TREADMILL

SERVICE MANUAL

TMX428
TMX428CP

TMX58

Revision 2 October 2015

TRACKMASTER Safety Information

Contact Information
The model TMX428 TRACKMASTER® treadmill is designed to be interfaced with a variety of
ECG and VO2 systems. If you have a question or need assistance, please contact your system
integrator first.

Manufactured by: Authorized Representative

In European Union
Full Vision Inc. (Regulatory affairs only)
3017 Full Vision Drive Emergo Europe
Newton, KS 67114 USA Molenstraat 15
http://www.full-vision.com 2513 BH The Hague
Phone: (316)-283-3344 The Netherlands
Fax: (316)-283-9522
Email: [email protected]

MODIFICATION IS PROHIBITED

The TRACKMASTER® is manufactured to exacting standards both in physical form

and in component selection. The components used in our products have been selected
with performance and medical safety in mind. The treadmill has been engineered and
certified to conform to the list of medical and safety regulatory standards which appear
on the next page. Modification or part substitution of any kind is strictly forbidden. Any
deviation in component replacement, physical or electrical modification will result in
loss of medical safety certification and warranty of this product. Modifications to this
equipment may put the patient at risk of electrical shock or hardware malfunction.

Contact TRACKMASTER® Service department for all your repair part needs.

MODIFICATION EST INTERDITE

Le TRACKMASTER® est fabriqué selon des normes rigoureuses tant dans la forme
physique et à la sélection des composants. Les composants utilisés dans nos produits ont
été sélectionnés avec la sécurité de la performance et médicale à l'esprit. Le tapis roulant
a été conçu et certifié conforme à la liste des normes réglementaires médicales et de
sécurité qui apparaissent sur la page suivante. Substitution de modification ou d'une
partie quelconque est strictement interdite. Tout écart dans le remplacement des
composants, physique ou modification électrique entraînera la perte de la certification de
la sécurité médicale et la garantie de ce produit. Apportées à cet appareil peuvent mettre
le patient au risque de choc électrique ou un dysfonctionnement du matériel.

Contacter TRACKMASTER® département service pour tous vos besoins en pièces de rechange.

TRACKMASTER® is a registered trademark of Full Vision Inc.

TRACKMASTER® is protected by the following US Patents: 5,431,613 and 5,320,589.

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Safety Information TRACKMASTER

Regulatory and Safety Conformance

TRACKMASTER® meets the following safety and regulatory standards for FDA Class 1 motor operated
®
physical medicine machines. TRACKMASTER has been tested by Intertek Testing Services N.A Inc., and is
listed by Engineering Testing Laboratories (ETL). However, the ultimate conformance to IEC 6060-1 2005-3rd
edition is the responsibility of the system integrator when combined with other equipment. Additionally, all
®
motorized equipment is potentially dangerous if used incorrectly. Before using the TRACKMASTER , follow
all precautions listed in this chapter and read the entire Owner’s Manual thoroughly. Use the
®
TRACKMASTER only as described.

UL 1647
Issue: 2011/04/21 Ed: 5 UL Standard for Safety for Motor-Operated Massage and
Exercise Machines

CAN/CSA C22.2#68
Issue: 2009/09/01 Ed: 7 Motor-Operated Appliances (Household and Commercial)
General Instruction No.1: 2010/02/01 - General Instruction No.2: 2010/09/28

CSA C22.2#60601-1
Issued: 2008/02/01 Ed: 3 Medical Electrical Equipment - Part 1: General
Requirements for basic Safety and essential performance

ICES 003 Industry Canada (IC) Verification

Issue: 2004/01/01 Issue No.4 Interference-Causing Equipment Standard, Digital
Apparatus

IEC 60335-1 Low Voltage Directive for the European Union (EU)
Issued: 2004/07/01 Ed: 4.1 Household and Similar Electrical Appliances - Safety -
Part 1: General Requirements; Corrigendum 1: 12/2005; Amendment 2: 05/2006;
Corrigendum: 08/2006

IEC 60601-1
Issued: 2005/01/01 Ed: 3 Medical electrical equipment Part 1: General requirements
for basic safety and essential performance Australia and Israel,

IEC 60601-1-2
Issued: 2007/03/01 Ed: 3.0 Medical Electrical Equipment - Part 1-2: General
Requirements for Basic Safety and Essential Performance - Collateral
Standard: Electromagnetic Compatibility - Requirements and Tests

AAMI ES60601-1
Issued: 2005/01/01 Medical electrical equipment Part 1: General requirements for
basic safety and essential performance.

IEC CISPR 11-1 EMC Directive for the European Union (EU)
Issued: A1:2010 Electromagnetic Compatibility Requirements for Household
Appliances, Electric Tools and Similar Apparatus Part 1: Emission Edition 5.0;

Federal Communications Commission (FCC) Verification for the United States

FCC 47CFR 15A
Issued: 2011/04/21 Title 47 CFR Part 15 Subpart A General Radiators Class A

Note: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC
Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a
commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in
accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a
residential area is likely to cause harmful interference in which case the user will be required to correct the interference at owner’s expense.

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TRACKMASTER Safety Information

Important Safety Information

The purchaser is solely responsible for the training, instruction, supervision and safety of all
users of the TRACKMASTER® treadmill, and to use it as intended by the manufacturer. This
device is intended to be used as a motion appliance to facilitate cardiac or VO2 medical
evaluation.

Before permitting anyone to use the TRACKMASTER®, 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 TRACKMASTER® as described in this
manual.
• Ask each user to perform a supervised "test usage" at minimum belt speed
to review and practice usage techniques.
• 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 Manual before operating the TRACKMASTER®.

• Assist in off-loading the patient in the event of abnormal or unexpected operation
of the treadmill.
• If the treadmill is not responding properly, stop the treadmill, assist in removing
the patient off the running belt, unplug the treadmill power supply, and seek
factory authorized repair before attempting to restart the treadmill.
• Never allow children or pets near the machine without qualified adult
supervision.
• Note the location of stop and/or emergency stop controls and their operation
before starting a test or workout.
• This device is not intended for use by persons with reduced physical, sensory or
mental capabilities, or lack of experience and knowledge unless they have been
given supervision or instruction concerning use of the appliance by a person
responsible for their safety.
• Verify the Patient and Operator both know how to stop the machine in the event
of malfunction or emergency.
• Patient should not wear loose fitting nylon material when exercising on this
treadmill to avoid generating Electro Static Discharge.
• Never attempt to remove any article of clothing while the running belt is moving.
• All persons on and around the treadmill must wear enclosed, protective footwear.
Shoe laces must be tight and not drape as to cause a trip or catch hazard. Sandals,
flip flops, slippers and the like are not considered enclosed, protective footwear.

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Safety Information TRACKMASTER

• Walk in the center of the running belt. Contact with the side rail and the moving
belt could cause injury.

• The Patient must always wear the Stop Tether lanyard wrist strap before
operating the TRACKMASTER®
• Place the treadmill on a hard, level and unobstructed surface. See Assembly /
Set-up
up instructions in Chapter 5 of this manual.
• Check input power cord connection and location for hazardous pinch points
before use.
• Check input communications cord connection (if equipped) for proper interface
with all equipment.
• Keep all cords clear of patient to avoid trip hazards.
• Never attempt to remove the motor pan hood or do electrical repairs yourself.
yourself
Repairs should only be done by a factory authorized repair provider.
• TRACKMASTER® when servicing, inspecting or cleaning
Always unplug the TRACKM
the treadmill.
• Routinely inspect the treadmill for loose parts.
• Inspect handrails and ensure they will support the patient properly.
• Always start the running belt at its slowest speed before starting your workout.
worko
• Do not step onto belt when it is moving.
• Always slow the running belt to its minimum speed before stopping.
• Keep hands, feet, and clothing away from any moving parts.
• Verify no one is near the elevation mechanism before operating
operating. Never put any
part of the body under any part of a running treadmill.
• Never drop or insert objects into any opening.
• Never drape garme
garments, hook-up leads, or other equipment over the side rails or
drop objects on the belt while the TRACKMASTER® is running.
• Do not allow moisture or oils to accumulate on equipment, creating a slip hazard.

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TRACKMASTER Safety Information

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

• 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.
• Power cord should be routed through frame mounted clamp and kept clear of the
elevation mechanism.
• Keep the power cord out of traffic areas and away from heated surfaces.
• Never use extension cords.
• Never operate the unit when it is wet.
• Never operate the unit if it is not operating properly.
• Always unplug the machine before service or maintenance is performed.
• Treadmill should be serviced by authorized technicians only.
• Operator should report any electrical shock when touching the treadmill and
discontinue use immediately.
• Never use the treadmill outdoors.
• Immediately discontinue use and unplug the treadmill if you smell the distinctive
odor of hot electrical components.

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

Consult your physician prior to using this appliance to determine your physical
readiness and capabilities. Stop exercising immediately and seek medical attention if
you experience chest pain, dizziness or shortness of breath or if you experience
symptoms of overexertion.

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

The potential for foot crush injury at frontal end of treadmill at lift mechanism
(landing gear) when treadmill is descending. Keep feet and hands away from this
area at all times.

Potential foot crush injury at rearward side rail, rear of side rail and rear roller
exists when treadmill approaches full elevation. Keep feet and hands away from this
area at all times.

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Safety Information TRACKMASTER

Information Importante de Sécurité

L’acheteur est entièrement responsable de l’utilisation, de la vigilance et de la sécurité des
utilisateurs du tapis roulant TRACKMASTER® telle qu’elles ont été prévues par le fabricant.
Cet appareil est destiné à être utilisé pour réaliser des entraînements physiques et faciliter
l’évaluation des capacités cardiaques ou de VO2 (Volume maximal d’oxygène).

Avant de permettre à quiconque d'utiliser le TRACKMASTER®, faites ce qui suit:

• Avertir l'utilisateur sur les risques de chute tandis que la ceinture est en
mouvement.
• Insister sur la nécessité d'être prudent.
• Démontrer le bon montage et démontage des méthodes.
• Montrez à chaque utilisateur comment utiliser l'TRACKMASTER® comme
décrit dans ce manuel.
• Demandez à chaque utilisateur d'effectuer un "usage test" supervisé à la
vitesse de la courroie minimum d'examiner et de pratiquer les techniques
d'utilisation.
• Des blessures graves pourraient résulter de la perte d'équilibre ou de chutes.
Pour réduire les risques de blessures graves, observer les précautions
suivantes.

• Lisez le manuel / Service du propriétaire avant de faire fonctionner le

TRACKMASTER®.
• Aider à déchargeant le patient en cas de fonctionnement anormal ou inattendu du
tapis roulant.
• Si le tapis roulant ne répond pas correctement, arrêter le tapis roulant, aider à
éliminer le patient hors du tapis roulant, débranchez l'alimentation tapis roulant, et
de rechercher usine réparation agréé avant d'essayer de redémarrer le tapis roulant.
• Ne jamais laisser les enfants ou les animaux domestiques à proximité de la machine
sans surveillance d'un adulte qualifié.
• Notez l'emplacement de l'arrêt et / ou les dispositifs d'arrêt d'urgence et leur
fonctionnement avant de commencer un essai ou d'entraînement.
• Cet appareil n'est pas destiné à être utilisé par des personnes dont les capacités
physiques, sensorielles ou mentales réduites, ou manquant d'expérience et de
connaissances à moins qu'elles n'aient été formées et encadrées pour l'utilisation de
cet appareil par une personne responsable de leur sécurité.
• Vérifiez que le patient et l'opérateur à la fois savoir comment arrêter la machine en
cas de panne ou d'urgence.
• Le patient ne doit pas porter de nylon amples lors de l'exercice sur ce tapis roulant
pour éviter de générer des décharges électrostatiques.
• Toutes les personnes sur et autour du tapis roulant doivent porter clos, chaussures de
protection. Lacets doivent être serrés et ne pende pas à provoquer une excursion ou
prendre des risques. Sandales, tongs, pantoufles et autres ne sont pas considérés
comme clos, chaussures de protection.
• N'essayez jamais de retirer tout article d'habillement tandis que le tapis roulant est en
mouvement.

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• Toutes les personnes sur et autour du tapis roulant doivent porter clos, chaussures de
protection. Lacets doivent être serrés et ne pende pas à provoquer une excursion ou
prendre des risques
risques. Sandales, tongs, pantoufles et autres ne sont pas considérés
comme clos, chaussures de protection.
• Promenade dans le centre de la bande de course. Contact avec le rail latéral et le tapis
roulant peut provoquer des blessures
blessures.

• Le patient doit toujours porter le bracelet de corde d'attache d'arrêt avant d'utiliser le
TRACKMASTER®.
• Placez le tapis roulant sur un disque. Surface plane et dégagée. Voir les instructions
Assemblée / Set-up dans le chapitre 5 de ce manuel.
• Vérifiez le branchement du cordon d'alimentation d'entrée et l'emplacement des
points de pincement dangereux avant utilisation.
• Vérifiez communications connexion du cordon d'entrée (le le cas échéant) pour
l'interface correcte avec tous les équipements.
• Gardez tous les cordons distance du patient afin d'éviter les risques de chute.
• Ne jamais essayer de retirer le capot du bac de moteur ou le faire vous-même les
réparations électriques
électriques. Les réparations doivent être effectuées par un fournisseur de
service autorisé de l'usine.
• Débranchez toujours le TRACKMASTER® lors de l'entretien,, l'inspection ou le
nettoyage du tapis roulant.
• Inspectez régulièrement le tapis roulant pour pièces détachées.
• Inspectez les mains courantes et de s'assurer qu'ils soutiendront le patient
correctement.
• Commencez toujours le tapis roulant à la vitesse la plus lente avant de commencer
votre séance d'entraînement.
• Ne pas marcher sur la bande quand il est en mouvement.
• Toujours ralentir le tapis roulant à la vitesse minimum avant de s'arrêter.
• Gardez les mains
mains, les pieds et les vêtements loin des pièces mobiles.
mobiles
• Vérifiezz que personne ne se trouve à proximité du mécanisme d'élévation avant de
l'utiliser. Ne mettez jamais aucune partie du corps sous une partie d'un tapis roulant.
• Ne jamais laisser tomber ou insérer des objets dans les ouvertures.
• Ne jamais drapé des vêtements, des fils de raccordement, ou tout autre équipement
sur les rails latéraux ou de supprimer des objets sur la ceinture alors que le
TRACKMASTER® est en marche.
• Ne laissez pas l'humidité ou des huiles de s'accumuler sur les équipements,
équipements créant un
risque de glissade
glissade.

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Safety Information TRACKMASTER

Des blessures graves ou même de mort par électrocution. Pour réduire les
risques de choc électrique, respectez les précautions suivantes.

• Pour débrancher le tapis roulant, placez le commutateur d'alimentation sur la position

OFF et retirez la fiche de la prise. Lorsque l'appareil est éteint, le feu vert sur
l'interrupteur d'alimentation est sombre.
• Ne jamais faire fonctionner l'appareil avec un cordon d'alimentation ou une fiche
endommagé.
• Le cordon d'alimentation doit être acheminé à travers le cadre pince monté et
maintenu claire d'un mécanisme d'élévation.
• Gardez le cordon d'alimentation en dehors des zones de circulation et loin des
surfaces chauffées.
• Ne jamais utiliser de rallonges.
• Ne jamais utiliser l'appareil quand il est mouillé.
• Ne jamais faire fonctionner l'appareil s'il ne fonctionne pas correctement.
• Toujours débrancher la machine avant que le service ou la maintenance est effectuée.
• Tapis roulant doit être réparé par un technicien agréé.
• L'opérateur doit signaler tout choc électrique en touchant le tapis roulant et cessez de
l'utiliser immédiatement.
• N'utilisez jamais le tapis roulant en plein air.
• Cessez immédiatement d'utiliser et débrancher le tapis roulant si vous sentez l'odeur
distinctive de composants électriques chauds.

Des blessures graves ou la mort peuvent entraîner un choc électrique survenant

pendant la défibrillation. Ne permettez jamais à des patients ou à proximité
opérateurs tapis roulant pendant la défibrillation.

Consultez votre médecin avant d'utiliser cet appareil pour déterminer votre niveau
de préparation physique et de capacités. Arrêtez immédiatement l'exercice et
consulter un médecin si vous ressentez des douleurs thoraciques, des
étourdissements ou un essoufflement ou si vous ressentez des symptômes de
surmenage.

Des blessures graves ou la mort pourraient résulter de l'exploitation du tapis

roulant en présence de vapeurs et antiseptiques explosives ou inflammables.

Lésion par écrasement du pied potentiel à la fin frontal de tapis roulant à

mécanisme de levage (train d'atterrissage) lorsque tapis roulant est en descente.
Gardez les pieds et les mains loin de cette région à tout moment.

Potentiel lésion par écrasement de la nourriture au rail latéral vers l'arrière, à

l'arrière de rail latéral et le rouleau arrière existe lorsque tapis roulant se rapproche
de l'élévation complète. Gardez les pieds et les mains loin de cette région à tout
moment.

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Content

Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

Regulatory and Safety Conformance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

Important Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii to ix

Chapter 1 Introduction
Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Serial Decal Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
RoHS/WEEE Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Equipment Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Warning and Caution Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Chapter 2 Specifications
Directional Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Safety Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Treadmill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Speed Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Incline Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Running Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Communication Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Floor Surface Footprint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Operating and Storage Condition Recommendations . . . . . . . . . . . . . . . . . . . . . . 2-2

Chapter 3 Power Requirements

Operating Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Receptacle Requirements (standard and optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Chapter 4 Hi Pot Test Instructions .............................................. 4-1

Chapter 5 Assembly and Setup

Safe Handling Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Initial Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
TMX428CP & TMX58 Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Final Setup - Running Belt Tracking Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Final Setup - Running Belt Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Final Setup - Drive Belt Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Final Setup - Test Plug Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Communication Access Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

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Chapter 6 Operation Instructions

Programmable Control Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Diagnostic Testing Mode Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Manual Mode Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Performance Information Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Stop Tether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Control Panel Button Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Workout Graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Built-in Program Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Pre-Programmed Cardiac Protocol Workouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Pre-Programmed Fitness Workouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
User Defined Programming Workouts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
TMX428 Software Download . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
TMX428CP LCD Software Download . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
TMX428 Series Dip Switch Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
TMX428 TMX428CP TMX58 Belt Speed Calibration Procedure
OEM/Maintenance Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
TMX428 TMX428CP TMX58 Belt Speed Calibration Procedure . . . . . . . . . . 6-13
TMX428 TMX428CP Verifying Belt Speed
Calibration in the Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
TMX428 TMX428CP TMX58 Elevation Calibration Procedure
OEM/Maintenance Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
TMX428 TMX428CP TMX58 Elevation Calibration Procedure . . . . . . . . . . . 6-19
TMX428CP TMX58 Parameter & History Screen . . . . . . . . . . . . . . . . . . . . . . . 6-22

Chapter 7 Preventive Maintenance

Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Weekly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Monthly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Semiannual Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Belt Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Running Belt Tracking Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Running Belt Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Drive Belt Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Exterior Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Running Deck Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

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TRACKMASTER

Chapter 8 Product Requirements

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Operational Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Software Requirements Speed Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Software Requirements Elevation Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Communication Hardware (RS232 Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Communication Hardware (USB Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Command Protocol A Input Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Command Protocol B Input Commands Acknowledgment . . . . . . . . . . . . . . . . . . 8-4
Command Protocol C Status Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Command Protocol D Status Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Communication Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Self Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Dip Switch Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Electrical Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Electrical Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Physical Requirement & Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
Schematic Universal Power Supply Board (FG0495). . . . . . . . . . . . . . . . . . . . . . . 8-9

Chapter 9 Trouble Shooting Matrix

Incoming Power 110-240VAC Flow Chart 1A . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -1
Inline Filter Incoming Power 110-240VAC Flow Chart 1B . . . . . . . . . . . . . . . . . 9 -2
Pacific Scientific Drive Incoming Power 110-240VAC Flow Chart 1C . . . . . . 9-3
Smart Power Supply Incoming Power 110-240VAC Flow Chart 1D . . . . . . . . . 9-4
Emergency Stop Flow Chart 1E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -5
Safety Pull Tether Flow Chart 1F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Communications RS232 Flow Chart 1G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -6
Communications USB Flow Chart 1H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -7
Smart Power Supply Error Code Identification Flow Chart 1I . . . . . . . . . . . . . . . 9 -8
Smart Power Supply Error Code 1 Flow Chart 1J . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -9
Smart Power Supply Error Code 2 Flow Chart 1K . . . . . . . . . . . . . . . . . . . . . . . . 9 -10
Smart Power Supply Error Code 3 Flow Chart 1L . . . . . . . . . . . . . . . . . . . . . . . . 9 -11
Smart Power Supply Error Code 4 Flow Chart 1M . . . . . . . . . . . . . . . . . . . . . . . . 9-12
Smart Power Supply Error Code 5 Flow Chart 1N . . . . . . . . . . . . . . . . . . . . . . . 9 -13
Smart Power Supply Error Code 6 Flow Chart 1O . . . . . . . . . . . . . . . . . . . . . . . . 9 -14
Smart Power Supply Error Code 7 Flow Chart 1P . . . . . . . . . . . . . . . . . . 9 -15 & 16
Smart Power Supply Error Code 8 Flow Chart 1Q . . . . . . . . . . . . . . . . . . . . . . . . 9-17
Smart Power Supply Error Code 9 Flow Chart 1R . . . . . . . . . . . . . . . . . . . . . . . . 9-18
Smart Power Supply Error Code 10 “Consult Factory for Trouble Shooting” 9-18
Control Console Communication Flow Chart 1T . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
Drive PC2303-012-N Status LED Code List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19

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 TRACKMASTER

Chapter 10 Removal and Replacement of Components

Hood Removal Procedure TMX428 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Drive Motor Replacement TMX428 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Drive Replacement TMX428 Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Front Roller Replacement TMX428 Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Rear Roller Replacement TMX428 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Running Belt Replacement TMX428 Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Running Deck Replacement TMX428 Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
Deck Cushion Replacement TMX428 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Motor Drive Belt Replacement TMX428 Series . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Elevation Actuator Replacement/Adjustment TMX428 Series . . . . . . . . . . . . 10-12
Smart Power Supply Relay Board Replacement TMX428 Series . . . . . . . . . . 10-13
Circuit Breaker Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
Relocate Emergency Stop Button and Stop Tether Switch . . . . . . . . . . . . . . . . 10-15
Validate Relocate ESB and STS Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16

Chapter 11 Established Component Replacement Times

Component Replacement Times TMX428 Series . . . . . . . . . . . . . . . . . . . . . . . . 11-1

Chapter 12 Parts List with Part Numbers

Motor Mount Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
Circuit Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
Elevation Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
Pull Tether Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
Emergency Stop Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
Motor Pan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
Motor Pan Assembly Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-9
Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-11
Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-13
TMX428CP Controller Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-15
TMX58Controller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-17

Appendix A Maintenance Log

TMX428 TMX428CP TMX58 Service Manual October 2015

TRACKMASTER Introduction

Introduction 1
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 use. The TRACKMASTER® treadmill has gained worldwide recognition as
one of the best and most dependable treadmills on the market. As a result,
TRACKMASTER® has thousands of successful installations across the globe.

TRACKMASTER® treadmills are designed and built to withstand the extraordinary demands
of medical motion devices. It is compatible with nearly all OEM testing devices. The model
TMX428 is designed for cardiac stress tests and Model TMX428CP for pulmonary function
testing.

This manual covers the installation & operation of your new treadmill. If you have questions,
contact your system integrator or TRACKMASTER® dealer. If you need further assistance,
please call the TRACKMASTER® Service Support team at (316)-283-3344.

Notices
Three different levels of notices throughout this manual alert you to important
information: Note, Caution, and Warning.
Avis
Les trois différents niveaux d’avis tout au long de ce manuel attirent votre
attention sur des renseignements importants : Note, Attention et
Avertissement.

