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Motorized Performance & Fitness Treadmills Includes servicing information on the models: 4Front Desmo Mercury Path Pro XL Desmo, Mercury, and Path models built after Jan. 2003 and contain- ing a Brushless Motor System Service Manual 05/2016 SM-MT-EN-02...
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European Representative Manufacturer WOODWAY GmbH WOODWAY USA, Inc. Steinackerstr. 20 W229 N591 Foster Ct. 79576 Weil am Rhein Waukesha, WI 53186 Germany Tel.: + 49 (0) 7621-940 999-0 Tel.: 1-262-548-6235 Fax.: + 49 (0) 7621-940 999-40 Fax.: 1-262-522-6235 E-mail: info@WOODWAY.de E-mail: info@WOODWAY.com...
Important Safety Instructions.......................7 Description of Warning Notices ....................9 Safety Notices on Device ......................10 1.3.1 4Front ................................10 1.3.2 Desmo / ELG / Mercury / Path / Pro / Pro XL ....................11 Introduction ......................... 13 Servicing Instructions Information ....................13 Limitation of Liability .........................
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Pro/Pro XL ..........................41 Parts Replacement ....................... 44 Ordering Parts ........................... 44 Display Replacement ......................... 44 6.2.1 Desmo ................................45 6.2.2 Mercury/Path ............................... 46 Display-to-Interface Cable Replacement ..................47 Side Cover Replacement ......................48 Motor Control Board Replacement ..................... 49 Interface Board Replacement .....................
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9.2.4 Incline System ............................... 80 Warranty Information ....................... 81 Maintenance Report ......................82 Disposal Notice ......................... 83 Table of Figures ......................... 84 Appendix .......................... 85 05/2016 – SM-MT-EN-02...
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German “Waldweg” (“Wald” = wood and “Weg”= way), the feel of running on a soft pine needle covered path in the forest. In 1983, a manufacturing license was awarded to Sakai Medical, for the use of WOODWAY technology in the Japa- nese marketplace.
A safety sign has been included with your treadmill. It is the responsibility of the owner to post this sign in a visible area near the machine. All WOODWAY treadmills are built to the specifications of and are intended for both commercial and residential use.
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This is for the user’s safety in case of an emergency. WOODWAY treadmills are built to handle runners weighing up to 800 lbs. (360 kg) at speeds between 0-4 MPH (0-6.5 km/h) and 400 lbs. (180 kg) at speeds up to 18 MPH (29 km/h).
Description of Warning Notices Warning notices indicate potential hazards or safety risks. They are indicated in this manual by a color-coded signal word panel (symbol with the appropriate signal word). All warning notices have the same design and the same standardized content design. Sample of a Warning Notice SIGNAL WORD Warning Text, Type, and Source of Danger...
Notice on Display 4Front, Left Side To prevent injury, stand on the side panels prior to starting the device. Read the op- erating instructions prior to use.
Warning to Not Tension Belt To prevent incorrectly tensioning running belt and causing damage or injury, call WOODWAY for proper instruction or to set up an appointment with a service techni- cian. This is located just inside the tread- mill side covers.
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Warning to Not Tension Belt To prevent incorrectly tensioning running belt and causing damage or injury, call WOODWAY Service for proper instruction or to set up an appointment with a service technician. This is located just inside the treadmill side covers.
Introduction Servicing Instructions Information This manual provides information on the safe servicing of the WOODWAY slat belt treadmill. For information on the operation of the treadmill, see the supplied User’s Manual. A condition for safe operation is compliance with all safety and operating instructions.
WOODWAY. Replacement Parts WOODWAY recommends the use of original replacement parts. Original replacement parts have particular qualities and ensure reliable and safe operation. Developed for specific use with the device ...
Customer Service For service questions contact the following: WOODWAY USA, Inc. W229 N591 Foster Ct. Waukesha, WI 53186 Contact Tel: 1 262-548-6235 Fax: 1 262-522-6235 E-Mail: service@WOODWAY.com Web: www.WOODWAY.com For faster processing of your request please have the following data and information available: ...
“O” position: Treadmill is turned off and the belt is free moving. Name Plate Each WOODWAY treadmill receives a serial number during production. Depending on the year of your model, it has an alphanumeric code with 7-8 characters or a numeric code with 9 digits.
