Sunday, February 21, 2016

Motus USA M990T- M990TL – Treadmill – Troubleshooting – error codes – Running belt lubrication – running belt adjustment – treadmill repair and service

Category: Treadmill Repair and Service 

Contents of this article 

  • Troubleshooting 
  • Error codes and causes 
  • Running belt adjustment 



Motus USA M990T- M990TL

Troubleshooting Guide
No power to treadmill console
PROBABLE CAUSE
Line voltage is not present at treadmill.
Circuit breaker on the rear of the Treadmill Is tripped. (Countries using 220V or 230V Supply Voltage)
Power-on switch with built-in circuit breaker is tripped. (US/Canada market or Japan market using 100V or 120V Supply Voltage)
Power-on Switch is damaged. Defective Line Filter.
Electronic components of Lift/Power Supply PCB are damaged. Fuses 1, 2 on Lift/Power Supply PCB.
CORRECTIVE ACTION
Check the main circuit breaker and wall outlet voltage at the Facility.
If wall outlet voltage is present, then replace line cord.
If tripped, a white button has popped out. Press the white button to reset the circuit breaker after eliminating the cause of the trip. The circuit breaker is located next to power ON/OFF switch on the outside of the treadmill.
In the United States, Canada and Japan, circuit breaker is combined with power ON/OFF switch. If tripped, the switch is turned to OFF position. Turn the switch on after eliminating the cause of the trip. Replace it if necessary
Replace Power-on Switch if the output voltage of Power Switch is not present.
Replace Line Filter if the output of Line Filter is not present.
Disconnect CN3 cable at Lift/Power Supply PCB and then measure the voltage between pin 2 and pin 1.
Measure the voltage between pin 2 and pin 3. The voltage should be 5VDC. If there is no voltage, replace the PCB.
Replace Fuses or the PCB.
No power to treadmill console
PROBABLE CAUSE
Defective wire harness
Defective MPU PCB
CORRECTIVE ACTION
Disconnect CN6 (3-pin connector) on MPU PCB (M990T/M995T) and then measure the voltage between pin 2 and pin 1 at the cable. Measure the voltage between pin 2 and pin 3 at the cable. If there is no voltage, replace the cable.
Disconnect CN1 (3-pin connector) on MPU (M990TL/M995TL) and then measure the voltage between pin 2 and pin 1 at the cable. Measure the voltage between pin 2 and pin 3 at the cable. If there is no voltage, replace the cable. If the cable is normal, secure the connector firmly. Replace MPU PCB.
Striding belt does not move or treadmill pauses randomly
PROBABLE CAUSE
Due to normal protective function. (E□□ is displayed on Console Display.)
Magnetic switch for emergency stop is not firmly attached.
Emergency Push Button Switch is locked. Insufficient power source
Unstable power connection.
RS485 connection for communication is loose. 3-pin connectors at MPU of Display Console or Lift/Power Supply PCB are not secure
CORRECTIVE ACTION
Mount magnetic switch in position.
If it is in position, adjust the position of magnetic sensor under properly or replace it if necessary.
Unlock it by rotating clockwise.
Plug treadmill into a dedicated 20-amp circuit. Find unstable connection at electrical outlet and at treadmill
If the Console display is normal, check the electrical connection between MPU of Console and Motor
Controller under motor hood is firm.
Check the connection is secure.
Treadmill pauses Randomly and then Program Profile Window of Console start displaying from the beginning as if Power-on Switch is turned on.
PROBABLE CAUSE
Power-on switch is unstable or defective.
Supply voltage to MPU PCB is too low.
Unstable cable connection.
CORRECTIVE ACTION
 Replace power-on switch.
If the voltage between pin 2 and pin 1 at CN1 on MPU
PCB (M990T/M995T) is under 4.8V, replace Lift/Power Supply PCB.
If the voltage between pin 2 and pin 1 at CN6 on MPU
PCB (M990T/M995T) is under 4.8V, replace Lift/Power Supply PCB
.
Check the connection between CN3 on Lift/Power
Supply PCB and CN1 (M990TL/M995TL) on MPU PCB is connected firmly.
Check the connection between CN3 on Lift/Power
Supply PCB and CN6 (M990T/M995T) on MPU PCB is connected firmly.
Maximum speed is reduced
PROBABLE CAUSE
The deck laminate worn through or the underside of striding belt became hard or glossy.
Manual lubrication is not sufficient.
Automatic lubrication system does not work.
CORRECTIVE ACTION
Replace belt and deck.
Check if the lubrication is proper by pushing striding belt backward using your feet while holding front handlebar after turn OFF the treadmill. If insufficient, apply lubrication.
