True Fitness 350 Black, Service Manual

Page 1: ...erve the right to revise this document at any time or to make changes to the product described within it without notice or obligation to notify any person of such revisions or changes 2004 True Fitnes...

Page 2: ...uld still have texture for grip bottom should be porous fabric not glazed smooth or hard Inspect deck surface should be free of scratches abrasions or blistering Listen for excessive bearing noise fro...

Page 3: ...True Fitness Treadmill Service Manual START Symptom guide Calibration Procedures Diagnostic Procedures Test Procedures Wiring Diagrams Part Manuals Page 1...

Page 4: ...Heart Rate Not Working Erratic Readings Page 8 Elevation Not Functional Page 9 Speed Fluctuation E2 Cal Page 10 Speed Fluctuation S4 E5 E2 E3 EPROM Page 11 No Display Page 12 Circuit Breaker Trips at...

Page 5: ...ut the incline being commanded Maximum or minimum elevation out of calibrated ranges Lube deck with True Fitness liquid silicone lubricant Inspect wax bar assembly on commercial models if worn to less...

Page 6: ...tup diagnostics Treadmill has lost calibration settings Perform Amp Draw Test Page 20 Perform Belt Deck Wear Test Page 24 Calibrate Treadmill Page 16 See appropriate Symptom Guide pages 10 11 Restart...

Page 7: ...peed at 4 MPH Check VDC across MTR 1 and MTR 2 with the motor leads connected to the motor the voltage should measure 10 VDC for every 1 MPH If voltage is missing or low Replace PWM If voltage is grea...

Page 8: ...et belt tension to 1 8 inch deflection or correct tension can be verified by twisting the belt almost to a 90 degree position Remove foreign object Perform the Amp Draw Test page 20 to check for exces...

Page 9: ...MOVEMENT pages 5 6 Perform Belt Deck Wear Test page 24 Perform Amp Draw Test page 20 Apply silicone Replace Deck and Belt May be related to electro static discharge Contact Technical support for assis...

Page 10: ...ure that the HR receiver is not touching metal and is mounted with the wires in a vertical position with the blue receiver facing the runner Does the receiver pick up a signal from the HR simulator If...

Page 11: ...or clip Cycle the power If the treadmill lowers itself then replace the lower limit switch Perform Incline potentiometer calibration procedure page 16 If incline nut is stripped replace incline nut Do...

Page 12: ...omer take corrective action Verify tach feedback accuracy through out the speed range If inaccurate perform speed sensor test page 21 Verify correct Speed sensor Gap Gap should be equal to the thickne...

Page 13: ...page 21 Check continuity of tach feedback portion of the data cable To identify tach feed back lines see wiring diagram section for specific model Check Adjust tread belt tension page 22 Perform speed...

Page 14: ...ary If Yes Check for 110 VAC at PWM across AC1 AC2 If Yes Replace PWM Check status LED 11 VDC on PWM See diagram pages 23 30 If not remove fuses and check continuity as replace as needed If Yes Check...

Page 15: ...Reconnect motor to the PWM if the breaker trips replace the motor Unplug incline motor Power on treadmill if breaker does not trip replace incline motor Unplug PWM power on machine If breaker doesn t...

Page 16: ...y adjusted and the switch is being made when the hex cam points press against the roller Disconnect the cable at J4 and check for continuity on cable Cable should have continuity if the switch roller...

Page 17: ...ile in calibration mode Press the Softer button LED D1 should light press the Firmer button LED D2 should light If the lights respond to the button then command is being sent from the upper board and...

Page 18: ...own on its own Wait for belt to stop Mode 3 Incline Press Select Enter 03 C3 for 450 appears in distance Press Grade Up to upper incline limit then back down slightly Save upper limit by pressing Star...

Page 19: ...the safety key The control panel will show Diagnostics Press the UP button Total Hours in whole hours Press the UP button Distance in miles two digits past decimal point Press the UP button Average S...

Page 20: ...Page 18...

Page 21: ...sor Test Page 21 Voltage to Drive Motor Test Page 21 Drive Motor Test Page 22 Drive Belt Tension Test Page 22 Tread belt Tension Test Page 22 Incline Potentiometer Calibration Test Page 23 Voltage to...

Page 22: ...s an AC clamp on ammeter Place the clamp around either of the power cord leads black or white Load test requires a person to walk on the tread belt for 5 10 minutes 2 5 mph w out load 2 0 2 5 AMPS AC...

Page 23: ...With no magnet in front of sensor 5 VDC Check the sensor on every magnet adjust sensor until voltage shows In calibration mode before pressing Start the tread belt can be moved manually and the Met li...