Note
Note statements provide additional information. For example:
NOTE: For maximum efficiency, the TRACKMASTER® must have its own dedicated power
outlet.

Note
Les déclarations des notes fournissent des informations supplémentaires. Par
exemple.

NOTE: Pour une efficacité maximale, le TRACKMASTER® doit avoir sa propre prise de
courant appropriée.

Caution
Caution notices inform you of potential hazards that could result in equipment
damage or injury to the user. For example:

October 2015 TMX428 TMX428CP TMX58 Service Manual 1-1

Introduction TRACKMASTER

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 may cause you to slip.

Attention
Les avis d’Attention vous informent des dangers potentiels qui risquent
d’entraîner des dommages à l’appareil ou des blessures pour l'utilisateur. Par
exemple:

N'utilisez pas des sprays à la silicone pour cirer la plate -forme du tapis
roulant. L’utilisation du spray à la silicone peut annuler la garantie. Cette
pulvérisation peut apporter des modifications à la surface qui peuvent
vous faire glisser.

Warning
Warning notices alert readers to hazards that will result in serious injury or
death. For example:

Never open the hood of the TRACKMASTER® while it is plugged into a

power outlet. Line voltage can cause severe injury or death.

Avertissement
Les avis d’avertissement alertent les lecteurs sur les dangers qui provoqueront
de graves blessures ou le décès. Par exemple:

Ne jamais ouvrir le couvercle du TRACKMASTER® alors qu’il est

branché sur une prise de courant. La ligne d'alimentation entraînera la
mort ou des blessures graves.

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 TRACKMASTER Introduction

Serial Decal Information

This information must be supplied when contacting the factory for parts or service.

Item Name Description

A Manufacturer Full-Vision Inc.
Full
B Model Number Identifies model of treadmill
C Part Number Manufacturers part number
D Voltage Specifies operating voltage of treadmill
E Hertz Specifies the electrical hertz of treadmill
F Amps S
Specifies amperage of treadmill
G Serial Number Manufacturers assigned serial number
H Mfg Date Manufacturers date code
I Type B Device is suitable for the external application of type “B”
Equipment applied parts.

European Union Disposal Requirements:

This equipment complies with the EU WEEE marking requirement for proper disposal of electrical
and electronic waste in accordance with the European Directive 20
2011/65/EU.. This directive calls for
separation and recovery or reuse of used electrical or electronic equipment upon end of life EEE
disposal.

The TRACKMASTER® must not be disposed of as unsorted municipal waste. Electrical or electronic
components must be collected separately and disposed of in accordance with your local requirements and
sources. The EEE program minimizes any potential effects oon
n the environment and user health by eliminating
the potential presence of hazardous substances in the waste stream. Customers should contact their local
authorities or TRACKMASTER® Distributor for guidance in complying with the directive.

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Introduction TRACKMASTER

Equipment Symbols The following symbols appear on the equipment.

Symboles de l'équipement Les symboles suivants apparaissent sur l'équipement

Reading of the Owner’s Manual is mandatory.

Lecture du manuel du propriétaire est obligatoire.
Elevation incline / decline adjustment.
Altitude ajustement de pente / recul.
Running belt speed adjustment.
Exécution de réglage de la vitesse de courroie.
This symbol warns of potential high electric voltage shock or injury potential. Areas
of the TRACKMASTER® where this symbol appears are to be accessed only by
trained service personnel
Ce symbole prévient de choc de tension électrique à fort potentiel ou potentiel de
blessure. Domaines de la TRACKMASTER® où ce symbole apparaît doivent être
accessibles uniquement par du personnel qualifié.
Protective earth (ground)
Mise à la terre
Alternating current
Courant alternatif
Device is suitable for the external application of the type “B” applied parts.
Dispositif approprié aux applications externes des pièces appliquées de type « B ».

Warning and Caution Symbols

Symboles d’Avertissement et d’Attention

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TRACKMASTER Specifications

Specifications 2
Directional Orientation
References to left, right, front, and rear are based on the assumption that you are
standing on the treadmill, facing the control console.

Patient Grab Rails

Emergency
Stop Button

Stop Tether

Side Rail Running

Belt

Elevation Landing Gear Rear Foot

(Non-Applied Part) (Non-Applied Part)

Safety Systems
• Dual comparative speed sensors
• Auto runaway shutdown
• Auto communication loss shutdown
• Manual twist lock Emergency Stop button
• Manual Stop Tether
• Braking system for safe patient offloading TMX428CP Programmable Control
• Fire rated motor pan hood enclosure

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Specifications TRACKMASTER

Treadmill
• Patient weight capacity 500 lb., 227 kg
• All steel construction with baked powder-coat finish
• Treadmill net weight: 425 lb., 193 kg

Drive System
• Heavy-duty 6-peak hp. brushless, DC servo motor
• 110-120VAC, 1-phase, 60 Hz, 20-amp power supply (standard)
• 220/240VAC, 1-phase, 50-60 Hz, 15-amp power supply (optional)

Speed Range
• 0.5 to 12 M.P.H, .80 to 19.3 K.P.H., Self-calibrating and adjustable in .1
M.P.H., .1 K.P.H increments. (standard)
• 0.1 to 15 M.P.H., .2 to 24.0 K.P.H., Self-calibrating and adjustable in .1
M.P.H., .1 K.P.H increments. (optional available on TMX428CP only)

Incline Range
• 0 to 25%, .5% incremental movements, self-calibrating.

Running Surface
• 22in. x 63in. 56cm x 160cm
• MasterTrack® running belt tracking system
• Cushioned running deck absorbs shock of foot falls
• Self lubricated and reversible running deck
• Step up height (7 inches., 18cm from floor)

Communication Ports
• RS232 Female Serial port and USB 1.0 “B”

Floor Surface Footprint

• 33in. x 78.5 in., 84cm x 200cm level surface. (See location requirements
chapter 5)

Operating and Storage Condition Recommendations

• Operating Temperature Range: 4.5° to +38° C (+40° +85° F)
• Storage Temperature Range: -40° to +70° C (-40° to +158° F)
• Operating and Storage Relative Humidity Range: 10% - 90%, non-condensing
• Altitude: -50 to 5,280 feet

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TRACKMASTER Power Requirements

Power Requirements 3
The TRACKMASTER® is designed to operate on a dedicated 110-120 VAC 20-amp power
supply or optional 220/240 VAC 15-amp. Make sure that the treadmill is connected to an
outlet that looks like the following illustration.

This product is equipped with a three-wire grounding-type plug. The plug will only fit into a
grounding-type outlet. This safety feature must not be disabled. Contact a qualified
electrician if you are unable to insert the plug into your outlet, or uncertain if the outlet meets
local electrical codes. Polarized outlets such as NEMA 5-20 and CEE7/7 must be verified for
proper polarity configuration before plugging in the TRACKMASTER®. Incorrect
polarization of the outlet could cause failure of onboard electrical components or cause
electrical shock. Proper grounding is necessary for the equipment to meet acceptable current
leakage standards consistent with the standards to which it was certified.

110-120VAC 220/240 VAC 220/240 VAC 230 VAC

NEMA 5-20R NEMA 6-15R CEE 7/7 EURO UK BS1363
Single Phase Split Phase Option Option

TRACKMASTER® treadmills must be grounded to reduce the risk of

electrical shock. If a malfunction occurs, grounding provides a path of least
resistance for an electric current. Ungrounded connections must not be used.

No other equipment may be used on the electrical circuit with the

TRACKMASTER®. Do not use extension cords. Using a shared or
unreliable circuit can also cause the TRACKMASTER® to unexpectedly
shut off, potentially resulting in injury to the patient.

Ensure the master power switch is in the off position before plugging
in the TRACKMASTER®. A power surge could damage the
sophisticated electronic system of the treadmill.

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Power Requirements TRACKMASTER

Spécifications électriques
Le TRACKMASTER® est conçu pour fonctionner sur un 110-120 VAC alimentation de 20
ampères dédié ou 15 ampères 220/240 VAC en option. Assurez-vous que le tapis roulant est
branché sur une prise qui ressemble à l'illustration suivante.

Ce produit est équipé d'une prise de terre à trois fils. La fiche ne peut être insérée dans une
prise de terre. Ce dispositif de sécurité ne doit pas être désactivé. Contactez un électricien
qualifié si vous ne parvenez pas à insérer la fiche dans la prise, ou incertaine si la sortie
répond aux codes électriques locaux. Prises polarisées comme NEMA 5-20 et CEE7 / 7
doivent être vérifiés pour la configuration de la polarité avant de brancher le
TRACKMASTER®. Polarisation incorrecte de la prise de courant peut provoquer une panne
des composants électriques embarqués ou provoquer un choc électrique. Mise à la terre est
nécessaire pour l'équipement pour répondre aux normes de fuite de courant acceptable qui
soit compatible avec les normes auxquelles elle a été accréditée

110-120VAC 220/240 VAC 220/240 VAC 230 VAC

NEMA 5-20R NEMA 6-15R CEE 7/7 EURO UK BS1363
Monophasés Phase divisée Choix Choix

Tapis roulants TRACKMASTER® doivent être mis à la terre pour

réduire le risque de choc électrique. En cas de dysfonctionnement,
la terre fournit un chemin de moindre résistance pour le courant
électrique. Connexions infondées ne doivent pas être utilisées.

Aucun autre équipement ne peut être utilisé sur le circuit

électrique avec le TRACKMASTER®. Ne pas utiliser de rallonges.
L'utilisation d'un circuit partagé ou non fiable peut aussi causer la
TRACKMASTER®. A fermer de façon inattendue off, ce qui
pourrait entraîner des blessures pour le patient.

S'assurer que le commutateur d'alimentation principal est en

position arrêt avant de brancher la TRACKMASTER®. Une
surtension peut endommager le système électronique sophistiqué
du tapis roulant.

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TRACKMASTER Hi-Pot Test

Hi Pot Test Instructions 4

This test must only be performed by a qualified electrician.
Your Trackmaster® Treadmill has been Hi-Pot tested at the factory just prior to shipment and
found to be within specifications. However, some facilities require Hi Pot test verification
before the treadmill is put into service. The following instructions must be followed to
prevent permanent damage to the Trackmaster® electronic control system. Failure to follow
these instructions will void your warranty.

NEVER USE AN AC HI-POT TESTER ON THIS TREADMILL!

Using an AC HI-Pot tester will permanently damage the DC
motor controller board rendering the treadmill inoperable.

Hi-Pot test instructions for Treadmills

1. Unplug the surge suppresser from the 2. Attach DC Hi-Pot tester ground clip to a known
main wire harness. chassis ground on the treadmill.

3. For 110V models: Test at 1.75 KV DC

for 60 seconds. This is equivalent to
1240 VAC.

4. For 220V models: Test at 2.10 KV DC

for 60 seconds. This is equivalent to 1488
VAC.

The tester should register a PASS for

either test.

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 TRACKMASTER Set-up Instructions

Assembly and Setup

5
TRACKMASTER® treadmills are shipped fully assembled and packaged in a knock down condition. They
are designed to pass through a standard 36” door opening measuring at least 35½. It will be necessary to
remove the door from the jam in most cases if the door is not capable of opening fully parallel to door
opening. After you have unpacked the treadmill and secured the handrail assembly to the frame, move the
treadmill to the area by rolling it on its front wheels. If your treadmill must pass through a door opening
less than 36”wide, additional disassembly will be required. This task should be performed by an authorized
service provider to ensure that the TRACKMASTER® is properly reassembled and functioning correctly.

Safe Handling Guidelines

Do not attempt to move the treadmill with the handrails in the shipping position due to the
possibility of cutting the internal wiring. You must either fully secure the handrails in their proper
position or secure handrails with 3/8-16 bolt in the folded position.

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 its wheels) and
push forward.

When you have maneuvered the treadmill into its location, gently lower the end of the bed
assembly to the floor.

The TRACKMASTER® weight is 425lbs. This requires 2 people to safely remove

it from the pallet and locate it in the facility.

If you are moving the treadmill over rough surface, such as pavement, use a
dolly under front of the treadmill to prevent damage to the wheels and lift
mechanism.
Le TRACKMASTER® pèse 193 kg ce qui exige 2 personnes pour le soulever de
la palette et l’installer en toute sécurité.

Si vous déplacez le tapis roulant sur une surface rugueuse, comme trottoir,
utiliser un chariot sous l'avant du tapis roulant pour éviter d'endommager les
roues et mécanisme de levage.

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 Set-up Instructions TRACKMASTER

Initial Setup
Tools required for assembly
5/16 Allen wrench (supplied)
1. The treadmill is shipped with the handrails loose, straddling the treadmill frame.
It is advised that you secure the handrails in their proper location before
removing the treadmill from the base of the crate. This prevents the internal
wires running down the handrail mount to the motor pan from being cut.
2. With the help of a 2nd person, swing the handrail assembly into the operating
position and insert (2) 3/8-16 bolts and 3/8 lock washer each side and tighten
securely.
3. Install (2) plastic caps each side for a finished look. Figure 5-1

Operating Position

Shipping Position
Figure 5-1
Insert (2) washer and bolts
each side.

Pivot Point
When folding handrails apply
cardboard between frame and
handrail to prevent handrail damage. Insert (2) caps each side
TMX428CP & TMX58 Control Assembly

4. Figure 5-2 shows the mounting

components included with the
shipment of the treadmill. The kit
contains:
• (4) ¼-20 bolts
• (1) Black cover
• (4) #10-32 Screws
• (2) Rubber isolators
• (4) Washers

Figure 5-2

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TRACKMASTER Set-up Instructions

5. Connect electrical connections from

the back of the console to the
connectors within the handrail cross
brace.
6. Attach the console to the console
supports with the hardware supplied
in the order shown in Figure 5-3.
Ensure the rubber pads are placed
between the steel mounting surface
and the back of the console. Tighten
bolts evenly.
7. Position the black cover and align
the holes in the side of the mount
Figure 5-3 with those in the cover. Secure cover
with (4) #10-32 screws.

Location
Place the TRACKMASTER® on a firm and level hard surface that is free of tile grout
lines. The illustration below shows the minimum recommended clearances from the
treadmill edges to any obstruction for dismount and safety purposes. Observe that
the operator should be stationed by the E-Stop.

3 ft. / 91.4 cm 5 ft. / 1.5m

6 ft. / 182.8 cm

3 ft. / 91.4 cm

1 ft. / 91.4 cm

The TRACKMASTER® conforms to FCC class A rating for electromagnetic emissions. It is

recommended not to place the treadmill closer than 5ft. (1.5m) from sensitive electronic
devices within the room or in an adjacent room. If an interference problem occurs, move the
treadmill farther away from the sensitive device or relocate either device to another area, or
consult with an EMI specialist for ways to shield the room from electromagnetic radiation.

Do not place it 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.

Ensure that power cords do not cross traffic areas. Exposed power cords can cause a fall,
resulting in injury.

Keep it away from sources of moisture, such as spas or fountains. Moisture can cause the
electronic circuitry to malfunction.

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Set-up Instructions TRACKMASTER

Le TRACKMASTER® est conforme à FCC classe A d'avis pour les émissions

électromagnétiques. Il est recommandé de ne pas placer le tapis roulant à moins de 5 pis.
(1.5m) à partir d'appareils électroniques sensibles dans la chambre ou dans une salle
adjacente. Si un problème d'interférence, déplacer le tapis roulant plus loin du dispositif
sensible ou déplacer soit appareil à un autre domaine, ou consulter un spécialiste EMI
des moyens pour protéger la chambre de rayonnement électromagnétique.
Ne le placez pas sur un tapis épais ou longs poils. Un tel tapis pourrait entraîner une
instabilité ou accumulation d'électricité statique, et les fibres de tapis pourrait se coincer
dans le tapis et endommager l'appareil.
Assurez-vous que les cordons d'alimentation ne traversent pas les zones de circulation.
Cordons d'alimentation exposées risqueraient de provoquer une chute, entraînant des
blessures.
Tenir à l'écart de toute source d'humidité, comme des spas ou des fontaines.
L'humidité peut provoquer le circuit électronique de dysfonctionnement.

Final Setup - Running Belt Tracking Adjustment

NOTE: Because this adjustment is not covered under your warranty, it is important that you review
these instructions thoroughly before proceeding. Uneven floors accelerate belt
misalignment. This situation may require more frequent adjustment to prevent belt damage.

The patented MasterTrack® Belt Tracking System significantly reduces the need to adjust the belt
on your TRACKMASTER®. However, when you operate your treadmill for the first time, you
may need to adjust the tracking of the belt to conform to your floor. You may also need to adjust
the tracking if you move the machine to another location. (See Preventative Maintenance chapter
7 for adjustment procedure.)

Final Setup - Running Belt Tension Adjustment

Your TRACKMASTER® running belt has been pre-tensioned at the factory and run for 16 hours
prior to shipment. It may, however, be necessary to adjust the belt tension when the treadmill is run
in its final location. A loose belt tends to hesitate or stick with a heavy foot plant. If your belt needs
tensioning, the adjustment procedure can be found in Preventative Maintenance chapter 7.

NOTE: Improper adjustment could cause the treadmill to hesitate and cause a trip and fall hazard.
Because this adjustment is not covered under your warranty, it is important that you
review these instructions thoroughly before proceeding.

Final Setup - Drive Belt Tension Adjustment

The drive belt tension has been set at the factory and is self adjusting to minimize
maintenance. This design will compensate for initial stretch of the drive belt and not
require further adjustment. If the belt becomes stretched and loose, refer to the
Preventative Maintenance chapter 7 for adjustment procedure.

NOTE: Because this adjustment is not covered under your warranty, it is important that you
review these instructions thoroughly before proceeding.

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Final Setup - Test Plug Procedure

Each TRACKMASTER® TMX428 Series treadmill includes
an RS-232 test plug that enables you to test the operation of
the treadmill without the ECG unit attached. The plug is
located on the left side of the treadmill secured to the frame
by Velcro. The plug is to be used only for testing the
treadmill. Do not stand on or use the treadmill while testing.

Circuit Breaker Array

Front of Treadmill

Incoming Power Cord

Test Plug Located on Left Side Main Power Switch

To use the test plug, observe the following procedure:

1. Turn the power "OFF" at the treadmill.

2. Disconnect RS232 or USB interface cable from the treadmill and plug in the test
connector.
3. Press and hold the button down on the test connector and turn treadmill power "ON".
Continue holding until treadmill begins to elevate.
4. Once this is initiated, each push of the button should elevate the treadmill by 5%.
5. When the treadmill reaches 20% elevation, the next push of the button will start the
treadmill running belt.
6. With each push of the button, the treadmill will increase speed by 2.5 miles per hour.
7. Once the treadmill reaches 10 mph, each push of the button will bring the speed down
2.5 miles per hour and simultaneously lower the elevation in increments of 5%.
8. When minimum speed and elevation is reached the next press of the button will cause
the treadmill running belt to stop.
NOTE: Successful completion of the preceding testing procedure ensures that the
treadmill is fully functional and responsive to command signals.
9. Remove the test connector.
10. Reconnect the RS232 or USB interface cable from the host computer. You are ready to
begin the set-up procedure prescribed by your medical test equipment supplier.

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Assembly and Setup TRACKMASTER

Communication Access Location

The communication ports are located at the very front of the treadmill near the center of the
unit. Two ports are offered with equal communication capability. The standard “Female”
RS232 port and a new USB “B” port offer connectivity diversification. You will need to
install the appropriate USB driver software in order to communicate with the
TRACKMASTER® You may download the appropriate driver based upon your computer OS
at http://www.ftdichip.com/Drivers/VCP.htm. When connecting to the USB port, ensure port
configuration is congruent with your software port identification.

RS232 Port USB “B” Port

“Female”

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TRACKMASTER Operating Instructions

Programmable Control Instructions

TMX428CP 6
The TRACKMASTER® TMX428CP Programmable Control model is a dual purpose treadmill capable of
running in diagnostic mode for cardiac stress testing or a VO2 pulmonary evaluation. The display
automatically changes from a blue, full information screen (typically found on fitness treadmills), to a
black screen with minimal status data upon initiating a test program within a 3rd party diagnostic computer
system. All control buttons in the console are disabled in this mode with the exception of the two stop
buttons located at the lower left and lower right of the control. The display will revert back to the full
information screen upon closing the diagnostic computer program.

DIAGNOSTIC TESTING MODE DISPLAY

The TRACKMASTER® TMX428CP Programmable Control model is a full-featured, stand-alone fitness

treadmill suitable for rehabilitation and general fitness applications. Additionally, it comes pre-
programmed with 10 workouts, including Pre-Programmed Protocols and Interval Fitness training
routines, in addition to 5 possible user defined workouts.

MANUAL MODE DISPLAY

Control Panel Display: The blue display screen in the center of the console provides information on how
to begin your workout and provides continuous user performance data throughout the workout session.
Additionally, it serves as a user interface allowing optional input of user information when a new workout
begins. The screen will prompt the user to input weight, age, and gender so that the onboard computer can
calculate a more accurate calorie burn and target heart rate. Heart rate measurement is accessible through
the use of the contact grips or by wearing a wireless pulse rate watch or chest strap. The display screen
allows the user to simultaneously monitor: time, speed, incline, distance traveled, pace, current heart rate,
calories burned and METS.

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Operating Instructions TRACKMASTER

The performance and feedback information provided on the blue display screen are defined as follows:
Time: The elapsed time of your workout session, beginning with the initial movement of the belt and
ending when the stop button are pressed.
Speed: The speed at which the belt is moving. The belt starts at .1 M.P.H. and has a top speed of 15
M.P.H. Belt speed can be increased or decreased in .1 M.P.H. increments. This feature is capable of
displaying KPH.
Incline: The degree of incline of the walking surface. The starting incline is 0% with a maximum of 25%.
The degree of incline can be increased or decreased in .5% increments.
Distance: The distance traveled in miles during the duration of the workout session, beginning with the
initial movement of the belt and ending when the stop button are pressed. The distance is measured in .1 of
a mile. This feature is capable of displaying in Kilometers.
Heart Rate: The user’s current heart rate calculated in beats per minute when wearing a wireless chest
strap, wireless watch monitor, or by using the contact grips.
Calories: An approximate calculation of cumulative K-CAL expenditure for the exercise session based on
your body weight and the level of difficulty at which you are exercising.
Pace: Displays the number of minutes needed to run one mile or kilometer.
METS: Displays MET level
Control Panel Button Descriptions:
NOTE: You must attach the Stop Tether lanyard strap to your wrist before pressing any other buttons on
the TRACKMASTER® control. The lanyard will stop the moving running belt should you fall.
Stop Tether: This switch is located on the console in the lower right hand portion, just right of center. It is
used in combination with a lanyard and wrist cuff which is to be worn by the user at all times during the
operation of the TRACKMASTER®. The opposite end of the lanyard has a plastic “C” shaped piece that
engages the Stop Tether which must be in place for the machine to run. Simply insert the clip on the shaft
directly behind the red cap on the switch. The TRACKMASTER® is designed to stop all functions upon
activation of the Stop Tether. Operation cannot resume until the “C” shaped clip is returned to its
operational position.

Start button: The green start button is used to begin a workout session. When a new user steps onto the
machine and the start up information is displayed on the screen, pressing the start button will immediately
begin a 3 second countdown of the belt start at minimum belt speed. When a user has previously selected a
pre-programmed workout, pressing the start button will start the first phase of the program.
Stop buttons: The red hexagon shaped stop buttons are used to end an exercise session. Anytime that it is
pressed during a workout session, the running belt will gently come to a stop and be locked into place for 2
minutes or until a new workout session is started. Upon pressing the stop button, the incline of the running
deck will decrease to 0 percent and the cumulative user data information will displayed for 60 seconds. To
start a new workout session, press the Start button or Program button.

