR (TEM 7 > WIRE INSULATON DIAMETER SHOULD NOT EXCEED MANUFACTURERS c RECOWNENDATION FOR ITEM 3 : MOTOR ASSY, ORNE a > nor snow 201 : 1 [11386600 [ZE> wre msuianion OAMETER SHOULD NOT EXCEED MANUFACTURERS pceeneesceennas cart a SOURCE CONTROL DRAWING [2 ws LECTREALYY coMNECTS DIRECTLY TO MOTOR FRAME Wi LESS TWaN ONE OMW CONTACT RESISTANCE : [ES AL, wike LENGTHS PER TABLE 1. _WIRES WITH TERMINALS ARE MEASURED we FROM THE CABLE CLAMP TO THE END OF THE TERMINAL ifs] TERM, SLORLS, FING, FiO | HOLEPSSHORTA wRBOSSN [be [aR] 14 WIRE, INSULATED, STRANDED | 14 AWG, 600v, ULIOTS, GRN/YEL| WS 1413) CLAMP, CABLE REGAL. 6623-3/8 = roe cro Tia WiRE, NSUATED, STRANDED | vaRwG, edoy, ULTOTS, BLD] W2 y MOTOR SPECI sual WIRE, INSULATED, STRANDED | T4ANG, 600V, ULTOTS. sRIN| WH § sf wlio TWRE, STRANGED TaN. 300v,_uci007, eLK| Ws fo NEMA FRAME usec SERVICE FACTOR 1.18 AMBIENT 40" C Mak Us jite ues a —|a TPTh Cont H86, EKG. 18 ANG | PANDUIT, CEYSGFIB-7-K ENCLOSURE FEN RP PROOF Locke ROTOR ToROYE 2 LB-FT Dury evens cont he eee eee } seu 2850 @ RATED LOAD LOCKED ROTOR AMPS ns yeup rise 2ts{ f= PLUG KEWNG. LONG NOSE | auP, 640630 ce pase — shoe BREAKDOWN TOROUE 128 LF INSULATION Class_@1 s]s[ f= ER, SLORLS, CLE SPLC | auP, 35653 S| FREQUENCY —___ 50 HZ POWER FACTOR 97m ROTATION OW ROTATION 2|3t ie a 88, 882257 LEAD END =a 2 | TUBING, viNYL (PvC) TYGON, B-44—4x vourase 230/240 ves EFFICIENCY-FUR LOAD _ 80% MIN stn ene — woroR wre xo 78% L010 - : =207 | worok Assy, ORE 30 HE, 2307240, SoHE VOLTAGE RANGE — 200-264 vies 50% Loan _—— tara oaciren mom non | SE, PROTECTOR ecvs0ov auto . —— = — s]5] 3 eco foe] Quinton [ani an TP] eps [OT Pecan reece et aren A T 307 ef FOS fesse, oe MOTOR ASSEMBLY, 3 90030 par ao E oot ee 00308, 30" Kouey pow ORIVE 1 030650 000335 cxaer [US MOTR *s.cunran feat mare [wen | pe ror ok =e Dl= 030658 To BO 3 4 3 z 7TABLE 1 aa wax WE NUMGER | WE LENGTH w2 la. DETAL A SHAFT _END 6250 P6245, ETAL A PRODUCTION001 _230/240V 50 HZ SCHEMATIC & WIRING DIAGRAM a a 01 250/240, 50HZ VIEW FROM OUISIDE OF MOTOR AT SWITCH END LEA WIRE INSULATION TO EXTEND MIN OF .25° INTO CONNECTOR INSULATION, PRODUCTION