TR22F Repair Manual (Electronics)

TR22F Repair Manual (Electronics)

Table of Contents 1-1-1. Product Picture - TR22F 1-2-1. Overlay - TR22F 1-3-1. Component Placement - TR22F Display Board 1-3-2. Component Placement - TR22F Lower Compartment 1-4-1. Display Block Diagram - TR22F 1-5-1. Cable Connections - TR22F Display Board 1-5-2. Cable Connections - TR22F Drive Board 1-6-1. LED Indicators - TR22F Display Board 1-6-2. Indicator LEDs - TR22F Drive Board 1-7-1. Electronic Specifications - TR22F 2-1-1. Electronic Malfunction Troubleshooting Table - TR22F 3-1-1. Troubleshooting Safety Key Malfunction - TR22F 3-2-1. Troubleshooting No Start Up - TR22F 3-2-2. Troubleshooting No Start Up - TR22F 3-3-1. Troubleshooting Key Malfunction Soft Keys - TR22F 3-4-1. Troubleshooting Key Malfunction Soft Keys TR22F 3-5-1. Troubleshooting No Incline Operation - TR22F 3-6-1. Troubleshooting Incline Position Malfunction - TR22F 3-7-1. Troubleshooting HTR Malfunction - TR22F 3-8-1. Troubleshooting Fuse Broke at Start -TR22F 3-8-2. Troubleshooting Fuse Broke after Motor Moves -TR22F 3-8-3. Troubleshooting Fuse Broke after Use - TR22F 3-9-1. Troubleshooting ERR-1 Appears before Motor Moves - TR22F 3-9-2. Troubleshooting ERR-1 Appears after Motor Moves - TR22F 3-10-1. Troubleshooting ERR-3 - TR22F 3-11-2. Troubleshooting ERR-7 - TR22F 3-12-1. Troubleshooting ERR-10 - TR22F 3-13-1. Troubleshooting ERR-14 - Motor Overheats - TR22F 3-13-2 Troubleshooting ERR-14 - Fold Up Switch - TR22F 3-14-1. Other Topics Basic Parameter Settings - TR22F 3-15-1. Other Topics Error Code Chart - TR22F

4-1-1. Inspection and Measurement Optic Sensor - TR22F 4-2-1. Inspection and Measurement Transformer - TR22F 4-3-1. Inspection and Measurement Motor Brushes - TR22F 4-4-1. Inspection and Measurement Motor Voltage Measurement - TR22F 4-5-1. Inspection and Measurement Incline Voltage Measurement TR22F 4-6-1. Inspection and Measurement VR Voltage Measurement TR22F 4-7-1. Inspection and Measurement Incline Motor and VR Calibration - TR22F 4-8-1. Inspection and Measurement Fold Up Switch Inspection - TR22F

1-1. Product Picture TR22F 1-1-1

1-2. Overlay - TR22F 1-2-1

1-3. Component Placement - TR22F Display Board Telemetry heart rate receiver board Safety key board Display board Bridge board HTR board 1-3-1

1-3. Component Placement - TR22F Lower Compartment Incline VR set Optic sensor Transformer DC incline motor Motor Drive board 110V L1,L2 Close 220V L1,L2 connect to Inductor Fold up switch 1-3-2

1-4. Display Block Diagram - TR22F Telemetry receiver board Display board Key pad 1 Key pad 2 Safety key Key pad 3 Bridge board Sensor L Sensor R HTR board AC1 AC2 FUSE SW Filter Drive board Motor Optic sensor Transformer Thermal sensor Fold up switch Incline motor Incline VR 1-4-1

1-5. Cable Connections - TR22F Display Board To keys on lower part of display board To keys on upper part of display board To telemetry heart rate receiver board To safety key board To drive board To HTR receiver board To keys on upper part of display board 1-5-1

1-5. Cable Connections - TR22F Drive Board To VR set To display board To display board To optic sensor To incline motor To motor thermal sensor and fold up switch To transformer Fold up switch To power supply AC1, AC2 To power supply AC1, AC2 1-5-2

1-6. LED Indicators - TR22F Display Board LED1 power indicator Lit indicates 5 VDC power supply. 1-6-1

