True PS900 User manual

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Remove & Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-29
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-42
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43-46
Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Electronics Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
LED Position Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
TABLE OF CONTENTS

Application: Light Commercial
Unit Weight: 312 lbs
Unit Dimensions: 31.5”Wx 82”L
Maximum User Weight: 350 lbs
Motor: 4 hp DC
Treadbelt Area: 22”W x 60”L
Power Supply: 115V AC
Display: Custom LCD
Warranty: Frame (Lifetime)
Parts (3)
Labor (1)
UNIT SPECIFICATIONS

3
SAFETY INFORMATION
This TRUE Fitness Technology Inc. equipment contains hazardous voltages and high speed moving parts.
Contact with these hazards may damage equipment and could potentially cause serious injury or even
death.
Only qualified personnel, (as outlined below), should install, operate and maintain this equipment.
Always properly ground equipment and lock out electric power (de-energize) before maintenance (unless
instructed to power equipment as part of a test procedure or an electrical check). TRUE recommends the
use of safety glasses when servicing equipment.
Using non-specified / unauthorized parts or components to repair equipment, or tampering with safety
devices/systems will result in dangerous conditions which can potentially cause damage to equipment,
severe personal injury or even death. Take note of and follow all safety instructions contained in this
manual.
This service manual does not claim to cover all detail or variations in TRUE Fitness equipment, nor
does it provide for all possible conditions encountered while installing, operating or maintaining this
equipment. If further information is desired or needed to address any particular installation, operation
or maintenance problem not covered in this document, contact your authorized factory representative at
800-883-8783.
(Exercise good judgment in selecting the appropriate tools for each repair application).
NOTE: It is the policy of TRUE Fitness Technology Inc. to continuously work toward product improvement.
We reserve the right to change product design and specifications without notice. Specifications within
this manual are subject to change without notice.

4
For the purpose of this manual, a qualified person is one that is:
a. Preferably, a technician certified through TRUE Fitness Technology, Inc. service school and / or a
technician from an authorized TRUE dealership.
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.
1. Always disconnect the power supply from the wall when working with equipment.
2. Ensure that the power cord is positioned away from heat sources and sharp objects.
3. Removing the motor cover will expose the technician to high-speed moving parts.
4. To prevent electrical shock, keep all electrical components free from water and other liquids.
5. Do not wear shoes with raised heels. (An athletic shoe is recommended)
6. Do not get on or off the treadmill with the treadmill in motion.
7. Do not leave unsupervised children near the bike during repair.
8. Remove jewelry, especially from neck.
9. Tie longer hair up and away from moving parts.
10. Do not wear loose clothing.
11. Remove neck ties.
12. Be cautious with tools around moving components.
13. Do not put fingers under moving components.
QUALIFIED PERSONNEL
SAFETY GUIDELINES

CAUTION
Alert indicators appear throughout the procedures of this manual to indicate potential hazard that the user
may encounter.
WARNING
DANGER
CAUTION
DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not avoided,
could result in serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury.
CAUTION without the safety alert exclamation point
indicates a potentially hazardous situation which, if not
avoided, may result in property damage and injury.
5
ALERT INDICATORS

REMOVE & REPLACE

Total Time Required:
7
Prerequisite Removals:
Summary of Procedure:
Tools Required:
1
CAUTION
Rear Cover
#2 Phillips
Screws
Overlay
2
4
Display Board
20:00
#1 & #2 Phillips Screwdriver
None
Turn the power to
the unit off and un-
plug the treadmill
from the wall to avoid
damaging equipment.
1. Using a #2 Phillips screwdriver, remove the 14 screws from the rear cover of the upper console (make sure
you have a firm grip on the rear cover during removal).
2. Remove the console plastic rear cover.
3. Disconnect the console cables from the upper computer board (see upper console wiring diagram for cable
info).
4. Using a #1 Phillips screwdriver, unscrew the 6 Phillips screws and remove the upper computer board.
5. Calibrate the treadmill after any board replacement (see calibration procedure).
4
Computer
Board