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Enter button: The yellow enter button is used to enter the user’s weight, age, and gender when prompted
by the display screen at the beginning of a workout session as well as entering data when creating or
modifying workout programs.
Cool Down button: The blue cool down button will incrementally slow the running belt speed down by
.1 mph or kph and decrease elevation by .5% elevation incrementally over 90 seconds every until the
running belt stops and elevation returns to 0% elevation.
Program / Select button: The black program button calls up a list of pre-programmed workouts and is
used to select segments of a workout when creating or modifying a workout routine.
Speed Minus “Slower”: The triangular speed minus button decreases the speed of the running belt by .1
mph or kph each time it is pressed while the belt is moving. Pressing and holding the speed minus
“slower” button while the belt is moving will decrease the speed of the running belt at an accelerated rate
until it is released.
Speed Plus “Faster”: The triangular speed faster button increases the speed of the running belt by .1 mph
or kph each time it is pressed while the belt is moving. Pressing and holding the speed plus “faster” button
while the belt is moving will increase the speed of the running belt at an accelerated rate until it is
released.
Quick Speed: The (5) quick speed buttons will rapidly bring the running belt speed to the speed selected
from 1 to 5 mph or K.P.H.
Incline Minus: The triangular incline minus button decreases the incline of the walking surface by .5
percent each time it is pressed while the running belt is operating. Pressing and holding the incline minus
button while the running belt is in motion will increase the rate of the command. However, it may take a
few seconds to reach the desired incline that is displayed on the information screen after the button is
released.
Incline Plus: The triangular incline plus button increases the incline of the walking surface by .5 percent
each time it is pressed while the running belt is operating. Pressing and holding the incline plus button
while the running belt is in motion will increase the rate of the command. However, it may take a few
seconds to reach the desired incline that is displayed on the information screen after the button is released.
Quick Incline: The (5) quick incline buttons will rapidly bring the running belt surface to the selected
incline from 3% to 15%.
WORKOUT GRAPHICS

1. The entire workout is represented in the form of a colored bar graph which depicts increasing workout
intensity as well as workout progression and current treadmill settings. These values can be displayed in
either Metric or English measurements.
2. Segments that have been completed will turn to MAGENTA. In the example above, the first two segments
of the workout have been completed leaving (7) segments yet to complete.
3. The GREEN portion of the bar represents an incline between 0 and 10%
4. The YELLOW portion of the bar represents an incline between 10% and 18%.
5. The RED portion of the bar represents an incline from 18% to 25%.
6. The BLACK horizontal bars represent the running belt speed. They will turn to WHITE when the segment
is completed.

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Operating Instructions TRACKMASTER

MANUAL OPERATION:
The default start-up screen allows the user to bypass the user data by simply pressing the START
button. To enter user data, complete steps 1-16. The user interface screen easily leads the user through
the appropriate steps to achieve a desired operation.
1. Press the ENTER button to input user information.
2. Optionally, press the START button to start the treadmill in a
non-defined run mode -OR-
3. Press the PROGRAM SELECT button to view and select a
Built-In routine. Go to step 15.
If you opted to input your user information, follow the next 12
steps
4. Press the + or – button until the desired age appears on the
screen.
5. Press the ENTER button to continue.
6. Press the + or – button until the desired weight appears on the
screen.
7. Press the ENTER button to continue.

8. Press the + or – button until the correct gender appears on the

screen.
9. Press the ENTER button to continue.

10. Press the + or – button until the desired heart rate appears on
the screen.
11. Press START to begin walking.

NOTE: The target heart rate function is only available through the
use of a wireless chest strap or pulse rate watch monitoring device.
NOTE: If the user exceeds the stated heart rate target, the screen
will flash a warning that the target heart rate has been exceeded.
The treadmill, however, will not stop. It is the responsibility of the
user to take further action.
12. Upon pressing the START button in step 11, the screen will
advise that the belt will start in a countdown of 3 as shown at
the right.

13. After the belt begins to move, elevation and speed control is
available through the use of the + / - keys as well as the quick
speed keys on the console.
14. Press the STOP key to immediately stop your workout or press
the COOL DOWN key to slowly decelerate the belt to a stop.

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BUILT-IN PROGRAM OPERATION

There are 10 pre-programmed workouts within the control. Select from (5) Pre-Programmed
protocols and (5) interval training routines. To access these programs, complete the following
steps: The following (5) Pre-Programmed Protocols are explained here.

15. In Step 3, the user selected the PROGRAM SELECT button

to access Built-In program routines. This screen requires the
user to select either Pre-Programmed Protocols, Fitness
Interval workouts, or to define a custom workouts by
utilizing the + - buttons. When the desired program is
highlighted, press the Yellow Enter button to select. If the
user selects Fitness Workouts, go to Step 17. If the user
selects the User Defined Program, go to Step 19.
16. Press the + or – button until the desired Protocol is selected.
When the desired program is highlighted, press the Green
Start button to start routine. The detailed description for each
Pre-Programmed Protocol bellow.

Pre-Programmed Protocol Workout Data

Bruce Protocol
Speed
Time KPM / MPH Incline
Warm-up 3 min 2.7 1.7 0%
Stage 1 3 min 2.7 1.7 10%
Stage 2 3 min 4.0 2.5 12%
Stage 3 3 min 5.7 3.4 14%
Stage 4 3 min 6.8 4.2 16%
Stage 5 3 min 8.1 5.0 18%
Stage 6 3 min 8.9 5.5 20%
Stage 7 3 min 8.9 6.0 22%
Cool-down 3 min 2.7 1.7 0%

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Operating Instructions TRACKMASTER

Gerkin Protocol (Firefighter’s Test)

Speed
Time KPM / MPH Incline
Warm-up 3 min 4.8 3.0 0%
Stage 1 1 min 7.2 4.5 0%
Stage 2 1 min 7.2 4.5 2%
Stage 3 1 min 8.0 5.0 2%
Stage 4 1 min 8.0 5.0 4%
Stage 5 1 min 8.8 5.5 4%
Stage 6 1 min 8.8 5.5 6%
Stage 7 1 min 9.7 6.0 6%
Stage 8 1 min 9.7 6.0 8%
Stage 9 1 min 10.5 6.5 8%
Stage 10 1 min 10.5 6.5 10%
Stage 11 1 min 11.3 7.0 10%
Stage 12 1 min 11.3 7.0 12%
Stage 13 1 min 12.0 7.5 12%
Stage 14 1 min 12.0 7.5 14%
Stage 15 1 min 12.9 8.0 14%
Stage 16 1 min 12.9 8.0 16%
Cool-down 3 min 2.7 1.7 0%

Naughton Protocol
Speed
Time KPM / MPH Incline
Warm-up 2 min 1.6 1.0 0%
Stage 1 2 min 3.2 2.0 0%
Stage 2 2 min 3.2 2.0 3.5%
Stage 3 2 min 3.2 2.0 7.0%
Stage 4 2 min 3.2 2.0 10.5%
Stage 5 2 min 3.2 2.0 14.0%
Stage 6 2 min 3.2 2.0 17.5%
Cool-down 3 min 1.6 1.0 0%

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Balke- Male
Speed
Time KPM / MPH Incline
Warm-up 2 min 2.7 1.7 0%
Stage 1 1 min 5.3 3.3 0%
Stage 2 1 min 5.3 3.3 2%
Stage 3 1 min 5.3 3.3 3%
Stage 4 1 min 5.3 3.3 4%
Stage 5 1 min 5.3 3.3 5%
Stage 6 1 min 5.3 3.3 6%
Stage 7 1 min 5.3 3.3 7%
Stage 8 1 min 5.3 3.3 8%
Stage 9 1 min 5.3 3.3 9%
Stage 10 1 min 5.3 3.3 10%
Stage 11 1 min 5.3 3.3 11%
Stage 12 1 min 5.3 3.3 12%
Stage 13 1 min 5.3 3.3 13%
Stage 14 1 min 5.3 3.3 14%
Stage 15 1 min 5.3 3.3 15%
Stage 16 1 min 5.3 3.3 16%
Stage 17 1 min 5.3 3.3 17%
Stage 18 1 min 5.3 3.3 18%
Stage 19 1 min 5.3 3.3 19%
Stage 20 1 min 5.3 3.3 20%
Stage 21 1 min 5.3 3.3 21%
Stage 22 1 min 5.3 3.3 22%
stage 23 1 min 5.3 3.3 23%
stage 24 1 min 5.3 3.3 24%
Stage 25 1 min 5.3 3.3 25%
Cool-Down 3 min 2.7 1.7 0%

Balke- Female
Speed
Time KPH / MPH Incline
Warm-up 2 min 2.7 1.7 0%
Stage 1 1 min 4.8 3.0 0%
Stage 2 1 min 4.8 3.0 2.5%
Stage 3 1 min 4.8 3.0 5.0%
Stage 4 1 min 4.8 3.0 7.5%
Stage 5 1 min 4.8 3.0 10%
Stage 6 1 min 4.8 3.0 12.5%
Stage 7 1 min 4.8 3.0 15.0%
Stage 8 1 min 4.8 3.0 17.5%
Stage 9 1 min 4.8 3.0 20.0%
Stage 10 1 min 4.8 3.0 22.5%
Stage 11 1 min 4.8 3.0 25.0%
Cool-Down 3 min 2.7 1.7 0%

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Operating Instructions TRACKMASTER

Pre-Programmed Fitness Workout Data

17. To access Pre-Programmed Fitness Workouts, use the + /
- key to highlight the selection and press the Yellow
Enter button.

18. The screen at the right shows the (5) Fitness workouts
the user can choose from. Select the desired Fitness
Workout by pressing the + / - button then press the
Yellow Enter button to input user information or press
the Green Start button to begin workout.

NOTE: Any of the Fitness Interval Training programs can

be altered in intensity merely by pressing + / - for belt speed
or incline. The control will remember that setting as it
transitions from one segment to the next.

INTERVAL WORKOUT
Speed
Time KPH / MPH Incline
Warm-up 1.5 min 4.8 3.0 0%
Stage 1 1.5 min 5.6 3.5 5%
Stage 2 1.5 min 4.8 3.0 2%
Stage 3 1.5 min 5.6 3.5 7%
Stage 4 1.5 min 4.8 3.0 5%
Stage 5 1.5 min 5.6 3.5 9%
Stage 6 1.5 min 4.8 3.0 5%
Stage 7 1.5 min 5.6 3.5 12%
Stage 8 1.5 min 4.8 3.0 5%
Stage 9 1.5 min 5.6 3.5 12%
Cool-Down 3.0 min 4.8 3.0 0%

SPEED INTERVAL WORKOUT

Speed
Time KPH / MPH Incline
Warm-up 1.5 min 4.0 2.5 0%
Stage 1 0.5 min 6.4 4.0 0%
Stage 2 1.5 min 4.0 2.5 0%
Stage 3 0.5 min 6.4 4.0 0%
Stage 4 1.5 min 4.0 2.5 0%
Stage 5 0.5 min 6.4 4.0 0%
Stage 6 1.5 min 4.0 2.5 0%
Stage 7 0.5 min 6.4 4.0 0%
Stage 8 1.5 min 4.0 2.5 0%
Stage 9 0.5 min 6.4 4.0 0%
Stage 10 1.5 min 4.0 2.5 0%
Stage 11 0.5 min 6.4 4.0 0%
Stage 12 1.5 min 4.0 2.5 0%
Stage 13 0.5 min 6.4 4.0 0%
Stage 14 1.0 min 4.0 2.5 0%
Cool-Down 3.0 min 3.2 2.0 0%

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HIGH INTENSITY SPEED INTERVAL

WORKOUT
Speed
Time KPH / MPH Incline
Warm-up 1.5 min 4.0 2.5 0%
Stage 1 1.5 min 6.4 4.0 0%
Stage 2 0.5 min 4.0 2.5 0%
Stage 3 1.5 min 6.4 4.0 0%
Stage 4 0.5 min 4.0 2.5 0%
Stage 5 1.5 min 6.4 4.0 0%
Stage 6 0.5 min 4.0 2.5 0%
Stage 7 1.5 min 6.4 4.0 0%
Stage 8 0.5 min 4.0 2.5 0%
Stage 9 1.5 min 6.4 4.0 0%
Stage 10 0.5 min 4.0 2.5 0%
Stage 11 1.5 min 6.4 4.0 0%
Stage 12 0.5 min 4.0 2.5 0%
Stage 13 1.5 min 6.4 4.0 0%
Stage 14 1.0 min 4.0 2.5 0%
Cool-Down 3.0 min 3.2 2.0 0%

PEAK INTERVAL WORKOUT

Speed
Time KPH / MPH Incline
Warm-up 1.5 min 4.0 2.5 0%
Stage 1 0.5 min 6.4 4.0 5%
Stage 2 1.5 min 4.0 2.5 3%
Stage 3 0.5 min 6.4 4.0 5%
Stage 4 1.5 min 4.0 2.5 3%
Stage 5 0.5 min 6.4 4.0 5%
Stage 6 1.5 min 4.0 2.5 3%
Stage 7 0.5 min 6.4 4.0 7%
Stage 8 1.5 min 4.0 2.5 5%
Stage 9 0.5 min 6.4 4.0 9%
Stage 10 1.5 min 4.0 2.5 7%
Stage 11 0.5 min 6.4 4.0 12%
Stage 12 1.5 min 4.0 2.5 10%
Stage 13 0.5 min 6.4 4.0 12%
Stage 14 1.0 min 4.0 2.5 3%
Cool-Down 3.0 min 3.2 2.0 0%

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Operating Instructions TRACKMASTER

HI INTENSITY PEAK INTERVAL

WORKOUT
Speed
Time KPM / MPH Incline
Warm-up 1.5 min 4.0 2.5 0%
Stage 1 1.5 min 6.4 4.0 5%
Stage 2 0.5 min 4.0 2.5 3%
Stage 3 1.5 min 6.4 4.0 5%
Stage 4 0.5 min 4.0 2.5 3%
Stage 5 1.5 min 6.4 4.0 5%
Stage 6 0.5 min 4.0 2.5 3%
Stage 7 1.5 min 6.4 4.0 7%
Stage 8 0.5 min 4.0 2.5 5%
Stage 9 1.5 min 6.4 4.0 9%
Stage 10 0.5 min 4.0 2.5 7%
Stage 11 1.5 min 6.4 4.0 12%
Stage 12 0.5 min 4.0 2.5 10%
Stage 13 1.5 min 6.4 4.0 12%
Stage 14 1.0 min 4.0 2.5 3%
Cool-Down 3.0min 3.2 2.0 0%

User Defined Programming

19. To access User Defined menu, use the + / - key
to highlight the selection and press the Yellow
enter button.

NOTE: Any of the User Defined Programs can be

altered in intensity merely by pressing + / - for belt
speed or Incline. The computer will remember that
setting as it transitions from one segment to the next.

20. The screen at the right shows the (5) Custom

Workouts the user can choose from. The control
has room for 10. Select the desired Custom
Workout by pressing the + / - button then press
the Green Start button to begin or press the
Yellow Enter button to modify an existing
workout. If no workouts exist and you press the
Start button, Screen 21 will appear.

21. Press the + / - buttons to input the variables a

field. Make sure your variable value is correct
before pressing the Black Program Select
button. Upon pressing this button. The cursor
will advance to the next variable field. Repeat
the steps above for all 3 fields. Press the Green
Start button to save the routine.

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TRACKMASTER Operating Instructions

TMX428 TMX58 Software Download

FGLF0495 Smart Power Supply
1. Copy the FVProg.ROM to an SD card (consult factory for
correct software version).
2. Locate the main power switch and set the switch in the off position.
3. Remove the motor pan hood screw to gain access to the Smart
Power supply circuit board.
4. Insert the SD card into the SD card reader slot as shown at right.
5. Switch the main power switch to the ON position. Be sure to keep hand away from electrical
components may cause a shock hazard.
6. There is a LED at D13 that will flash at a slow rate of .5 seconds per flash while the system is
searching for the SD card and reprogramming the processor.
7. Once the program is loaded, the LED should light solid. The down relay will also turn on to
initialize the system.

TMX428CP TMX58 Software Download

FGLF0496 LCD Control
1. Copy the THORCONS.ROM to an SD card (consult factory for
correct software version).
2. Locate the main power switch and set the switch in the off position.
3. Remove the upper plastic console screws (10X) to gain access to
the LCD Screen circuit board.
4. Insert the SD card in to the SD card reader slot as shown at right.
5. Switch the main power switch to the ON position. Be sure to keep hand away from electrical
components may cause a shock hazard.
6. There is a LED at LED1 that will flash at a slow rate of .5 seconds per flash while the system is
searching for the SD card and reprogramming the processor. During the download process the
LCD screen will remain black until the new software has been fully loaded.
7. Once the program is loaded, the LED should rapidly flash. The blue screen will display the
Welcome Screen.

TMX428 Series Dip Switch Configuration

Position Dip Switch 1: When in the “OFF” position, units are set to English “MPH”
in the “ON” position, units are set to Metric “KPH”.

Position Dip Switch 2: When in the “OFF” position, a communication disconnect

stop timeout is 2.5 seconds, in the “ON” position, the communication disconnect
stop timeout is extended to 4 seconds.

Position Dip Switch 3 (Software Version 1.43 & later FGLF0495 Smart Power Supply): When in
the “OFF” position for Trackmaster Interface Protocol, in the “ON” position New Customer
Interface Protocol.

Test Plug Speed Calibration Dip Switch Position (Software Version 1.43 & later FGLF0495
Smart Power Supply): When switch 1, 2 & 3 in the “ON” position and switch 4 in the “OFF”.
Turn power off insert test plug into RS232, while holding test plug button turn power on.
Continue holding button until running belt starts to move, this initiated Speed Calibration Routine.
Release the button, the treadmill will increase to maximum speed then back to zero speed. When
successful the D13 light will remain solid.

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Operating Instructions TRACKMASTER

TMX428 TMX428CP Belt Speed Calibration Procedure

OEM/Maintenance Version
Tools Required
Calibration Program (Full Vision Treadmill PS Control Version 1.2 or Newer)
Stop watch or watch with a second hand
Chalk or some other temporary marking device
Computer or laptop
Serial Communication Cable
USB Communication Cable

1. Plug treadmill to power supply.

2. Turn ON Treadmill.
3. Connect computer or laptop to treadmill RS232 port or USB mini port.
4. Open Full Vision Treadmill PS New Cal software.

5. Select Comport and press .

6. When connected the light will flash green yellow
continuously. When communication is not present the light will stay a solid
yellow, verify cable connection and verify comport setting.
7. Select tab.
8. Remove all tools from running belt and stand clear of running surface.
9. Select .
10. Observe: Running belt will pause for approximately 8 seconds and slowly
increase speed establishing multiple calibration points.
11. When calibration routing is complete and successful Speed Calibration table will
automatically update Measured Speed ( ). When
calibration routine fails ( ), consult factory for assistance.
12. At this point running belt calibration is complete.
13. To set MPH versus KPH, position dip switch 1 when in the “OFF” position, units
are set to English, and in the “ON” position, units are set to Metric.
14. Select tab and select and the running belt will start at .1 mph.
15. To change speed select or and adjust to desired speed.
16. Measure belt with MPH/KPH gauge or using “TMX428, TMX428CP, and
TMX58 Verifying Belt Speed Calibration in the Field”. Verify within
specification +/- 2%, if not within specification consult factory for assistance.
17. Repeat process for 2, 3, 5, 7, & 12 MPH or 4, 6, 8, 12 & 19 KPH.
18. To stop running belt select .

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TRACKMASTER Operating Instructions

TMX428 TMX428CP Belt Speed Calibration Procedure

Tools Required
Calibration Program (Full Vision Treadmill PS New Cal)
Stop watch or watch with a second hand
Chalk or some other temporary marking device
Computer or laptop
Serial Communication Cable
USB Communication Cable

1. Plug treadmill to power supply.

2. Turn ON Treadmill.
3. Connect computer or laptop to treadmill RS232 port or USB mini port.
4. Open Full Vision Treadmill PS New Cal software.
5. Select Comport and press Connect.
6. Verify communications is receiving and sending data.
7. Remove all tools from running belt and stand clear of running surface.

8. Select
9. Observe: Running belt will pause for approximately 8 seconds and slowly
increase speed establishing multiple calibration points.
10. When calibration routing is complete and successful ( ) value
will automatically update Cal Speed Fields. When calibration routine fails
( ), consult factory for assistance.
11. At this point running belt calibration is complete.
12. To set MPH versus KPH, position dip switch 1 when in the “OFF” position, units
are set to English, and in the “ON” position, units are set to Metric.

13. Select or and the running belt will start at .1

mph.
14. To change speed select and type desired speed.
15. Measure belt with MPH/KPH gauge or using “TMX428, TMX428CP, and
TMX58 Verifying Belt Speed Calibration in the Field”. Verify within
specification +/- 2%.
16. Repeat process for 2, 3, 5, 7, & 12 MPH or 4, 6, 8, 12 & 19 KPH.
17. If not with tolerance, verify and , then
recalibrate belt.
18. Repeat steps 13 thru 16 until within tolerance.

19.

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Operating Instructions TRACKMASTER

TMX428CP TMX58 Belt Speed Calibration Procedure

Tools Required
Stop watch or watch with a second hand
Chalk or some other temporary marking device

PRESS “ENTER” TOINPUT

USER INFORMATION

PRESS “START” TO BEGIN

EXERCISE ROUTINE

PRESS“PROGRAM SELECT” TO BEGIN

PROGRAMEXERCISE ROUTINE

1. To gain access to the parameter screen, hold down TMX428 VERSION 0.4

on QUICK SPEED 4 for approximately 4 seconds. ENTER: NEXT PROG: PREV +- EDIT START: EXIT

P00 1 P01 400000 P02 33 P03 160

2. Using the ENTER or PROGRAM SELECT P04 100 P05 150 P06 0 P07 0
P08 0 P09 0 P10 135 P11 1000
to highlight . P12 25 P13 0 P14 0 P15 19
P16 96 P17 198 P18 305 P19 400
3. Remove all tools from running belt and stand P20 495 P21 990 P22 11 P23 35
P24 0 P25 160 P26 342 P27 1000
clear of running surface. P28 1000 P29 7615 P30 0 P31 0
P32 0 P33 4000 P34 0 P35 5
4. To start the calibration procedure hold down on P36 7 P37 4753
C00 1 SPD 0.0 ELE 0.0
QUICK SPEED 2
5. Observe: Running belt will pause for approx 8 seconds and slowly increase speed
establishing multiple calibration points.
6. When calibration routing is completed and successfully value P13 will automatically
update Cal Speed Fields . When calibration routine fails, value P13 will
display . Consult factory for assistance.
7. At this point, running belt calibration is complete.

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TRACKMASTER Operating Instructions

TMX428CP TMX58 Belt Speed Calibration

Procedure Continuation
8. To set MPH versus KPH, position dip switch 1 when in the “OFF” position, units are
set to English, and in the “ON” position, units are set to Metric.
9. Select START twice to start countdown 3, 2, 1 the running belt will start at .1 mph.
10. Measure belt with MPH/KPH gauge or using “TMX428, TMX428CP, TMX58
Verifying Belt Speed Calibration in the Field”. Verify within specification +/- 2%.
11. Repeat process for 2, 3, 5, 7, & 12 MPH or 4, 6, 8, 12 & 19 KPH.
12. If not with tolerance, adjust P29 value then recalibrate belt.
13. Repeat steps 9 thru 11 until within tolerance.