Page 24: ...also possible to twist the belt you should be able to twist the belt almost to a vertical position TREADBELT TENSION TEST This test will address belt slipping and is used in any roller replacement or...

Page 25: ...As the unit inclines during calibration watch the numbers in the Distance window if they do not increase by at least 60 from the zero value an E1 Minimum error will result Then the zero value may need...

Page 26: ...any abrasions or scratches are found replace the deck Push Off Test Place the machine in Calibration mode elevate to the highest elevation speed should be set to 0 Stand on the tread belt positioning...

Page 27: ...WIRING DIAGRAMS 350 Gray Page 26 350 Black Page 27 400 Page 28 450 500 700 Page 29 500CI 750CI Page 30 750 NON P Page 31 750 Page 32 Page 25...

Page 28: ...Page 26 350 Gray Wiring Diagram...

Page 29: ...Page 27 350 Black Wiring Diagram...

Page 30: ...Page 28 400 Wiring Diagram...

Page 31: ...Page 29 450 500 700 Wiring Diagram...

Page 32: ...Page 30 500CI 750CI Wiring Diagram...

Page 33: ...Page 31 500CI 750CI Wiring Diagram...

Page 34: ...Page 32 750 Wiring Diagram...

Page 35: ...Model 350 450 Parts List 350 P HRC Page 34 350PB HRCB Page 37 400 P HRC Page 39 450 P HRC SS100 SS90 Page 41 Page 33...

Page 36: ...RLAY PWM LOWER BOARD PWM 70013500 PWM SCREW 10 32 X 3 8 PPHTF 70350300 SPEED SENSOR 70202600 SPEED SENSOR 70350300 EXTENDER WIRE FROM SENSOR PWM 70190800 SPEED SENSOR SCREW DATA CABLE 70138600 6 CONDU...

Page 37: ...32 X 1 1 4 PPH FRONT ROLLER 70217500 FRONT ROLLER ASSY 70188500 FR ROLLER BOLT 1 4 20 X 2 Gr 5 Hex Hd 70185300 FR ROLLER NUT 1 4 20 NYLOC NUT REAR ROLLER 70188000 REAR ROLLER ASSY 70175100 REAR ROLLE...

Page 38: ...198900 LOWER HANDRAIL BUSHING 3 8 OD X 1 70183101 H BAR NUT PLATE PEDESTAL 70157000 PED STAR WASHER 1 4 I D INTERNAL TOOTH WASHER 70186600 PEDESTAL WELDMENT 70179901 STRAP CLAMP PED 70155900 PED SCREW...

Page 39: ...0243203 CIRCUIT BOARD SPEED SENSOR 70243300 SPEED SENSOR SCREW 4 40X1 4 DATA CABLE 70264100 6COND CORD DATA CABLE 350PB HRCB 70264000 8COND CORD DATA CABLE 350PB 70190100 8 CONDUCTOR INTERFACE CABLE H...

Page 40: ...70232700 DECK BUMPERS FRONT ROLLER ADJUSTABLE 70260100 FRONT ROLLER W 8 MAGNETS 70188500 FRONT ROLLER BOLT 1 4 20X2 GR 5 70185300 FRONT ROLLER NYLOK NUT 1 4 20 REAR ROLLER 70188000 REAR ROLLER 7022080...

Page 41: ...M W O Hardware 7T008500 Speed sensor 7T013900 PWM W O Hardware 230V Filter 7T014800 Filter EMI 400 250V 10A CP6 1022C 7T014000 Bracket Filter 400 T 2 0 7T014100 Bracket Screw Phillips Head M5X0 8X6L U...

Page 42: ...400RFMB Series Tread belt 7T008300 Tread belt Deck 7T008600 Deck pre drilled Front Roller 7T008100 Front Roller Rear Roller 7T008200 Rear Roller 7T009200 Roller Cover L 7T009300 Roller Cover R Stradd...

Page 43: ...1 450P DOT OVERLAY 99 PRESENT 70242112 450HRC DOT OVERLAY 99 PRESENT PWM SS100 70113900 MOTOR CONTROLLER SS100 SS90 70132500 MOTOR CONTROLLER SS90 70013500 PWM SCREW 10 32 X 3 8 SPEED SENSOR SS100 STY...

Page 44: ...ADBELT DECK 70157700 FLEX DECK 70020200 DECK SCREW 10 32 X 1 1 4 FRONT ROLLER SS100 NARROW 70123800 FRONT ROLLER SS100 96 xxxx 99 70217000 450 FRONT ROLLER 6 8XXXX 99 99 81023G TO 70359200 450 ADJ ROL...

