TMX425 Series Owners Manual April 2008

TRACKMASTER

CONTACT INFORMATION The model TMX425 TRACKMASTER® treadmill is designed to be interfaced with a variety of EKG systems. If you have a question, please contact the stress system manufacturer first. Manufactured by Full Vision Inc. 3017 Full Vision Drive Newton, KS 67114 http://www.full-vision.com phone: (316) 283-3344 fax: (316) 283-3350

Authorized Representative In European Union (Regulatory affairs only) Emergo Europe Molenstraat 15 2513 BH The Hague The Netherlands (31) (0) 70 345-8570 telephone (31) (0) 70 345-7299 fax

Before permitting anyone to use the treadmill, do the following: • Warn each user about the risk of falling while the belt is in motion. • Stress the need for caution. • Demonstrate the proper mounting and dismounting methods. • Show each user how to use the treadmill as described in this manual. • Ask each user to do a supervised "test walk" at minimum belt speed to review and practice walking techniques.

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Printed in USA. TRACKMASTER®is a registered trademark of JAS Manufacturing Co., Inc. TRACKMASTER is protected by the following US Patents: 5320589, 5431613. All other patents pending. Polar® is the registered trademark of Polar CIC Inc.

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Contents

Chapter 1

Introduction... 1-1 Notices... 1-1 Drawings... 1-2 Directional Orientation... 1-2 Directional Orientation... 1-2 Customer Service... 1-2 Equipment Symbols... 1-3 Warning and Caution Decals... 1-3 RoHS/WEEE Directive... 1-4

Chapter 2

Specifications... 2-1 Treadmill... 2-1 Drive System... 2-1 Speed Range... 2-1 Incline Range... 2-2 Running Surface... 2-2 Floor Surface Requirements... 2-2 Operating and Storage Condition Recommendations... 2-2 Installation After Long Period of Storage... 2-2

Chapter 3

Safety Information... 3-1

Chapter 4

Grounding Instructions... 4-1

Chapter 5

Assembly and Setup... 5-1 Initial Setup... 5-1 Safe handling Guidelines... 5-2 Location... 5-3 Power Requirements... 5-3 Final Setup Test Plug Procedure... 5-3 Final Setup Running Belt Adjustment... 5-4 Final Setup Running Belt Tension... 5-5 Final Setup Drive Belt Adjustment... 5-5

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Chapter 6

Preventive Maintenance... 6 -1 Daily Maintenance... 6 -2 Weekly Maintenance... 6-2 Monthly Maintenance... 6-2 Semiannual Maintenance... 6-2 Belt Cleaning and Inspection... 6-3 Running Belt Adjustment... 6-3 Running Belt Tension Adjustment... 6-4 Drive Belt Tension Adjustment... 6-5 Exterior Care... 6-6 Elevation Screw Lubrication... 6-6 Running Board Removal and Maintenance... 6-7 Internal Circuit Breaker Location and Resetting... 6-7

Chapter 7

Component Replacement... 7-1 Running Belt Replacement... 7 -1 Roller Removal... 7-2 Drive Motor Removal... 7-4 Inverter Drive... 7-5

Chapter 8

Troubleshooting... 8 -1 Power On Indicator Not Illuminated... 8 - 1 Facility Circuit Breaker Trips When Powering Up... 8 -1 Treadmill Will Not Start... 8-2 Running Belt Slips When In Use... 8-2 Running Belt Is Off-Center... 8 -2

Appendix A Maintenance Log... A-1 Appendix B Drawings... B-1 Appendix C FVX328C Manual Controller Operating Instructions/Drawings ... C-1 Appendix D FVX328CP Programmable Controller Operating Instructions/Drawings ... D-1

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Introduction

1 Introduction Congratulations on the purchase of your new TRACKMASTER® treadmill. These fine machines have been in production since 1977 and represent state-of-the-art design for heavy-duty institutional treadmills. Thousands of facilities have enjoyed years of daily use provided by dependable TRACKMASTER® treadmills. TRACKMASTER® treadmills are designed and built to withstand the extraordinary demands of fitness clubs, corporate health centers, hospital wellness programs, physical therapy facilities, and cardiac rehabilitation facilities. Model TMX425 is designed for cardiac stress and pulmonary function testing. This manual covers the installation, operation, and service of your new TRACKMASTER® treadmill. If you have questions, first consult this manual. If your questions are still unanswered, please call your distributor.

Notices Three different levels of notices throughout this manual alert you to important information: Note, Caution, and Warning.