14. Press

TMX428, TMX428CP, TMX58 Verifying Belt Speed

Calibration in the field
Tools Required
Stop watch or watch with a second hand
Chalk or some other temporary marking device

1. Verify a point on the run belt that can be seen plainly with each full revolution;
this could be the seam or a chalk line you make on the belt.
2. Start the treadmill and adjust the speed to 1 mph/1.6kph.
3. Start the stopwatch when the mark on the belt passes an established point on the
treadmills side rail.
4. Count the number of passes the mark makes in a 60 second period.
5. The count should be 8 passes plus about 7” (although 8 passes is within the
advertised 2% accuracy).
6. Next set speed to 5mph/8.0kph, once again count the passes the belt makes this
time in a 15 second period. You should get 10 passes + about 7”, but 10 passes is
satisfactory.
7. Last set the speed to 10 mph/16.1kph, this time use a 9 second time period.
8. The mark on the belt should pass the point 12 times plus 8”, 12 passes being
within the required specification.
9. This should verify the treadmill is within required tolerance of speed.

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Operating Instructions TRACKMASTER

TMX428 TMX428CP Elevation Calibration Procedure

OEM/Maintenance Version
Tools Required
Calibration Program (Full Vision Treadmill PS Control Version 1.2 or Newer)
Tape Measure
¼” Nut Driver or Flat Headed Screw Drive
T15 Torx Screw Driver
Computer or laptop
Serial Communication Cable
USB Communication Cable

1. Plug treadmill to power supply.

2. Turn ON Treadmill.
3. Connect computer or laptop to treadmill RS232 port or USB mini port.
4. Open Full Vision Treadmill PS New Cal software.

5. Select Comport and press .

6. When connected the light will flash green yellow
continuously. When communication is not present the light will stay a solid
yellow, verify cable connection and verify comport setting.
7. Select tab.
8. To set the 0% Elevation and Upper Elevation limits on travel.
9. Select 5% Test Position to elevate the treadmill 5% and cycle treadmill power
(by resetting the power the treadmill will automatically find the lower limit position).
10. Using a tape measure, verify the 0% elevation (Refer to TMX428, TMX428CP, &
TMX58 Elevation Chart).
10A. If the zero position requires adjustment, remove actuator top cover.
10B. If position is low, adjust the upper cam (by hand) clockwise
into the limit switch. If position is high adjust the upper cam
by hand counterclockwise away from limit switch.
10C. Repeat step 8 to reestablish 0% elevation.
11. Make adjustment to 25% default value to value select 24% test position
and verify with a tape measure that the value is 18.0” to 18.1”.
12. The lower Cam should almost be in contact with limits switch.
13. If the Upper Elevation Limit is reach prior to reaching target
the treadmill will automatically reset to the 0% elevation.
13A. If this happens, using a large (.375” wide) flat blade screw
driver, rotate the lower switch cam counterclockwise the
proper amount to assure the treadmill will not elevate past 25%.
13B. If the cam was turned to adjust the lower switch, the upper cam will need to
be reset to zero to allow the treadmill to park in the correct position. Repeat
Step 8 to reestablish 0% elevation.

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TRACKMASTER Operating Instructions

TMX428 TMX428CP Elevation Calibration Procedure

OEM/Maintenance Version Continuation
14. Select .5% Test Position .
15. Using the tape measure verify the angle within spec +/- 2% (Refer to TMX428,
TMX428CP, & TMX58 Elevation Chart).
16. If incorrect, make adjustments to compensate in .5% elevation box and then type new
value and select OK or Enter.

17. Select .5% Test Position and recheck measurement.

18. Repeat procedure for 5%, 10%, 15%, 20% and 25%.
19. Cycle power to return treadmill to 0% elevation.
20. Select on the Full Vision Treadmill Control software.
21. If Actuator cap was removed replace cap.

TMX428 TMX428CP Elevation Calibration Procedure

Tools Required
Calibration Program (Full Vision Treadmill PS New Cal)
Tape Measure
¼” Nut Driver or Flat Headed Screw Drive
T15 Torx Screw Driver
Computer or laptop
Serial Communication Cable
USB Communication Cable

1. Plug treadmill to power supply.

2. Turn ON Treadmill.
3. Connect computer or laptop to treadmill RS232 port or USB mini port.
4. Open Full Vision Treadmill PS New Cal software.
5. Select Comport and press Connect.
6. Verify communications is receiving and sending data.
7. To set the 0% Elevation and Upper Elevation limits on travel.
8. Increase elevation to 5% and cycle treadmill power (by resetting the power the
treadmill will automatically find the lower limit position).
9. Using a tape measure, verify the 0% elevation (Refer to TMX428, TMX428CP, &
TMX58 Elevation Chart).

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Operating Instructions TRACKMASTER

TMX428 TMX428CP Elevation Calibration Procedure

Continuation
9A. If the zero position requires adjustment, remove
actuator top cover.
9B. If position is low, adjust the upper cam (by hand)
clockwise into the limit switch. If position is high
adjust the upper cam by hand counterclockwise
away from limit switch.
9C. Repeat step 8 to reestablish 0% elevation.
10. Make adjustment to Increase incline to 25% and verify
with a tape measure that the value is 18.0” to 18.1”.
11. The lower Cam should almost be in contact with limits switch.
12. If the Upper Elevation Limit is reach prior to reaching target
the treadmill will automatically reset to the 0% elevation.
12A. If this happens, using a large (.375” wide) flat blade
Screw driver, rotate the lower switch cam counterclockwise the proper
amount to assure the treadmill will not elevate past 25%.
12B. If the cam was turned to adjust the lower switch, the upper cam will
need to be reset to zero to allow the treadmill to park in the correct
position. Repeat Step 8 to reestablish 0% elevation.
13. Adjust incline to .5% grade.
14. Using the tape measure verify the angle within spec +/- 2% (Refer to TMX428,
TMX428CP, & TMX58 Elevation Chart).
15. If incorrect, make adjustments to compensate in .5% elevation box and then type new
value and select OK or Enter.

16. Lower incline & raise back up to .5% and recheck measurement.
17. Repeat procedure for 5%, 10%, 15%, 20% and 25%.
18. Return to 0% elevation.
19. Select Disconnect on the Full Vision Treadmill PS New Cal software.
20. If Actuator cap was removed replace cap.

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TRACKMASTER Operating Instructions

TMX428CP TMX58 Elevation Calibration Procedure

Tools Required
Tape Measure
¼” Nut Driver or Flat Headed Screw Driver
T15 Torx Screw Driver

1. Plug treadmill to power supply.

2. Turn ON Treadmill.
3. To set the 0% Elevation and Upper Elevation Limits.
4. Start treadmill, increase elevation to 5% and cycle treadmill power (by resetting
the power, the treadmill will automatically find the lower limit position).
5. Using a tape measure, verify the 0% elevation (Refer to TMX428, TMX428CP, &
TMX58 Elevation Chart).
5A. If the zero position requires adjustment, remove
actuator top cover.
5B. If position is low, adjust the upper cam (by hand)
clockwise into the limit switch. If position is high,
adjust the upper cam by hand counterclockwise
away from limit switch.
5C. Repeat step 8 to reestablish 0% elevation.
6. To gain access to the parameter screen hold down
on QUICK SPEED 4 for approximately 4 seconds.
7. Using the ENTER or PROGRAM SELECT
to highlight .
8. Adjustment to with any + or – key.
9. Using the ENTER or PROGRAM SELECT ,
highlight .
10. Increase elevation to 25% (verify with a tape measure that the value is 18.0” to 18.2”).
11. The lower Cam should almost be in contact with limits switch.

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Operating Instructions TRACKMASTER

TMX428CP TMX58 Elevation Calibration Procedure

Continuation

12. If the Upper Elevation Limit is reached prior to reaching target

the treadmill will automatically reset to the 0% elevation.
12A. If this happens, using a large (.375” wide) flat blade
Screw driver, rotate the lower switch cam counterclockwise the proper
amount to assure the treadmill will not elevate past 25%.
12B. If the cam was turned to adjust the lower switch, the upper cam will
need to be reset to zero to allow the treadmill to park in the correct
position. Repeat Step 8 to reestablish 0% elevation.
TMX428 VERSION 0.4
13. To gain access to the parameter screen, hold down ENTER: NEXT PROG: PREV +- EDIT START: EXIT

on QUICK SPEED 4 for approximately 4 seconds. P00

P04
1
100
P01
P05
400000
150
P02
P06
33
0
P03
P07
160
0
P08 0 P09 0 P10 135 P11 1000
P12 25 P13 0 P14 0 P15 19
14. Using the ENTER or PROGRAM SELECT , P16 97 P17 195 P18 295 P19 388
P20 484 P21 990 P22 11 P23 35
highlight . P24 0 P25 160 P26 342 P27 1000
P28 1000 P29 7615 P30 0 P31 0
P32 0 P33 4000 P34 0 P35 5
15. To adjust elevation use any + or – key to .5% grade. P36 7 P37 4753
C00 1 SPD 0.0 ELE 0.0

16. Using the tape measure verify the angle within spec +/- 2% (Refer to TMX428,
TMX428CP, & TMX58 Elevation Chart).
17. If incorrect, make adjustments to compensate on parameter P15 = .5% elevation and then
use any + or – key to adjust value.
18. Lower incline & raise back up to .5% and recheck measurement.
19. Repeat procedure for P16=5%, P17=10%, P18=15%, P19=20% and P20=25%.
20. Return to 0% elevation.
21. If Actuator cap was removed, replace cap.

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TRACKMASTER Operating Instructions

TMX428 TMX428CP TMX58 Elevation Chart

G
F
E
D
FLOOR C
A B

SHOWN 4:1 FOR DETAIL Dim. Grade Inches MM

A 0% 2.64” 67mm
B .5% 3.35” 85mm
C 5% 5.92” 150.4mm
D 10% 9.18” 233.2mm
FLOOR
E 15% 12.45” 316.2mm
90
F 20% 15.12” 384.0mm
G 25% 17.88” 454.2mm
MEASURMENT SHOULD BE TAKEN
FROM THE BOTTOM EDGED OF THE
SIDERAIL PERPENDICULAR TO FLOOR

TMX428 TMX428CP TMX58 Elevation Actuator Adjustment

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Operating Instructions TRACKMASTER

TMX428CP & TMX58 PARAMETER SCREEN

To gain access to the parameter screen hold down on QUICK SPEED 4 for approximately
4 seconds.

Parameter screen description: TMX428 VERSION 0.4C

• P02 Stop History ENTER: NEXT PROG: PREV +- EDIT START: EXIT

• P05 Maximum Speed Setting

P00 1 P01 400000 P02 33 P03 160
• P09 Accurate Speed B (External Sensor) P04 100 P05 150 P06 0 P07 0
• P10 Software version (Lower Board) P08 0 P09 0 P10 135 P11 1000
• P14 Accurate Speed A (Motor Controller) P12 25 P13 14925 P14 0 P15 19
P16 96 P17 198 P18 305 P19 400
• P15-P20 Elevation Calibration Points P20 495 P21 990 P22 11 P23 35
• P22 Run Time P24 0 P25 160 P26 342 P27 1000
P28 1000 P29 7615 P30 0 P31 0
• P30 Calibration Fail Code (0=Calibrated)
P32 0 P33 4000 P34 0 P35 5
• C00 Setting = 1 Quick Speed Enabled P36 7 P37 4753 C00 1
Setting = 3 Quick Speed Disable C01 0.1 C02 25.0 SPD 0.0 ELE 0.0
• C01 Minimum Start Speed 0.0 to 1.0 MPH
• C02 Maximum Elevation
• SPD Manual Control Speed Any +or- Key
• ELE Manual Control Elevation Any +or- Key

Note: Do not alter any parameter values without Consulting the factory. Altering the
parameter may cause the treadmill to malfunction.

TMX428CP & TMX58 STOP HISTORY

To view history highlight the P2 parameter and hold down on the QUICK SPEED 2 for
approximately 5 seconds.

Using the + or – key, this allows you to highlight a specific stop code and receive a breif
description for stopping (Example 34 is NORMAL STOP).

STOP HISTORY (00=MOST RECENT)

• Start Rejected (8 or 40)
• Stop due to kill switch open (16 or 48) +- SELECT COOL DOWN:EXIT
#00 34 #01 544 #02 34 #03 34
• Motor Controller Fault (64 or 96) #04 34 #05 34 #06 34 #07 34
• Overspeed Motor Controller (128 or 160) #08 34 #09 34 #10 34 #11 34
#12 34 #13 34 #14 34 #15 34
• Overspeed External Speed Sensor (256 or 288)
#16 34 #17 34 #18 34 #19 34
• Speed Delta Error (512 or 544)
• Set Speed to Zero Command (1024 or 1056)
• Auto Stop Command (2048 or 2080)
• Measured Zero Speed Error (8224) NORMAL STOP

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TRACKMASTER Preventive Maintenance Instructions

7
Preventive Maintenance

Regular cleaning and maintenance is essential to keep your TRACKMASTER® operating at

its best for many years. We recommend that you record all maintenance and service in a log
(as shown in Appendix A).

Before cleaning the TRACKMASTER® turn the main power switch

to OFF, and disconnect the treadmill from its power outlet. Never use
wet cleaning materials near a power source: you could suffer an
electrical shock.

Avant de nettoyer le TRACKMASTER® placez l’interrupteur

principal sur la position OFF(ARRET), puis débranchez le cordon
d’alimentation de la prise électrique. Ne jamais utiliser des solvants
liquides ou des chiffons mouillés près dune source électrique:
électrique vous
pourrez souffrir d’un choc éle
électrique.

To preserve the condition of your warranty, make sure that all repair procedures
(other than normal maintenance) are performed by an authorized and qualified
service provider. Contact customer support with any questions at (316) 283-3344.
283

Use only TRACKMASTER® replacement parts. Using other parts may void
your warranty and may cause your TRACKMASTER® to malfunction.

Daily Maintenance
• Wipe the treadmill to remove soil, moisture, and perspiration.
• Clean the hood and handrails with a soft cloth, dampened with a solution of
warm water and mild detergent.
• Do not use harsh chemicals on the LCD screen.
• Remove stubborn stains and scuff marks with a nonabrasive, industrial strength
cleaner, such as Formula 409®. Spray all cleaners
ners on a terrycloth-type
terrycloth cloth
(avoid
avoid spraying cleaner directly onto the treadmill
treadmill).
• Ensure that the treadmill is functioning properly.

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Instructions TRACKMASTER

Weekly Maintenance
• Vacuum around and under the treadmill. Clean all exposed surfaces with a
vacuum cleaner. Avoid moving the TRACKMASTER® from its original
position as moving it will compromise the original belt tracking setting.
• Check running belt tension.
• Observe running belt tracking, correct as required.

Monthly Maintenance
• Belt cleaning and inspection.

Semiannual Maintenance
• Evaluate the condition of the deck and belt.
• Belt adjustment needs to be performed to assure proper belt alignment.
• Check running belt adjustment.
• Check drive belt tension adjustment.
• Clean and lubricate the treadmill elevation screw.

NOTE: Use only TRACKMASTER® replacement parts. Using other parts may void
your warranty and may cause your TRACKMASTER® to malfunction.

Belt Cleaning and Inspection

1. Turn treadmill main power switch ON.

2. Start treadmill at .5 mph. With a damp small towel wipe excessive dirt from
running belt keeping the towel in the center of the length of the treadmill. Avoid
getting the towel near the rear roller.
3. When belt is clean, stop treadmill.
4. Inspect running belt for tears or nicks. If damaged, replace the belt.
5. Perform Running Belt Tracking Adjustment and Belt Tension Adjustment.

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TRACKMASTER Preventive Maintenance Instructions

Running Belt Tracking Adjustment

This procedure requires the following tool:
• ¼” Allen wrench

NOTE: Because this adjustment is not covered under your warranty, it is important that
you review these instructions thoroughly before proceeding.

The patented MasterTrack®Belt Tracking System significantly reduces the need to

adjust the belt on your TRACKMASTER®. However, when you operate your
TRACKMASTER® for the first time, you may need to adjust the tracking of the belt
to conform to your floor. You may also need to adjust the tracking if you move the
machine to another location.

Your running belt should remain centered, although a slight amount of movement to
the left or right is normal during use. Do not allow the running belt to travel all the
way to either side.

To adjust the belt tracking, do the following:

1. Turn the treadmill’s power switch to ON.

2. Increase the speed to 3 mph.

3. Observe the left side of the running belt as it travels over the rear roller. If the
belt runs to the right side of the roller, turn the right bolt 1/8th turn clockwise,
and turn the left bolt one-eighth turn counterclockwise.
NOTE: When tightening one side of the belt, always loosen the opposite side one-half as
much. This procedure provides finer control, with a smaller impact on the belt
tension.

Check the belt after 2 minutes, with the treadmill running at approximately 7 mph. If
the belt does not correct itself, continue with slight turns until the belt is in the center
of the rear roller. If the belt runs toward the left side of the roller, reverse the
adjustments.

NOTE: Uneven floors accelerate belt misalignment. This situation may require more
frequent adjustment to prevent belt damage.

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Instructions TRACKMASTER

Running Belt Tension Adjustment

The running belt may stretch and loosen with regular use. This looseness is
noticeable when the belt tends to hesitate or stick. Adjust the tension on the belt
by following the procedure and referring to the illustration below.

1. Turn the treadmill’s power switch to ON.

2. Start treadmill and increase to 1 mph
3. Start walking on the treadmill, grab side handrail and apply pressure with your
foot to create resistance on running belt.
4. If running belt hesitates or slips on front drive roller, tighten both tension bolts
½ turn (Clockwise).
5. Repeat steps 2 thru 4 until running belt stops slipping.

NOTE: When running belt is too tight the edge of belt will curl causing premature
running belt failure.

TENSION BOLTS

Drive Belt Tension Adjustment

This procedure requires the following tool:
1
• /8” Allen Wrench
• ¾” Socket or Box Wrench
• ¾” Wrench
• Tape measure

NOTE: Because this adjustment is not covered under your warranty, it is important that you
review these instructions thoroughly before proceeding.

7-4 TMX428 TMX428CP TMX58 Service Manual October 2015

 TRACKMASTER Preventive Maintenance Instructions

NOTE: The drive belt may stretch and loosen with regular use. This looseness may
result in a flapping noise under the hood.

1. MAKE SURE THE TREADMILL IS SWITCHED TO THE OFF POSITION

AND DISCONNECTED FROM ITS POWER OUTLET.
2. Remove the (5) #10-32 screws located on the bottom hood with 1/8” Allen wrench.
3. With the ¾” socket and wrench loosen the TENSION ADJUSTMENT back nut.
4. Drive Belt Tension Configuration:
4A. Deflection configuration, press down on drive belt between motor and front
roller with approximately 5 lbs of force to achieve ¼” to 3/8”. If adjustment is
needed make small adjustment until drive belt deflects approx ¼” to 3/8”.
4B. Measure from the head of the ½”-13 bolt to the motor housing. The spring
compression should be 1-3/16” or 30mm. using a ¾” wrench turn the
TENSION BOLT clockwise to compress the spring. To decrease compression,
turn the wrench counter clockwise.
5. When the desired drive belt tension is achieved, tighten the TENSION
ADJUSTMENT back nut.

NOTE: Failure to lock the TENSION ADJUSTMENT back nut will allow the drive belt
tension to become loose.

6. When the treadmill is properly adjusted, reinstall the hood with

(5) #8-32 screws.

Deflection Tension Configuration

¼ to 3/8 DEFLECTION
5 LBS

TENSION
Spring Tension Configuration ADJUSMENT
TENSION BOLT
BACK NUT

NOTE: When drive belt is over tensioned, the belt

tension will cause motor noise. This could
result in premature motor life failure.

TENSION
1-3/16” or 30mm SPRING ADJUSMENT
COMPRESSION BACK NUT

October 2015 TMX428 TMX428CP TMX58 Service Manual 7-5

Instructions TRACKMASTER

Exterior Care
The powder-coat finish on your TRACKMASTER® is an extremely durable
finish and requires minimal care. Do not allow perspiration to build up on
your treadmill. Wipe the unit daily.

Elevation Screw Lubrication

The Elevation Screw must be cleaned and lubricated every 6 months to
maintain proper operation of the treadmill. Failure to perform this
maintenance function will result in premature wear and ultimate failure of the
lift mechanism.
This procedure requires the following tools:
• TRACKMASTER® grease (Part # 317-160-165)
• Clean, lint-free cloth
• Small paint brush

1. Raise the TRACKMASTER® to its maximum elevation.

2. Turn the main power switch to the OFF position, and unplug the treadmill
from its outlet.
3. Using a lint-free cloth, remove the old lubricant and accumulated dust
from the elevation screw.
4. Use a small brush to reapply a thin coat of grease to the threads of the
elevation screw. Do not use too much grease—the excess could squeeze
onto the floor and create a slip-and-fall hazard.
5. Return the unit to service.

Running Deck Maintenance

®
The TRACKMASTER running deck is maintenance–free and offers (2)
running deck surfaces for double the life of ordinary treadmills.

NOTE: 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 may
result in hesitation or excessive belt slip.

If running deck surface becomes grooved due to wear, it can be renewed by

flipping the deck to the opposite side.

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TRACKMASTER Product Requirements

Product Requirements 8
FG0495 Smart Power Supply
INTRODUCTION
The TMX428, TMX428CP Universal Power Supply (UPS) treadmill control provides a means of
controlling belt speed and elevation for the treadmill through the use of either an RS-232 serial
port or USB port. The communication protocol is based on the industry standard. In addition to
the physical interfaces with the controlling system (PC), the motor controller and elevation motor,
the UPS also includes an interface to an emergency stop switch and an SD card. The UPS
supplies interfaces with a console, a soft stop switch, an output expansion port, and a low voltage
fan that will not be covered in this document.

SCOPE
This document only applies to the electronic control for the TMX428 & TMX428CP.
Specifications for the mechanical treadmill, elevation motor assembly, belt motor and motor
controller are not covered in this document.

OPERATIONAL OVERVIEW

When power is applied to the unit, the UPS reads the contents of the non-volatile memory and
verifies the calibration contents with a checksum. If the contents are not valid, the calibration
constants are set to non-operational values and the unit is put into a state where operation is
suspended pending re-calibration.

If the contents are valid, the unit enters a startup mode where the system checks to see if it should
enter self test mode (described in the SELF TEST MODE section) and begins to find the zero
elevation point by turning on the elevation motor in the down direction. If motion is not detected
for two seconds, the system assumes that the lower elevation limit has been reached. During the
“elevation zeroing” time, if a command to start the belt is received from the PC, it is assumed that
the PC is not aware of the UPS power cycle and the unit will enter a non-responsive state (waiting
for either a communication timeout or a stop command). If the elevation limit is found without
receiving a start belt command, the UPS enters the operational mode with a set speed and set
elevation of zero.
In operational mode, the unit continuously controls the belt speed output, the belt enable output,
and the outputs to raise or lower the elevation based on the current set points for speed and
elevation. Through the use of either communication port, the unit accepts commands to modify
the belt state, the belt speed, and the deck elevation. The current state of the control may also be
queried through the use of this serial port. As commands are received to change the set point
speed or set point grade, they are checked for format and range. Pending approval, the new set
points are adopted and adjustments are made to the state of the outputs.
Speed control is done in a closed loop that monitors the belt speed using two different speed
references. The first is a magnetic reed switch located on the motor side of the belt pulley, and

October 2015 TMX428 TMX428CP TMX58 Service Manual 8-1

Product Requirements TRACKMASTER

the second is a speed reference supplied by the motor controller. A speed calibration is required
to provide a target speed output for a given set point. After the initial target is reached, the speed
inputs are constantly monitored to make adjustments to the speed output and to detect over speed,
zero speed, or speed sensor comparison fault conditions. In the case of a fault condition, the belt
is stopped and operation is suspended.
Elevation position control is done using relays to turn on the elevation motor in the up or down
direction depending on the current set point. A micro switch input is used to determine the
position of the elevation motor by counting revolutions of the elevation motor’s internal gearing.
An elevation calibration is required to provide an accurate number of counts from zero to full
elevation. No closed loop control is done for positioning elevation.