Page 45: ...Model 500 550 Parts List 500 P HRC SS100 SS90 Page 44 500Z ZT P HRC Page 48 540 P HRC CI NON Z Page 51 540Z ZT P HRC CI Page 54 550 P HRC Page 57 550z P HRC CI Page 59 550 ZTX P HRC CI Page 61 Page 43...

Page 46: ...TY SWITCH NUTS 70185400 HEART RATE RECEIVER 70138500 POLAR HEART RATE CHEST STRAP 70284100 Old 500 70240503 EXTRUSION PANEL CLIP 26 3 4 OVERLAY SS100 OVERLAY 70119301 500 NON OVERLAYS SS100 70119901 5...

Page 47: ...J10 V BELT ELEVATION MTR 70113200 ELEVATION MOTOR 70118900 SWIVEL PIN 70183200 INCLINE START CAPACITOR 70115500 CLEVIS PIN 3 8 DIA 1 1 2 LONG 70116700 COTTER HAIR PIN 062 DIA 70022600 SET SCREW INCLIN...

Page 48: ...K BUMPER SCREWS 70020200 DECK SCREW 10 32 X 1 1 4 FRONT ROLLER SS100 70119500 FRONT ROLLER 95 WIDE WITH 4 MAG 70207800 ROLLER SCREW 70217300 FRONT ROLLER ASSY 99 97 70255400 FRONT ROLLER ASSY ADJ 00 H...

Page 49: ...9500 PED WELDMENT 500CI 98 99 00 98 W LETTER 70233300 PED WELDMENT 500 NON P HRC 99 00 70233400 PED WELDMENT 500CI 99 00 70204200 RAM RAILS NON CHR FRAME 70155200 BUMPER FEET LUBRICATION 70348900 LUBE...

Page 50: ...500ZT 70328101 500Z ZT P PANEL SERIES 70328200 500Z ZT HRC PANEL 70290601 PANEL BOTTOM CONSOLE 70294301 PANEL LF LWR GRIP CLOSURE 70290801 PANEL RT LWR GRIP CLOSURE 70290701 HANDLE LT CONSOLE 7029080...

Page 51: ...100 ROCKER ON OFF SWITCH CIRCUIT BREAKER 70017200 15 AMP CIRCUIT BREAKER TREADBELT 70159400 22 X 119 3 4 2PLY TREADBELT ZT 70321600 NEW ZT 20 X112 1 4 TREADBELT DECK 70157900 FLEX DECK ZT 70324300 500...

Page 52: ...30900 RIGHT RAM RAIL PEDESTAL 70325000 PEDESTAL WELDMENT ROUNDED ZT 70336900 500ZT PEDESTAL WELMENT 70304200 pedestal screw for zt 70156900 RUBBER WEAR STRIP FOR BASE PED FRAME 70262401 FRAME WELDMENT...

Page 53: ...243200 SPEED SENSOR 70243300 SCREW 4 40x1 4 PPH SELF TAPPING DATA CABLE 70337900 540NON P DATA CABLE 70337800 540 HRC DATA CABLE 70337700 540 CI DATA CABLE 70104000 SCREW 10x1 2 PPH DRIVE MOTOR 703255...

Page 54: ...EW 10 32x1 4 PPH TFS Bo ON OFF SWITCH 70251100 ROCKER ON OFF SWITCH CIRCUIT BREAKER 70017200 15 AMP CIRCUIT BREAKER TREADBELT 70290000 BELT 22x119 3 4 ST E5 2Ply Lo 70289900 540 ORTHO TREADBELT DECK 7...

Page 55: ...0 NON CNR RAILS RAM PEDESTAL 70288600 PEDESTAL WELDMENT ROUNDED 70156900 RUBBER WEAR STRIPS FRAME 70289700 FRAME WELDMENT RND ADJ FRONT 70155200 BUMPER FEET 70020200 SCREW 10 32x1 1 4 70019300 SCREW 1...

Page 56: ...THE REG 70299201 540Z ZT CI PANEL 540Z 70298900 PANEL SCREW 70331000 MAGNET SAFETY KEY 70290602 Panel Back Cover OVERLAY PWM 70132500 PWM MOTOR CONTROLLER 540 ZT SERIES 70342900 540 ZT MOTOR CONTROLL...

Page 57: ...120500 LOWER LIMIT SWITCH WIRE ELEVATION RACK ZT 70281003 540ZT ELEVATION RISER ASSY 70154600 ELEVATION BLOCK ASSY POWER CORD 70253100 POWER CORD 9FT ON OFF SWITCH 70251100 ROCKER ON OFF SWITCH CIRCUI...

