True Fitness TREADMILL 2011, Service Manual

Page 1: ...Proprietary Confidential TRUE Fitness Technology Inc 2011 TREADMILL SERVICE MANUAL ...

Page 2: ...ential TRUE Fitness Technology Inc b A service technician trained on comparable fitness equipment currently employed as a fitness equipment technician and experienced with the hazards involved with its installation operation and maintenance Tread Service Manual July 2011 2 ...

Page 3: ...ge 15 16 E2 Cal 17 E5 Sensor 18 22 Misc Symptoms No Console Display 23 24 No Erratic Heart Rate 25 No Fan 26 No Safety Key Detected 26 No Sound Channels on Wireless 26 No Response Touchscreen Keys 27 Touch Screen Will Not Function 28 No IPOD detected 29 No TV Poor Quality 29 TEST PROCEDURES Amp Draw Test 30 Speed Sensor Test 31 Potentiometer Test 32 34 Voltage to Incline Motor Test 35 Table of Con...

Page 4: ...8 Lubrication Instructions 39 General Maintenance 40 Appendix A AC Lower Board LEDs General LEDs 41 42 Status LEDs 43 46 Appendix B Smart Card LEDs 47 Appendix C Calibration 48 Appendix D TV tuner Set Up 49 51 Appendix E Wireless Card Set up 52 53 Appendix F Universal Console Model Config 54 55 Appendix G Software Installation 15 Touchscreen 56 58 11 and 2 Window 59 Table of Contents 4 Tread Servi...

Page 5: ...nd On 6 Default Weight 150 7 DM LC Backlight 45 8 DM Contrast 40 9 MC Backlight 9 10 MC Contrast 35 11 HR Priority 0 12 C Safe Enable Disabled 13 Reset Model Def not used 14 Error Log 1 5 1 Version 2 Hours 3 Distance 4 Program Starts 5 Display Test 6 HR Test 7 B Light Test 8 Contrast Test 9 LCB Control Test 10 CS BV Test 11 Smartcard Motor Board 12 Remote Key Test 13 Current Test RPM only 14 Safe ...

Page 6: ...Def Weight 150 9 Cool Down Disable 10 Contrast 160 11 Left BK LT 63 12 Right BK LT 63 13 HR Priority Tele Error Log 1 5 11 WINDOW DISPLAY Press CLEAR ENTRY until the screen blanks then press and hold ENTER B Press 20173 Service Mode 1 Version Test 2 Checksum 3 Display Test 4 Keyboard Test 5 HR Test 6 LWR CNTL BD Test 7 LCD Settings Test 8 Aux Board Test 9 Vart Test 10 Safe SW Test 11 BV Setup 12 W...

Page 7: ...ss 48362 Configuration Mode 1 Model 2 Max Speed 3 Max Grade 4 Hours 5 Distance 6 LCD Contrast 7 Left Backlight 8 Right Backlight 9 HR 10 Elevation Cal 11 Gear Ratio 12 Grade Max 13 Cool Down 14 Max Program Time 15 Default Program Time 16 Reset Time 17 Language 11 WINDOW DISPLAY cont Tread Service Manual July 2011 ...

Page 8: ...e brake system Press and hold the top left corner of screen until the True emblem will begin to flash after 4 seconds Press and hold Manual Workout Button to reveal list of options 1 Configure Displays the current model setup 2 Calibration Speed Elevation Calibration 3 Diagnostics Check hours distance error log 4 Production Tests Test various functions 5 Utilities Install software TV tuner setup t...

Page 9: ...ITH SMART CARD INTERFACE TES900 TLC900 and TPS850 This system is basically the same as the above AC smart card system however no motor transmit and receive LEDs are lit on the DC smart card 3 DC DRIVE All TPS series except TPS850 Z5 series This system is the same as all our traditional DC drive systems SYMPTOM GUIDE A DRIVE SYSTEM OVERVIEW In this summary we are going to cover basic troubleshootin...

Page 10: ... board which in turn sends an AC voltage to the windings of the elevation motor There are two sets of windings on the AC incline motor one for each direction of motor movement The elevation motor has a potentiometer that sends a feedback voltage back to the upper control board This voltage is converted into a digital signal and is displayed on the upper board during Calibration Mode see pg 47 10 o...