Check if the lubrication is proper by pushing striding belt backward using your feet while holding front handlebar after turn OFF the treadmill. If insufficient, apply lubrication.
Verify lubricant tank is not empty, or lubrication system works well.
Incline is not adjusted by Incline Up or Incline-Down Button.
PROBABLE CAUSE
Touch-Sensitive Buttons does not work.
Unplugged or defective cables.
Unplugged or defective cable
Lift/Power Supply PCB is damaged.
CORRECTIVE ACTION
If all 3 lamps on Start/Stop, Speed Down and Speed UP do not light up, replace the Touch-Sensitive Key PCB.
If a lamp on Start/Stop, Speed Down or Speed UP does not light up any more than before pressing each button, replace the Touch-Sensitive Key PCB.
Check the connection between CN4 on Lift/Power
Supply PCB and CN2 (M990TL/M995TL) on MPU PCB is exact or connected firmly.
Check the connection between CN4 on Lift/Power
Supply PCB and CN3 (M990TL/M995TL) on MPU PCB is exact or connected firmly.
Check the cable from the incline motor is connected firmly to CN20 on Lift/Power Supply PCB.
Replace Lift/Power Supply PCB
Speed is not adjusted by Speed Up or Speed-Down Button.
PROBABLE CAUSE
Touch-Sensitive Buttons does not work. Unplugged or defective cable
RS485 connection for communication is loose. 3-pin connectors at MPU of Display Console or Lift/Power
Supply PCB are not secure.
Motor Controller or MPU PCB is defective.
CORRECTIVE ACTION
If all 3 lamps on Start/Stop, Speed Down and Speed UP do not light up, replace the Touch-Sensitive Key PCB.
If a lamp on Start/Stop, Speed Down or Speed UP does not light up any more than before pressing each button, replace the Touch-Sensitive Key PCB.
Check the cable from the Drive motor is connected firmly to the terminal of Motor Controller..
If the Console display is normal, check the electrical connection between MPU of Console and Motor
Controller under motor hood is firm.
Check the connection is secure.
Replace Motor Controller or MPU PCB if necessary.
Protective Function & Display Code
If a treadmill stops suddenly, it means a protective function works properly. This is normal function to protect the treadmill. As the result of
protective function, a code indicating the cause of error is displayed on the display console or the display panel of Motor Controller (or Motor
Inverter) which is located under motor hood. Motor is driven directly by Motor Controller according to the command from the console.
If this protective function occurs, turn off the treadmill and then turn on the treadmill after 20 seconds even though the cause is eliminated. Even
though the cause is eliminated, the treadmill stop due to protective function will remain unsolved if you turn on the treadmill within 20 seconds after
turning off the treadmill.
E04 Overcurrent
Excessive current flows in Motor Controller. In other word, the
Motor Controller output current exceeds the rated current by more than approximately 180%.
- The load is in abnormal condition like impact load.
- A main circuit element is defective.
- The output is short
Overheated Motor Controller caused by worn or damaged belt and deck.
- Reduce impact load or lubricate between belt and deck
- Replace Motor Controller with new one. - - Check the cables and wires between motor and Motor Controller are loose or if there is any short between wires
E05 Overload
An excessive load is applied to motor, which is judged by detecting Motor Controller output current.
- Lubricate between belt and deck
E07 Overvoltage
Unexpected high voltage is detected at DC voltage of Motor Controller.
- Input voltage of Motor Controller is too high.
- Check the input voltage fluctuates abnormally.
- Don’t push the striding belt backward.
E60 Communication Error
- Regenerative energy from motor is too much.
- External noise
- Trouble in internal memory due to or high temperature.
- Cable connection between MPU and Motor Controller
compulsorily by foot.
- Replace Motor Controller cable with new one
- Replace Motor Controller with new one
E09 Low voltage
Unexpected low voltage is detected at DC voltage of Motor Controller.
- Input voltage of Motor Controller is too low.
- Instantaneous power failure
- Check the input voltage to treadmill.
- Connect the treadmill to dedicated circuit.
- Supply stable power to treadmill
E34 Short-circuited output
Excessive current flows in Motor Controller when the output of Motor Controller is short
- Check the cables and wires between motor and Motor Controller are loose or if there is any short circuit between wires.
E08 EEPROM
Trouble in internal EEPROM due to high temperature. A lot of parameters are saved in the EEPROM.
- Make a service call.