1-6. Indicator LEDs - TR22F Drive Board LED 7 MC indicator Flashing indicates an incoming optic sensor signal. LED 2 Lit indicates VCC power supply. LED 4 M-Temp Lit indicates motor temperature is too hot. LED5 INC-DN Lit indicates incline is operating downward. LED6 INC-UP Lit indicates incline is operating upward. LED 3 EMG Lit indicates motor circuit error. Transformer fuse 1-6-2

1-7. Electronic Specifications - TR22F Specification Details Notes Exterior power supply 110V / 220V Motor DC motor (with internal thermal switch) With brushes With heat protection Optic sensor Infrared optic sensor Speed range KPH: 0.8-16.0(KPH) MPH: 0.5 10.0(MPH) Power: DC motor 40V Incline Incline range: 0% -15% VR calibration: 0%= 1.20V; 15% = 3.57V Display LCD display Windows TIME / DISTANCE / CALORIE / PULSE Workout programs PROGRAM 1 PROGRAM 5 INTV1 / INTV2 Heart rate control program HRC 65% / HRC 85% Heart rate HTR / telemetry 1-7-1

2-1. Electronic Malfunction Troubleshooting Table - TR22F Malfunction Circumstance Inspection and test points Components to Safety key malfunction No start up No start up Telemetry heart rate malfunction Contact heart rate malfunction Put safety key in place. Display has no reaction. Safety key appears on the display. Power on indicator does not light. Power on indicator lights but the display does not light. Telemetry heart rate malfunction Contact heart rate malfunction 1. Inspect the cable connections on the lower part of the display and safety key. 2. Inspect the safety key magnet. 3. Inspect the safety key board. 1. Inspect the power cord connection. 2. Inspect all cable connections. 3. Inspect the fuse, the fuse holder, and the power switch. 4. Drive board components have an electrical short. Replace the drive board. 1. Inspect all cable connections, including connector cables. 2. Inspect whether drive board LED2 lights: a. If LED2 lights, inspect and test the transformer fuse. 3. Inspect whether LED1 on the display lights. a. If LED1 does not light, inspect the data cable from the display to the drive board. b. If LED1 does light, inspect the display program IC. Re-install the display IC. 1. Inspect the heart rate transmitter strap and its batteries. Replace batteries if they have not been replaced recently. 2. Inspect the receiver board cables. 3. Test or replace the receiver board. 4. Inspect for environmental interference, for example, from speakers and lights. 1. Inspect the HTR wire connections on the bridge board. 2. Inspect the HTR indicator light. 3. Replace the HTR board. replace Safety key board 1. Fuse, fuse holder 2. Drive board 1. Transformer 2. Drive board 3. Display board program IC 1. Heart rate transmitter 2. Heart rate receiver board 1. HTR board (Heart touch rate = contact heart rate) Notes 2-1-1

2-1. Electronic Malfunction Troubleshooting Table - TR22F Incline position is not correct. Key malfunction ERR 1 Incline position on display differs from actual position. Key does not operate or operates continually. Motor does not rotate, ERR 1 appears. ERR 1 Motor operates, ERR 1 appears. 1. Inspect all cable connections. 2. Inspect drive board incline VR voltage across red and green wires. Normal: 0% = 1.20 VDC, 15% = 3.57 VDC. If not, recalibrate the incline VR. 3. If VR voltage fluctuates greatly, the VR is bad. Replace the VR. If the VR voltage is correct but the height is incorrect, replace the display board. 1. Inspect the soft key connection. 2. If the <program> or <change> key is bad, replace the upper soft keys on the display. 3. If other keys malfunction, replace the lower soft keys on the display. 1. There is no power to the motor; the motor cannot operate. 2. Inspect the motor brushes. 3. Measure voltage from the drive board to the motor. If there is no voltage, replace the drive board. If there is voltage, inspect the following: a. transformer voltage. b. whether the EMG indicator lights. c. whether IGBTs have an electrical short. Replace the drive board. 4. Inspect motor brushes or the commutator. 1. The program did not detect the optic sensor signal. 2. Inspect the CLK indicator on the drive board. a. If the CLK indicator is not lit, clean or replace the optic sensor. b. If the CLK indicator lights normally, inspect the data cable from the display to the drive board. Re-install the display IC. 1. VR 2. Display board 1. Soft keys (upper) 2. Soft keys (lower) 1. Drive board 2. Motor brushes, motor 1. Optic sensor 2-1-2