Page 11: ...he incline digital value displayed in calibration mode reads approx 6500 7500 The DC voltage across the orange and blue wires of the potentiometer should read approx 4 47 As the treadmill inclines the displayed value increases while the VDC decreases CS 550 800 PS series with 11 console 28 At zero incline the incline digital value displayed in calibration mode reads approx 28 The DC voltage across...

Page 12: ...nsole At zero incline the incline digital value displayed in calibration mode reads approx 14000 16000 The DC voltage across the orange and blue wires of the potentiometer should read approx 4 47 As the treadmill inclines the displayed value increases while the VDC decreases ELEVATION OVERVIEW cont Tread Service Manual July 2011 12 ...

Page 13: ... Belt speed ramping too fast Can be caused by same issues as E2 CAL Pg 17 E2 RECAL E3 EPROM Computing error of upper board processor Call Tech Support for further troubleshooting E4 STUCK KEY Control button continuously activated Replace overlay On machines with center pod overlay disconnect center pod overlay cable to determine which overlay is defective On TPS series treads surface mounted switc...

Page 14: ...eversed Most likely cause is incorrectly installed separate potentiometer cable on TPS style incline systems INCLINE OPEN Elevation motor is disconnected Check all elevation connections Check continuity on elevation and data cables RPM MISMATCH Belts moving speed from RS232 cable does not match RPM detected by smart card Most likely caused by improper model configuration CONSOLES BD LOST Console s...

Page 15: ...EDs check data cable for continuity If there is illumination of a incline LED and no motor movement listen to the motor If there is a humming noise coming from the motor and no movement replace the motor If the LED s illuminate and there is no motor humming check the 3 amp slow blow fuse on the lower board for continuity This fuse protects the 18 volt system that controls the elevation relays If t...

Page 16: ...itch the digital value can be adjusted by disconnecting the elevation motor from the incline rack and manually turning the linear shaft of the incline motor until it reads the correct digital value at 0 or 3 On treadmills with internal limit switches in the incline motor the ideal zero will be set when the internal switch activates A value reading 255 or 0 often indicates over travel of the potent...

Page 17: ...ation to the highest level and remove safety key While standing on the belt push away from the handle bar If there is high friction between the belt and deck it will be difficult to push away Units with low friction will be easy to push away High friction can lead to excess amp draw on the motor The motor may overcompensate causing an error code If this is not addressed it will lead to motor contr...

Page 18: ...r can occur for different reasons which we have listed below First if there is a break in the main data cable the speed feedback information will not make it back to the upper board Check to see if there is speed feedback in the upper board while in calibration Next check continuity on the data cable to verify there is no break in the connection If the upper board command signal is not being recei...

Page 19: ...k code will only display as long as the lower board has not been reset There currently is no drive fault error reporting on the upper board DC DRIVES Check to see if the PWM light is lit on the lower board If this LED is illuminated there should be belt movement and there should be AC or DC voltage being sent to the motor depending on the type of drive system in question Measure the output pins to...

Page 20: ...ashes on the lower board and the Smart Board if applicable when moving the drive motor and running belt by hand If there is no LED flashing on either board proceed to the following steps If the LED flashes perform a continuity check on the data cable If the cable checks good replace the upper board All current production models have a RPM LED on the lower boards E5 SENSOR 20 Tread Service Manual J...

Page 21: ...n our newer AC drive systems for the TCS Series Reads off wheel on drive motor On the optical sensor measure DC volts between pins 2 and 3 of the speed sensor plug while plugged into the lower board There should be a reading of 5VDC on to below 1VDC off Readings of 1 90VDC or higher during the off cycle could cause the RPM LED to not cycle and will result in a speed error If this speed sensor test...

Page 22: ...ED on the lower board enter calibration and check for speed feedback in the upper panel display Check the data cables for continuity or try a known good 20 pin cable between the MCB and the Smart Board and the 10 pin console cable If there is still no speed feedback in the upper panel replace the upper panel E5 Sensor only occurs under load Most common cause his high belt and deck friction Perform...

