True Fitness TREADMILL 2011 Service Manual
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True Fitness TREADMILL 2011 Service Manual

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2011 TREADMILL
SERVICE MANUAL
Proprietary & Confidential
TRUE Fitness Technology, Inc.

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Summary of Contents for True Fitness TREADMILL 2011

  • Page 1 2011 TREADMILL SERVICE MANUAL Proprietary & Confidential TRUE Fitness Technology, Inc.
  • Page 2 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. Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.

  • Page 3: Table Of Contents

    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 Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.
  • Page 4 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 Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.
  • Page 5 16.BV Setup 17.Watch Dog Test To exit : Press Start – Watch Dog Test will count down & system will clear Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.
  • Page 6 11. Left BK LT (63) 11. BV Setup 12. Right BK LT (63) 12. Watch Dog Test 13. HR Priority (Tele) Error Log 1-5. Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.
  • Page 7 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 Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.

  • Page 8: Diagnostics

    3.Diagnostics (Check hours, distance, error log) 4.Production Tests (Test various functions) 5.Utilities (Install software, TV tuner setup, touch screen setup) Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.

  • Page 9: Drive System Overview

    SYMPTOM GUIDE A. DRIVE SYSTEM OVERVIEW In this summary we are going to cover basic troubleshooting techniques used in the industry to diagnose and repair True Fitness treadmills more quickly and efficiently. Current True treadmills use 3 types of drive system: 1.

  • Page 10: Elevation System Overview

    Note: On units with Smart Board -> 5 volts originates at Smart Board. All other units, -> 5V originates at upper board Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.
  • Page 11 4.47 VDC. As the treadmill inclines, Window the displayed value decreases while the VDC Note: See TRUE Dealer Portal for older model elevation values decreases. Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.
  • Page 12 4.47 . As the treadmill inclines the displayed value increases while the VDC decreases. Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.

  • Page 13: Error Codes

    E5: SENSOR Upper control board detecting Pg. 17-22 (aka NO SPEED any or below acceptable speed. PULSE): Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.
  • Page 14 Check connections and cable continuity between smart card and lower control board. Make sure RS232 cable is orientated correctly. Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.
  • Page 15 E1 STALL The elevation up and down LED’s on the lower boards of all True Fitness Treadmills are used for elevation troubleshooting. These LED’s illuminate when a command is received from the upper control board to raise or lower the incline.

  • Page 16: E1 Stall/ E1 Range

    A value reading 255 or 0 often indicates over travel of the potentiometer or a wire disconnect between the potentiometer and the upper control panel. Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.

  • Page 17: E2 Cal

    •Replace running belt and deck as needed •Check the line voltage for fluctuations. This can cause erratic speeds. Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.

  • Page 18: E5 Sensor

    If the upper board command signal is not being received at the lower board there will be no belt movement. Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.
  • Page 19 Measure the output pins (to the drive motor) on the lower board. When checking output voltage the motor or load must be connected to the motor controller when measuring this voltage. Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.
  • Page 20 If the cable checks good, replace the upper board. All current production models have a RPM LED on the lower boards. Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.
  • Page 21 If this speed sensor test is successful replace the lower board. If the speed sensor test fails replace the speed sensor. Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.
  • Page 22 E5 Sensor ( only occurs under load) Most common cause his high belt and deck friction. Perform amp draw test on pg: 29 Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.

  • Page 23: Misc Symptoms

    Check for power LED on adapter. If on, check for 12 VDC at console connection. www.truefitness.com Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.
  • Page 24 NO CONSOLE DISPLAY 20 PIN CABLE PINOUT Z SERIES, TPS800-900 12 PIN CABLE PINOUT PS 75,100, 300 Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.

  • Page 25: No/ Erratic Heart Rate

    If there is no continuity through the grips to the computer board, replace the grip assembly or HR wires. Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.

  • Page 26: No Fan

     Only applies to 2 window or 11” LCD consoles with wireless card option.  Reprogram wireless card (see pg: 51-52) Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.

  • Page 27: No Response Touchscreen Keys

    5. Follow the on screen instructions to CALIBRATE your display. Once all TARGETS have been pressed, press the blue HOME button to complete TOUCHSCREEN CALIBRATION. Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.

  • Page 28: Touch Screen Will Not Function

    When step 3 is complete press “HOME”. Check for function of the touch screen. If touch screen continues to not function replace console. Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.