Note Note statements provide additional information, such as the following: Note: For maximum safety and efficiency, the treadmill must have its own dedicated power outlet.

Caution Caution notices inform you of potential hazards that could result in equipment damage or injury, such as the following:

CAUTION

April, 2008

Do not use silicone sprays to wax your treadmill deck. Using silicone sprays may void the warranty. Such sprays can bring about surface changes that cause you to slip.

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Warning Warning notices alert readers to hazards that will result in serious injury or death, such as the following:

WARNING

Never open the hood of the treadmill while it is plugged into a power outlet. Line voltage will cause severe injury or death.

Drawings Appendix B, C, and D display assembly drawings.

Directional Orientation References to left, right, front, and rear are based on the assumption that you are standing on the treadmill, facing forward.

Customer Service If you need service and/or replacement parts for your TRACKMASTER® treadmill, please contact your distributor. Please include the treadmill serial number in all correspondence. Note: Your TRACKMASTER® treadmill was carefully tested and left the factory in optimum working condition. If any damage occurs during shipping, note the damage on the shipping documents, contact the shipper immediately, and file the appropriate claims. Please have the model and serial numbers ready when you contact your distributor.

Serial Decal Information

Item

Name

Description

A B C D E F G H

Manufacture Model Number Part Number Voltage Hertz Amps Serial Number Type B Equipment

Full-Vision Inc. Identifies model of treadmill Manufacturers part number Specifies operating voltage of treadmill Specifies the electrical of treadmill Specifies amperage of treadmill Manufacturers assigned serial number Device is suitable for the external application of type “B” applied parts.

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Introduction

Equipment Symbols

The following symbols appear on the equipment.

This symbol means that you must pay attention to the documents delivered with this equipment. It calls notice to the things to which you must pay special attention during operation and when the equipment is operated in conjunction with other equipment. Protective earth (ground)

Alternating current

Device is suitable for the external application of the type “B” applied parts.

Warning and Caution Symbols

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Trackmaster’s Obligations Under RoHS/WEEE Directives: As of this date, and perhaps until 2008 – 2010, Medical Treadmill sales to EU countries are exempt from the requirements of RoHS as per Annex 1A of the WEEE directive, medical devices, because the treadmill has been determined to be a class 1 medical device in the EU. There is a possibility that this exemption will be permanent. Under the WEEE directive, producers are financially responsible for the collection and treatment of waste electrical and electronic equipment. In the context of RoHS and WEEE, producer is defined in the European Commission’s Directive as “any person who irrespective of the selling techniques: • Manufactures and sells EEE under his own brand • Resells under his own brand, equipment produced by other suppliers • Imports or exports EEE on a professional basis into a Member State” The OEM or importing distributor is recognized as the “producer” by definition of the European Commission. Full-Vision, Inc. assumes no liability under the WEEE directive.

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Specification

2 Specifications The specifications discussed in this chapter apply to the TRACKMASTER® TMX425 treadmill.

Treadmill

• •

500-lb capacity Steel chassis with TGIC Polyester powder-coat finish

Drive System • • •

Heavy-duty 2-hp AC inverter duty motor 200-240VAC, 1-phase, 50-60 Hz, 15-amp (13 amp-Europe) power supply 115VAC, 1-phase, 50-60 Hz, 20-amp power supply (optional)

Note: To function properly, each treadmill must have an electrical line dedicated to its exclusive use. A non-dedicated line could cause your treadmill to malfunction. In addition, there must be sufficient amperage to handle all equipment supplied by the overall electrical circuit. Check with your local electrician if you have any questions regarding power requirements.

Speed Range • • •

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0.5 to 10 mph (standard 115V) 0.5 to 12 mph (standard 220V) 0.8 to 19 kmh (optional)

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Incline Range •

0 to 25%

Running Surface • • • •

22 in. x 63 in. cushioned lubricated low-profile (7 in. from floor)

Floor Surface Requirements •

33 in. x 88 in. level surface

Operating and Storage Condition Recommendations Operating Temperature Range: 0 to +40 deg. C (+32 to +105 deg. F). Storage Temperature Range: -20 to +70 deg. C (-4 to +158 deg. F). Operating and Storage Relative Humidity Range: 8% - 80%, non-condensing. Altitude: -50 to 10,000 feet.

Installation After Long Period of Storage Storage exceeding three years, Contact Factory Immediately prior to plugging in treadmill. Failure to do so will cause inverter drive to FAIL!