Power may be removed from the unit by opening the normally closed switch connected to the
emergency stop input, or by removing AC power from the system. In both cases, the outputs will
be put into a non-energized state that will correspond to the belt being shut off and the elevation
motor being disengaged.

SOFTWARE REQUIREMENTS

SPEED CONTROL

There are two outputs required for speed control. The belt enable output must be energized to put
the belt into a run mode. The speed control output is a 4kHz 1024 count pulse width modulated
(PWM) output supplied directly to the motor controller. Based on calibration, the speed is
controlled by outputting a PWM speed reference to the motor controller and enabling the belt run
output. The speed inputs are averaged over a two second period to provide measured speed
accuracy of 0.01mph or less.

If the speed of either input is measured to be more than 0.5mph over the set point, or the
difference between speed inputs is measured to be more than 0.5mph, the belt will shut off
automatically. If the speed measured is more than 3mph over the set point, the belt enable signal
will be turned off immediately. If the motor controller activates a fault signal to the UPS, the
system will shut down immediately.

If the measured speed is within range, it is used to make minor adjustments to the speed output
when it is determined that the actual speed and measured speed differ by more than 0.08 mph.
These small adjustments (1:1024) are only allowed to be at 4 second intervals to provide for the
settle time of the motor and heavily averaged speed input.

ELEVATION CONTROL

The elevation position is constantly monitored by counting and recording changes in the state of
the elevation micro switch sensor. Each debounced state is counted as positive if the elevation
motor is engaged in the up direction and negative if it is engaged in the down direction. Using
this count and the calibration numbers, the elevation position is controlled by turning on the
motor in the desired direction and counting until the target number of counts has been reached.
At that time, the elevation motor is disengaged until another set point position is requested.

8-2 TMX428 TMX428CP TMX58 Service Manual October 2015

TRACKMASTER Product Requirements

COMMUNICATION HARDWARE (RS-232 Option)

- DB9 Connector 9 pin PC/AT Style

Pin Description
2 Transmit Data
3 Receive Data
5 Signal Ground
- RS232 (+/- 10V)
- 4800 Baud
- No Parity
- 8 Data Bits
- 1 Stop Bit
- Full Duplex

COMMUNICATION HARDWARE (USB Option)

- PC USB Host Port

- UPS USB Peripheral Port Mini-B Connector
- FTDI FT232RL Virtual Communication Port Driver required
- 4800 Baud
- No Parity
- 8 Data Bits
- 1 Stop Bit
- Full Duplex

COMMAND PROTOCOL

The Trackmaster Serial Communications Protocol consists of two types of commands, which are
INPUT COMMANDS and STATUS REQUESTS. When a command is sent to the serial port, it
is decoded and executed. The corresponding acknowledgement is then transmitted via the serial
port. The controller transmits acknowledgments and data only in response to a command.

A - INPUT COMMANDS

ASCII CODES
HEX DECIMAL

A0 160 - Start Belt - Communication Disconnect Stop Enabled (Note 1)

A1 161 - Start Belt - Communication Disconnect Stop Disabled (Note 2)
A2 162 - Stop Belt
A3 163 - Set speed to the next 4 bytes of ASCII data (Note 3)
A4 164 - Set Elevation to the next 4 bytes of ASCII data (Note 4)
A5 165 - Set Time to the next 4 bytes of ASCII data (Note 5)
A6 166 - Set Protocol to the next 2 bytes of ASCII data (Note 5)
A7 167 - Set Stage to the next 2 bytes of ASCII data (Note 5)
A8 168 - Reset Distance, Total Time, and Energy to 0 (Note 5)
A9 169 - Set Weight to the next 4 bytes of ASCII data (Note 5)
AA 170 - Auto Stop - Sets speed and elevation to minimum and stops belt.
AB 171 - Auto Cool Down - Sets speed and elevation to minimum.
AC 172 - Toggle Transmit Acknowledge Data Flag (Note 6)

October 2015 TMX428 TMX428CP TMX58 Service Manual 8-3

Product Requirements TRACKMASTER

B - INPUT COMMAND ACKNOWLEDGEMENT

ASCII CODES
HEX DECIMAL

B0 176 - Ack. Start Belt - Communication Disconnect Stop Enabled

B1 177 - Ack. Start Belt - Communication Disconnect Stop Disabled
B2 178 - Ack. Stop Belt
B3 179 - Ack. Set Speed
B4 180 - Ack. Set Elevation
B5 181 - Ack. Set Lap or Stage Time (Note 7)
B6 182 - Ack. Set Protocol (Note 7)
B7 183 - Ack. Set Stage (Note 7)
B8 184 - Ack. Reset Distance, Total Time, and Energy (Note 7)
B9 185 - Ack. Set Weight (Note 7)
BA 186 - Ack. Auto Stop
BB 187 - Ack. Auto Cool Down
BC 188 - Ack. Toggle Transmit Acknowledge Command Data Flag
BE 190 - Input Command Data Out of Range
BF 191 - Illegal command or command not recognized

C - STATUS REQUEST

ASCII CODES
HEX DECIMAL

C0 192 - Xmit Belt Status

C1 193 - Xmit Current Actual Speed
C2 194 - Xmit Current Actual Elevation
C3 195 - Xmit Current Set Speed
C4 196 - Xmit Current Set Elevation
C5 197 - Xmit Current Time (Note 8)
C6 198 - Xmit Total Time (Note 8)
C7 199 - Xmit Current Distance (Note 8)
C8 200 - Xmit Current Protocol (Note 8)
C9 201 - Xmit Current Stage (Note 8)
CA 202 - Xmit Current Weight (Note 8)
CB 203 - Xmit Current Calories (Note 8)
CC 204 - Xmit Current Total VO2 (Note 8)
CD 205 - Xmit Current Mets (Note 8)

8-4 TMX428 TMX428CP TMX58 Service Manual October 2015

TRACKMASTER Product Requirements

D - STATUS RESPONSE
ASCII CODES
HEX DECIMAL
D0 208 - Ack. Belt Status followed by 1 byte of data
31h = Belt Stopped
32h = Belt Started Comm. Disconnect Stop Enabled
33h = Belt Started Comm. Disconnect Stop Disabled
D1 209 - Current Belt Speed follows as 4 bytes of ASCII data (Note 3)
D2 210 - Current Elevation follows as 4 bytes of ASCII data (Note 4)
D3 211 - Current Set Belt Speed follows as 4 bytes of ASCII data (Note 3)
D4 212 - Current Set Elevation follows as 4 bytes of ASCII data (Note 4)
D5 213 - Current Lap Time follows as 4 bytes of ASCII data (Note 9)
D6 214 - Current Total Time follows as 4 bytes of ASCII data (Note 9)
D7 215 - Current Distance follows as 4 bytes of ASCII data (Note 9)
D8 216 - Current Protocol follows as 2 bytes of ASCII data (Note 9)
D9 217 - Current Stage follows as 2 bytes of ASCII data (Note 9)
DA 218 - Current Weight follows as 4 bytes of ASCII data (Note 9)
DB 219 - Current Calories follow as 4 bytes of ASCII data (Note 9)
DC 220 - Current Total VO2 follows as 4 bytes of ASCII data (Note 9)
DD 221 - Current Mets follow as 4 bytes of ASCII data (Note 9)

COMMUNICATION NOTES
Note 1 - The Communication Disconnect Stop Enable mode is a safety feature that stops the belt when a
command is not received from the host within 0.5 seconds.

Note 2 - The Communication Disconnect Stop Disable mode allows the belt to run without sustained
communication at 0.5 second intervals.

Note 3 - All speed formats are 4 digit ASCII characters in tenths of distance per hour. For instance, to set
the speed to 4.0 mph, the set speed command would be followed by 0040.

Note 4 - All elevation formats are 4 digit ASCII characters in tenths of percent inclination. The last digit
must be ASCII 0 or 5. For instance, to set the elevation to 5%, the set elevation command would be
followed by 0050. An attempt to send a value that is not in a half percent increment (e.g. 4.3%) will result
in a data out of range reply.

Note 5 - These Input commands sent by the host are accepted by the treadmill, but not implemented
functionally. For instance, a command to set the weight to 150 pounds will be accepted but will not be
used. Further queries of the weight will return 0.

Note 6 - The toggle transmit acknowledge data flag is initially cleared. When set by sending the toggle
transmit acknowledge command, the output response will always be followed by the input string received
from the host. Sending this command when the flag is set will result in it being cleared again.

Note 7 - These Input Command Responses are not functional and will always consist of zero valued data.

Note 8 - These Status commands sent by the host are accepted by the treadmill, but not implemented
functionally. For instance, a command to query the current calories will be accepted, but a value of zero
will always be returned.

Note 9 - These Status Command Responses are not functional and will always consist of zero valued data.

Note 10 –The emergency stop switch will remove power from the treadmill control board to guarantee a
stop condition. When this occurs and the emergency stop button is subsequently released, the control will
be in the same state as when the unit is powered up using the main power switch. Therefore, it is necessary

October 2015 TMX428 TMX428CP TMX58 Service Manual 8-5

Product Requirements TRACKMASTER
in either powerup state to guard against inadvertent restarts if the host doesn’t recognize the situation and is
continuously sending out belt start commands. The method used to guard against this situation is to reject
any start command received within 3 seconds of powering up and finding the zero elevation position. If a
start command is ejected, all further start commands will also be rejected until the unit is reset or a stop
command is received or communication ceases for 20 seconds.

SELF TEST MODE

On power up, the UPS sends out a special test character ‘T’ and checks to see if it is returned. This is a
check for a shorting jumper across the transmit and receive lines of the RS-232 serial port. Note that it is
not possible to enter self test using the USB port. If the RS-232 lines are determined to be shorted, the UPS
enters the self test mode. During the self test mode, 14 stages of speed and elevation set points are used to
exercise the inputs and outputs. Upon completion of each new set point, another character is sent out and
the process is repeated to advance to the next stage. In this way, the shorting jumper can be removed at any
point to stop the staging process. The following table shows the sequence of self test stages:

Stage Incline Speed (mph)

1 5% 0.0
2 10% 0.0
3 15% 0.0
4 20% 0.0
5 20% 1.0
6 20% 2.5
7 20% 5.0
8 20% 7.5
9 20% 10.0
10 15% 7.5
11 10% 5.0
12 5% 2.5
13 0% 1.0
14 0% 0.0

CALIBRATION
Both a speed and an elevation calibration method are provided in the UPS software. The elevation
calibration requires manually adjusting the deck to find the sensor counts for 7 fixed elevation
positions and is not recommended for field adjustment without special treadmill interface software.
During speed calibration, the speed reference output is swept across its range and speed measurements
are made at 15 points. This function is also only available through the use of special treadmill
interface software.

DIP SWITCH SETTINGS

A dip switch is located on the UPS at location SW2. An arrow indicates the “ON” position, and each
switch is numbered 1-4. Currently, only two of the switches are read by the UPS, and both are only
checked on powerup so changing the switches while the system is running will not have an effect until
power is cycled. Switch 1 is the Unit selection switch. When in the “OFF” position, units are set to
English, and in the “ON” position, units are set to metric. Switch 2 is a long timeout option. When
Switch 2 is in the “OFF” position, a communication disconnect stop timeout is 2.5 seconds, but when
switch 2 is in the “ON” position, the communication disconnect stop timeout is extended to 4 seconds.
Position Dip Switch 3 (Software Version 1.43 & later FGLF0495 Smart Power Supply): When in the
“OFF” position for Trackmaster Interface Protocol, in the “ON” position New Customer Interface
Protocol. Test Plug Speed Calibration Dip Switch Position (Software Version 1.43 & later FGLF0495
Smart Power Supply): When switch 1, 2 & 3 in the “ON” position and switch 4 in the “OFF”.

8-6 TMX428 TMX428CP TMX58 Service Manual October 2015

TRACKMASTER Product Requirements

ELECTRICAL INPUTS

A) Instrument Power: 230VAC or 120VAC supplied through two 1/4 Amp breakers in
parallel for control board power. 230VAC or 120VAC supplied through two 3 Amp breakers
in parallel for elevation motor power.

B ) Elevation Sensor Input : A two wire interface for detecting the presence of a closed
microswitch on the elevation motor.

C) Speed Sensor Input : A three wire interface for detecting the state of a magnetic reed
switch on the motor shaft (only two conductors are used).

D) Serial Port Input : An electrically isolated RS-232 serial port from the host controller.

E) USB Port Input : An electrically isolated USB port from the host controller.

F) Motor Controller Fault – Fault signal supplied from motor controller.

G) Voltage Selection Switch : The onboard input voltage selection switch allows the unit to
be used at 115VAC or 230VAC.

H) Emergency Stop Switch : A normally closed switch input used to switch power to the UPS
control must be rated at 24 Volts DC and 3 Amps continuous duty.

ELECTRICAL OUTPUTS

A) Elevation Motor : AC Common is permanently provided to the elevation motor. In

addition, the 120/230VAC hot input for motor elevation power is switched through a 10 Amp
relay to either the up or down input to the elevation motor.

B) Motor Controller Drive Enable Output : An optically isolated output is provided to switch
on the start input circuit for the belt drive. This output is to provide no more than 2mA.

C) Speed Output : A PWM signal for speed is provided to the motor controller. The signal is
toggled between the motor controller’s signal reference voltages (5Vdc). The maximum
current for this output is 2mA and the maximum voltage is 15Vdc.

D) Serial Port Output : An electrically isolated RS-232 level (not to exceed +/- 10VDC) is
provided to the host controller.

E) USB Port Output : An electrically isolated USB port to the host controller not to exceed
5V or 100mA.

October 2015 TMX428 TMX428CP TMX58 Service Manual 8-7

Product Requirements TRACKMASTER

ELECTRICAL CONNECTIONS

A) Input Power Header : An Amp - 641968-1 four pin MATE & LOCK header is provided
for instrument power.

B) Elevation Output Header : An Amp 641968-1 three pin MATE & LOCK headers is
provided for output power to the elevation motor.

C) Elevation Input Header : A 3 pin 0.156” pitch header is provided for the input from the
elevation sensor.

D) Speed Input Header : A 2 pin 0.156” pitch header is provided for the input from the
magnetic reed switch speed sensor.

E) Motor Controller Interface : A 10 pin 0.1” pitch header is provided for interfacing to the
motor controller.

F) RS-232 Interface : A DB9 Connector 9 pin PC/AT Style is provided for interfacing with
the host controller.

F) USB Interface : A Mini-B right angle USB Connector is provided for interfacing with the
host controller.

H) Emergency Stop Switch : Two 0.187” quick connect blade terminals are provided for an
emergency stop switch input.

PHYSICAL REQUIREMENTS AND RESTRICTIONS

A) The printed circuit board should be a rigid 1/16” thick, FR4, SMOBC circuit board with 2
ounce copper.

B) Galvanic isolation between the AC power circuits and the low voltage electronic circuits
should be guaranteed.

C) Outer Dimensions : 6”T x 9”W x 2.5”D (max).

D) Mounting position : The board shall be capable of being mounted with the PCB either
parallel or perpendicular to the bottom pan of the treadmill.

E) Environment : 0 - 70 deg. C ambient temperature.

F) High level vibrations from adjacent equipment may be present.

G) After installation into the treadmill, expect the board to experience moderate shock
impulses during shipment.

8-8 TMX428 TMX428CP TMX58 Service Manual October 2015

TRACKMASTER Product Requirements

UNIVERSAL POWER SUPPLY BOARD (FG0495)

October 2015 TMX428 TMX428CP TMX58 Service Manual 8-9

TRACKMASTER Troubleshooting

Troubleshooting
9
Incoming Power 110-240VAC Flow Chart 1A

1A
Turn treadmill power switch
Verify Nameplate Voltage for to the off position (0).
proper treadmill operating
power. 110-120VAC or
220/240VAC.
Disconnect power cord from
treadmill and wall outlet.
Verify power panel circuit
breaker is turned on and
voltage is available at wall
receptacle. Check power
cord for Yes
Replace power cord.
damage?
Verify available power and
treadmill voltage requirements
are compatible. No
Measure continuity thru the
20amp circuit breaker.
Verify treadmill power switch
is in the off (0) position.

Verify the power cord is Circuit

No Replace 20amp Circuit
plugged in treadmill circuit breaker has
continuity. Breaker.
breaker, and then plug power
cord into dedicated circuit wall
receptacle. Yes
Verify the power cord is
Turn treadmill power switch is plugged in treadmill circuit
in the on (1) position. breaker, and then plug power
cord into dedicated circuit wall
receptacle.

Is the green No
power circuit Turn treadmill power switch in
breaker lit? the on (1) position.

Yes
1B
Is the green
pg 9-2 No Verify power from power
power circuit
breaker lit? panel.

Yes
1B
pg 9-2

October 2015 TMX428 TMX428CP TMX58 Service Manual 9-1

Troubleshooting TRACKMASTER

Incoming Power Inline Filter Flow Chart 1B

1B

Is the Green Is the Red D7

LED1 lit on Yes LED lit on Smart Yes
Drive Power Supply?
PC2303-012-N? 1D
1C
pg 9-3 pg 9-4
No No

Verify treadmill power switch Verify wire connectors are Turn treadmill power switch in
is in the off (0) position. secure between power switch the on (1) position.
and inline filter.

Is the Green LED1

lit on Drive
Verify treadmill power switch No Yes
PC2303-012-N?
is in the off (0) position. Is the Red D7 LED
lit on Smart Power 1C 1D
Supply?
pg 9-3 pg 9-4

Verify Inline filter continuity

thru filter.

Does the Inline No Replace Inline

filter have
continuity? Filter.

Yes

1C 1D
pg 9-3 pg 9-4

9-2 TMX428 TMX428CP TMX58 Service Manual October 2015

TRACKMASTER Troubleshooting

Incoming Power Drive PC2303-012-N Flow Chart 1C

1C

Verify incoming voltage

110-120VAC.
Is the Green
LED1 lit Yes
on Drive
PC2303-012-N? 1D
pg 9-4
No

Verify treadmill power switch

is in the off (0) position. Is Voltage
between Black Yes Green Light should be lit
on Drive PC2303-012-N
and Brown wire
110-120VAC? Reference 1C.
Verify wire connectors and
quick disconnect are secure
between Inline filter and TB1 No
Yes Replace Drive
connection on Drive
PC2303-012N
PC2303-012-N.
Voltage No
120VAC? Verify incoming voltage
Turn treadmill power switch in 220/240VAC
the on (1) position. No
Voltage Yes
220VAC?

Is the Green
No
LED1 lit
on Drive
PC2303-012-N?
Is Voltage
between Black Yes Green Light should be lit
Yes on Drive PC2303-012-N
and Brown wire
220-240VAC? Reference 1C.
1D
pg 9-4
No
Replace Drive
PC2303-012N

October 2015 TMX428 TMX428CP TMX58 Service Manual 9-3

Troubleshooting TRACKMASTER

Smart Power Supply Incoming Power 110-240VAC Flow Chart 1D

1D

Verify incoming voltage 110-120VAC

Is the Red D7
LED lit on Smart Yes
Power Supply
PCBLF0443-1? 1E
pg 9-5
No

Verify treadmill power switch

is in the off (0) position. Is Voltage Red D7 LED Light should
between Red Yes be lit on Smart Power
and Blue wire Supply PCBLF0443-1
Verify wire connectors Inline 110-120VAC? Reference 1D.
filter, 1/4amp breaker, and JP2
are connection on Smart No
Replace Smart Power
Power Supply PCBLF0443-1.
Supply PCBLF0443-1.

Verify incoming voltage 220/240VAC

Verify 1/4amp breakers are
not tripped.

Turn treadmill power switch in Is Voltage Red D7 LED Light should

between Red Yes be lit on Smart Power
the on (1) position.
and Blue wire Supply PCBLF0443-1
220-240VAC? Reference 1D.
Yes
No Replace Smart Power
Is the Red D7
No Voltage Supply PCBLF0443-1.
LED lit on Smart
Power Supply 120VAC?
PCBLF0443-1? No

Voltage Yes
Yes 220VAC?
No
1E
pg 9-5

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 TRACKMASTER Troubleshooting

Emergency Stop Flow Chart 1E Is the Red D13

No Verify treadmill power switch
LED lit on Smart
Power Supply is in the off (0) position.
1E PCBLF0443-1?

Yes Verify the continuity of the Emergency

1F Stop Harness with an OHM meter to
Is the Red D13
Yes pg 9-5 ensure the wire is not damaged.
LED lit on Smart
Power Supply
PCBLF0443-1? 1F Verify wire connectors on the Emergency No
pg 9-5 Stop and quick disconnect on connector Wires Yes
No J4 & J5 are a secure connection on Smart Damaged?
Power Supply PCBLF0443-1. Replace
Verify treadmill power switch Emergency
is in the off (0) position. Stop Harness.

Is the Red D13

Verify the Emergency Stop LED lit on Smart Turn treadmill power switch
Button is released. Power Supply in the on (1) position.
PCBLF0443-1?

Turn treadmill power switch in Replace Yes Red D13 LED Light should
the on (1) position. Emergency be lit on Smart Power Supply
Stop Button. No PCBLF0443-1 Reference 1E.

Pull Tether Flow Chart 1F

Is the Red D12
No Verify treadmill power switch
LED lit on Smart
Power Supply is in the off (0) position.
1F PCBLF0443-1?

Yes Verify the continuity of the Emergency

Is the Red D12 1G Stop Harness with an OHM meter to
LED lit on Smart Yes pg 9-6 ensure the wire is not damaged.
Power Supply
PCBLF0443-1? 1G Verify wire connectors on the Emergency No
pg 9-6 Stop and quick disconnect on connector Wires Yes
No J6 & J7 are a secure connection on Smart Damaged?
Power Supply PCBLF0443-1. Replace
Verify treadmill power switch Emergency
is in the off (0) position. Stop Harness.

Is the Red D12

Verify the Pull Tether Clip LED lit on Smart Turn treadmill power switch
connected to Pull Tether. Power Supply in the on (1) position.
PCBLF0443-1?

Turn treadmill power switch in Yes Red D12 LED Light should
Replace Pull
the on (1) position. be lit on Smart Power Supply
Tether. No PCBLF0443-1 Reference 1E.

October 2015 TMX428 TMX428CP TMX58 Service Manual 9-5

 Troubleshooting TRACKMASTER

Communication RS232 Flow Chart 1G

1G

When connecting Full Replace Communication

Vision Treadmill PS Cable.
New Cal Software, are
you Recd and Sent Yes
Yes information?
1I Is
Verify Communication cable Communication
has not been damaged. Cable
No
Damaged?

Communication should be No
Verify treadmill power switch
is in the off (0) position. restored (Reference 1G).

Connect Communication
Cable.
No

Verify the Emergency Stop Verify Communication cable Is

Button is released or Pull Communication
is connected at both ends. Cable
Tether missing. Connected?

Communication should be Yes

No restored (Reference 1G).

Press connect on the Yes

Turn treadmill power switch is Full Vision Treadmill
in the on (1) position. PS New Cal Software
are you Recd and Sent
information? 1I
pg 9-8

9-6 TMX428 TMX428CP TMX58 Service Manual October 2015

 TRACKMASTER Troubleshooting

Communication RS232 Flow Chart 1H

1H

Download the appropriate drive based on your computer

When connecting Stress OS at http://www.ftdichip.com/Drivers/VCP.htm or
System or Full Vision
Yes refer to the TRACKMASTER® owner’s manual. When
Treadmill PS New Cal
Software, you received connecting to the USB port, ensure port configuration
missing driver error code. matches with your software port identification.