DO NOT BEND OR REMOVE PRONGS. The plugs are polarized, meaning the prongs are different sizes and the plug can only fit in the outlet one way; if the plug does not fit, reverse the plug. If other power cord plugs are required, please contact WOODWAY. 3.3.1...
3.3.2 Description Parameters 230 VAC Voltage* Requires at least 230 V from wall outlet Frequency 50 Hz Current 13 Amp Dedicated line required (cannot share neutral line) Wall Outlet Requirements Outlet Compatibility G/BS 1363 plug * If voltage falls 10% below 230 V, treadmill will shut off and reset 3.3.3 Germany Description...
(motor), Pos. 5: capacitor wire and black wire (motor) Phoenix; incoming power- Pos. 1: black, Pos. 2: green, Pos. 3: red For entering software onto the interface board (only done on-site at WOODWAY) Molex; alternate side-switch harness plug-in, used in Elites and situations where normal display is not used and side-switches are needed (not currently in use) DB9;...
4.1.2 ESI Interface Board Explanation LED 1 (Yellow) Goes out when upper-limit switch is tripped LED 2 (Yellow) Goes out when lower-limit switch is tripped LED 3 (Yellow) Goes on when power to running surface break is applied; not currently in use LED 4 (Yellow) Goes on when elevation motor is going down;...
4.2.1 Wiring Connections 120 VAC Wire AC1: Red Neutral Wire AC2: Black Motor Wires R: White S: Black T: Red Unused Wires BUSS+ BUSS- 4.2.2 Diagnostic Lights Green LEDs (Steady): Drive enabled- RUN or OK (Blinking): Drive enabled- RUN or OK, faults stored in memory Red LEDs See the following tables: Red LEDs (steady)
4.2.3 Encoder Connector (P1) Pin 1 +5 VDC, red Pin 2 Common, black Pin 3 Output U, violet Pin 4 Output V, white/brown Pin 5 Output W, white/orange Pin 6 +5 VDC, (not used) Pin 7 Output A, brown Pin 8 Output B, blue Pin 9 Common, (not used)
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4.2.6 Fault Storage Process The following fault storage processes are possible with the drive board: LED Display Process Notes Normal Power ON RUN LED on briefly Process (no faults saved) Normal operat- RUN LED stays on ing mode while motor rotates Normal Power ON RUN LED on briefly...
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LED Display Process Notes Fault Change fault All LEDs OFF for 5 Display mode seconds Mode (cont.) Ground fault Display (if appli- cable); the num- ber blinking is the number of occur- rence Belt off fault Display (if appli- cable); the num- ber blinking is the number of occur- rence...
Fault Storage Process Diagram Brushless Motor/Drive 4.3.1 Brushless Motor 8-pole construction (smooth rotation) Brushless permanent magnet Industrial 1000-line encoder with com- Sinusoidal windings mutation tracks, sealed and isolated 2.5 HP continuous (6 HP max.) Class F insulation rating, 311°...
The treadmill can be delivered in various states of assembly. Disassembly/assembly may be required for moves or relocation into other rooms. NOTE In WOODWAY performance and fitness treadmills, standard (inch) screws and nuts are used, with few exceptions. These are not compatible with metric fastening elements!
1x Phillips head screwdriver, #1 - Remove the covers on the left and right. Fig. 6 4Front assembly, side panel - Insert wire and protective cover into the guard rail tube to prevent damage during insertion. Fig. 7 4Front assembly, wiring - Prepare the mount for the tube.
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Fig. 9 4Front assembly, inserting tubes - Pull the wire and protective cover out of the railing tube. Fig. 10 4Front assembly, connection 1 - Lay the wire with protective cover behind the railing mount. Fig. 11 4Front assembly, connection 2...
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Fig. 12 4Front assembly, connection 3 - Tighten railing mount bolts. Fig. 13 4Front assembly, fixing the railing - Replace the right and left side panels and fix them with screws. Fig. 14 4Front assembly, side panel...
Desmo Tools required for assembly: 1 x Phillips head screwdriver, #2 1 x box wrench, ½” - Insert the railing tube into the mounts on both sides. Note: Be careful not to pinch yourself! Fig. 15 Desmo assembly, inserting tubes - Pull the display and protective conductor wires out of the bottom of the railing tube.