Page 58: ...SIDE STICK T 70243400 BLUE TAPE STR CVR 1 2X150FT ROLL 70329600 SILVER sst tape 70086700 STRADDLE COVER SCREW RAMRAILS 70330800 LEFT RAM RAIL 70330900 RIGHT RAM RAIL PEDESTAL 70325100 PEDESTAL WELDMEN...

Page 59: ...7900 550 P INTERFACE CABLE 70337800 550 HRC INTERFACE CABLE 70337700 550 CI INTERFACE CABLE DRV MTR 70325500 3HP DRIVE MOTOR DRV BELT 70006300 210J10 POLY V BELT ELEVATION MTR 70113200 ELEVATION MOTOR...

Page 60: ...STRADDLE COVERS 70162109 LT AND RT ALUM STRADDLE COVER PEDESTAL 70277600 PEDESTAL WELDMENT ROUNDED FRAME 70276000 ADJ FR ROLLER FRAME WELDMENT LUBRICATION 70348900 LUBE STICK 70349000 SILICONE PACKET...

Page 61: ...43300 SPEED SENSOR SCREW DATA CABLE 70337900 550Z P DATA CABLE 70337800 550Z HRC DATA CABLE 70337700 550Z CI DATA CABLE DRIVE MOTOR 70325500 3HP DRIVE MOTOR DRV BELT 70006300 210J10 DRIVE BELT ELEVATI...

Page 62: ...FT ROLL BLUE TAPE 70086700 6X1 STRADDLE COVER SCREW RAMRAILS 70330800 LEFT RAM RAIL 70330900 RIGHT RAM RAIL CARRIAGE ASSY 550Z CI 70240900 ADJ MOTOR ASSY 550Z CI 70241100 COVER PAN WELDMENT 70239200 S...

Page 63: ...y Panel Assy 70299007 550ZTX P CONTROL PANEL 70298707 550ZTX HRC CONTROL PANEL 70329900 550ZTX CI CONTROL PANEL PWM 70342900 MOTOR CONTROLLER Speed Sensor 70243200 Speed Sensor DATA CABLE 500zt 703413...

Page 64: ...ONT ROLLER REAR ROLLER 70352000 REAR ROLLER STRADDLE COVERS 70343800 ALUM STRADDLE COVER RH LH RAMRAILS 70330800 LH RAM RAIL 70330900 RH RAM RAIL 70347500 INTERCHANGABLE RAM RAILS RT LT PEDESTAL 70325...

Page 65: ...Model 600 750 Parts List 600 P HRC Page 64 600Z 700Z P HRC Page 67 700 P HRC SS100 SS90 Page 70 700A P HRC Page 73 725 P HRC Page 76 750 P HRC CI Page 79 Page 63...

Page 66: ...R CONTROLLER 02 PRESENT 70013500 PWM SCREW SPEED SENSOR 70243200 CIRCUIT BOARD SPEED SENSOR 70243300 SPEED SENSOR SCREW DATA CABLE 70337900 NON HRC DATA CABLE 70337800 P DATA CABLE DRV MTR 70325500 3H...

Page 67: ...SCREW 10 32 X 1 1 4 BUMPER KIT 70155200 BUMPER FEET 70020200 10 32 X 1 1 4 PPH SCREW 70232700 FLEX BUMPER 70086700 BUMPER SCREW 6 X 1 FRONT ROLLER ADJUSTABLE 70255400 ADJ FRONT ROLLER 70188500 BOLT A...

Page 68: ...PEDESTAL 70264600 WELDED PEDESTAL 600 NON CI 70155900 SCREW PED 1 4 20 X 5 8 70157000 INTERNAL TOOTH STAR WASHER PED 70269800 BOTTLE HOLDER MOLDED PLASTIC 70019300 SCREW BOTTLE HOLDER FRAME 70262401 F...

Page 69: ...rol Board Only 70298213 700Z HRC Control Board Only International 70298452 700Z NONEX Control Board Only 70298254 700Z PEX Control Board Only 70298253 700Z HRCEX Control Board Only 70290601 PANEL BOTT...

Page 70: ...RCUIT BREAKER TREADBELT 70317300 600Z 20 X108 TREADBELT 70317400 700Z 22 X119 3 4 TREADBELT DECK 70157900 600Z FLEX DECK 70276700 700Z FLEX DECK FRONT ROLLER 70352200 600Z ADJ FRONT ROLLER 70352400 70...