E12 Tripped out due to external input signal
Failure caused intentionally by input terminal. It is not implemented in the treadmill.
Replace the Motor Controller
E14 Ground fault trip
Grounding protection when an Motor Controller output line dropped to earth. Current leaks from an output cable or the motor to ground.
- Check the cables and wires from Motor Controller are dropped to the earth.
E21 Temperature trip
The temperature of power module in Motor Controller is too high.
Overheated Motor Controller caused by worn or damaged belt and deck.
- Ambient temperature is too high.
- Do not place heat generating device near the treadmill.
Replace the deck or belt.
Lubrication
Basically, initial lubrication is performed at factory, but the oil could be dried during transportation or stock in your warehouse.
As soon as you complete installing, please lubricate and then make sure that oil is enough or not as below.
1) Turn off treadmill.
2) Push the striding belt backward using your feet while holding the front handle bar or side handle bar.
3) You can judge whether the friction is enough or not by feeling the smooth move of the belt. Lubrication is needed if the belt is not pushed well.
# Lubricant prevents the belt and deck from being damaged by frictional heat, which extends life span of the deck and belt.
# Use the lubricant provided by Motus only.
How to manage automatic lubrication system (M990T, M990TL)
A certain amount of oil is lubricated automatically every lubrication interval which is preset at Manager Mode. Default lubrication amount and lubrication interval are set up to, for instance, 30cc and 500km, respectively, which can be set at Manager Mode. Therefore, it is recommended that fitness club manger set up the lubrication amount and interval according to club condition. A volume of lubricant tank is about 270cc, and if residual amount of oil is less than 20%, the warning SYMBOL is displayed on the screen with a beep. At that time, fill the tank as instructions below.
1) Turn OFF the treadmill and open motor hood.
2) Open the cap of oil tank by turning it with hand.
3) Fill the empty tank fully with the oil provided by Motus. Keep in mind that automatic lubrication system doesn’t work properly if oil is not filled full.
4) Close the cap of oil tank and put the motor hood in place.
5) Turn ON the treadmill. Message indicating oil lack will be still displayed on the screen with the beep.
6) To input “finishing oil-filling”, press buttons in the order as below.
‘INCLINE DOWN’ -> ‘INCLINE UP’ -> ‘SPEE DOWN ’ -> ‘SPEED UP’ -> ‘ENTER’
Keep in mind that this step must be done after filling the tank fully.
7) The warning SYMBOL and beep disappears.
How to Align Striding Belt
The belt is properly aligned at the factory before shipment. However, while delivering or exercising, the belt can be misaligned from the original center position. The correct alignment or striding belt is critical to the smooth operation of the treadmill.
When the belt is off center to either right direction or left direction
1) Level and stabilize the treadmill prior to any alignments or tracking adjustments.
* The belt may move off center by using the treadmill on uneven surface.
2) Turn on the treadmill and then check if the belt drifts off center or not while treadmill is operated with the speed of 5km/h for a few minutes.
3) Turn off the treadmill after keeping in mind whether the belt is off center to which direction, left or right.
4) Make sure the striding belt has completely stopped.
5) Find the right belt tensioning bolt in the rear end cap of the treadmill. Make tracking adjustments using the 10 mm hex key wrench provided as shown.
# If the belt is off center to the right, turn the right adjusting bolt 1/4 turn clockwise, which brings the striding belt back to the left.
# If the belt is off center to the left, turn the right adjusting bolt 1/4 turn counterclockwise, which brings the striding belt back to the right.
Note: Do not turn the adjusting bolt more than ¼ at a time. Over-tightening the bolt can damage the treadmill. Do not exceed one full turn of the adjusting bolts in either direction.
6) Turn ON the treadmill, press START/STOP, and then operate the treadmill with the speed of 5km/h.
7) Observe the striding belt for a few minutes. The belt should be centered on the deck.
8) If you need additional alignment, repeat step 2) through 7) of this procedure until the belt is properly aligned.

CAUTION: If you hear any chafing, the belt is not center-aligned or the belt appears to be getting damaged, stop the treadmill and contact authorized local dealer.