2-1. Electronic Malfunction Troubleshooting Table - TR22F ERR 3 Display speed differs from actual speed. 1. Inspect KPH/MPH setting. 2. Inspect the optic wheel teeth. 3. Replace the optic sensor. 4. Replace the drive board. ERR 7 ERR7 appears at startup. 1. Inspect the incline VR cable connection. 2. Usually ERR7 indicates the display is stuck at either the highest or lowest position. 3. Inspect whether LED5 and LED6 light on the drive board. If lit, the display or cable malfunction may be causing a malfunction. 4. Inspect whether the drive board emits voltage to the incline motor. If not, replace the drive board. 5. Recalibrate the incline set or replace the incline set as a test. ERR14 ERR14 Display shows ERR14. The motor overheat protective function operates. Display shows ERR14, the fold up mechanism malfunctions. 1. Inspect the motor thermal switch wire and the fold up wire connection. 2. Inspect the motor thermal switch wire. Feel the motor. Is it hot? 3. If the motor is hot and the unit has been in use, turn off the unit. Let the unit rest one half hour or more. Then turn off the unit. 4. If ERR14 appears repetitively and the motor is hot, lubricate or replace the walk belt. 5. If steps above do not solve the problem, replace the motor. 1. Inspect the thermal switch and fold up switch cables. 2. Inspect whether the fold up switch has operated inappropriately. During normal operation, the fold up switch cannot touch the unit frame. 1. Optic sensor 2. Drive board 1.VR 2. Drive board 1. Drive board 2-1-3

2-1. Electronic Malfunction Troubleshooting Table - TR22F Main fuse is broken. Main fuse is broken. Main fuse is broken. Show total distance Telemetry heart rate malfunction Turn on unit. The fuse blows. Press the speed up key. The motor start up fuse blows. In use, the main fuse blows. No heart rate reading, please check transmitter 1. Inspect whether the power cord has an electrical short. 2. Drive board components have an electrical short. Replace the drive board. 1. Inspect the motor for abnormalities. 2. Replace the drive board. 3. Replace the motor. 1. Inspect whether the main power voltage is too low. Normal is 110V or 220V +- 10%. 2. Inspect whether the walk belt is too tight. 3. Inspect the walk belt for wear. Lubricate or replace it. 4. Inspect the condition of the fuse holder and fuse. 5. Replace the drive board. 6. Inspect motor brushes. Do not put the safety key in place. Press and hold the <CHANGE> key for three seconds. The program IC version, metric/imperial unit selection, total distance, and total time appear. 1. This error statement appears when the display IC does not receive the HRC signal. 2. Inspect whether the heart rate transmitter strap is fastened securely. 3. Replace transmitter strap batteries or the transmitter strap itself. 1. Drive board 1. Motor 2. Drive board 1. Walk belt 2. Drive belt 3. Drive board 1. Heart rate transmitter 2-1-4

Troubleshooting Model: TR22F Malfunction: Safety key malfunction Circumstance: Put the safety key in place. The display shows no reaction. Safety key appears. Possible cause: Safety key board malfunction Troubleshooting: 1. Inspect the safety key magnet. 2. Inspect bridge board connections. 3. Test or replace the safety key board. Safety key cable Display Board Safety key board Bridge board Bridge board Safety key board Safety key reed switch test Put safety key magnet in place Do not put the safety key magnet in place Reed switch: electrical continuity Reed switch: electrical open ON OFF 3-1-1

Troubleshooting Model: TR22F Malfunction: No start up. Unit does not operate. Circumstance: Turn unit power on. The power indicator does not light. Possible cause: Incoming power supply or component malfunction. Troubleshooting: 1. Inspect the power cable connection. 2. Inspect cable connections under the motor cover. 3. Inspect the main fuse, fuse holder, and power switch. 4. Inspect the drive board components for signs of burning. Or replace the drive board as a test. Inspect the main fuse, fuse holder, and power switch. Display board AC1 AC2 FUSE SW Filter Drive board Drive board 3-2-1