If input power has not been applied to the drive for a period of time exceeding three years, the electrolytic DC bus capacitors within the drive can degrade, resulting in excessive leakage current. This may result in premature failure of the drive controller.

Severe damage to the inverter drive can result if it is operated after a long period of storage or inactivity without reforming the DC bus capacitors! Contact the factory for proper instruction.

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Safety Information

3 Safety Information TRACKMASTER® treadmills meet or exceed all applicable product safety requirements for motor-operated exercise machines. TRACKMASTER® is listed by Engineering Testing Laboratories (ETL); however, all motorized equipment is potentially dangerous if used incorrectly. Before using the TRACKMASTER® treadmill, follow all precautions listed in this chapter, and read the entire Owner’s Manual thoroughly. Use the TRACKMASTER® treadmill only as described.

Serious injury could result from loss of balance or falls. To reduce the possibility of serious injury, carefully observe the following precautions. •

Read this Owner’s/Service Manual before operating the treadmill.

•

Wear appropriate clothing and running shoes.

•

Place the treadmill on a level, unobstructed surface.

•

Connect the treadmill to a dedicated, properly grounded outlet that supplies the correct voltage and amperage.

•

Never stand on the belt when starting the treadmill.

•

Do not step onto or off the belt when it is moving.

•

Always slow the treadmill to its minimum speed before stopping.

•

Never allow children or pets near the machine without careful supervision.

•

Keep hands, feet, and clothing away from any moving parts.

•

Never drop or insert objects into any opening.

•

Avoid draping towels over the safety side rails or dropping objects on the belt while the treadmill is running.

•

Never place any foreign object on the treadmill.

•

Verify no one is near the elevation mechanism before operating to avoid pinch points.

•

Operator should be aware of speed malfunction and be ready to assist patients and stop treadmill if necessary.

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•

Operator should be aware of elevation malfunction and be prepared to assist patient and stop treadmill if necessary.

•

Operator should always be aware of improper treadmill response to commands.

•

Check treadmill before use. This includes: – Check power cord connection and location for hazardous pinch points. – Check emergency stop button for proper operation. – Check interface cable to ensure it is secure and not cut or piched. – Verify ECG communication is correct.

•

Verify operator knows how to stop the treadmill in the event of malfunction or emergency.

•

Make operator aware if treadmill is not responding properly to commands.

•

Keep all cords clear of operator to avoid trip hazards.

•

Operator should not wear loose fitting nylon material when exercising on treadmill to avoid generating ESD.

•

Operator needs to be aware of and note any components of the treadmill that are loose.

•

Do not allow moisture or oils to accumulate on treadmill, creating a slip hazard.

Serious injury or death could result from electric shock. To reduce the possibility of electric shock, carefully observe the following precautions.

• • •

•

Connect the treadmill only to a dedicated, properly grounded outlet. See “Grounding Instructions” on the next page. Always unplug the treadmill from the electrical outlet before cleaning it. To disconnect the treadmill, set the power switch to the OFF position, and remove the plug from the outlet. When the power is off, the green light on the power switch is dark. Never operate the unit with a damaged power cord or plug.

If the power cord is damaged, it must be replaced by a qualified service provider. Contact your distributor. Use only TRACKMASTER® replacement parts. Using other parts may void your warranty and may cause your treadmill to malfunction.

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• • • • • • • • • • •

Safety Information

Never operate the unit with a damaged power cord or plug. Never operate the unit when it is wet. Never operate the unit if it is not operating properly. Never use extension cords. Keep the power cord out of traffic areas and away from heated surfaces. Always unplug the machine before service and maintenance are performed. Never use the treadmill outdoors. Operator should report any shock when touching the treadmill and discontinue use immediately. Treadmill should be serviced by authorized technicians only. Power cord should be routed through clamp and kept clear of elevation mechanism. Personnel present when treadmill is in use need to be aware of the distinctive odor of hot electrical components.

Serious injury or death could result from electric shock occurring during defibrillation. Never allow patient or operators near treadmill during defibrillation.

Before beginning any exercise program, check with your physician to determine your present physical condition and capabilities regarding aerobic exercise. Know your limits and requirements for warm-up, target, and maximum heart and breathing rates; duration of exercise; cool-down periods; and recovery heart rates. Stop exercising immediately if you feel faint or dizzy, or if you experience symptoms of overexertion.

Serious injury or death could result from operating treadmill in the presence of explosive or flammable vapors and antiseptics.