Total Time Required:
8
Prerequisite Removals:
Summary of Procedure:
Tools Required:
Contact heart rate sensor
grip assembly
1
2
3
4
#1 Phillips
Screws
Sensor Plate
Lead
Quick-slide
Connector
Male Blade
Connector
Grip Assembly
Contact Heart Rate Grips
20:00
Razor Knife or Pocket Knife, #1 Phillips
Screwdriver
None
Sensor
Plate
1. Using a razor knife, carefully pry the upper sensor plate from the contact heart rate sensor grip assembly.
NOTE: If sensor plate becomes damaged replace the plate and adhesive material that anchors it in place.
2. Gently pull the sensor plate lead through the access hole in the grip.
3. Turn the sensor plate over in order to have access to the quick slide connector. Remove quick slide connector
from male blade connector. Repeat steps 1 through 3 for the lower sensor plate.
NOTE: Wires must remain connected to the same plate as originally installed. Do not change the wire positions.
Doing so will lead to incorrect wire readings.
4. Using a #1 Phillips screwdriver, loosen and remove the two grip assembly screws.
5. Split the seam of the hand grip and pry apart with a razor knife or pocket knife. Remove the bottom of the
grip assembly and then the top.
6. When assembling new heart rate grip assembly, ensure that adhesive is placed between sensor plates and
grips.

Total Time Required:
9
Prerequisite Removals:
Summary of Procedure:
Tools Required:
Motor Cover
1
Pedestal #2 Phillips
Screws
Motor Cover Lift
5:00
#2 Phillips Screwdriver, Bungie Cord
None
(For complete removal see pedestal procedure)
CAUTION
Turn the power to the
unit off and unplug
the treadmill from the
wall to avoid injury.
1. Using a #2 Phillips screwdriver, remove 4 screws (2 per side) on the base of the motor cover.
2. Slide the motor cover up the pedestal and suspend to the console with a bungie cord.

Total Time Required:
10
Prerequisite Removals:
Summary of Procedure:
Tools Required:
1
#2 Phillips
Screws
5mm
Allen
Bolts
3Motor Cover
Pedestal
Pedestal
15:00
#2 Phillips Screwdriver, 5 mm Allen Wrench
None
(Uprights)
CAUTION
Turn the power to the
unit off and unplug
the treadmill from the
wall to avoid injury.
1. Using a #2 Phillip screwdriver, remove the 4 screws at the base of the motor cover.
2. Remove the 6 plastic caps from the motor cover.
3. Using a 5 mm allen wrench, remove the 6 allen bolts (3 per side).
4. Lift the motor cover up, clip the wire-tie and disconnect the console cable from the lower board.
5. Lift the pedestal and lay the pedestal down on the straddle covers.
NOTES: Make sure the lower control cable is disconnected and has cleared the opening on the frame before pull-
ing the pedestal completely off.

Total Time Required:
11
Prerequisite Removals:
Summary of Procedure:
Tools Required:
Controller
15:00
#2 Phillips Screwdriver
Motor Cover Lift
(Lower Board)
Turn the power to the
unit off and unplug
the treadmill from
the wall to avoid se-
rious injury or death.
DANGER
1. Using a #2 Phillips screwdriver, remove the two screws that fasten the controller to the frame and lift the
controller out of the motor pan.
2. Disconnect the console cable.
3. Disconnect the potentiometer connection.
4. Disconnect the incline motor power connection.
5. Disconnect the AC leads, hot (black) and neutral (white).
6. Disconnect the motor leads, MTR1 (red) and MTR2 (black).
7. Disconnect the speed sensor.
8. Remove the controller.
9. Run calibration on treadmill after replacing the controller (see calibration procedure).
NOTE: Heat-paste has been applied beneath the controller. Be careful when removing the controller so as not to
get paste on clothing or other equipment.
#2 Phillips
Screws
2
3
5
7
6
4
1
WHT
BLK
RED
BLK