Troubleshooting Model: TR22F Malfunction: No start up. Unit does not operate. Circumstance: Turn unit power on. The power indicator does not light. Possible cause: 1. AC power supply enters the drive board, goes through the fuse, into the transformer, then into the drive board. 2.Cables are not connected properly, or the drive board is malfunctioning. Troubleshooting: 1. Inspect all cable connections. 2. Inspect whether LED2 on the drive board lights. A. If LED2 does not light, inspect the transformer fuse and measure transformer input and output voltages. 3. Inspect whether LED1 on the display board lights. A. If it does not light, inspect cable connections from the display to the drive board. B. If it does light, inspect the display IC. Re-install the display IC. LED1 power indicator Lit indicates incoming 5V power supply. Program IC LED2 VCC power AC1 LED1 Display board Transformer voltage Transformer VAC (red-red) (blue-blue) 110V (red) 220V(blue) black-black 12.5V white-white 12.5V orange-orange 29V yellow-yellow 11.5V 濾波器 AC2 Drive board Transformer FUSE LED2 Inspect the transformer fuse 3-2-2

Troubleshooting Model: TR22F Malfunction: Telemetry heart rate malfunction Circumstance: Telemetry heart rate malfunction Possible cause: 1. Transmitter battery voltage is too low. 2. Telemetry receiver board malfunction 3. Environmental interference, possibly from lights or speakers Troubleshooting: 1. Replace the transmitter strap or its batteries. 2. Inspect the receiver board wire connection. 3. Replace the receiver board. Telemetry heart rate receiver board Display board Heart rate receiver Telemetry transmitter (battery location) Transmitter 3-3-1

Troubleshooting Model: TR22F Malfunction: Key malfunction soft keys Circumstance: Press display keys. Display shows no reaction, or keys operate continually. Possible cause: 1. Bridge board soft key connections are not connected properly. 2. Soft keys are bad. Troubleshooting: 1. Inspect bridge board soft key connections. 2. Replace soft keys. Key pad 1 Display board Key pad 1 Bridge board Soft key connection Bridge board Key pad 3 3-4-1

Troubleshooting Model: TR22F Malfunction: Incline does not operate up or down. Circumstance: Press incline keys. Incline does not operate up or down. Possible cause: 1. Cables are not connected properly. 2. Drive board or VR malfunction. Troubleshooting: 1. Inspect all cable connections. 2. Measure whether transformer incline voltage is 29 VAC. 3. Inspect whether incline UP/DN indicators light when incline keys are pressed. If LEDs do not light, inspect cable connections and the display. If LEDs light, inspect whether the drive board emits voltage to the incline. If yes, the incline is defective. If not, replace the drive board. Incline gear box Inspect display board cable connections and the program IC. Incline VR set Measure incline VR voltage (red-green wires) 0% 1.20V 15% 3.57V Display board Test incline motor voltage: white-green 40V or -40V Transformer Drive board Incline up/down indicators VR sets Incline motor Measure voltage from the transformer to the incline orange-orange 29 VAC 3-5-1

Troubleshooting Model: TR22F Malfunction: Incline position malfunction Circumstance: The incline setting and actual incline position differ. Possible cause: 1. VR wear 2. Display board incline setting circuit malfunction Troubleshooting: 1. Inspect all cable connections. 2. Measure VR wires to the drive board: red-green 0% 1.20 VDC 15% 3.57 VDC If not, re-calibrate the incline set. 3. If the VR voltage fluctuates greatly, the VR set is broken. Replace the VR set. 4. If the VR voltage is correct, replace the display as a test. Inspect the display cable connections and program IC Incline VR set Display board Drive board Measure incline VR voltage (red-green wires) 0% 1.20 V 15% 3.57 V VR sets Incline motor 3-6-1

Troubleshooting Model: TR22F Malfunction: HTR malfunction Circumstance: Contact heart rate (HTR) value malfunction Possible cause: 1. HTR cable malfunction 2. HTR board malfunction 3. Display cable connection malfunction Troubleshooting: 1. Inspect the display cable connections. 2. Inspect bridge board HTR cable connections. 3. Inspect contact heart rate cable connections. 4. Inspect HTR board LEDs. 5. Replace the HTR board. HTR cable connection Display board HTR board HTR cable connection Bridge board Bridge board HTR board SENSOR-R SENSOR-L 3-7-1