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Safety Information

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Notes

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Ground Instruction

4 Grounding Instructions TRACKMASTER® treadmills must be grounded to reduce the risk of electric shock. If a malfunction occurs, grounding provides a path of least resistance for an electric current. Ungrounded connections may cause electrical shock. This product is equipped with a three-wire grounding-type plug. The plug will fit into only a grounding-type outlet. This is a safety feature-do not disable the plug’s third (grounding) pin with an adapter! Contact a qualified electrician if you are either (1) unable to insert the plug into your outlet, or (2) uncertain that the outlet is grounded and meets local codes. The treadmill is designed to operate on a 200-240VAC/15-amp (13 amp-Europe) service (unless you ordered the 115VAC/20-amp power supply option). Make sure that the treadmill is connected to an outlet that looks like the following illustration. Never use an adapter or extension cord with this product. If you have any questions or experience any problems, contact your distributor.

115 VAC NEMA 5-20R

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200-240 VAC NEMA 6-15R

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Notes

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Assembly and Setup

Assembly and Setup

5

TRACKMASTER® treadmills are shipped fully assembled unless otherwise specified. After you have unpacked the treadmill, move it to the area by rolling it on its front wheels (when the treadmill is required to pass thru a 32” door you may need to remove handrail). If your treadmill is shipped partially disassembled, refer to The Packing List/ Assembly Sheets for assembly. ________________________________________________________________ CAUTION

The treadmill is 475 lbs this requires 2 people to safely remove from pallet and locating the treadmill in the facility. __________________________________________________________________________________________________

Initial Setup Handrail Removal Tools required for assembly Flat head screw driver 3/16 Allen wrench 1/4 Allen wrench For treadmills required to pass thru a 32” door you may need to remove handrail, please follow the instructions below. 1. Remove dome plug on interior of center handrail with flat head screw driver to gain access to 5/16 x 3” long socket head bolt. 2. Remove the 5/16 x 3” long hex bolt and lock washer with 1/4 Allen wrench. 3. Remove the tube connector and spacer. 4. Loosen (2) 5/16 x 1” button head bolts at the bottom of handrail connected to the frame. 5. Repeat steps 1 thru 4 for the opposite handrail. 6. With the handrails loose pull handrails together gently to provide clearance in a 32” doorway. 7. Reference SAFE HANDLING GUIDLINE when moving treadmill. 8. When treadmill is located for use perform step 1 thru 5 in reverse to reinstall handrails.

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Safe Handling Guidelines ƒ ƒ ƒ

Lift the end of the bed assembly to a comfortable height, keeping knees bent and back straight as you lift. Rotate the treadmill in the direction you want to go (the treadmill will pivot on it wheels) and push forward. When you have maneuvered the treadmill into its location gently lower the end of the bed assembly to the floor.

_________________________________________________________ CAUTION

If you are moving the treadmill over a rough surface, such as pavement, use a dolly under the front of the treadmill to prevent damage to the wheels. ________________________________________________________________________________________

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Assembly and Setup

Location Place the treadmill on a level, stable surface-short-pile industrial carpeting is acceptable. ________________________________________________________________ CAUTION

Do not place the treadmill on thick or long-pile carpeting. Such carpeting could cause instability or static build-up, and carpet fibers could get caught in the belt and damage the unit. Provide adequate clearance around the treadmill, away from obtrusive objects. Obstructions can cause injury to the user or damage to the treadmill. Keep the treadmill away from sources of moisture, such as spas or fountains. Moisture can cause the electronic circuitry to malfunction. Use caution when locating treadmill where potential electromagnetic interference between the treadmill and other devices together. Devices should be carefully observed to ensure that EMI does not degrade performance. __________________________________________________________________________________________________

Power Requirements Your TRACKMASTER® treadmill operates on a 200-240VAC, 15-amp (13 amp-Europe) service. The treadmill requires an approved outlet (see Chapter 4, “Grounding Instructions”) that is properly grounded, includes a 15-amp (13 amp-Europe) circuit breaker. No other equipment may be used on the treadmill circuit. Do not use extension cords. Using an ungrounded, shared, or otherwise improper circuit will void the machine's warranty and may result in major damage to your treadmill's electronic circuits. Using a shared circuit can also cause the treadmill to unexpectedly shut off, resulting in injury to the user. Ensure that power cords do not cross traffic areas. Exposed power cords can cause a fall, resulting in injury. Before plugging the power cord into its power outlet, ensure that the treadmill master power switch is in the OFF position . A power surge through the treadmill electronics could trip the treadmill’s circuit breakers.

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