Total Time Required:
12
Prerequisite Removals:
Summary of Procedure:
Tools Required:
5
8mm Allen
Bolt
17mm Nut
Incline Motor
4
Lifer
U-Shaped
pins
R-Pins 2
Incline Motor
45:00
Flathead Screwdriver, #2 Phillips Screwdriver, 8 mm Allen Wrench,
17 mm Open-Ended wrench, Rubber Mallet
Motor Cover Lift
Turn the power to the
unit off and unplug
the treadmill from
the wall to avoid se-
rious injury or death.
DANGER
1. Disconnect the incline motor cables from the lower board and, using a #2 Phillip screwdriver, remove the
ground cable from the frame.
2. Using a flat head screwdriver, pull out the two R-pins from either side of the incline motor.
3. Using a 2x4 or other object, prop the front end of the treadmill up to remove the weight from the riser assembly.
4. Using a flat head screwdriver, carefully pry out the two Lifer U-shape pins from either side of the incline motor.
5. Using an 8 mm allen wrench and 17 mm open-ended wrench, remove the allen bolt and nut from the base of the
incline motor and remove the incline motor from the frame.
6. Before reinstalling incline motor, plug motor into lower board and allow lower limit to be set by the motor.
NOTE: This must be done prior to securing motor to treadmill frame. Verify the pot setting of the new motor by
plugging into the lower board and entering calibration mode. The value should be between 220-230. If not, drive
the motor to that value by holding up or down. The motor shaft will spin so do not hold the motor by the shaft.
7. When reinstalling the incline motor, use a rubber mallet to install the Lifer U-shape pins.
8. Calibrate the treadmill after replacing the incline motor (see calibration procedure).

Total Time Required:
13
Prerequisite Removals:
Summary of Procedure:
Tools Required:
Drive Belt
2
Motor
Flywheel
8mm Allen
Bolts
3
Motor
20:00
6 mm Allen Wrench, 12 mm Open-
Ended Wrench, Needlenose Pliers,
8 mm Hex Socket
Motor Cover Lift
Turn the power to the
unit off and unplug
the treadmill from
the wall to avoid se-
rious injury or death.
DANGER
1. Using a 6 mm allen wrench and 12 mm open-ended wrench, release tension on the belt by loosening the
12 mm nut and then backing out partially, but not removing, the tensioner bolt. This will require turning the
machine on its side in order to reach the tensioner bolt which is located on the belt-side edge of the motor pan.
2. Using an 8 mm hex socket, remove the 4 allen bolts that fasten the motor to the frame.
3. Slide the drive belt off of the motor.
4. Using a pair of needle nose pliers, disconnect MTR1 and MTR2 wires from controller.
5. Using a #2 Phillips screwdriver, disconnect the motor ground wire from the treadmill frame.
6. Using a #2 Phillips screwdriver, disconnect the wire tie down that screws into the frame.
7. Remove motor from unit.
8. After reinstalling the new motor, run a drive belt tension procedure (see drive belt tension test procedure).
9. Calibrate the treadmill after replacing the motor (see calibration procedure in the test procedures section).
1
12 mm Nut
6 mm Allen
Bolt

Total Time Required:
14
Prerequisite Removals:
Summary of Procedure:
Tools Required:
#2 Phillps
Screws 1
Straddle
Cover Rear
End Cap (L)
Straddle
Cover Rear
End Cap (R)
Straddle Cover Rear End Caps
1. Using a #2 Phillips screwdriver, remove two screws (one per cap) and remove the rear end caps.
5:00
#2 Phillips Screwdriver
None