Page 71: ...ELDMENT FRAME 70262405 600Z WLD RND ADJ ROLLER FRAME 70276003 700Z FRAME W ADJ FR ROLLER AUTO WAXER 70280800 AUTOWAXER LUBRICATION 70348900 LUBE STICK 70349000 SILICONE PACKET 1 APPLICATION Replacemen...

Page 72: ...LAR CHEST STRAP HEART RATE 70273800 CONTACT H R TRANSMITTER 70182800 SAFETY SWITCH ASSY 700 70209700 PUSH BUTTON SAFETY SWITCH SS90 TON SAFETY SWITCH SS90 OVERLAY SS100 STYLE 70119301 700NON SS100 OVE...

Page 73: ...RQUE ARM 70115500 CLEVIS PIN 3 8 DIA 1 1 2 IN LONG 70116700 HAIR COTTER PIN 062 DIA 70022600 SET SCREW INCLINE CONE POINT LLS 70121000 LOWER LIMIT SWITCH 70018100 CHERRY SWITCH 70120500 LOWER LIMIT SW...

Page 74: ...EAR ROLLER SS90 70005600 ROLLER SCREW 3 8 16X3 4 70005500 ROLLER BOLT 3 8X16X3 HX HD BOLT 70073900 OLD STYLE STRADDLE COVERS 70162107 STRADDLE COVER ALUM 46 13 16 70030901 3 8 X1 16 X 36YD DBLE STK TA...

Page 75: ...ERLAY 70279101 700A HRC DOT OVERLAY 3lbs 70219200 MOTOR CONTROLLER 5592 DCI Green 70219201 MOTOR CONTROLLER 02 70013500 SCREW 10 32x3 8 PPH TFS Bo 70282700 CHOKE ASSY 1lbs 70243200 SPEED SENSOR 702433...

Page 76: ...1 4 20x1 70303700 POWER CORD 12 14 3 SJTW Black STRT 70125700 SCREW 10 32x1 4 PPH TFS Bo 70013500 SCREW 10 32x3 8 PPH TFS Bo 70251100 ROCKER ON OFF SWITCH 70017200 15 AMP CIRCUIT BREAKER 9lbs 70317400...

Page 77: ...RYWALL SCREW 70274105 CHR RAM RAIL 70280600 NON CHR RAIL ram 70210600 10x3 4 PPH TEK Screw boo 70277601 PEDESTAL WELDMENT ROUNDED 70156900 RUBBER WEAR STRIPS 70276003 FRAME WLDMNT 70155200 BUMPER FEET...

Page 78: ...0239800 HEART RATE TRANSMITTER 70245100 PLASTIC COVER HR CONTROL OVERLAYS 98 STYLE 70160815 725 NON OVERLAY SS90 98 70160816 725P OVERLAY SS90 98 70160814 725HRC OVERLAY SS90 98 99 00 STYLE 70242310 7...

Page 79: ...LIMIT TO PWM WIRE ELEVATION RACK 70281002 ELEVATION RACK 70122800 ELEV SCREW 1 4 20X1 SOCKET HEAD 70116900 LOCK NUT 1 4 20 ZINC COURSE THREAD 70176700 MOLDED WHEEL 3 8 BEF AUG 99 70003100 MOLDED WHEEL...

Page 80: ...00 STRADDLE COVER TAPE 108FT DBL STK 70243400 STRADDLE COVER BLUE TAPE150 FT RAMRAILS 70274101 RAM RAILS CONTACT HEART RATE 70210600 RAIL SCREW 10X3 4 PEDESTAL 70233501 PEDESTAL WELDED 70156900 RUBBER...

Page 81: ...P DOT OVERLAY 99 PRESENT 70242610 750CI DOT OVERLAY 99 PRESENT PWM 70183500 MOTOR CONTROLLER BEFORE 08 00 70183502 PWM WITH CHOKE AFTER 08 00 70264800 MOTOR CONTROLLER 220V 70013500 10 32X3 8 SCREW PW...

Page 82: ...X 15 16 COTTER PIN LLS 70121000 LLS 70125700 10 32 X 1 4 Screw for LLS Bracket 70120500 LLS TO PWM WIRE ELEVATION RACK 70281004 ELEVATION RISER ASSY 70154600 ELEVATION BLOCK ASSY 70122800 1 4 20 SOCKE...

Page 83: ...10 X 3 4 SCREW PEDESTAL 70233601 ROUNDED PEDESTAL WELDMENT 70156900 RUBBER WEAR STRIP 70269800 BOTTLE HOLDER 70019300 BOTTLE HOLDER SCREW 10X3 4 FRAME 70227501 FRAME WELDMENT ROUNDED GRAY 70155200 BU...