Page 23: ... there will not be 11VDC available to the upper control board Check the fuses on the lower board If the AC and VCON 11VDC LEDs are lit and there is still no display look for damage on the data cable and check for 11VDC on the data cable at the control board Refer to the unit s wiring diagram for the print out on the specific data cable being tested If there is 11VDC from the data cable at the disp...

Page 24: ...fidential TRUE Fitness Technology Inc Proprietary Confidential TRUE Fitness Technology Inc 20 PIN CABLE PINOUT Z SERIES TPS800 900 12 PIN CABLE PINOUT PS 75 100 300 NO CONSOLE DISPLAY 24 Tread Service Manual July 2011 ...

Page 25: ...p Verify that the treadmill is connected to a dedicated line 15 amp circuit and is not on an extension cord Do an outlet test to check for 110V to 120V on the wall outlet Ensure that the Polar HR receiver is not touching any metal and is mounted with the wires in a vertical position with the receiver facing the runner If HR receiver is mounted correctly but still not Polar HR replace the Polar hea...

Page 26: ...itch wire not connected properly Commonly plugged into fan connection not SAFE SW connection on universal console control board Defective safety switch Check continuity of cable with known good magnetic safety key Wrong safety key or key is missing magnet Internal issue with control board Jumper across the two pins of connection on upper board If the control board does recognize safety key problem...

Page 27: ...begins to flash on and off Stop pressing left corner 2 Then press and hold the MANUAL WORKOUT key in the bottom right corner of the HOME screen The MAINTENANCE screen will appear at this point 3 Press the UTILITES button 4 Press the TOUCHSCREEN CALIBRATION button 5 Follow the on screen instructions to CALIBRATE your display Once all TARGETS have been pressed press the blue HOME button to complete ...

Page 28: ...ss hold UP grade and MINUS speed 2 After 10 15 seconds touch screen calibration will display 3 Software version If software version below 1 8 Press each of the 3 targets as they appear on the screen If software version above or equal to 1 8 Press each of the 9 targets as they appear on the screen 4 When step 3 is complete press HOME 5 Check for function of the touch screen 6 If touch screen contin...

Page 29: ...ng 3 Insufficient signal strength Please note for optimal TV image results sufficient signal strength must be received by the Touch Screen display It is the responsibility of the customers facility to provide the optimum signal strength values listed below to each individual exercise machine Tread Service Manual July 2011 NO IPOD DETECTED 1 Try newer generation IPOD The universal consoles will onl...

Page 30: ...mph 5 At 2 5 mph the treadmill should be drawing 2 0 4 0 AMPS AC Load At 5 0 mph the treadmill should be drawing 3 0 6 0 AMPS AC Load 6 Higher than normal amp draws without load may signal that running belt tension is too tight or that there is a problem in the drive motor or controller 7 If amp draw is higher than expected only under a load lubricate the running deck and running belt If amp draw ...

Page 31: ...that the speed LED blinks on the lower board when there is movement at the speed sensor 3 If the Speed LED does not blink replace the speed sensor Optical Sensor Test TCS Series On the optical sensor measure DC volts between pins 2 and 3 of the speed sensor plug while plugged into the lower board There should be a reading of 5VDC on to below 1VDC off Readings of 1 90VDC or higher during the off cy...

Page 32: ...rresponds to model and console configuration 3 This number will move up or down in value depending on the model Most PS treadmills digital value will move up from 20 30 4 A digital value of 0 or 255 often indicates a control cable open or a failure of signal to panel This test will expose the tech to a potential shock hazard Exercise caution when performing this procedure This test is designed to ...

Page 33: ...ometer connection by testing for voltage on the elevation POT cable on the controller See lower board drawing for specific location NOTE Unplug treadmill before disconnecting and reconnecting cables 1 Power treadmill up and test the following 2 Voltage across 5VDC and GND should be 5VDC 3 Voltage across the signal and Ground should be approx 4 5 VDC at zero incline As the unit inclines this value ...

Page 34: ...Proprietary Confidential TRUE Fitness Technology Inc Proprietary Confidential TRUE Fitness Technology Inc TEST PROCEDURES Incline Potentiometer Test Cont 34 Tread Service Manual July 2011 ...