Total Time Required:
15
Prerequisite Removals:
Summary of Procedure:
Tools Required:
13mm
Bolts
1
Straddle Covers
Straddle Covers
1. Tilt the unit on its side to access the underside of the treadmill.
2. Using a 13 mm open-ended wrench, loosen the 8 bolts (4 per side) two turns but do not remove the bolts.
3. Slide the straddle cover off toward the rear of the treadmill.
NOTE: When replacing the straddle covers, be sure to slide the straddle cover fully forward on the treadmill or the
end cap will not fit properly.
10:00
13 mm Open-Ended Wrench
Straddle Cover Rear End Caps
3

Total Time Required:
16
Prerequisite Removals:
Summary of Procedure:
Tools Required:
Front
Roller 1
Frame
8mm Allen
Bolt
6
Drive
Belt
5
Front Roller
30:00
6 mm Allen Wrench, 8 mm Hex Socket,
12 mm & 14 mm Open-Ended Wrenches
Motor Cover Lift, Straddle Cover Rear End Caps
Turn the power to the
unit off and unplug the
treadmill from the wall
to avoid serious injury.
WARNING
1. Using a pen or crayon, mark the location of the position of the shaft on the frame on the runner’s right side for
accurate reinstall.
2. Using an 6 mm allen wrench and 12 mm open-ended wrench, loosen, but do not remove, the nut to release
tension on the drive belt (see drive motor procedure).
3. Loosen the drive motor bolts and slide the motor toward the front roller (see drive motor procedure).
4. Using an 8 mm hex socket, loosen the two allen bolts with washers (1 per side) on each side of the rear roller to
release tension on the running belt.
5. Remove the drive belt (refer to the drive motor removal procedure).
6. Using an 8 mm hex socket and 14 mm open-ended wrench, remove the bolt and nut from the front roller.
7. Slide the front roller out from the running belt by lifting from the pulley side and sliding the roller out of the left
side bracket, then sliding the roller out the left side.
NOTE: When reinstalling the front roller, be sure to set correct tension on the drive motor belt and the tread belt
(see test procedures section).

Total Time Required:
17
Prerequisite Removals:
Summary of Procedure:
Tools Required:
8mm Allen
Bolts
1
Rear
Roller
Rear Roller
15:00
8 mm Hex Socket
Straddle Cover Rear End Caps, Straddle Covers
Turn the power to the
unit off and unplug the
treadmill from the wall
to avoid serious injury.
WARNING
1. Using an 8 mm hex socket, remove the two allen bolts with washers (1 per side) on each side of the
rear roller.
2. Lift the rear roller up and slide out of the belt.
NOTE: When reinstalling the rear roller, be sure to set correct tension on the drive motor belt (see test
procedures section).

Total Time Required:
18
Prerequisite Removals:
Summary of Procedure:
Tools Required:
5mm Allen
Bolts
1
Running
Deck
Running
Belt
Belt & Deck
50:00
5 mm Allen Wrench
Straddle Cover Rear End Caps, Straddle Covers, Motor
Cover Lift, Front Roller, Rear Roller
Turn the power to the
unit off and unplug the
treadmill from the wall
to avoid serious injury.
WARNING
1. Using a 5 mm allen wrench, remove the 10 allen bolts, (5 per side), from the top of the running deck.
NOTE: The four rear deck bolts (2 per side) have nuts that are not welded to the frame).
2. Remove the running deck and running belt from the treadmill.
NOTE: When reinstalling the belt and deck, be sure to set correct tension on the drive motor belt and the tread
belt (see test procedures section).

TROUBLESHOOTING

20
Diagnostics
1. Enter diagnostics mode by holding the and buttons while placing the safety
key.
2. The message center will display: “Diagnostics”.
3. Press the button once to display Total Hours, (in whole hours).
4. Press the button again to display Distance, (in miles to two digits past the decimal
point).
5. Press the button again to display Average Speed, (in mph).
6. Press the button again to display the Error Log. See Error Messages section for
description of error codes.
7. Remove the safety key to exit diagnostics and resume normal treadmill operation.