Troubleshooting Model: TR22F Malfunction: The fuse has broken. Circumstance: Turn on unit. The fuse immediately blows. Possible cause: 1. Components and the frame have an abnormal electrical short. 2. Drive board component malfunction Troubleshooting: 1. Inspect the power cord. Is the cord insulation broken and creating an electrical short? 2. Replace the drive board as a test. (Drive board malfunctions are the most common source of blown fuses.) 3. Replace the filter. Fuse and power switch Drive board AC1 FUSE SW Filter Drive board AC2 3-8-1

Troubleshooting Model: TR22F Malfunction: The fuse has broken. Circumstance: Press the speed key. Motor rotates. Fuse blows. Possible cause: 1. Motor has an abnormal, internal electrical short. 2. Drive board malfunction Troubleshooting: 1. Replace the drive board as a test. 2. Replace the motor as a test. 3. Replace the optic sensor as a test. Display board Sensor Motor Drive board Drive board Sensor Motor 3-8-2

Troubleshooting Model: TR22F Malfunction: The fuse has blown. Circumstance: After a period of use, the fuse suddenly breaks. Possible cause: 1. Fuse holder malfunction 2. Deck or belt wear 3. Drive board malfunction Troubleshooting: 1. Inspect the fuse and fuse holder installation. 2. Inspect the mechanics: A. Walk belt wear, lubrication B. Inspect walk belt tightness. Is it too loose? 3. Replace the drive board as a test. 4. Inspect the motor brushes. Drive board Display board Motor Drive board Sensor Motor 3-8-3

Troubleshooting Model: TR22F Malfunction: Error 1 Malfunction: Press the speed key. Speed engages. Before the motor rotates, Error 1 appears. Possible cause: 1. Motor does not rotate. Drive board or motor malfunctions. Troubleshooting: 1. Inspect all cable connections. 2. Inspect the display board IC connection. 3. Measure motor voltage from the drive board. Is there voltage across M+,M-? If not, replace the drive board. If so, A. inspect transformer output voltage. B. inspect whether the EMG LED lights. C. Do IGBTs have an electrical short? 4. Inspect motor brushes and commutator. Inspect the display cable connections and program IC. Display board Measure transformer voltage EMG indicator Transformer Drive board Sensor Motor Inspect motor brushes Measure motor M+,M- voltage 3-9-1

Troubleshooting Model: TR22F Malfunction: Err 1 Circumstance: Press Speed key. Motor rotates. Err1 appears. Possible cause: 1. Motor rotates optic sensor malfunctions Troubleshooting: 1. Inspect all cable connections. 2. Inspect whether CLK indicator on drive board flashes. If not, optic sensor is malfunctioning. Suggestion: A. clean the optic sensor sensor head. B. replace the optic sensor. 3. If the CLK indicator lights, inspect: A. cable connections B. main IC connections. Inspect the display cable connections and the IC connection. Display board Inspect the optic sensor CLK indicator Drive board Sensor Motor Motor Inspect motor brushes 3-9-2

Troubleshooting Model: TR22F Malfunction: Err 3 Circumstance: Display speed and actual speed differ. Possible cause: 1. Optic wheel teeth or optic sensor malfunction 2. Drive board malfunction Troubleshooting: 1. Inspect whether optic wheel teeth are missing. 2. Replace the optic sensor as a test. 3. Replace the drive board. Display board Inspect optic sensor and wheel. CLK indicator Drive board Sensor Motor 3-10-1

Troubleshooting Model: TR22F Malfunction: Err 7 Circumstance: Display shows ERR 7. Possible cause: 1. Drive board or VR malfunction made the incline stick at highest or lowest level. Troubleshooting: 1. Turn on unit power. Do not press any keys. Inspect drive board incline indicators LED5 and LED6. A. If LED5 or 6 lights, either the display or cable connections are at fault. B. If not lit, inspect whether the drive board emits voltage to the incline motor. If LEDs do not light, replace the drive board. If LEDs light, recalibrate the incline motor and VR Or replace the VR. Incline voltage from drive board: Display board +40V or -40V. Inspect the display cable connections and program IC connections. If the incline exceeds range, recalibrate incline set. VR wires red green: 0% = 1.20V Drive board VR sets Incline motor Incline up/dn indicators 3-11-1