Page 35: ...utton on the console A reading of 110V to 120V AC indicates normal output 8 A reading of 0 VAC indicates no output 9 Switch power to treadmill off and disconnect from wall 10 Place the voltmeter leads across the white and red wires 11 Plug treadmill power cord into wall and power up 12 With the leads attached push the DOWN button on the console 13 A reading of 110V to 120V AC indicates normal outp...

Page 36: ...the test does not carry you 3 4 of the running belt length lubricate the running belt and running deck using only TRUE proprietary lubricant NOTE Use only TRUE supplied silicone Use 1 4 of bottle provided with the treadmill or one packet of TRUE silicone Lubrication should be applied every 5 1 2 months If the machine is used for more than 3 4 hours per day lubricate every 3 months 6 After lubricat...

Page 37: ...these conditions before a adjusting tension 1 Set the speed to 2 5 mph and walk heavily on the running belt at stomping against the running belt movement 2 If the running belt hesitates or slips tighten both rear roller bolts 1 4 of a turn 3 Repeat step three until no hesitation or slip occurs Also check for these conditions at higher speeds Note A loose drive belt will cause a similar hesitation ...

Page 38: ...ng belt tracking from the rear of the machine 4 Adjust the rear roller to compensate for running belt misalignment 5 If the running belt is tracking to the right tighten the right rear roller bolt in 1 4 turn increments until the belt is properly aligned 6 If the running belt is tracking to the left tighten the left rear roller bolt in 1 4 turn increments until belt is properly aligned CARE AND MA...

Page 39: ... Use a clean cloth towel to remove debris from deck underside of the walk belt Commercial Residential Step 3 Apply Silicone to treadmill The deck underside of the walk belt should be clean and free from any foreign matter Use a clean terrycloth towel to remove debris from deck underside of the walk belt Cut the corner of the single application lube packet and apply it to the foam surface of the ap...

Page 40: ...Proprietary Confidential TRUE Fitness Technology Inc Proprietary Confidential TRUE Fitness Technology Inc 40 Tread Service Manual July 2011 ...

Page 41: ...Proprietary Confidential TRUE Fitness Technology Inc Proprietary Confidential TRUE Fitness Technology Inc APPENDIX A COMMERCIAL LOWER CONTROL BOARD 41 Tread Service Manual July 2011 ...

Page 42: ... a few minutes after the AC power is removed This is because high voltage DC power is still present on board Do not touch or remove board when this LED is illuminated VDSP LED Turns on when the power supply to the motor controller is present CAUTION This is a floating ground hot and isolated from the chassis ground Do not hook this ground reference to the chassis ground DN LED This LED indicates a...

Page 43: ...ndition Indication When a system error occurs appropriate action is taken and the error is reported All errors are given an error code that is sequentially blinked out via LED 5 and LEDs 1 3 Only the last error is reported LED 1 to LED 3 will blink together at a slow rate that is easily countable to indicate the error code This code will be blinked out in incremental sequences and will be repeated...

Page 44: ...VERVOLTAGE MAX_VDC1 9 CRITICAL DCLINK BUS OVERVOLTAGE MAX_VDC2 10 DCLINK BUS UNDERVOLTAGE 11 ILLEGAL SPEED COMMAND 12 PHASE OVER CURRENT RMS 13 FAULTY SPEED SENSOR 14 HEAT SINK OVER TEMPERATURE 15 OVER TEMPERATURE ON MOTOR OR DRIVE 16 RESERVED 17 BRAKE GATE DRIVER FAULT 18 PHASE A LOW GATE DRIVER FAULT 19 PHASE B LOW GATE DRIVER FAULT 20 PHASE C LOW GATE DRIVER FAULT 21 OUTPUT PEAK OVER CURRENT 22...

Page 45: ...tance of phase on drive motor b Replace drive motor 7 Phase is open a Check connections and verify resistance of phase on drive motor b Replace drive motor 8 The unit will shut down and will display both blink 8 and blink 9 a Replace speed sensor 9 If unit displays this error the unit will shut down and will display both blink 8 and blink 9 a Replace speed sensor 10 Under supply voltage Usually ca...

Page 46: ...lace controller 15 Drive motor is overheating a Check for proper ventilation Replace drive motor 16 Reserved Not currently in use 18 Peak overcurrent a Replace controller and drive motor 19 Peak overcurrent a Replace controller and drive motor 20 Peak overcurrent a Replace controller and drive motor 21 Peak overcurrent a Replace controller and drive motor 22 Peak overcurrent a Replace controller a...

Page 47: ...Proprietary Confidential TRUE Fitness Technology Inc Proprietary Confidential TRUE Fitness Technology Inc APPENDIX B SMART CARD LEDS 47 Tread Service Manual July 2011 ...

Page 48: ...rting the safety key B Touchscreen display Press and hold upper left corner of display Once TRUE logo flashes press MANUAL WORKOUT button press CALIBRATION button Note Do not press start unless you intend to begin the calibration process After entering the calibration mode press Start to calibrate the treadmill 1 The unit will begin incline and then decline showing the digital value in the upper c...

Page 49: ...Proprietary Confidential TRUE Fitness Technology Inc Proprietary Confidential TRUE Fitness Technology Inc 49 APPENDIX D TV TUNER SET UP Tread Service Manual July 2011 ...

Page 50: ...Proprietary Confidential TRUE Fitness Technology Inc Proprietary Confidential TRUE Fitness Technology Inc 50 Tread Service Manual July 2011 ...

Page 51: ...Proprietary Confidential TRUE Fitness Technology Inc Proprietary Confidential TRUE Fitness Technology Inc 51 Tread Service Manual July 2011 ...

Page 52: ...TION TEST will display ENTERING BV SETUP MODE 1 Press the START key on center pod once so that VERSION TEST reads on display 2 Press the ENTER key repeatedly until BV SETUP is displayed 3 Press the START key on center pod to enter BV SETUP mode ENTER PROG MODE will display 4 Press the 2 key to select BV Series 2 LOAD BV SERIES 2 will display NOTE These Displays are optimally designed to work with ...

Page 53: ...mal display mode The first TV transmitter audio channel saved will become TV CHAN 1 and the next TV transmitter audio channel saved will become TV CHAN 2 etc PROGRAMMING THE NEXT TV PRESET CHANNEL and remaining channels Repeatedly press the VOL Λ key until you hear the TV audio that you want to program and then press the MUTE key to save it Use this same procedure to program all other preset chann...

Page 54: ...at steps 6 and 7 4 Within 5 seconds enter access code 48362 Press ENTER key on main display Display will show READING CONFIG 5 After a few seconds one of four model numbers will display See list at top of page 6 Use the SPEED or keys to scroll through the model selection list to select your specific model with or without the decline foot option 7 After selection push the START key 8 Display will b...

Page 55: ... Fitness Technology Inc 55 B TOUCHSCREEN MODEL CONFIGURATION 1 Press and hold upper left corner of display Once TRUE logo flashes press MANUAL WORKOUT button 2 MAINTENANCE menu appears 3 Press the UTILITIES button 4 Press the RESET CONFIGURATION button Tread Service Manual July 2011 ...

Page 56: ...Proprietary Confidential TRUE Fitness Technology Inc Proprietary Confidential TRUE Fitness Technology Inc APPENDIX G SOFTWARE INSTALLATION A 15 Touch Screen Display Tread Service Manual July 2011 56 ...

Page 57: ...Proprietary Confidential TRUE Fitness Technology Inc Proprietary Confidential TRUE Fitness Technology Inc Software Installation for Touch Screen Tread Service Manual July 2011 57 ...

Page 58: ...Proprietary Confidential TRUE Fitness Technology Inc Proprietary Confidential TRUE Fitness Technology Inc Software Installation for Touch Screen Tread Service Manual July 2011 58 ...

Page 59: ... storage device in the USB slot 2 Press and hold the STOP button on the center pod assy 3 When the screen blanks out press and hold CHANNEL UP until the code update appears on the screen 4 Press ENTER the USB device will begin uploading software 5 When the upload is finished the screen will return to the normal screen 6 Remove USB device from console Tread Service Manual July 2011 ...