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- Remove electronic cover plate on the right side of the treadmill frame using a Phillips screw driver. Fig. 18 Desmo assembly, electronic cover plate - Lay the wire through the hole in the console. Fig. 19 Desmo assembly, connection 1 - Attach the protective conductor (green) to the contact tab on the housing.
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- Connect the display cable to the circuit board. Note: Do not connect to the position marked with the red “X” in Fig. 10! Fig. 21 Desmo assembly, connection 3 - Connect the wires to the frame with the sup- plied wire ties.
- Position the side covers so that a ¼ in. (5 mm) gap is visible. - Then tighten all screws. Note: The side covers must not be in contact with the running surface or drive belts on the rear left side! Fig.
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- Insert wire and protective cover into the guard rail tube to prevent damage during insertion. Fig. 27 Mercury/Path assembly, wiring - Prepare the mount for the tube - Loosen bolts if necessary. Fig. 28 Mercury/Path assembly, tube mount - Insert the railing tube into the mounts. Note: Do not damage the wires! Be careful not to pinch yourself!
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- Pull wire and protective cover out of the railing tube (hole in railing tube). Fig. 30 Mercury/Path assembly, connection 1 - Lay the wire with protective cover through the hole in the console. Fig. 31 Mercury/Path assembly, connection 2 - Attach the protective conductor (green) to the contact tab on the housing.
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- Connect the display cable to the circuit board. Note: Do not connect to the position marked with the red “X” in Fig. 31! Fig. 33 Mercury/Path assembly, connection 4 - Tighten railing mount bolts. Fig. 34 Mercury/Path assembly, fixing the railing - Replace electronic cover plate on the right side of the treadmill frame.
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- Slide the side covers on both sides and fix with screws (do not tighten the screws yet). Fig. 36 Mercury/Path assembly, side covers - Slide the cover plates over the tube on both sides and fix with screws. - Tighten large screws first, then the rest. Note: Ensure distance between side covers and running surface.
Pro/Pro XL Tools required for assembly: 1 x combination wrench, ½” 1 x SW13 ratchet wrench, ½” 1 x Phillips screwdriver, #2 1 x Allen key, ¼” - Insert both sides of the railing into the mounts. - First slide the cover plates over the railing.
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- Pull the wire and wire protection out of the side of the railing tube and lay it along the railing mount to the circuit board. Fig. 41 Pro/ProXL assembly, connection 1 - Attach the protective conductor (green) to the contact tab on the housing.
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- Tighten railing mount bolts on the right side. Fig. 44 Pro/ProXL assembly, fixing the railing 1 - Tighten railing mount bolts on the left side. Fig. 45 Pro/ProXL assembly, fixing the railing 2 - Slide the side covers on both sides and fix with screws.
► Ensure the device cannot be switched back on. Ordering Parts Original WOODWAY parts can only be ordered through WOODWAY Customer Service. Before ordering replacement parts, you will need to know the serial number of your ma- chine (located on name plate on back of display or inside of the frame near the front of the machine).
6.2.1 Desmo Fig. 47 Display replacement, Desmo Display board Cup holder Display board screws Display back Front housing Display back screws Wire form screws Standard screwdriver Tools Needed Phillips head screwdriver Removal Perform the following steps in order to properly remove the Desmo display: Unplug treadmill from power source.
Installation Perform the following steps in order to properly reinstall the Desmo display: Attach display housing to wire form using hardware removed above. Re-attach all cables. Test the new board. Make sure treadmill operates as expected without issues. Re-install back cover using hardware removed above. Re-install cup holders by sliding them down onto their posts and lining up the “T”...
Installation Perform the following steps in order to properly reinstall the Mercury/Path display: Re-attach all cables. Test the new board, making sure the treadmill operates as expected without issues. Re-install display housing back on the handrail (Pos. 3). Check to make sure there are no loose or extra parts. Display-to-Interface Cable Replacement Standard screwdriver Tools Needed...
Side Cover Replacement Fig. 49 Side cover replacement Boot Side cover Boot screw Side cover screw Tools Needed Standard screwdriver Phillips head screwdriver Removal Perform the following steps in order to properly remove the side cover: Remove the trim plate/boot screws using either the standard/Phillips head screw- driver and slide the trim plate/boot up the handrail slightly (Pos.