No
After installing USB driver and configured
the port setting, reference 1H.

When connecting Full

Vision Treadmill PS
New Cal Software are
you Recd and Sent
Yes information?
1I Replace Communication
pg 9-8 Cable.
No
Yes
Verify treadmill power switch
is in the off (0) position.
Is
Verify Communication cable Communication
has not been damaged. Cable
Verify the Emergency Stop Damaged?
Button is released or Pull
Tether missing.
Communication should be No
restored (Reference 1G).
Turn treadmill power switch in
the on (1) position.
Connect Communication
Cable.
No

Press connect on the Is

Full Vision Treadmill No Verify Communication cable Communication
PS New Cal Software is connected at both ends. Cable
are you Recd and Sent Connected?
Yes information?
1I
pg 9-8 Communication should be Yes
restored (Reference 1G).

October 2015 TMX428 TMX428CP TMX58 Service Manual 9-7

 Troubleshooting TRACKMASTER

Smart Power Supply Error Code Identification Flow Chart 1I

1I

Verify the error code by counting the flashes. Is the Red LED D13
Yes flashing on the
The error flashes are very consistent and then a
Smart Power Supply
long pause. PCBLF0443-1?

No
Reference Smart Power Supply Error Code, 1
Flow Chart 1J pg 9-9. Reason for error flashes Verify the Emergency Stop Button is
Bad Speed Calibration. released or Pull Tether missing.

Reference Smart Power Supply Error Code 2, Verify when the Emergency Stop
Flow Chart 1K pg 9-10. Reason for error Button is released the Smart Power
flashes Elevation Error. Supply PCBLF0443-1 initial power up
returns to the parked position.
Reference Smart Power Supply Error Code 3,
Flow Chart 1L pg 9-11. Reason for error
flashes Missing Speed Signal from Motor Treadmill should
Controller. be operational.

Reference Smart Power Supply Error Code 4,

Flow Chart 1M pg 9-12. Reason for error
flashes Over Speed Error Based on Motor
Control Signal. Reference Smart Power Supply Error Code 8,
Flow Chart 1Q pg 9-17. Reason for error flashes
Motor Control Reports Fault.
Reference Smart Power Supply Error Code 5,
Flow Chart 1N pg 9-13. Reason for error
flashes Missing Signal from External Speed
Sensor. Reference Smart Power Supply Error Code 9,
Flow Chart 1R pg 9-18. Reason for error flashes
Start Belt Command Received during
Reference Smart Power Supply Error Code 6, Initialization.
Flow Chart 1O pg 9-14. Reason for error
flashes Over Speed Bases on External Speed
Sensor. Reference Smart Power Supply Error Code 10,
pg 9-18 consult the factory for trouble shooting.

Reference Smart Power Supply Error Code 7,

Flow Chart 1P pg9-15 & 9-16. Reason for
error flashes Excessive Speed Mismatch
(Motor Controller Signal VS External Speed
Sensor).

9-8 TMX428 TMX428CP TMX58 Service Manual October 2015

TRACKMASTER Troubleshooting

Smart Power Supply Error Code 1 Flow Chart 1J “Bad Speed Calibration”

1J Yes 1I
pg 9-8

Is the Red LED D13

No Is the Red LED D13 No
flashing 1 time with a Treadmill should
flashing on the
4 second pause on the
Smart Power Supply be operational.
Smart Power Supply
PCBLF0443-1?
PCBLF0443-1?

Yes
Using the Full Vision Treadmill
Verify treadmill power switch PS New Cal software connect
is in the off (O) position. communication thru RS232 or
USB.

Perform Test Plug Procedure

to test elevation & treadmill Select the
running belt, see Section 5-5 treadmill will start out slow and
for instructions. increase speed to maximum.

Turn the treadmill power switch

Did treadmill OFF (O) for 10 seconds then
cycle according to No turn the power switch ON (-).
Test Plug
Procedure?

Yes Is the Red LED D13 Yes 1I

flashing on the
Connect Stress System & Smart Power Supply pg 9-8
perform test. PCBLF0443-1?

No

Did treadmill Treadmill should

respond to Test No be operational.
Procedure?

Yes

Return Treadmill
to service.

October 2015 TMX428 TMX428CP TMX58 Service Manual 9-9

 Troubleshooting TRACKMASTER

Smart Power Supply Error Code 2 Flow Chart 1K “Elevation Error”

1K Yes 1I
pg 9-8

Is the Red LED D13

No Is the Red LED D13 No
flashing 2 times with Treadmill should
flashing on the
4 second pause on the
Smart Power Supply be operational.
Smart Power Supply
PCBLF0443-1?
PCBLF0443-1?

Yes Verify Elevation Voltage JP1

Turn the treadmill power switch

OFF (O) for 10 seconds then
turn the power switch ON (-).

Did the Red LED

D9 light Up No
momentarily?

Yes
Turn the treadmill power switch Turn the treadmill power switch
OFF (O). OFF (O).

Remove the black cap from actuator; & verify wires Verify Elevation Voltage JP1
are not disconnected to the reed switch or limit between Incline Down Red &
switch. Incline Common White.

Turn the treadmill power switch

ON (-).

Perform Test Plug Procedure Connect Stress System &

to test elevation & treadmill perform test.
Yes Did the Volt
running belt, see Section 5-5 meter
for instructions. momentarily read
incoming voltage?
Did treadmill No
Did treadmill Yes respond to
cycle according to Test No
Test Plug Procedure? Replace Smart Power
Procedure? Supply PCBLF0443-1.
Yes
No
Return Treadmill Replace Elevation
Replace Elevation Actuator.
to service.
Actuator.

9-10 TMX428 TMX428CP TMX58 Service Manual October 2015

 TRACKMASTER Troubleshooting

Smart Power Supply Error Code 3 Flow Chart 1L “Missing Speed Signal From Motor Controller”
1L Yes 1I
pg 9-8

Is the Red LED D13

No Is the Red LED D13 No
flashing 3 times with Treadmill should
flashing on the
4 second pause on the
Smart Power Supply be operational.
Smart Power Supply
PCBLF0443-1?
PCBLF0443-1?

Yes

Turn the treadmill power

switch OFF (O). Was the harness Yes Replace Harness
damaged?
317-160-208.
Verify the harness between Drive PC2303-012-N
and Smart Power Supply PCBLF0443-1 is
properly connected and not damaged. No

Was the harness No

properly Connect harness.
connected?

Yes

Verify the harness between Motor Was the harness Yes Replace Motor
PMC5FA-00101-03 and Drive PC2303-012-N damaged?
317-160-197.
is properly connected and not damaged.

No

Was the harness No

properly Connect harness.
connected?

Yes

Send a Start Belt Command

or Press Start if equipped
with controller. Turn the treadmill power
switch ON (-).

Replace Drive No Did the

running belt Is the Red LED D13 No
PC2303-012-N Yes on the Smart Power
start? Supply PCBLF0443-1
Return Treadmill Yes on continuously?
to service. 1I
pg 9-8

October 2015 TMX428 TMX428CP TMX58 Service Manual 9-11

 Troubleshooting TRACKMASTER

Smart Power Supply Error Code 4 Flow Chart 1M “Over Speed Error Based on Motor
Controller Signal”

1M Yes 1I
pg 9-8

Is the Red LED D13

No Is the Red LED D13 No
flashing 4 times with Treadmill should
flashing on the
4 second pause on the
Smart Power Supply be operational.
Smart Power Supply
PCBLF0443-1?
PCBLF0443-1?

Yes

Turn the treadmill power switch

OFF (O) for 10 seconds then
turn the power switch ON (-).

No Is the Red LED D13 Send a Start Belt Command or Press

on the Smart Power
Start if equipped with controller
Supply PCBLF0443-1
on continuously? Yes increase speed to 10mph.
1I
pg 9-8

With the treadmill

running at 10.0 mph
No
for 1 minute, is the
Red LED D13 on?

Replace Drive
PC2303-012-N
Yes 317-160-196

Return Treadmill
to service.

9-12 TMX428 TMX428CP TMX58 Service Manual October 2015

 TRACKMASTER Troubleshooting

Smart Power Supply Error Code 5 Flow Chart 1N “Missing Signal from External Speed Sensor”

1N Yes
1I
pg 9-8

Is the Red LED D13

No Is the Red LED D13 No
flashing 5 times with Treadmill should
flashing on the
4 second pause on the
Smart Power Supply be operational.
Smart Power Supply
PCBLF0443-1?
PCBLF0443-1?

Yes

Turn the treadmill power switch Send a Start Belt Command or Press
OFF (O) for 10 seconds then Start if equipped with controller.
turn the power switch ON (-). Speed the treadmill up to 1 mph.

No Is the Red LED D13

on the Smart Power
Supply PCBLF0443-1 With the treadmill
on continuously? running at 1.0 mph
1I for 1 minute, is the
pg 9-8 Red LED D13 on? Yes
Yes
Verify that the speed sensor gap to flywheel
magnet is 1/16” and connector is secure on J10
on the Smart Power Supply PCBLF0443-1. Treadmill should
No be operational.

Is the Red LED D13

flashing 5 times with
Verify when the fly wheel magnet passes by the
4 second pause on the
speed sensor that D10 LED on the Smart Power Smart Power Supply
Supply PCBLF0443-1 the red led light is on PCBLF0443-1?
then goes out after the speed is not present.

Yes
Replace Speed Sensor
317-160-034

Is the Red LED D10 on

the Smart Power Supply
PCBLF0443-1 flashing Yes Replace Smart Power Supply
ON & Off when passing 317-160-199
by flywheel magnet?

No

October 2015 TMX428 TMX428CP TMX58 Service Manual 9-13

 Troubleshooting TRACKMASTER

Smart Power Supply Error Code 6 Flow Chart 1O “Over Speed Base On External Speed Sensor”

1O Yes
1I
pg 9-8

Is the Red LED D13

No Is the Red LED D13 No
flashing 6 times with Treadmill should
flashing on the
4 second pause on the
Smart Power Supply be operational.
Smart Power Supply
PCBLF0443-1?
PCBLF0443-1?

Yes

Turn the treadmill power switch Send a Start Belt Command or Press
OFF (O) for 10 seconds then Start if equipped with controller.
turn the power switch ON (-). Speed the treadmill up to 10 mph

No Is the Red LED D13

on the Smart Power
Supply PCBLF0443-1 With the treadmill
on continuously? running at 10.0
1I mph for 1 minute,
pg 9-8 is the Red LED Yes
Yes D13 on?
Verify that the speed sensor gap to flywheel
magnet is 1/16” and connector is secure on J10
on the Smart Power Supply PCBLF0443-1. Treadmill should
No be operational.

Is the Red LED D13

Verify when the fly wheel magnet passes by the flashing 6 times with
speed sensor that D10 LED on the Smart Power 4 second pause on the
Supply PCBLF0443-1 the red led light is on Smart Power Supply
PCBLF0443-1?
then goes out after the speed is not present.

Yes
Replace Speed Sensor
317-160-034

Is the Red LED D10 on

the Smart Power Supply
PCBLF0443-1 flashing Yes Replace Smart Power Supply
ON & Off when passing 317-160-199
by flywheel magnet?

No

9-14 TMX428 TMX428CP TMX58 Service Manual October 2015

 TRACKMASTER Troubleshooting

Smart Power Supply Error Code 7 Flow Chart 1P “Excessive Speed Mismatch”
1P Yes 1I
pg 9-8

Is the Red LED D13

No Is the Red LED D13 No
flashing 7 times with Treadmill should
flashing on the
4 second pause on the
Smart Power Supply be operational.
Smart Power Supply
PCBLF0443-1?
PCBLF0443-1?

Yes

Turn the treadmill power

switch OFF (O). Was the harness Yes Replace Harness
damaged?
317-160-208.
Verify the harness between Drive PC2303-012-N
and Smart Power Supply PCBLF0443-1 is
properly connected and not damaged. No

Was the harness No

properly Connect harness.
connected?

Yes

Verify the harness between Motor Was the harness Yes Replace Motor
PMC5FA-00101-03 and Drive PC2303-012-N damaged?
317-160-197.
is properly connected and not damaged.

No

Was the harness No

properly Connect harness.
connected?

Yes
Turn the treadmill power switch
OFF (O) for 10 seconds then
turn the power switch ON (-).

No Is the Red LED D13

on the Smart Power
Supply PCBLF0443-1
on continuously?
1I
pg 9-8
Yes

A B

October 2015 TMX428 TMX428CP TMX58 Service Manual 9-15

 Troubleshooting TRACKMASTER

A B

Verify that the speed sensor gap to flywheel Turn the treadmill power
magnet is 1/16” and connector is secure on J10 switch ON (-).
on the Smart Power Supply PCBLF0443-1.

Is the Red LED D13 No

on the Smart Power
Supply PCBLF0443-1
Verify when the fly wheel magnet passes by the on continuously?
speed sensor that D10 LED on the Smart Power 1I
Supply PCBLF0443-1 the red led light is on pg 9-8
then goes out after the speed is not present. Yes

Send a Start Belt Command or Press

Start if equipped with controller.
Speed the treadmill up to 10 mph

Is the Red LED D10 on

the Smart Power Supply With the treadmill
PCBLF0443-1 flashing Yes
running at 10.0
ON & Off when passing
by flywheel magnet? mph for 1 minute,
is the Red LED Yes
D13 on?

No
Treadmill should
Replace Smart Power Supply be operational.
No
317-160-199
Replace Drive
PC2303-012-N
317-160-199

9-16 TMX428 TMX428CP TMX58 Service Manual October 2015

 TRACKMASTER Troubleshooting

Smart Power Supply Error Code 8 Flow Chart 1Q “Motor Control Reports Fault”
1Q Yes
1I
pg 9-8

Is the Red LED D13

No Is the Red LED D13 No
flashing 8 times with Treadmill should
flashing on the
4 second pause on the
Smart Power Supply be operational.
Smart Power Supply
PCBLF0443-1?
PCBLF0443-1?

Yes

Turn the treadmill power

switch OFF (O).

Verify the harness between Drive PC2303-012-N

and Smart Power Supply PCBLF0443-1 is
properly connected.

Was the harness No

properly Connect harness.
connected?

Yes

Verify the harness between Motor

PMC5FA-00101-03 and Drive PC2303-012-N
is properly connected.

Was the harness No

properly Connect harness.
connected?

Yes

Send a Start Belt Command

or Press Start if equipped
with controller. Turn the treadmill power
switch ON (-).

Did the running

Replace Drive No
belt start? Is the Red LED D13 No
PC2303-012-N Yes on the Smart Power
Supply PCBLF0443-1
Return Treadmill Yes on continuously?
to service. 1I
pg 9-8

October 2015 TMX428 TMX428CP TMX58 Service Manual 9-17

 Troubleshooting TRACKMASTER

Smart Power Supply Error Code 9 Flow Chart 1R “Start Belt Command Received During
Initialization”

1R Yes 1I
pg 9-8

Is the Red LED D13

No Is the Red LED D13 No
flashing 9 times with Treadmill should
flashing on the
4 second pause on the
Smart Power Supply be operational.
Smart Power Supply
PCBLF0443-1?
PCBLF0443-1?

Yes

Turn the treadmill power switch Inspect interface cable between Is the RS232 or
USB Interface
OFF (O). the Treadmill & Stress System
cable damaged? Yes
cables for damage.

No Replace Interface
No Is the Red LED D13 cable.
on the Smart Power Turn the treadmill power switch ON (-).
Supply PCBLF0443-1
on continuously?
1I
pg 9-8

With the treadmill

Send a Start Belt Command or Press Yes
running at 10.0 mph Return Treadmill
Start if equipped with controller for 1 minute is the
increase speed to 10mph. to service.
Red LED D13 on?

No
1I
pg 9-8

Smart Power Supply Error Code 10

Consult the factory for trouble shooting.

Full Vision Inc.
3017 Full Vision Drive
Newton, KS 67114 USA
http://www.full-vision.com
Phone: (316)-283-3344
Fax: (316)-283-9522
Email: [email protected]

9-18 TMX428 TMX428CP TMX58 Service Manual October 2015

 TRACKMASTER Troubleshooting

Control Console Communication Flow Chart 1S

1S

Treadmill should
be operational.

Do you see the Welcome

screen?
Yes
Turn the treadmill power switch OFF (O).

Verify the harness between LCD Screen PCB0444-1 J8

connector and Smart Power Supply PCBLF0443-1 J12
connector is properly connected. Inspect cable to see if
damaged or loose connector.

No

Is the screen displaying

ESTABLISHING
COMMUNICATION? No Is the RS232 or
Yes Yes
USB Interface
cable damaged?

Replace Communication
Turn the treadmill power switch ON (-). cable 317-160-264

No Did the Welcome

No
Verify the Emergency Stop Button is released. screen appear?

Replace Smart
Power Supply
Yes 317-160-199
Did the Welcome
No
screen appear? Treadmill should
be operational.
Replace LCD Screen
417-160-017.
Yes

Treadmill should
be operational.

October 2015 TMX428 TMX428CP TMX58 Service Manual 9-19

Troubleshooting TRACKMASTER

Drive PC2303-012-N Status LED Code List

When the drive is faulted, the Status LED blinks out the fault code. The Status LED
blinks the proper number of times, pauses with the Status LED off, and then repeats
the blink code.

Status Code Description Fault Retention

No Blink No faults, power stage enabled -
Fast Blink No faults, power stage disabled -
LED Off Ac line power insufficient -

1 Blink PWM_CMD Stuck Low Latched (Consult Factory)

2 Blink Gcoder Feedback Error Latched (Consult Factory)
3 Blink Not Used -
4 Blink Output Over Current Latched (Consult Factory)
5 Blink Control Supply Under Voltage Self Resetting
6 Blink Drive Over Temperature Latched (Consult Factory)
7 Blink Bus Over Voltage Self Resetting
8 Blink Output Short Circuit Latched (Consult Factory)

9-20 TMX428 TMX428CP TMX58 Service Manual October 2015

TRACKMASTER Removal and Replacement of Components

Removal and Replacement 10

of Components

Hood Removal Procedure TMX428 Series

Tools Required
1/4” Hex Socket or Flat Blade Screw Driver

1. Turn the treadmill’s power switch to the OFF position.

2. Unplug the treadmill from the wall receptacle.
3. Allow treadmill to discharge for 3 minutes.
4. Remove the 5 hood securing screws (2 on the front and 3 on the back side of
the treadmill).
5. Remove hood and set aside.
6. Reverse procedure to reinstall hood.

(5) Screw HHWHTS #8-32 x 3/8” Long

October 2015 TMX428 TMX428CP TMX58 Service Manual 10-1

Removal and Replacement of Components TRACKMASTER

Drive Motor Replacement TMX428 Series

Tools Required
1/4” Hex Socket or Flat Blade Screw Driver
7/16” wrench and socket
9/16” wrench and socket
¾” wrench and socket
3/16” Hex wrench or Hex socket
3/32” Hex wrench or Hex socket
Approximate time to complete 1.75 hrs

1. Elevate the treadmill with test plug to approximately 15% grade.

2. Turn the treadmill main power switch to the OFF position.
3. Unplug the treadmill from the wall receptacle.
4. Allow treadmill to discharge for 3 minutes.
5. Remove the (5) hood securing screws.
6. Remove hood and set aside.
7. Remove Motor Feedback 6 pin cable on J1 from drive.
8. Remove Motor Power 4 pin cable on TB2 from drive.
9. With ¾” wrench and socket loosen spring tension, slide belt off the sprocket
allowing the motor to pivot, gaining access to the motor mount bolts.
10. With ¼” hex socket or flat blade screw driver remove the (4) ¼” plastic
clamps on the Motor Feedback & Power wires.
11. With 7/16” wrench and socket remove the 4 bolts securing the motor mount to
the frame.
12. Lift the motor assembly out of the treadmill.
13. With 9/16” wrench and socket remove the pivot bolt.
14. Remove drive sprocket from motor shaft by loosening the two 3/32” set
screws on its hub, then slide it off.
15. Remove flywheel from motor shaft by loosening the two 3/16” set screws on
its hub then slide it off.
16. Slide the flywheel and 1/8” key on the new motor shaft; make sure the
flywheel does not rub the plastic housing creating a motor noise.
17. Slide drive sprocket and 1/8” key on the motor shaft approximately in the
same location from old motor.
18. Tighten the setscrews on the hub, first the one the key then the other one.
19. Reinstall the new motor to existing motor base plate.
20. Tighten the pivot bolt until free movement of the motor is removed.
21. Reinstall motor, making sure the isolator mounts are in place.
22. When tightening the 4 bolts, tighten equality without over tightening.

10-2 TMX428 TMX428CP TMX58 Service Manual October 2015

 TRACKMASTER Removal and Replacement of Components

23. Adjust speed sensor to magnet on the flywheel to approximately 1/16”

24. Reinstall (4) ¼” plastic clamps on the Motor Feedback & Power wires.
25. Reconnect Motor Feedback 6 pin cable to J1 on the drive.
26. Reconnect Motor Power 4 pin cable to TB2 on the drive.
27. See Drive Belt Tension Adjustment 7-4 & 7-5 to tension drive belt properly.
28. After installation run treadmill checking for excess vibration and noise from
the motor area.
29. Replace the hood and screws (5).

(4) ¼”-20 Nuts

(4) ¼” Flat Washer Motor Assembly

Belt Tension Spring

(4)Screw HHWHTS #8-32 x 3/8” lg

(4) ¼” Clamp Plastic
(4) MTR Isolation Spacer

(4) MTR Isolation Stem

(4) ¼” Fender Washer TB2 Drive Connector

(4) ¼”-20 x 1-1/4” Lg J1 Drive Connector

October 2015 TMX428 TMX428CP TMX58 Service Manual 10-3

Removal and Replacement of Components TRACKMASTER

Drive Replacement TMX428 Series

Tools Required
1/4” Hex Socket or Flat Blade Screw Driver
5/16” Hex Socket with 6” Extension or Nut Drive
Approximate time to complete .75 hrs

1. Elevate the treadmill to approximately 15% grade.

2. Turn the treadmill main power switch to the OFF position.
3. Unplug the treadmill from the wall receptacle.
4. Allow treadmill to discharge for 3 minutes.
5. Remove the (5) hood securing bolts.
6. Remove hood and set aside.
7. Remove Motor Feedback 6 pin cable on J1 from drive.
8. Remove 10 pin communication cable on J2 from drive.
9. Remove Incoming Power 4 pin connector on TB1 from drive.
10. Remove Motor Power 4 pin cable on TB2 from drive.
11. Remove the 3 pin connector from Regen Circuit board on front side of drive.
12. With 5/16” socket loosen front two screws and remove the back screw.
13. The drive will slide back allowing the drive to be removed.
14. Reverse procedure to reinstall Drive; see Chapter 6 Speed Calibration Procedure.