  • Page 29: No Ipod Detected

    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. Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.

  • Page 30: Test Procedures

    Higher than normal amp draws signal running belt and running deck friction which may require lubrication or replacement. Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.

  • Page 31: Speed Sensor Test

    If this speed sensor test is successful replace the lower board. If the speed sensor test fails replace the speed sensor. Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.

  • Page 32: Potentiometer Test

    4. A digital value of 0 or 255 often indicates a control cable open or a failure of signal to panel. Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.
  • Page 33 NOTE: All the above voltages are while the unit is at zero incline, or on units that have decline- minus 3. Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.
  • Page 34 TEST PROCEDURES Incline Potentiometer Test (Cont.) Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.

  • Page 35: Voltage To Incline Motor Test

    13. A reading of 110V to 120V AC indicates normal output. 14. A reading of 0VAC indicates no output. Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.

  • Page 36: Test Procedures (Cont.)

    7. If the treadmill does not carry you 3/4 of the running belt length after lubrication, replace or flip the running belt and running deck. Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.

  • Page 37: Running Belt Tension Test

    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 under load Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.

  • Page 38: Running Belt Alignment

    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. Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.

  • Page 39: Care And Maintenance

    If the test does not carry you at least ¾ of the way to the end of the machine, lubricate the belt using True Fitness liquid silicone (perform step 2 before lubricating). After lubricating the belt/deck perform the push off test to verify proper lubrication.

  • Page 40: General Maintenance

    Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.

  • Page 41: General Leds

    A: COMMERCIAL LOWER CONTROL BOARD APPENDIX Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.
  • Page 42 At high duty cycles, the LED would appear to be “on” all the time. This LED turns off each time the encoder wheel passes/is interrupted through SPEED LED speed pickup. Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.

  • Page 43: Status Leds

    Note: When error is present at the time of a service call, please record the error sequence for diagnosis purposes and fault reporting Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.
  • Page 44 PHASE A HIGH GATE DRIVER FAULT PHASE B HIGH GATE DRIVER FAULT PHASE C HIGH GATE DRIVER FAULT DCLINK BUS OVERVOLTAGE Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.
  • Page 45 Replace controller. command Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.
  • Page 46 23 Peak overcurrent Replace controller and drive motor 24 Peak overcurrent Replace controller and drive motor 25 Controller caps overcharge Replace controller Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.

  • Page 47: Appendix B: Smart Card Leds

    APPENDIX B: SMART CARD LEDS Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.

  • Page 48: Appendix C: Calibration

    3. Calibration Successful or Cal Good are the preferred messages. If there is a problem with the system an error code will display. Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.

  • Page 49: Appendix D: Tv Tuner Set-Up

    APPENDIX D: TV TUNER SET-UP Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.
  • Page 50 Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.
  • Page 51 Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.

  • Page 52: Appendix E: Wireless Card Set-Up

    9 to LOAD BV SERIES 9 for Cardio Theater transmitters. This may allow for reception under these circumstances. Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.
  • Page 53 •To exit programming mode, Press and hold the CLEAR ENTRY key until display blanks and resets to normal operate mode. TV Programming is now complete. Should you need technical assistance for your TRUE Fitness product contact TRUE Fitness Technical Support at 1-800-883-8783 Proprietary & Confidential Proprietary &...

  • Page 54: Appendix F: Universal Console Model Config

    9. Do not hit any other keys. Turn Treadmill power switch OFF and then turn power ON. 10. Calibrate treadmill per the Treadmill Calibration procedure within Console Assembly Instructions Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.
  • Page 55 Once TRUE logo flashes, press MANUAL WORKOUT button 2. MAINTENANCE menu appears. 3. Press the UTILITIES button 4. Press the RESET CONFIGURATION button Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.

  • Page 56: Appendix G: Software Installation

    APPENDIX G: SOFTWARE INSTALLATION A. 15” Touch Screen Display Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.
  • Page 57 Software Installation for Touch Screen Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.
  • Page 58 Software Installation for Touch Screen Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.

  • Page 59: 11" And 2-Window

    5. When the upload is finished the screen will return to the normal screen 6. Remove USB device from console Proprietary & Confidential Proprietary & Confidential Tread Service Manual - July 2011 TRUE Fitness Technology, Inc. TRUE Fitness Technology, Inc.

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