Motor Control Board Replacement Fig. 50 Motor controller replacement Motor control board screws Boot screws Motor control board Boot Motor power wire terminals Side cover screws 10. P1 connector Side cover 11. P2 connector Electrical cover Electrical cover screws 05/2016 – SM-MT-EN-02...
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Tools Needed Standard screwdriver Phillips head screwdriver Removal Save all removed hardware for installation of replacement parts. Perform the following steps in order to properly remove the motor controller: Unplug the treadmill from the power source. Ensure that it cannot be turned back Identify the side of the treadmill with the AC power cord coming out of it (right side running direction).
Interface Board Replacement Fig. 51 Interface board replacement J5 connector Interface board J6 connector Interface board screws J10 connector J1 connector J9 RS-232 port J2 connector J3 connector Tools Needed Standard screwdriver Phillips head screwdriver Removal Perform the following steps in order to properly remove the interface board: Unplug treadmill from the power source.
Installation Perform the following steps in order to properly reinstall the interface board: Using either the standard/Phillips head screwdriver, attach the four #6 (32 x ¼”) Phillips pan head machine screws and four #6 internal tooth lock washers that hold down the interface board.
Side Switch Assembly Replacement Save all removed hardware for installation of replacement parts. Fig. 53 Side switch assembly replacement PCB screws Overlay Handrail Side switch PCB Plastic housing Standard screwdriver Tools Needed Phillips head screwdriver Removal Unplug the treadmill from the power source. Ensure it cannot be turned back on.
Re-attach the overlay by peeling the sticker paper off the back and carefully replac- ing the overlay on the PCB. Make sure the overlay is centered and no edges are sticking up (Pos. 1). Foot Assembly Replacement Save all removed hardware for installation of replacement parts Fig.
Removal Unplug treadmill from the power source. Ensure that it cannot be turned back on. Remove the side covers (see Section 6.10). Remove the handrail assembly from the frame (see Section 6.10). Lay 2 lifting bars on the floor (AC bracket side) next to the machine. Using two persons, carefully tip the machine on its side.
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Removal Unplug treadmill from the power supply. Ensure it cannot be turned back on. Remove silver plates on the old contact heart rate grips by prying up the edge of the plate with the small standard screwdriver (Pos. 1). Carefully, remove the wire attached to each plate by gripping the connector with the pliers (Pos.
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Standard screwdriver Tools Needed Phillips screwdriver Wrench, ” or ½” 9/16 Wire cutters Ty-wraps Removal Unplug the treadmill from the power source. Ensure it cannot be turned back on Remove the side covers (see Section 6.10). If the treadmill has an electrical cover, remove the 6 screws holding the cover in place and remove the electrical cover (Pos.
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Removal Unplug the treadmill from the power source. Ensure it cannot be turned back on. Remove the side covers from the treadmill (see Section 6.10). Remove the handrail assembly from the frame (see Section 6.10). Remove the running belt (see Section 6.15). Using the ½”...
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Removal Unplug the treadmill from the power source. Ensure it cannot be turned back on. Remove the treadmill side covers (see Section 6.10). If the treadmill has an electrical cover, remove the 6 screws holding the cover in place. Remove the electrical cover. Using the ¾”...
6.14 Brushless Motor Replacement In the following figures, the running belt and handrails have been removed only to im- prove the view. DO NOT REMOVE the running belt or handrails; they should remain in- stalled during the replacement process. Save all removed hardware for installation of replacement parts. 05/2016 –...
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Fig. 59 Brushless motor replacement Motor control board Side cover Motor access opening Boot 10. Motor power terminals (R, S, T) Boot screws 11. Motor control connector (P1) Side cover screws 12. Motor mounting hardware Electrical cover 13. Drive belt Electrical cover screws 14.
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Removal Unplug the treadmill from the power source. Ensure the treadmill cannot be turned back on. Remove the trim plate/boot screws using either standard/Phillips head screwdriver and slide the trim plate/boot up the hand rail slightly (Pos. 2, 3). Remove the 2 silver screws located on both ends of the side cover (Pos. 4). Remove the side covers from the treadmill (Pos.