Remove back screw

10 Pin J2 Connector

6 Pin J1 Connector

Motor Power TB2 Connector

Connector
Incoming Power TB1 Connector
Connector
Motor Pan
Regen 3 Pin Connector
Drive
Drive Ground to Main
Wire Harness Loosen 2 Front Screws

10-4 TMX428 TMX428CP TMX58 Service Manual October 2015

TRACKMASTER Removal and Replacement of Components

Front Roller Replacement TMX428 Series

Tools Required
1/4” Hex Socket or Flat Blade Screw Driver
3/16” Hex Wrench or Hex Socket
Approximate time to complete 45min

1. Turn the treadmill main power switch to the OFF position.

2. Unplug the treadmill from the wall receptacle.
3. Allow treadmill to discharge for 3 minutes.
4. Remove the (5) hood securing bolts.
5. Remove hood and set aside.
6. Use the 3/16” Allen wrench or socket to remove the button head Allen bolt
securing the left and right end caps from the rear of the treadmill.
7. Remove the end caps and place to the side.
8. Use a ¼” Allen wrench or socket to completely remove left and right tension bolts
from rear roller. When removing the tension bolts maintain equal tension on the
bolts to avoid stripping the threads on the tension bolt or roller.
9. Push rear roller forward as far as it will go.
10. Use a ¼” Allen wrench or socket to remove the bolt securing the front roller to the
treadmill frame.
11. Push the front roller from the right side of the treadmill to the left side and lift
roller up; slip timing belt off the front roller. Lift the front roller up and out of the
treadmill. Use caution to avoid pinching the timing belt.
12. Slide the front roller between the running belt, place the timing belt over the
sprocket of the front roller between the running belt and place the timing belt over
the sprocket of the front roller. Replace the front roller. Verify the guide for the
belt deck and rollers is to the left during installation. Verify the timing belt goes
around the front roller sprocket and that it
is not pinched.
13. Replace the securing bolt and tighten.
14. Align the bolt holes on the rear roller with
the access hole of the end caps. Start the
tensioning bolts on the rear roller but do
not tighten.
15. Replace the left and right end caps and
replace securing screws. Bolt 5/16-18 x 2” Lg
16. Adjust the tension of the running belt; see
Chapter 7 Running Belt Tension Procedure. Lock Washer 5/16”

Flat Washer 5/16”

Front Roller

October 2015 TMX428 TMX428CP TMX58 Service Manual 10-5

Removal and Replacement of Components TRACKMASTER

Rear Roller Replacement TMX428 Series

Tools Required
1/4” Hex Socket or Flat Blade Screw Driver
3/16” Hex Wrench or Hex Socket
Approximate time to complete 45 min
1. Turn the treadmill main power switch to the OFF position.
2. Unplug the treadmill from the wall receptacle.
3. Allow treadmill to discharge for 3 minutes.
4. Remove the (5) hood securing bolts.
5. Remove hood and set aside.
6. Use the 3/16” Allen wrench or socket to remove the button head Allen bolt
securing the left and right end caps from the rear of the treadmill.
7. Remove the end caps and place to the side.
8. Use a ¼” Allen wrench or socket to completely remove left and right tension
bolts from rear roller. When removing the tension bolts maintain equal tension
on the bolts to avoid stripping the threads on the tension bolt or roller.
9. Use a ¼” Allen wrench or socket to completely remove left and right tension
bolts from rear roller. When removing the tension bolts maintain equal
tension on the bolts to avoid stripping the threads on the tension bolt or roller.
10. Push rear roller forward as far as it will go.
11. Use a ¼” Allen wrench or socket to remove the bolt securing the front roller
to the treadmill frame.
12. Push the front roller from the right side of the treadmill to the left side and lift
roller up; slip timing belt off the front roller. Lift the front roller up and out of
the treadmill. Use caution to avoid pinching the timing belt.
13. Push the rear roller from right side of the treadmill to the left side and lift
roller up and out to remove. Replace the rear roller.
14. Slide the front roller between the running belt, place the timing belt over the
sprocket of the front roller between the running belt, and place the timing belt
over the sprocket of the front roller. Replace the front roller. Verify the guide
for the belt deck and rollers is to the left during installation. Verify the
timing belt goes around the front roller sprocket and that it is not pinched.
Replace the securing bolt and tighten.
15. Align the bolt holes on the rear roller with
the access hole of the end caps. Start the
tensioning bolts on the rear roller but do
not tighten.
16. Replace the left and right end caps and
replace securing screws.
17. Adjust the tension of the running belt; see
Chapter 7 Running Belt Tension Procedure.
Tension Bolts

10-6 TMX428 TMX428CP TMX58 Service Manual October 2015

TRACKMASTER Removal and Replacement of Components

Running Belt Replacement TMX428 Series

Tools Required
¼” Allen wrench or socket
3/16” Allen wrench or socket
½” Wrench or socket with extension
Jack stand or block capable of supporting the weight of the rear of the treadmill
Approximate Time to Complete – 60 min

1. Elevate treadmill to 12%.

2. Turn treadmill main power switch to the OFF position.
3. Unplug treadmill plug from the wall receptacle.
4. Allow treadmill to discharge for 3 minutes.
5. Remove the (5) hood securing bolts.
6. Set hood to the side of treadmill.
7. Lift rear of the treadmill and place jack stands or block to support the rear of the
treadmill.
8. Use the 3/16” Allen wrench or socket to remove the bolt securing the left and right end
caps from the rear of the treadmill.
9. Remove the end caps and place to the side.
10. Use a ¼” Allen wrench or socket to completely remove left and right tension bolts from
rear roller. When removing the tension bolts maintain equal tension on the bolts to
avoid stripping the threads on the tension bolt or roller.
11. Push rear roller forward as far as it will go.
12. Lift the edge of the running belt up, use 3/16” Allen wrench or socket and remove the
(4) flat head Allen screws which secure the running deck cross braces. There are (4)
screws total, (2) on the left side and (2) on the right side.
13. Push the deck to one side of the treadmill and from the other side lift the edge of the
deck up and out over the rail; place deck to the side
14. Use a ¼” Allen wrench or socket to remove bolt securing the front roller to the treadmill
frame.
15. Push the front roller from the right side of the treadmill to the left side and lift roller up
and slip timing belt off the front roller. Lift the front roller up and out of the treadmill.
Use caution to avoid pinching the belt.
16. Slide the rear roller out of the rear of the treadmill side rails and remove from the
treadmill.
17. Use ½” wrench or socket with extension to remove the (4) bolts securing the deck cross
braces to the treadmill side channels. Remove the cross braces from the treadmill. Use
caution to avoid damage to the antistatic tinsel run between the (2) front bolts. Set the
cross braces and the tinsel off to the side. Verify all pieces of the deck cushions are
accounted for and set off to the side.
18. Remove old running belt and replace with new running belt. Verify the guide for the
belt deck and rollers is to the left during installation.

October 2015 TMX428 TMX428CP TMX58 Service Manual 10-7

 Removal and Replacement of Components TRACKMASTER

19. Replace the (2) deck bbraces and deck cushions; start the deck braces securing bolts but
do not tighten them. Replace the antistatic tinsel using the (2) from deck brace bolts.
20. Replace the rear roller; push the rear roller as far forward as possible. Do not replace or
start thee tensioning bolts at this time. Verify the guide for the belt deck and rollers is to
the left during installation.
21. Slide the front roller between the running belt, place the timing belt over the sprocket of
the front roller between the running belt, and pplace
lace the timing belt over the sprocket of
the front roller. Replace the front roller. Verify the guide for the belt deck and rollers is
to the left during installation. Verify the timing belt goes around the front roller sprocket
and that it is not pinche
pinched. Replace the securing bolt and tighten.
22. Lift up the edge of the running belt and slide the deck onto the deck braces.
23. Tighten the cross brace securing bolts. Use se caution to avoid over tightening the bolts.
bolts
24. Align the bolt holes on the rear roller with th thee access hole of the end caps. Start the
tensioning bolts on the rear roller but do not tighten.
25. Replace the left and right end caps and replace securing screws.
26. Adjust the tension of the running belt; see Chapter 7 Running Belt Tension
Procedure.
27. Reinstall hood by reversing procedure.
Running Belt
Stretch Adjustment Marks

Preset to .125 for

proper belt tracking.
Front Roller
See Note 2
Roller Bolt

Drive Belt

Flat Head
Allen Screw
Rear Roller
See Note 3 Deck Rail
Belt Tension Plate Support
Tension Bolt
See Note 1 Running Deck

End Cap Bolt

Deck Rail Nut
End Cap NOTES:
1. ADJUSTMENT SCREWS MUST BE MATCH
TIGHTENED. PROPER TENSTION IS ACHIEVED
WHEN BELT CAN’T SLIP ON PULLEYS WHEN IN
OPERATION ACHIEVED WHEN BELT CAN’T SLIP
ON PULLEYS WHEN IN OPERATON.
2. ADJUST DRIVE BELT TENTION PULLING ALL
FREE PLAY OUT OF BELT. DO NOT OVER
TIGHTEN CAUSING THE BELT TO STRETCH.
3. MOVE REAR PULLEY SIDE TO SIDE IN CHANNELS
TO OBTAIN FRONT TO REAR BELT ALIGNMENT
ALIGNM
AND TRACKING.
10-8 TMX428 TMX428CP TMX58 Service Manual October 2015
TRACKMASTER Removal and Replacement of Components

Running Deck Replacement TMX428 Series

Tools Required
¼” Allen Wrench or Socket
3/16” Allen Wrench or Socket
½” Wrench or Socket with Extension
Jack stand or block capable of supporting the weight of the rear of the treadmill
Approximate Time to Complete – 30 min

1. Elevate treadmill to 12%.

2. Turn treadmill main power switch to the OFF position.
3. Unplug treadmill plug from the wall receptacle.
4. Allow treadmill to discharge for 3 minutes.
5. Remove the (5) hood securing bolts.
6. Set hood to the side of treadmill.
7. Lift rear of the treadmill and place jack stands or block to support the rear of the
treadmill.
8. Use the 3/16” Allen wrench or socket to remove the bolt securing the left and right end
caps from the rear of the treadmill.
9. See Running Belt Replacement TMX Series 428 Series assembly drawing.
10. Remove the end caps and place to the side.
11. Use a ¼” Allen wrench or socket to completely remove left and right tension bolts
from rear roller. When removing the tension bolts maintain equal tension on the
bolts to avoid stripping the threads on the tension bolt or roller.
12. Push rear roller forward as far as it will go.
13. Lift the edge of the running belt up, use 3/16” Allen wrench or socket and remove the
six flat head Allen screws which secure the running deck cross braces. There are (6)
screws total, (3)on the left side and (3) on the right side.
14. Push the deck to one side of the treadmill and from the other side lift the edge of the
deck up and out over the side rail.
15. The deck is now ready for maintenance, replacement or to be flipped.
16. Lift up the edge of the running belt and slide the deck onto the deck braces. Replace
the screws securing the deck to the deck braces and tighten. Verify the guide for the
deck is to the left during installation.
17. Tighten the cross brace securing bolts. Use caution to avoid over tightening the bolts.
18. Align the bolt holes on the rear roller with the access hole of the end caps. Start the
tensioning bolts on the rear roller but do not tighten.
19. Replace the left and right end caps and replace securing screws.
20. Adjust the tension of the running belt; see Chapter 7 Running Belt Tension
Procedure.
21. Reinstall hood by reversing procedure.

October 2015 TMX428 TMX428CP TMX58 Service Manual 10-9

Removal and Replacement of Components TRACKMASTER

Deck Cushion Replacement TMX428 Series

Tools Required
¼”Allen Wrench or Socket
3/16” Allen Wrench or Socket
½” Wrench or Socket with extension
Jack stand or block capable of supporting the weight of the rear of the treadmill
Approximate Time to Complete – 60 min
1. Elevate treadmill to 12%.
2. Turn treadmill main power switch to the OFF position.
3. Unplug treadmill plug from the wall receptacle.
4. Allow treadmill to discharge for 3 minutes.
5. Remove the (5) hood securing bolts.
6. Set hood to the side of treadmill.
7. Lift rear of the treadmill and place jack stands or block to support the rear of the treadmill.
8. Use the 3/16” Allen wrench or socket to remove the bolt securing the left and right end
caps from the rear of the treadmill.
9. Remove the end caps and place to the side.
10. Use a ¼” Allen wrench or socket to completely remove left and right tension bolts from
rear roller. When removing the tension bolts maintain equal tension on the bolts to avoid
stripping the threads on the tension bolt or roller.
11. Push rear roller forward as far as it will go.
12. Lift the edge of the running belt up, use 3/16” Allen wrench or socket and remove the (2)
flat head Allen screws which secure the running deck cross brace with the damaged deck
cushions.
13. Use a ½” wrench or socket with extension to remove the (2) bolts securing the deck cross
brace to the treadmill side channels. Remove the cross braces from the treadmill. Use
caution to avoid damaged to the antistatic tinsel run between the (2) front bolts if the front
cross brace is being removed.
14. Use a ½” socket to remove the rubber deck cushion(s) from the brace.
15. Replace the damaged deck cushion and use ½” socket to remove the bolt securing the
rubber deck cushion(s) from the brace.
16. Verify the placement of the deck cushion(s) by referring to the Running Belt Replacement
TMX428 Series assembly drawing.
17. Replace the deck brace and deck cushions, start the deck brace securing bolts but do not
tighten them. Replace the antistatic tinsel using the two front deck brace bolts if removed.
(Fitness Only)
18. Lift up the edge of the running belt and slide the deck onto the deck braces. Replace the
screws securing the deck to the deck braces and tighten. Verify the guide for the deck is to
the left during installation.
19. Tighten the cross brace securing bolts. Use caution to avoid over tightening the bolts.
20. Align the bolt holes on the rear roller with the access hole of the end caps. Start the
tensioning bolts on the rear roller but do not tighten.
21. Replace the left and right end caps and replace securing screws.
22. Adjust the tension of the running belt; see Chapter 7 Running Belt Tension Procedure.
23. Reinstall hood by reversing procedure.

10-10 TMX428 TMX428CP TMX58 Service Manual October 2015

TRACKMASTER Removal and Replacement of Components

Motor Drive Belt Replacement TMX428 Series

Tools required
1/4” Hex Wrench or Hex Socket
3/4" Open-end Wrench & Hex Socket
1/4” Hex Nut Driver or Flat Blade Screw Driver
Tape Measure
Approximate time to complete 1.5 hrs
1. Elevate treadmill to 12%.
2. Turn treadmill main power switch to the OFF position.
3. Unplug treadmill plug from the wall receptacle.
4. Allow treadmill to discharge for 3 minutes.
5. Remove the (5) hood securing bolts.
6. Set hood to the side of treadmill.
7. With ¾” wrench and socket, loosen spring tension & slide belt off the sprocket
allowing the motor to pivot.
8. Using 7/16” socket and wrench, remove the (6) bolts securing the “Bracket Motor Right
Hand”.
9. Loosen rear belt tension bolt, allowing the rear roller to move forward towards the front
roller.
10. Remove hex socket head cap screw retaining the front roller on the right hand side.
11. Now, lift right hand end of the front roller up enough to remove the drive belt.
12. Reverse procedure to install new drive belt.
13. After installation follow drive belt/running belt: see Chapter 7 Running Belt Tension
Procedure and Drive Belt Tension Procedure.

Bracket Motor Right Hand

Motor Tension

Drive Belt

(6) Bolt 1/4”-20 x 1 1/4" Long

(6) Bolt 1/4” Flat

(6) Bolt 1/4” Lock
(6) Bolt 1/4”- 20 Nut

October 2015 TMX428 TMX428CP TMX58 Service Manual 10-11

Removal and Replacement of Components TRACKMASTER

Elevation Actuator Replacement/Adjustment TMX428 Series

Tools Required
2 - 9/16” Wrenches
renches or Sockets
3/8” Wide Flat Blade
lade Screwdriver
Shipping blanket, carpet, or cardboard
1/4” Hex Nut Driver
river or Flat Blade Screw Driver
Tape measure
Trackmaster grease “Part Number 317-160-165
Approximate time to complete 1.5 hrs
1. Turn
urn treadmill main power switch to the OFF position.
2. Unplug treadmill plug from the wall receptacle.
3. Allow treadmill to discharge for 3 minutes.
4. Move the treadmill to an area large enough to lay treadmill on its side.
5. Remove the (5) hood securing bolts.
6. Set hood to the side of treadmill.
7. Unplug the treadmill actuator harness (this is a six-conductor
conductor connector attached to the actuator).
actuator
8. Cut the Zip tie that holds the wire to the motor pan gusset.
9. With blanket in suitable spot
spot, place a foot on the treadmill side channel and grasp the handrail;
handrail pull
the treadmill towards you and allow it to gently come to rest on its side.
10. With the 9/16” wrench and socket remove the top and lower bolt
bolts from the actuator.
11. When removing the bolts from the actuator: watch out for nylon washers on each side of the
actuator.
12. Prior to installing the new actuator, preset the zero position. Looking
king from the bottom (tube end).
Lightly turn the tube clockwise until it bottoms the threads or stops, ensure that the motor shaft
does not turn! Now turn it counter clockwise a 1 1/2 turn turns (540°) and continue turning it until bolt
holes in the tube is aligned with holes as it is installed.
13. Reverse procedure to install the actuator back into the treadmill. Be sure to use Trackmaster grease
(quality moly based grease) on both the bolts and nylon washer
washers retaining it.
Note: Over tightening the lower bolt will lead to a popping or creaking noise, as the treadmill is elevating.
14. After installation, follow the calibration of grade using the grade recalibration instruction for your
model of treadmill, then check for proper operation.

Actuator Nut
Actuator
Nylon Washer “Apply Trackmaster
Grease to pivot”
Actuator Spacer Apply Trackmaster
Washer Grease
Actuator Bolt Elevation
Treadmill Frame Assembly
Actuator Nut
Nylon Washer
Lower Actuator Bolt

10-12 TMX428 TMX428CP TMX58 Service Manual October 2015

TRACKMASTER Removal and Replacement of Components

Smart Power Supply Relay Board Replacement TMX428 Series

Tools required
Wire Cutters or Utility Knife
Grounding Wrist Strap
1/4” Hex Nut Driver or Flat Blade Screw Driver
5/16” Hex Nut Driver
3/32” Flat Blade Electronics Screwdriver
Approximate time to complete 1.25 hrs
1. Turn treadmill main power switch to the OFF position.
2. Unplug treadmill plug from the wall receptacle.
3. Allow treadmill to discharge for 3 minutes.
4. Remove the (5) hood securing bolts.
5. Set hood to the side of treadmill.
6. Put on the grounding wrist strap, ground it to the power cord ground screw.
7. Unplug the 4-conductor JP2 and 3-conductor JP1 plugs from the SPSR Board (smart
power supply relay board).
8. Unplug Cooling Fan J1-Red and J2-Blk single conductor spades from the SPSR Board.
9. Unplug E-Stop J4-Black and J5-Gray single conductor spades from the SPSR Board.
10. Unplug Pull Tether J6-Black and J7-Gray single conductor spades from the SPSR Board.
11. Unplug Speed Sensor J10-two conductor from the SPSR Board.
12. Unplug Elevation Count Sensor J11-three conductor from the SPSR Board.
13. Unplug Drive Harness J15-ten conductor from the SPSR Board.
14. Remove the RS232 harness J13 by unscrewing the (2) flat head screws retaining it to the
SPSR Board.
15. Cut the Zip tie on USB harness J14 and unplug from the SPSR Board.
16. Remove two control board bracket screws
17. Remove screw that holds circuit board to control board bracket. Relocate standoff and
spacer transfer to new Power supply board.
18. Remove the nylon nuts on the four corners of the SPSR Board.
19. IMPORTANT! Once removed, Note the position of the voltage switch.
20. Set switch on new board the same. IF WRONG DAMAGE WILL OCCUR!
21. Reverse procedure to install the SPSR Board back into the treadmill.
22. After installation, follow recalibrate the treadmill using the recalibration instruction for
your model of treadmill, then check for proper operation.

Nylon Screw & Standoff

Control Board Bracket

Control Board Nut

Control Board Screw

October 2015 TMX428 TMX428CP TMX58 Service Manual 10-13

Removal and Replacement of Components TRACKMASTER

Circuit Breaker Replacement

Tools Required
1/4” Hex nut driver or flat blade screw driver
3/32” Flat blade electronic screwdriver
Approximate time to complete .25 hrs
1. Turn the treadmill main power switch to the off position.
2. Unplug treadmill plug from the wall receptacle.
3. Allow treadmill to discharge for 3 minutes.
4. Remove the (2) screws retaining the circuit breaker mounting plate.
5. Gently pull the plate out allowing wires to feed through the hole.
6. Unplug the (2) wire connectors off the circuit breaker to replace. When replacing more than one,
perform the replacement one at a time to keep the wires on the correct value of circuit breaker.
7. Using a small electrical flat blade screwdriver push the holding clips on the sides of the breaker in
to allow it to slide out of the plate. These are located on the backside of the plate (made as part of
the breaker housing).
8. Install the new circuit breaker by sliding it into the hole until it snaps into place.
9. Reattach the wire connector by sliding them on to the terminals.
10. Once all desired breakers have been replaced, reinstall the plate with the (2) screws.
11. After installation check the unit for proper operation.

3 AMP Fuse Circuit Board Mounting Plate

(BLK & WHT Wires)
1/4 AMP Fuse (BLK & RED Wires)
3 AMP Fuse
(BRN & BRN Wires)
1/4 AMP Fuse (BRN & BLUE Wires)

10-14 TMX428 TMX428CP TMX58 Service Manual October 2015

TRACKMASTER Removal and Replacement of Components

Relocate Emergency Stop Button (ESB) and Stop Tether Switch (STS)
Tools Required STS
1/8” Allen Wrench
1/4” Flat Blade Screwdriver
ESB
2 Pair Flat Nose Pliers
Approximate time to complete 1 hrs
1. Turn the treadmill main power switch to the OFF position.
2. Unplug treadmill plug from the wall receptacle.
3. Allow treadmill to discharge for 3 minutes.
4. Using a 1/8” Allen wrench, remove the (4) 10-32 screws (Fig. A)
holding the ESB & STS assembly to the fabricated handrail.
10-32 Screw

ESB or STS Screwdriver

Assembly 1/8” Allen
Wrench
Fabricated
Fig. A Handrail
Fig. B
5. Using a flat head screwdriver, remove the ESB & STS
assembly from the fabricated handrail (Fig. B).
6. Completely removing the ESB & STS assembly and gently pulling to expose the wires.
7. Using two pairs of pliers, gently separate the connectors on the ESB (Fig. C).
8. On the STS using a pair of pliers, remove the connector from the tether assembly (Fig. D).

STS Connection on
outer spade blades.

Fig. D
Fig. C J6 & J7
9. Reverse Steps 1 thru 8 to reinstall ESB & STS.
10. Remove the (5) hood securing bolts.
11. Remove hood and set aside.
12. Since relocating the ESB & STS, we will need to
swap J4 & J5 with J6 & J7 on the controller board.
Use caution; carefully remove the wires with pliers
and slowly wiggle up and down while pulling. J4 & J5
Avoid causing excessive flexing to the board.
13. Replace the hood. Secure the hood using original screws.

October 2015 TMX428 TMX428CP TMX58 Service Manual 10-15

Removal and Replacement of Components TRACKMASTER

Validate Relocate ESB and STS Operation

Tools Required
Test Plug
Approximate time to complete .25 hrs
1. Plug treadmill power cord back into wall outlet.
2. Turn on the ON/OFF switch on the front of the treadmill.
3. Using the test plug, elevate the treadmill to 20% elevation and 2 mph.
4. Pull the STS tether. The treadmill should come to a gradual stop and stay at 0 mph for
approximately 3 minutes. You may hear the motor humming as it applies resistive load when you
try to move the belt.
5. Restore the STS and restart the treadmill using the test plug. Elevate the treadmill to 20% elevation
and 2 mph.
6. Press the ESB; the treadmill will come to a gradual stop with the running belt will freewheel.
7. The validation of relocating the ESB and STS is now complete, once the treadmill has passed the
above test.
8. Check to make sure all screws are properly tightened.