Troubleshooting Model: TR22F Malfunction: ERR 10 Circumstance: The walk belt suddenly rotates quickly. Possible cause: 1. Drive board IGBT has an electrical short. The protective circuit fails. 2. The protective circuit fails, prompting the error code. This cause is unlikely. Malfunction: 1. Replace the drive board. 2. Inspect the optic sensor. IGBT Display board Drive board Optic sensor Drive board Sensor Motor 3-12-1

Troubleshooting Model: TR22F Malfunction: ERR 14 Circumstance: Display shows ERR 14, the motor overheat error. Possible cause: 1. Motor is excessively hot; overheat protective circuit operates. Troubleshooting: 1. Inspect the motor thermal switch and fold-up switch cable connections. (These two cables are connected.) 2. Inspect the motor cover. Is it hot? 3. If it is hot and the unit has been in use for a long period of time, the motor overheat protective function is operating. Turn off the unit. Let it sit without use for half an hour. 4. If ERR14 often appears, please lubricate the walk belt and deck. If the belt is worn, replace it. 5. If replacing the walk belt does not remedy the situation, the motor is suspect. Motor thermal switch cable Display board Fold up switch In normal operation, the fold up switch does not contact the frame. Drive board Fold up sensor Thermal switch Motor 3-13-1

Troubleshooting Model: TR22F Malfunction: ERR 14 Circumstance: Display shows ERR 14. The fold up switch operates. Possible cause: 1. Fold up switch operates inappropriately. Troubleshooting: 1. Inspect the motor thermal switch and fold up switch cable connections. (These two cables are connected.) 2. Inspect whether the fold up switch operated inappropriately. In normal operation, the frame should not contact the fold up switch. Motor thermal switch cable connections Display board Drive board Fold up switch In normal operation, the fold up switch does not contact the frame. Fold up switch Thermal switch 3-13-2

Other Topics Model: TR22F Item: KPH/MPH unit selection, total distance, total time, display board/drive board program versions Method: 1. Do not put the safety key in place. Press and hold the <CHANGE> key for three seconds to enter the basic parameter setting mode. 2. Program version Display shows CTL TR20H-2A (CTL indicates the display board). DRV TR20DRV-1A (DRV indicates the drive board). Press the <ENTER> key to proceed to the next step. 3. KPH/MPH setting Display shows either KPH or MPH. Press the < > / < > key to select your preferred unit of measurement. Then press the <ENTER> key to confirm your choice and proceed to the next step. 4. Total distance Display shows TOTAL DISTANCE. The DISTANCE indicator lights. The number that appears represents total distance. 5. Total time Display shows TOTAL TIME. The TIME indicator lights. The number that appears represents total time. Press the <ENTER> key to leave the basic parameter setting. 3-14-1

Other Topics Model: TR22F Item: Error Code Table E-1 : Display board main program has not received the optic sensor signal. E-3 : Display setting and actual speed differ. E-7 : The display detected that the incline VR voltage is too high or too low, indicating that the incline is stuck in the wrong position. E-10 : The motor suddenly sped up. E-14 : 1. Motor temperature is excessively high. 2. The fold up indicator signal operated. 3-15-1

Inspection and Measurement Inspection point: TR22F optic wheel, optic sensor Inspection method: 1. Inspect the optic wheel placement. The optic wheel should rotate in the center of the optic sensor. It should not touch the optic sensor. 2. Inspect whether optic wheel teeth have broken. 3. Pull the walk belt to allow the optic wheel to move. Inspect whether LED7 on the drive board flashes. When a tooth of the optic wheel is in the center of the optic sensor, LED7 on the drive board does not light. When a tooth of the optic wheel is not in the center of the optic sensor, LED7 on the drive board lights. 4. The optic sensor includes an infrared transmitter and a receiver. Inspect whether the optic sensor is dirty. If so, wipe it clean. LED7 optic sensor signal indicator Optic sensor Optic wheel 4-1-1