When preparing to install the replacement running belt, make sure to place the belt on the treadmill right-side-up (i.e. not upside-down or backwards); the runner should be able to see and read the WOODWAY name on the belt. Using 2 people, lower the running belt over the top of the treadmill (lower the drive shaft side first).
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If any slat screws/clips are not tight and/or in good condition, tighten and/or replace them. If belt tension is not within specifications at the time of inspection, please call WOODWAY Customer Service to help determine the root cause and any corrective pro- cedures. Model 4FRONT 8 ½”...
Calibration WOODWAY treadmills use an incline system with a toothed rack and gear drive. For sys- Incline System tems with an incline of 15% to 25% similar components are used; they differ with re- spect to the movement of the toothed rack.
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Standard LED Mercury, Path, Desmo (00 – 04) Group Training 4Front, Pro, Pro-XL Personal Trainer LCD 4Front, Pro, Pro-XL Personal Trainer LCD Desmo (2005+), ELG Personal Trainer LCD Mercury, Path, Desmo (00 – 04) 05/2016 – SM-MT-EN-02...
Calibrating the Elevation If it is determined that the potentiometer needs to be adjusted, you will need a 5/64” Allen wrench to loosen the display set screw. Personal Trainer LCD To adjust elevation (incline) through the treadmill’s LCD or Color LCD display board, per- (All) form the following: Turn the treadmill display board ON.
Personal Trainer LCD The procedure for calibrating belt movement differs slightly between models. To adjust belt movement of the 4Front treadmill through the color LCD display, do the following: 4Front, Pro, Pro-XL Turn the treadmill OFF and back ON again by the main power switch.
OFF at the main power switch to exit Calibration Mode. Troubleshooting If you have problems with your treadmill, please consider the answers to the following questions before calling WOODWAY Customer Service. What are the make, model, and serial number? ...
Attach the leads to Pin 1 and Pin 2 (red and black) on the J10 connector. Good voltage should be between 12-15 VDC. If voltage is bad, the interface board should be replaced. Contact WOODWAY Customer Service. If voltage is good, the issue is with either the display-to-interface cable or the display board.
If LED 2 is OFF, the lower limit switch is engaged or is defective and will not allow the treadmill to lower. If the limit switch is defective, replace the J10 bracket. Contact WOODWAY Cus- tomer Service. If the limit switch is engaged by the cam, loosen the nut that holds the cam (be- hind the J10 bracket) using a 7/16”...
Note: Excessive grease causes clotting and collecting of dust. Broken guide roller: Contact WOODWAY Customer Service to replace the guide roller. Incline motor: A break may be stuck or the motor may have stopped. See Section 8.4.
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The 3 components that are supposed to read and send the magnet signal are the dis- SAFE: Replace play, cable, and interface board. Magnet error messages indicate that the treadmill is Magnet not recognizing the emergency stop magnet. Desmo Evo ’05 Series Model ...
Cleaning and Maintenance General Periodic cleaning and inspection of your WOODWAY treadmill will help to lengthen its life while keeping it looking like new. Preventative maintenance makes it easier to locate potential issues that might not otherwise be noted. See the supplied User’s Manual for a guideline of the recommended cleaning and maintenance intervals.
Fig. 60 Lubrication, axle bearing 9.2.2 Running Surface Belt, Drive Axle The teeth on the bottom of the tread belt are sufficiently lubricated in the factory to minimize noise. The teeth do not need to be lubricated. When the running surface belt rubs on the side of the guide rollers, the use of a small amount of lubricant (Molykote or similar product) on the edges of the slats can contribute to noise reduction.
9.2.4 Incline System The incline systems on WOODWAY treadmills are lubricated by the manufacturer. The system must be checked when used over several hours or in a very dusty environment. If required, apply a small amount of lubricant to the chain and the incline drive racks.
(5) years after original installation. A direct payment, or credit toward the pur- chase of a new WOODWAY, of 20% of the purchase price of the treadmill will be made to the original owner of a WOODWAY treadmill. This guarantee is limited to the original owner.
Disposal Notice Electrical and electronic devices must be disposed of separately from normal household waste. An appropriate waste disposal company should be contacted. Properly dispose of the device at the end of its service life (e.g. the local collection point for waste separation): ...
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