10-16 TMX428 TMX428CP TMX58 Service Manual October 2015

TRACKMASTER Established Component Replacement Times

Established Component Replacement Times 11

Hood Removal Procedure TMX428 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 min
Drive Motor Replacement TMX428 Series . . . . . . . . . . . . . . . . . . . . . . . . . 1 h r 3 0 min
Drive Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 5 min
Front Roller Replacement TMX428 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 0 min
Rear Roller Replacement TMX428 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 5 min
Running Belt Replacement TMX428 Series . . . . . . . . . . . . . . . . . . . . . . . . 1 h r 3 0 min
Running Deck Replacement TMX428 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 0 min
Deck Cushion Replacement TMX428 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 hr
Motor Drive Belt Replacement TMX428 Series. . . . . . . . . . . . . . . . . . . 1 h r 2 0 min
Elevation Actuator Replacement/Adjustment TMX428 Series . . . . . . . 1 h r 3 0 min
Smart Power Supply Relay Board Replacement TMX428 Series . . . . 1 h r 1 5 min
Circuit Breaker Replacement TMX428 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 0 min
Relocate ESB and STS TMX428 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 hr
Validate Relocate ESB and STS Operation TMX428 Series . . . . . . . . . . . . . . . . 2 0 min
Replace Emergency Stop Button (ESB) TMX428 Series . . . . . . . . . . . . . . . . . . . 3 0 min
Replace Stop Tether Switch (STS) TMX428 Series . . . . . . . . . . . . . . . . . . . . . . . 3 0 min
Replace Handrail Right or Left Handrail TMX428 Series . . . . . . . . . . . . . . . . . . 3 0 min
Replace Handrail Center TMX428 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 0 min
Handrails take off and reinstall for moving TMX428 Series . . . . . . . . . . . . . . . 4 5 min
Main power switch check and replacement TMX428 Series . . . . . . . . . . . . . . . . 3 0 min
Run belt tracking and tension adjustment TMX428 Series . . . . . . . . . . . . . . . . . 2 5 min
Power cord replacement TMX428 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 min
CE filter replacement TMX428 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 0 min
Ohmite resistor replacement TMX428 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 0 min
Frame replacement TMX428 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 h r 3 0 min
Motor pan replacement TMX428 Series. . . . . . . . . . . . . . . . . . . . . . . . . . . 7 h r 3 0 min
Side channel replacement Left or Right TMX428 Series . . . . . . . . . . . 3 h r 1 5 min
Rear Foot Replacement TMX428 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 0 min
Isolator Replacement (6 isolator & belt tracking) TMX428 Series . . . 2 h r 1 5 min
Main wire harness TMX428 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 0 min
Speed Sensor Replacement TMX428 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 min
End Cap Replacement TMX428 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 min
Rubber Stripping On Side Channel Replacement TMX428 Series . . . . . . . . . . 1 5 min
Wheel Replacement Both TMX428 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 min
RS232 Harness Replacement TMX428 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 0 min
USB Harness Replacement TMX428 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 0 min
Recalibrate Speed, includes time to download software TMX428 Series. . . . . 3 0 min
Recalibrate Speed TMX428 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 0 min
Recalibrate Elevation, included time to download software TMX428 Series . 4 0 min
Recalibrate Elevation TMX428 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 0 min

NOTE: Unless otherwise noted, all times are assumed to be for a treadmill fully assembled! In the
event that components serviced share like disassembly procedure, both times will not apply.
Example (with replacement of wire harness, speed sensor could also be replaced for no
additional time). All other services not listed, including combinations of above listed services
will be appointed a reasonable time by the manufacturer only! If in doubt call the manufacture
before performing services (316)283-8110.

October 2015 TMX428 TMX428CP TMX58 Service Manual 11-1

Established Component Replacement Times TRACKMASTER

11-2 TMX428 TMX428CP TMX58 Service Manual October 2015

TRACKMASTER Parts List with Part Numbers

Parts List with Part Numbers

12
Motor Mount Assembly

NOTES:
1. WHEN INSTALLING THE FLYWHEEL & DRIVE
SPROCKET, TIGHTEN SET SCREWS ON KEY
WAY FIRST, AND THEN TIGHTEN THE
SECOND SET SCREW TO MOTOR SHAFT.
2. WHEN TIGHTENING ITEMS 5 & 6, CONTINUE
TIGHTENING UNTIL MOTOR CANNOT MOVE
SIDE TO SIDE.

Item Description Part Number Qty

1 DC Motor Base 317-701-001 1
2 Motor DC Servo PMCFA-00101-03 317-160-197 1
3 Sprocket Drive 530-5MGT-15 317-160-201 1
4 Flywheel DC W/Magnet .50 dia 317-160-200 1
5 HHCS 7/16-14 x 5” Lg 001-2332 1
6 NLN 7/16-14 001-2333 1
7 HHCS ½-13 3” Lg All Thread 001-2348 1
HHCS ½-13 5” Lg All Thread (Alternative) 001-2331
8 Spring Motor Tension (Alternative) 317-160-218 1
9 HN ½-13 Gr5 001-1390 3

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Circuit Board Assembly

NOTES:
APPLY BLUE LOCKTITE
THREADLOCKER TO ITEM 8

Item Description Part Number Qty

1 Bracket Circuit Board 317-709-001 1
2 Board FG0495-0 Universal Power Supply 317-160-199 1
3 HN #8-32 Nylon 001-1763 4
4 Mount Inverter Isolation 317-160-040 4
5 HHWHTS #8-32 x .375 001-1744 4
6 RHMS #6-32 x 2.5” Lg 001-1890 1
7 Standoff Round .50 Lg .166 ID 001-1854 1
8 K-Lock Nut #6-32 001-1858 1
9 Trim Black 3” Lg 001-102-044 1

Elevation Assembly

APPLY MOLY BASED GREASE 2X

Item Description Part Number Qty

1 Elevation Weldment TMX428 317-702-002 1
2 Spanner Wheel 317-160-054 2
3 Wheel Landing Gear 317-160-005 2
4 HHCS 3/8-16 x 3.25 Lg Gr5 001-1519 2
5 NLN 3/8-16 001-1430 2

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Pull Tether Assembly

NOTE: ATTACHED WRIST STRAP TO CLIP
KILL SWITCH CLIP COMES WITH A DOUBLE KNOT.
AS PART OF 317-160-226

Item Description Part Number Qty

1 Tether Pull w/Wrist strap 317-160-229 1
2 E-Stop Kill Switch LS500 317-160-226 1
3 Cap 1.50 x 4.00 LPDE BLK Modified 317-160-230 1
Emergency Stop Assemblies

Item Description Part Number Qty

1 Emergency Stop IDEC 317-160-268 1
2 Cap 1.50 x 4.00 LPDE BLK Modified 317-160-230 1
3 Emergency Stop RAFI (Alternative E-Stop) 317-160-212 1
4 Bolt HHCS ¼-20 x ¾” Lg Gr 5 001-1186 1
5 Flat Washer ¼” 001-1439 1
6 Lock Washer ¼” 001-1450 1
7 Nut HN ¼-20 Gr 5 001-1386 1

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Motor Pan Assembly

DC MOTOR MOUNT ASSEMBLY

CIRCUIT BOARD MOUNT ASSEMBLY

ALTERNATIVE RESITOR

TAP 10-32 HOLE AND SAND

POWDER COAT MATERIAL
FOR PROPOR GROUND
CONNECTION

ALTERNATIVE SWITCH

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Motor Pan Assembly

Item Description Part Number Qty

1 Motor Pan Weldment 317-700-001 1
2 HHCS ¼-20 x 1.25 Lg Gr 2 001-1159 4
3 FW ¼” Dia (Above) 001-1439 4
Fender Washer ¼” Dia 1” OD (Bellow) 001-1888 4
4 Motor Isolation Stem 317-160-216 4
5 Motor Isolation Spacer 317-160-217 4
6 NLN ¼-20 001-1427 4
7 Actuator 115V 317-160-090 1
Actuator 220V 317-160-029
8 HHCS 3/8-16 c 5.0” Lg Gr 5 001-1743 1
9 FW 3/8” Dia 001-1441 3
10 Washer Nylon 317-160-086 3
11 NLN 3/8-16 001-1430 1
12 Fan Assembly DC W/Connector 317-160-202 1
13 RHMS #6-32 x .50” Lg 001-1851 4
14 K-Lock Nut #6-32 001-1858 4
15 Resistor Omite 85/150MJ40R0DE 317-160-233 1
Alternative Resistor Omite
16 HNS #8-32 Flange 001-1636 7
17 HHWHTS #8-32 X .50” Lg 001-1764 7
18 Filter CorCom F4635 317-160-240 1
19 Drive DC Servo PC2303-012-N 317-160-196 1
20 Regen Module RA2302
21 RHMS #10-32 X .375 LG 001-1755 6
22 NYLON ISOLATOR #10-32 317-160-259 5
23 Plate Breaker Trackmaster 317-710-001 1
24 Breaker 3 amp 317-160-220 2
25 Breaker ¼ amp 317-160-024 2
26 HHWHTS #8-32 x .375” Lg 001-1744 2
27 Switch TA35-C324-L200C0 317-160-256 1
Alternative Switch “Schurter Power Entry Module” 317-160-139
28 RHMS #6-32 x .50” Lg 001-1851 2
29 K-Lock Nut #6-32 001-1858 2
30 POWER CORD INLET C-20 4793.4000 317-160-257 1
31 PLATE SWITCH TMX428 317-718-001 1

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Motor Pan Assembly Wiring

DC MOTOR ASSEMBLY DC DRIVE MOTOR
CONNECTOR PE,W,V,U

DC DRIVE MOTOR
FEEDBACK CONNECTOR

115V CONFIGURATION 220V CONFIGURATION

BLACK (110-120) BLANK

BLANK BLACK (208-240)
BROWN (HOT) BROWN (HOT)
BLANK BLANK

RESITOR OMITE
DRIVE DC SERVO PC2303-012-N

.060 GAP
DC FAN WIRE RED
DC FAN WIRE BLACK
CONNECT 2 PIN CONECTOR
BROWN WIRE ON TOP
ORANGE WIRE ON TOP

CIRCUIT BOARD ASSEMBLY

ITEM 12 SHEET 1 OF 2
CONNET COLOR CONFIGURATION

WHITE (COMMON) MULTIPLE GROUND

RED (INCLINE UP) CONNECTION
BLACK (INCLINE DOWN)

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Motor Pan Assembly Wiring

HARNESS CONNECTOR
BLACK
BREAKER 3 AMP
HARNESS CONNECTOR
BREAKER ¼ AMP DRIVE BROWN

BLK BLK
RED WHT CIRCUIT BOARD
ASSEMBLY
BRN
CONNECTOR COLOR CONFIGURATION
BRN
BRN
BLU RED (INCLINE COMMON)
DRIVE GROUND ON
NYLON STANDOFF WHITE (AC COMMON
FILTER CORCOM F4635 BLUE (INCLINE HOT)
BROWN (AC HOT)
ALTERNATIVE POWER
SWITCH

POWER SWITCH
ASSEMBLY

HARNESS JUMPER (BROWN)

HARNESS JUMPER (BLACK) MAIN WIRE HARNESS (GRN/YEL)

MAIN WIRE HARNESS (BROWN)

GROUND HARNESS (GRN/YEL) MAIN WIRE HARNESS (BLACK)

ZIP TIE USB WIRE TO

NYLON STANDOFF

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Motor Pan Assembly Wiring

Item Description Part Number Qty

1 Screw HHWTS #8-32 x .375 Lg 001-1744 4
2 Clamp Plastic ¼” ID 317-160-227 4
3 Harness 110V DC Treadmill 317-160-261 1
Harness 220V DC Treadmill 317-160-262
4 Harness Resistor 417-160-026 1
5 Speed Sensor 317-160-034 1
6 Harness Elevation 317-160-231 1
7 HH Screw #10-32 x .375 Lg GRD 317-160-076 2
8 Harness Motor Controller 417-160-031 1
9 Harness Ground 317-160-070 2
10 Harness Main DC Treadmill 317-160-247 1
11 Harness Jumper 317-160-071 2
12 LW #10 EXT Tooth 001-1751 1
13 Surge Suppressor 317-160-129 1
14 Decal Ground 317-160-273 1
15 Cable RS232 Panel Mount 317-160-236 1
16 Cable USB Panel to USB B 317-160-237 1
17 Plate RS232 & USB 317-160-254 1
18 HHCS #8-32 x .50 Lg 001-1764 2
19 HNS #8-32 Flange Nut 001-1636 2
20 Decal Caution 317-160-274 2
21 Zip Tie 8” Lg 317-160-280 1
22 Zip Tie 4” Lg 317-160-075 1
23 RMHS #4-40 x .375 Lg 001-2360 2

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Frame Assembly

APPLY MOLY BASED GREASE

2X

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Frame Assembly

ACTUATOR INSTALLATION NOTES:

1. PRIOR TO INSTALLATION OF BOLT, TURN
ACTUATOR END CLOCKWISE UNTIL IT STOPS.
NEXT TURN COUNTER CLOCKWISE 1 ½ TURN OUT
PLUS ANY ADDITIONAL REVOLUTION TO ALLOW
BOLT ALIGNMENT.
2. WHEN TIGHTENING ELEVATION BOLT AND NUT,
THE WASHERS MUST MOVE FREELY.

Item Description Part Number Qty

1 Motor Pan Assembly TMX428 317-Various
Various 1
2 Side Channel LH Weldment 317-704-001
001 1
3 Side Channel RH Weldment 317-705-001
001 1
4 Rear Foot 317-706-001
001 1
5 Stem Bumper 317-160-141
141 2
6 Bracket Motor Pan Right 317-708-001
001 1
7 Bracket Motor Pan Left 317-707-001
001 1
8 Bolt HHCS ¼-20 20 x .75” Lg Gr 5 001-1186
1186 26
9 Flat Washer ¼” Dia 001-1439
1439 26
10 Lock Washer ¼” Dia 001-1450
1450 26
11 Nut HN ¼-2020 Grade 5 001-1386
1386 26
12 Landing Gear Assembly 317-702-001
001 1
13 Bumper 1.8” Dia Black 317-160-106
106 2
14 Shoulder Bolt HSHSS 5/8” Dia x 1” Lg 001-1730
1730 2
15 Elevation Delrin Spacer 317-160-060
060 4
16 Flat Washer ½” Dia 001-1443
1443 2
17 Nylon Lock Nut NLN ½” ½”-13 001-1676
1676 2
18 Bolt HHCS 3/8-1616 x 3” Lg Grade 5 001-1699
1699 1
19 Washer Nylon 317-160-086
086 4
20 Nylon Lock Nut 3/8-1616 001-1430
1430 1
21 Belt Drive 317-160-026
026 1
22 Anti Slip Safety Walk “Cut 1.5” x 4” 317-160-084
084 2

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Deck Assembly

STRETCH ADJUSTMENT MARKS 4X

SEE NOTE 2

INSTALL CAMBER
UP

SEE NOTE 3

SEE NOTE 1

NOTES:
1. ADJUSTMENT SCREWS MUST BE MATCH
TIGHTENED. PROPER TENSION IS ACHIEVED
WHEN BELT CAN’T SLIP ON PULLEYS WHEN IN
OPERATION ACHIEVED
2. ADJUST DRIVE BELT TENSION
TEN PULLING ALL FREE
PLAY OUT OF BELT. DO NOT OVER TIGHTEN
CAUSING THE BELT TO STRETCH.
3. MOVE REAR PULLEY SIDE TO SIDE IN CHANNELS
TO OBTAIN FRONT TO REAR BELT ALIGNMENT
AND TRACKING.

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Parts List with Part Numbers TRACKMASTER

Tension Deck Assembly

Item Description Part Number Qty

1 Frame Assembly TMX428 317-Various 1
2 Belt Running with V-Guide 317-160-002 1
3 Bolt HHCS 5/16-18 x .75” Lg 001-1167 6
4 Lock Washer 5/16” Dia 001-1451 7
5 Flat Washer 5/16” Dia 001-1440 9
6 Deck Support Channel Weldment 317-379-001 3
7 Deck Isolator 1.75” Dia with Stud 317-345-003 6
8 Flange Lock Nut HNS 5/16-18 001-1398 6
9 Deck Running Board 317-160-025 1
10 Screw HSFCHCS 5/16”-18 x 1.5” Lg PLTD 001-1739 6
11 Roller Front 317-160-156 1
12 Set Screw 5/16”-18 x 1.75” Lg 317-160-224 1
13 Nut FHNZ 5/16-18 Grade 5 001-1387 1
14 Bolt HSHCS 5/16”-18 x 2” Lg PLTD 001-1748 1
15 Rear Roller 317-160-157 1
16 Belt Tension Plate 317-649-001 2
17 Screw HSHCS 5/16”-18 x 3” Lg PLTD 001-1737 2
18 End Cap LH 317-160-175 1
19 End Cap RH 317-160-176 1
20 Screw HSBHCS 5/16”-18 x 1” Lg PLTD 001-1735 2
21 Extrusion Anti Skid Rubber 60” LG 317-160-055 2

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Final Assembly
CONNECT CABLE TO ESB CONNECT CABLE TO PULL TETHER
ROUTE WIRES THRU CONNECT CONTACT I&I ROUTE
CENTER & LEFT HAND THRU LEFT HANDRAIL

OUTSIDE CONTACT

DETAIL 1

SEE DETAIL 1

Final Assembly Circuit Board Connection

CONNECT PULL TETHER
CABLE TO J7 & J6

CONTROLLER OPTION
CONNECT CONSOLE
COMMUNICATION CABLE TO J12

CONNECT EMERGENCY STOP

CABLE TO J4 & J5

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Parts List with Part Numbers TRACKMASTER

Final Assembly
Item Description Part Number Qty
1 Running Deck Assembly TMX428 317-Various 1
2 Handrail RH TMX428 317-712-001 1
3 Handrail LH TMX428 317-713-001 1
4 Washer Nylon 317-160-086 2
5 Lock Washer 3/8” 001-1452 4
6 Screw HSHCS 3/8”-16 x 1” Lg PLTD 001-1859 6
7 Dome Plug 317-180-008 4
8 Handrail Center TMX428 317-711-001 1
9 Screw HSBHCS ¼”-20 x ¾” Lg 001-2351 8
10 Harness ESB & Pull Tether 317-160-263 2
11 Pull Tether Assembly 317-720-001 1
12 Emergency Stop Assembly RAFI 317-721-001 1
Emergency Stop Assembly IDEC 317-722-001
13 Riv-Nut ¼”-20 001-1686 1
14 Power Cord 110-120 VAC C-19 NEMA 5-15 317-160-228 1
Power Cord 220-240 VAC C-19 NEMA 6-15 317-160-242
Power Cord 200-240 VAC C-19 CEE 7/7 EURO 317-160-189
Power Cord 230 VAC C-19 UK BS1363 317-160-188
15 Decal Hi-Pot Power Cord 317-160-258 1
16 Clamp Support 317-160-092 1
17 Lock Washer ¼” 001-1450 1
18 Bolt HHCS ¼”-20 x ¾” Lg Gr 5 001-2351 1
19 Hood TMX428 317-160-235 1
20 Decal Caution 317-160-018 1
21 Screw HHWHTS #8-32 x 3/8” Lg 001-1744 5
22 Test Plug 317-187-003 1
23 Velcro Hook Backing 1” lg. 317-160-056 1”
24 Velcro Backing 1” Lg. 317-160-057 1”
25 Decal Serial 317-Various 1
26 Decal ETL 317-160-130 1
27 Decal Wheelie Bin 317-160-164 1

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TMX428CP Controller Assembly

CONNECT CABLE TO PULL TETHER

CONNECT CONTACT I&I ROUTE
THRU LEFT HANDRAIL

OUTSIDE CONTACT

CONNECT TO
ESB HANRESS

CONNECT TO J8
ON LCD SCREEN
CONNECT TO J10
ON LCD SCREEN

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Parts List with Part Numbers TRACKMASTER

TMX428CP Controller Assembly

Item Description Part Number Qty

1 Console Plastic LCD Configuration 317-160-270 1
2 Membrane TMX428 Overlay 317-160-232 1
3 E-Stop Kill Switch LS500 317-160-226 1
4 Harness Jumper Pull Tether 317-160-266 1
5 Board FG0960-0 Console 417-160-017 1
6 RHMS #6-32 3/8” Lg 001-1745 4
7 Harness Communication Jumper 317-160-265 1
8 Back Plate Fitness Panel 317-731-001 1
9 Fastener ¼-20 UNC Riv-Nut 001-1686 4
10 Rubber Control Dampener 317-160-277 2
11 Handrail Controller TMX428CP 317-719-001 1
12 Flat Washer ¼” Dia 001-1439 4
13 Lock Washer ¼” Dia 001-1450 4
14 Screw BHSCS ¼”-20 x ¾” 001-2351 4
15 Polar Board FG0315 317-160-168 1
16 Velcro Hook 5/8” x 2” Lg 317-160-056 1
17 Velcro Loop 5/8” x 2” Lg 317-160-057 1
18 Polar Cable 3 pin 12” CA0045 317-160-169 1
19 K-Lock Nut #6-32 001-1823 10
20 Cover Plastic Controller 317-160-234 1
21 Screw HSBHCS 10-32 x ½” Lg 001-2334 4
22 Tether Pull W/Wrist Strap 317-160-229 1
23 Fair-Rite Ring 0446164951 317-160-290 1
24 Fair-Rite Ring 0461164281 317-160-291 1

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TMX58 Controller Assembly

CONNECT CABLE TO PULL TETHER

CONNECT CONTACT I&I ROUTE
THRU LEFT HANDRAIL

CONNECT TO
OUTSIDE CONTACT
ESB HANRESS

CONNECT TO J10
ON LCD SCREEN

CONNECT TO J8
ON LCD SCREEN

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Parts List with Part Numbers TRACKMASTER

TMX58 Controller Assembly

Item Description Part Number Qty
1 Console Plastic LCD Configuration 317-160-270 1
2 Membrane TMX428 Overlay 317-160-232 1
3 E-Stop Kill Switch LS500 317-160-226 1
4 Harness Jumper Pull Tether 317-160-266 1
5 Board FG0960-0 Console 417-160-017 1
6 RHMS #6-32 3/8” Lg 001-1745 4
7 Harness Communication Jumper 317-160-265 1
8 Back Plate Fitness Panel 317-731-001 1
9 Fastener ¼-20 UNC Riv-Nut 001-1686 4
10 Rubber Control Dampener 317-160-277 2
11 Handrail Controller TMX58 317-714-001 1
12 Flat Washer ¼” Dia 001-1439 4
13 Lock Washer ¼” Dia 001-1450 4
14 Screw BHSCS ¼”-20 x ¾” SS 001-1796 4
15 Polar Board Royal Medical 317-160-221 1
16 Velcro Hook 5/8” x 3” Lg 317-160-056 1
17 Velcro Loop 5/8” x 3” Lg 317-160-057 1
18 Polar Cable 3 pin 12” CA0045 317-160-169 1
19 K-Lock Nut #6-32 001-1823 10
20 Cover Plastic Controller 317-160-234 1
21 Screw HSBHCS 10-32 x ½” Lg 001-2334 4
22 Tether Pull W/Wrist Strap 317-160-229 1
23 Harness Jumper Polar Grip 317-160-267 1
24 Harness Grip ESD 317-390-015 2
25 Grips Polar Kit 317-390-008 1
26 Shim Grip Cap 317-390-013 2
27 Shim Grip 317-390-012 2
28 Fair-Rite Ring 0446164951 317-160-290 1
29 Fair-Rite Ring 0461164281 317-160-291 1

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 Appendix

Maintenance Log
A
Serial #_______________________________Date Purchased_______________

Purchased From ________________________Phone_______________________

DATE HOURS SERVICE COMPLETED COST

 Full Vision Inc.
3017 Full Vision Drive
Newton, KS. 67114
www.full-vision.com

© Full Vision Inc. 2013