Inspection and Measurement Inspection point: TR22F transformer Inspection method: 1. Inspect whether the transformer fuse has blown. 2. Measure transformer voltage. 3. Set the multi-meter to the AC setting. Place probes as follows: Transformer cables Voltage red-red or blue-blue (input voltage) 110V (red)/220v(blue) black-black (normal power) 12.5V white-white (normal voltage) 12.5V orange-orange (incline voltage) 29V yellow-yellow (normal voltage) 11.5V Transformer connector Transformer fuse 4-2-1

Inspecting and Measuring Inspection point: TR22F motor brushes Inspection method: 1. Inspect motor brushes. A. Inspect brush length. If brushes are shorter than 0.7mm, replace the brushes. B. Inspect the brush surface. It should be smooth. If there are grooves, the commutator might be faulty. C. Inspect whether brush copper wires have changed color. If so, replace the brushes. Brush length should exceed 0.7 mm. This image shows brushes that are too short. Motor brushes If copper wires have changed color, connections are bad. Replace the brushes. Brush ends shown here have scratches, a sign of irregular wear. Replace brushes like these. Motor brushes 4-3-1

Inspection and Measurement Inspection point: TR22F motor voltage test at the drive board Inspection method: 1. Select the VDC setting on the multi-meter. Place probes on M+M- connectors on the drive board. 2. Press the SPEED< > key. The motor should operate, allowing you to measure motor voltage. Speed Drive board voltage Motor specifications Highest speed 100-120 VDC 110V Lowest speed 210-230 VDC 220V 4-4-1

Inspection and Measurement Inspection point: TR22F incline voltage measurement at the drive board Inspection method: 1. Do not press any key. Incline indicators do not light. The drive board does not emit voltage to the incline motor. The incline motor does not operate. 2. Select the VDC setting on the multi-meter and test as follows. Incline key Indicator on drive board Drive board incline voltage Incline operation INCLINE < > LED5 lights (DOWN) green-white +40 or -40V Incline operates down INCLINE < > LED6 lights (UP) green-white +40 or -40V Incline operates up Incline motor connection on drive board Incline indicators (LED5 LED6) on the drive board 4-5-1

Inspection and Measurement Inspection point: Measuring VR voltage on the drive board Inspection method: 1. Select the VDC setting on the multi-meter. Place probes on the VR set red-green wires. 2. If the VR voltage fluctuates widely, the VR is bad. Replace it. Incline key Drive board VR voltage Incline position 0% Red-green 1.20V At red line (calibration point) 15% Red-green 3.57V Longest position Incline VR connector at the drive board Incline red calibration line 4-6-1

Inspection and Measurement Inspection point: Incline motor and VR calibration Inspection method: I. Calibration goals Adjust the incline set tube to the red calibration line. Adjust the VR voltage across red and green wires to 1.20V. II. Calibration steps: Step 1. Adjust the incline tube to the red calibration line as follows: A. Remove VR set screws. Remove the VR cap. B. Rotate the VR to set voltage across red and green wires to 2.5V. C. Press the INCLINE< >/< > keys to operate the incline up or down, making the incline tube return to the red calibration line. Step 2. Adjust the VR voltage across red and green wires to 1.20V. A. Rotate the VR to set voltage across red and green wires to 1.20V. B. Use screws to secure the VR cap back into place. Step 3. When calibration is complete, test incline operation as follows. A. Press the Incline< > key. The incline should operate to 15%. Measure incline VR voltage. It should be 3.57V. B. Press the Incline< > key. The incline should operate to 0%. Measure incline VR voltage. It should be 1.20V. Incline position Incline set Incline VR Treadmill position 0% At red calibration line 1.20V Level position 15% At longest point 3.57V Highest position VR voltage adjustment Incline red calibration line 4-7-1

Inspection and Measurement Inspection point: Fold up switch inspection Inspection method: 1. Fold up switch and motor thermal sensor cable connections. 2. Inspect fold up cable connections. 3. Inspect the fold up switch and unit position. Drive board LED4 operates as follows: Unit Fold up switch Drive board LED 4 In normal use Not touching unit Not lit Abnormal Touches unit Lit LED4 M_TEMP indicator Lit indicates error Fold up switch should not touch unit 4-8-1