True Fitness TREADMILL 2011 Service Manual

Proprietary & Confidential TRUE Fitness Technology, Inc.

2011 TREADMILL

SERVICE MANUAL

Proprietary & Confidential 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

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SYMPTOM GUIDE Diagnostics……………………………………5-8 Drive System Overview………………………..9 Elevation System Overview………………10-12 Error Codes

Definitions………………………………13-14

E1 Stall/ E1 Range...…………………..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 Contents

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Test Procedures(cont.)

Push Off Test …………..................................36

Running Belt Tension Test …………………..37 Care and Maintenance

Running Belt Alignment……………………....38

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

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2 WINDOW DISPLAY

 Press CLEAR ENTRY until the screen blanks then press hold

ENTER. [ or Hold speed Up () Key while inserting safety key ]

 A. Input 10101 (Basic Mode) B. Input 20173(Service Mode)

1. Units (English)

2. Max Time (99)

3. Default Time (30)

4. Reset (60 sec)

5. Sound (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 Switch Test

15.Program Usage

16.BV Setup

17.Watch Dog Test

To exit : Press Start – Watch Dog Test will count down & system will clear

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A. press 10101 (Manager Mode)

1. Hours

2. Distance

3. Units

4. Max Program Time (99)

5. Def Program Time (30)

6. Reset Time (30)

7. Audible Sound (On)

8. 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. Watch Dog Test

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C. Press 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.)

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15” Touch Screen

The Maintenance Mode is designed to help the tech determine certain faults in the upper control boards and feedback from the 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, touch screen setup)

Tread Service Manual - July 2011

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Upper Board

Smart Board

Lower Board

Drive Motor

Feed Back

Command Signal

The new TCS Series treads with the smart card system utilize a digital signal for both command and feedback. This signal cannot be tested with normal field equipment. Diagnostics must be done using the status lights on both the lower control board and smart card.

2. DC DRIVE WITH 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 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. AC DRIVE WITH SMART CARD INTERFACE (TCS Series and TLC1100).

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ELEVATION SYSTEM OVERVIEW

 The elevation systems on all True Treadmills use AC

(Alternating Current) motors to lift the treadmill to the desired elevation. This system uses a command from the upper control board that is sent to the lower 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 Note: On units with Smart

Board -> 5 volts originates at Smart Board. All other units,

-> 5V originates at upper board

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ELEVATION SYSTEM OVERVIEW

(CONT.)

 How this feedback is displayed varies with different models

and different consoles:

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Note: See TRUE Dealer Portal for older model elevation values

Treadmill Series

Digital Value

Notes

CS 500, 550, 800 &

ES900 with

Touchscreen

With decline foot

14000 - 16000

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.

CS 500, 550, 800 &

ES900 with

Touchscreen

No decline foot

6500 - 8500

At zero incline the 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 the black and white wires(TPS series) or (orange and blue

on TCS series) of the potentiometer should

read approx. 4.47 VDC . As the treadmill inclines, the displayed value increases while the VDC decreases

CS 500,LC series,

PS series with

2

Window

228

At zero incline the incline digital value displayed in calibration mode reads approx.

228. The DC voltage across the orange and blue wires of the potentiometer should read approx. 4.47 VDC. As the treadmill inclines,

the displayed value decreases while the VDC

decreases.

Tread Service Manual - July 2011

Proprietary & Confidential TRUE Fitness Technology, Inc.

D. TCS800 w/ touchscreen console:

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.)

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B: ERROR CODES

13

GENERIC ERROR CODES

Error

Reason

Resolution

E1 RANGE

Elevation feedback values are

out of the minimum or

maximum range.

Pg. 15

-16

E1 STALL

Elevation feedback value does not change when elevation motor is commanded.

Pg. 15

-16

E2 CAL

Speed feedback is too far out of the calibrated range.

Pg.

17

E2: OVERSPEED

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 switches activate control. Remove switch board from

front plastic to determine if

functioning properly

E5: SENSOR (aka NO SPEED PULSE):

Upper control board detecting any or below acceptable speed.

Pg.

17-22

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ERROR CODES ASSOCIATED WITH NEW

SMART CARD

WRONG CONFIG: Smart card not compatible with configuration. Check configuration of upper console.

SMART CARD COM: Lost communication between smart card and upper control board. Check main data cables for continuity and

proper connections. Check status LEDS on smart card.

MOTOR MISMATCH: Motor type (AC vs DC) doesn’t match

smart card type (AC vs DC). INCLINE REV ERROR: Elevation direction is reversed. 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 communication is lost. Check

continuity of data cable and connections.

MOTOR BD COMM (AC ONLY): The motor controller’s

communication is lost between controller and smart card. Check

connections and cable continuity between smart card and lower control

board. Make sure RS232 cable is orientated correctly.

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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. If there is no illumination of incline LEDs, 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 there is no continuity, replace the fuse.

If the fuse blows a second time replace the lower board.

Caution! Unplug unit before removing fuses!

E1 STALL

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• If the value at zero or -3% incline is outside the acceptable range (see pg. 11) of the correct digital value, the machine will give an elevation error (either E1 Stall or E1 Range depending on model).

• On units with an external limit switch, 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 potentiometer or a wire disconnect between the potentiometer and the upper control panel.

E1 STALL/ E1 RANGE

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 This error will occur if the upper and the lower boards lose their

calibration parameters. See calibration procedure(pg 47)

Note: May be caused by speed fluctuation.

•Check for high friction by performing a Push-off test.(pg 35)

•To perform this test raise the elevation 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 controller failure.

•Replace running belt and deck as needed

•Check the line voltage for fluctuations. This can cause erratic

speeds.

E2 CAL

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E5 Sensor Error (without belt movement):

If the upper control board does not see adequate feedback from the speed sensor when the belt is being commanded to move this error will occur.

This error 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 received at the lower

board there will be no belt movement.

E5 SENSOR

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Tread Service Manual - July 2011

True Fitness TREADMILL 2011 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual