True Fitness 455 Pediatric Treadmill User Manual
Contents
1. ELEVATION HARDWARE LLS ELEVATION RACK 15lbs WHEEL POWER CORD 70242103 70150000 70177400 70132500 70013500 70243200 70243300 70337800 70325900 70006300 70113200 70115500 70116700 70118900 70183200 70013500 70121000 70125700 70120500 70281001 70176701 70253100 70008200 455 Parts List 455 treadmil parts list DESCRIPTION Control Panel Assembly SAFETY SWITCH ASSY REMOVABLE SAFETY KEY MOTOR CONTROLLER SS90 PWM SCREW 10 32 X 3 8 CIRCUIT BOARD SPEED SENSOR SP SENSOR SCREW 4 40 X 1 4 450 HRC DATA CABLE 3HP DRIVE MOTOR 10 MPH8 mph 210J10 POLY V DRIVE BELT INCLINE MOTOR 3 8 X 1 1 2 CLEVIS PIN 1 16 DIA X 1 5 16 COTTER PIN TORQUE ARM SWIVEL PIN START CAPACITOR FOR INCLINE MOTOR SCREW FOR START CAPACITOR LOWER LIMIT SWITCH LLS SCREW 10X 1 4 LLS TO PWM WIRE ELEVATION RISER SUB ASSY Molded wheels 9 FT POWER CORD STRAIN RELIEF BUSHING ON OFF SWITCH 70251100 ROCKER ON OFF SWITCH CIRCUIT BREAKER 70017200 15 AMP CIRCUIT BREAKER SWITCH TREADBELT 9lbs 70159300 17 3 4 X 107 3 4 2 PLY TREADBELT DECK 40lbs 70157700 FLEX DECK 70020200 DECK SCREW 10 32 X 1 1 4 FRONT ROLLER 455 front roller 9lbs 70359200 450 455 ADJ ROLLER REAR ROLLER 13lbs 70359000 REAR ROLLER 70158900 ROLLER BOLT 70159000 5 16 INTERNAL TOOTH LOCK WASHER STRADDLE COVERS 70162101 LT 8 RT STRADDLE COVERS 70030900 3 8 X 1 16 X 108 FT DBL STICK TAPE 70243400 BLUE TAPE 1 22. Page 19 Page 19 Page 19 Page 20 Page 20 Page 21 Page 16 TEST PROCEDURES GROUNDED OUTLET TEST This test is very important for optimal HRC and incline operation Set voltmeter for Volts AC Place 1 lead in the right side of the outlet hot Place 1 lead in the ground plug A properly grounded outlet vvill read 110 VAC AMP DRAW TEST This test is a good indicator of the wear condition of the belt and deck and the need for lubrication The treadmill circuit breaker will trip at 15 amps so be sure the voltmeter you are using is rated for at least 15 amps when you are load testing the treadmill This test can be performed either on one of the AC power cord leads or on one of the DC motor leads from the PWM to the motor Testing the amp draw at certain speeds without load and with load will signal whether higher than normal amp draw is a result of PWM failure or increased friction from belt and deck wear AC AMP DRAW PROCEDURE This procedure requires 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 2 5 mph with load 2 75 3 75 AMPS AC 4 0 mph w out load 3 5 4 0 AMPS AC 4 0 mph with load 5 0 7 0 AMPS AC DC AMP DRAW PROCEDURE This procedure can be performed with an ordinary voltmeter Note Be sure the voltmeter is rated to handle 15 DC amps Disconnect the red motor lead
3. from MTRI on the PWM Connect the voltmeter to MTR 1 on the PWM and the other voltmeter lead to the red motor lead so that the voltmeter completes the connection of the PWM to the motor 2 5 mph w out load 4 5 5 0 AMPS DC 2 5 mph with load 7 0 8 0 AMPS DC 4 0 mph w out load 5 0 5 5 AMPS DC 4 0 mph with load 8 5 9 0 AMPS DC Higher than normal amp draws without load may signal that belt tension is too tight or there is a problem in the Drive Motor or PWM Perform the Drive Motor Test and visually check the motor brushes before replacing the PWM Higher than normal amp draws with load after normal readings without load signal belt and deck friction which may require lubrication or replacement Page 17 TEST PROCEDURES SPEED SENSOR TEST This test is used to verify sensor operation in conditions of speed fluctuation E2 Cal error S4 Sensor error E2 Overspeed error or Unsuccessful Calibration 455 Treadmill Set voltmeter to volts DC Treadmill power on and speed at 0 mph Attach voltmeter leads across outside 2 contacts at J1 on PWM With magnet in front of sensor 0 VDC 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 light will blink when a magnet is in front of the sensor VOLTAGE TO DRIVE MOTOR TEST This test is used to diagnose conditions of NO Belt Movement or Speed
4. speed should be set to 0 Stand on the tread belt positioning yourself close to the console push off with moderate force The elevation combined with your weight and the force of the push should cause the belt to carry you all the way to the end of the machine If the test does not carry you to the end of the machine lubricate the belt using True Fitness liquid silicone After lubricating the belt deck perform the push off test again If it does not pass the test after lubricating replace the belt and deck Note Residential treadmills may only carry about ya of the distance of the deck due to higher tension on the belt HOLIMS FM todd ALIHM N3349 e BLIHM wove As AA DS YINVIVO LINOHIO HOLON A9V18 SNITONI j YOLOW O UWI O YOLOW JAIYO SJOPOW OOP UO ajqejigAB JON ONO SISSVHO GTSIHS_ oz Gasn LON A INMONI OY3Z a Zi Lins SAG an e u ti ma g St 1 0 NMd HATIOHINOI HOLOIN 90A ZI pe MOE 3 er oi ONYNINOS GaadSWMd or AV TH3AO WOUJ MWE e ie Sie J18V9 NOSY AWO NMOG ANTONI 8 i aN IDA St INMONI Z an AWO dh 3NNMON Fe ie a Nn A Ce nn Y on TANVI 104LNOI n JE ee AA pon an NOILONN NOILISOd SSINAVH FUIM YIdAN webera Bum 00r W Page 22 Page 23 VVEIGHT PART CONTROL PANEL 455 PWM ss90 3lbs SPEED SENSOR SS90 STYLE DATA CABLE DRV MTR 44lbs DRV BELT ELEVATION MTR 10lbs
5. trouble shooting should be performed in calibration mode Page 14 Symptom Probable Cause Possible short in treadmill vviring CIRCUIT BREAKER TRIPS Motor issues Incline motor drawing treadmill down Bad PWM Too much tension on belt or obstruction under belt Weakened circuit breaker or High belt deck friction Corrective Action Power off the treadmill and inspect all wiring for shorts or burned areas Secure all connectors Disconnect motor leads from the PWM Power on treadmill press start If the breaker does not trip check the motor brushes and perform the motor test procedure page 19 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 trip replace PWM Check for correct tension adjustment page 20 Check for obstruction remove obstruction Perform AC Amp Draw Test page 17 at circuit breaker If draw is less than 15 amps continuously replace breaker Perform Amp Draw test page 17 If Amp draw is higher than recommended try push test page 21 procedure Recommended Tools Allen Key set Needle nose pliers Socket set Multi meter Note All trouble shooting should be performed in calibration mode Page 14 Calibration Procedures 455 Calibration Enter Calibration Mode by holding the Up and Dow
6. Corrective Action Recommended Tools Liquid silicone single use pack Liquid Silicone Applicator Vacuum Shop towel Lube deck with True Fitness liquid silicone lubricant Inspect wax bar assembly on commercial models if worn to less that Va inch in thickness replace wax bar Remove motor cover and vacuum dust from area Wipe down the exposed area of the deck beside the straddle covers with a clean dry cloth Check Replace motor brushes as needed Reset timer Perform Speed Sensor Test page 21 See Elevation Not Functional page 9 See Elevation Not Functional page 9 See Elevation Not Functional page 9 Symptom ERROR MESSAGES cont d E20 OVERSPEED E2C CALIBRATE E3E EEPROM E2R RECALIBRATE Probable Cause Belt speed ramping too fast Micro controller cannot adjust belt speed to target Software error during treadmill startup diagnostics Treadmill has lost calibration settings Corrective Action Recommended Tools Multi meter Phillips head screwdriver Perform Amp Draw Test Page 17 Perform Belt Deck Wear Test Page 21 Calibrate Treadmill Page 14 See appropriate Symptom Guide pages 10 11 Restart Treadmill if error persists replace control panel Recalibrate Treadmill Page 14 IF unit loses programs replace control panel Symptom Probable Cause Treadmill in need of calibration NO BELT MOVEMENT Missing command to PWM
7. Fluctuations Set voltmeter to volts DC and adjust speed on Control Panel to 4 mph Attach red voltmeter lead to MTR1 on PWM with motor wires attached Attach black voltmeter lead to MTR2 on PWM with motor wires attached 0 VDC signals no PWM output 166 VDC signals open circuit in motor or motor connection Operating voltage will lay between 0 VDC and 166 VDC NOTE The reason that we do not narrow down PWM output voltage is that the PWM output is a pulse signal The sampling rate of the voltmeter used will determine what output voltage the voltmeter is able to read Page 18 TEST PROCEDURES DRIVE MOTOR TEST This test is used in conditions of No Belt Movement Unplug treadmill and set voltmeter to volts DC Disconnect motor leads from PWM Place 1 voltmeter lead in each motor wire Gently spin the motor flywheel and check for voltage DC 2 5 VDC means normal motor operation 0 VDC means motor malfunction DRIVE BELT TENSION TEST This test is used in front roller replacement and in conditions of belt slipping Place two fingers on top of the drive belt halfway between the front roller pulley and the drive motor pulley With moderate pressure push down on belt If belt deflects down more than 1 8 tighten motor mounts If belt deflects down less than 1 8 loosen motor mounts It is 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
8. Missing incorrect voltage to motor Damaged motor Corrective Action e Run calibration page 14 e Is PWM light blinking illuminated when fast button is pushed NO Check continuity on wire harness if harness has continuity breaks replace the harness If harness has continuity replace the upper panel Refer to wiring harness diagram for your model YES move on to next step wire harness and control panel are OK With treadmill in calibration mode page 14 Set speed 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 greater than 20 VDC MPH motor may have open windings With PWM LED Blinking Illuminated move the tread belt with your foot to see if motor begins to move on its own If motor begins to move inspect the condition of the brushes and the commutator If brushes are bad replace brushes If motor doesn t turn or has a damaged com segment replace motor Continue on next page Recommended Tools Multi meter PWM Motor test cables Note All trouble shooting should be performed in calibration mode Page 16 Symptom NO BELT MOVEMENT cont d Probable Cause Motor turns but belt does not Belt cannot be moved manually foreign object under belt Corrective Action Check belt tension Set belt tension to 1 8 inc
9. True Fitness Service Manual 455 Pediatric Treadmill True fitness technology Inc makes no representations or warranties regarding the contents of this manual We reserve 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 Fitness Inc All rights reserved Printed in the United States of America 865 Hoff Road O Fallon MO 63366 1 800 426 6570 Fax 636 272 3026 www truefitness com Revision 9 2004 Treadmill Preventative Maintenance Checklist Run calibration or run a manual program and watch and listen for anything out of the ordinary e Perform a push off test page T 7 to check for proper lubrication If excessive friction is found and lubrication doesn t correct the problem perform the amp draw test page T1 2 se Inspect the belt surfaces topside should still have texture for grip bottom should be porous fabric not glazed smooth or hard s Inspect deck surface should be free of scratches abrasions or blistering e Listen for excessive bearing noise from a standing position in the front and rear roller and motor Check for front roller belt slippage and belt tension adjustment Look for slippage on drive pulley se Inspect adjust tracking of belt e Vacuum out motor area being careful not to damage PWM se Inspect drive belt for wear and crac
10. X 150 FT ROLL PEDESTAL 455 pedestal 70233800 ROUND PEDESTAL WELDMENT 70155900 PEDESTAL SCREWS FRAME 450 455 70255903 FRAME WELDMENT ADJ FRONT ROLLER 70155200 BUMPER FEET 70020200 BUMPER FEET SCREW 10 32X1 1 4PPH LUBRICATION 70348900 LUBE STICK 70349000 SILICONE PACKET 1 APPLICATION Pediatric Handrails 70226501 455 Pediatric Handrails Page 24
11. address belt slipping and is used in any roller replacement or deck replacement Ensure that the drive belt is properly tensioned before adjusting tread belt tension Belt and deck wear and or lack of lubrication can cause the tread belt to show symptoms similar to loose tread belt tension check these conditions before adjusting tread belt tension Turn treadmill on and adjust speed to 2 mph Walk heavily on the belt pulling slightly against belt movement If hesitation or slip is detected tighten tread belt tension bolts Va turn Repeat until no hesitation or slip is encountered Check at higher speeds Tread belt tension is too tight if the belt feels stiff to touch with no give or the belt groans against the rollers You should be able to insert your hand between the belt and deck palm up almost to your thumb when the belt is at proper tension TEST PROCEDURES INCLINE POTENTIOMETER CALIBRATION TEST This test can correct El Minimum conditions and aid in diagnosis of incline problems with finding zero or target incline 455 Set voltmeter to Ohms Q with treadmill unplugged from wall Place 1 voltmeter lead on pin 3 Blue and 1 lead on pin 2 Orange Check for 800 Ohms 455 In calibration mode before pressing Start the Distance window displays the incline number With the treadmill at zero the number should be between 160 and 180 0 often indicates a wire harness misconnection or failure of signal to panel As the unit inclines duri
12. e Defective Start Capacitor Defective PWM Corrective Action Recommended Tools Test 110VAC outlet for proper Multi meter grounding If unit has not been calibrated Alligator clip calibrate Ensure that incline cables are secure on Verify the lower limit switch is properly Note connected to the PWM All trouble Remove the LLS wire from the PWM and short the two posts of the connector shooting should together with an alligator clip Cycle the be performed in power If the treadmill lowers itself calibration then replace the lower limit switch mode Perform Incline potentiometer calibration procedure page 20 Fagor If incline nut is stripped replace incline Do Up Down command LED s light If No skip to defective PWM section If yes does motor hum with no movement If yes check the leads to the capacitor for breaks if no breaks replace capacitor If No replace PWM If no Up Down LED s light check continuity on data cables If cables are good replace Upper Panel If cables bad Replace data cables Symptom Probable Cause Corrective Action Recommended Tools SPEED FLUCTUATION Perform Push Off Test page 21 Multi meter Speed Fluctuation E2 CAL Due to high friction Perform Amp Draw Test page 17 Socket Set Silicone Lubrication Packet Silicone Lubrication Applicator Speed Fluctuation Check Line voltage for fluctuations Due to Voltage Have customer take corrective action fl
13. e performed in calibration mode Page 14 Symptom Probable Cause Incorrect povver HEART RATE a NOT WORKING ERRATIC READINGS Improper treadmill grounding Improper heart rate receiver mount Defective Chest Strap Defective receiver Radio Frequency Interference Corrective Action Recommended Tools Verify that the treadmill is connected to Multi meter a dedicated line 15 amp circuit and not on an extension cord Move to proper outlet Test 110 VAC outlet for proper ground Heart rate simulator Double sided tape Proper grounding is vitally important Ensure that the pedestal wire harness ground lead is secure Note All trouble shooting should be performed in calibration mode Page 14 Ensure 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 yes replace chest strap Does the heart rate LED on the control panel blink If not then replace the receiver Locate RF sources and use process of elimination Common sources of RF interference are Invisible fences for pets wireless networks cordless phones Cell phones radios home security sensors etc Symptom ELEVATION NOT FUNCTIONAL El ERROR Probable Cause Improper grounding Calibration May cause unit to drift up amp down without command Unit is stuck at full inclin
14. h deflection or correct tension can be verified by twisting the belt almost to a 90 degree position e Remove foreign object Perform the Amp Draw Test page 17 to check for excessive amp draw damage Recommended Tools Note All trouble shooting should be performed in calibration mode Page 14 Symptom TREADBELT STOPS DURING WORKOUT Error Code displays Go to page 3 amp Page 4 Probable Cause Loose safety key connection Belt movement issue Worn Deck Belt Occurs when making changes to speed or elevation Overloaded house circuit Continuity connection to motor Tread belt not centered or obstructed Corrective Action Check safety key to ensure that it is seating properly Check connection sensitivity If treadmill will not reset with cycling the power go to NO BELT MOVEMENT pages 5 amp 6 Perform Belt Deck Wear Test page 21 Perform Amp Draw Test page 17 Apply silicone Replace Deck and Belt May be related to electro static discharge Contact Technical support for assistance Verify the treadmill is on a dedicated circuit with at least a 15 amp breaker Have customer supply a dedicated circuit Reconnect or replace motor wires or connectors Tension tread belt page 19 Center tread belt Remove obstruction Recommended Tools Liquid silicone single use pack Liquid silicone Applicator Multi meter Socket set Note All trouble shooting should b
15. king se Wipe down machine leave it in better condition than you found it True Fitness Treadmill Service Manual SIARI Symptom guide Calibration Procedures Diagnostic Procedures Test Procedures Wiring Diagrams Part Manuals Page 1 Page 2 SYMPTOM GUIDE Error Code Definitions oooooooo Page 3 4 No Belt Movement sis e room oo Page 5 6 Tread Belt Stops During Workout Page 7 Heart Rate Not Working Erratic Readings Page 8 Elevation Not Functional o o o Page 9 Speed Fluctuation E2 Cal ooooooo o Page 10 Speed Fluctuation S4 ES E2 E3 EPROM ak coi sr ra aed Page 11 No Display eduardo Page 12 Circuit Breaker Trips at Start Up Page 13 Calibration Procedures ooooooooooooo o Page 14 Diagnostics ka aaa Page 15 Symptom ERROR MESSAGES SIL LUBE INCLINE Probable Cause Indicates that the accumulated distance is such that the deck needs to be lubed Indicates that the accumulated distance is such that the machine needs to be cleaned Indicates that the accumulated time on the treadmill is such that the motor brushes need to be changed checked Cannot read speed sensor Incline reading not changing when commanded Incline reading has changed without the incline being commanded Maximum or minimum elevation out of calibrated ranges
16. n keys while inserting the safety key In message center window displayed Press Start to Calibrate NOTE In Calibration mode it is possible to check if the speed sensor is reading all the front roller magnets the Met light will light when a magnet is in front of the sensor Speed must be less than 1 mph Press Start Reset to begin calibration Treadmill will elevate and speed up slow down Wait for belt to stop Message center window will display Successful or will indicate error area Remove and re insert safety key Check operation of treadmill DIAGNOSTICS To enter diagnostic mode press and hold the FAST and SLOW buttons while pushing in 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 Speed in mph Error List This is an error log but just a list of errors possible on the unit S1 Lube S2 Clean S3 Motor S4 Sensor El Minimum E2 Overspeed E2 Cal E3 EPROM Remove Safety Key to exit Diagnostics Page 15 TEST PROCEDURES Grounded Outlet Test Amp Draw Test Speed Sensor Test Voltage to Drive Motor Test Drive Motor Test Drive Belt Tension Test Tread belt Tension Test Incline Potentiometer Calibration Test Voltage to Incline Motor Test Belt Deck Wear Test Push Off Test Page 17 Page 17 Page 18 Page 18
17. ng calibration watch the numbers in the Distance window if they do not increase by at least 60 from the zero value an El Minimum error will result Then the zero value may need to be reset to a lovver value If incline potentiometer needs adjustment remove swivel pins and use Up and Down keys to make adjustment See diagram on T 6 VOLTAGE TO INCLINE MOTOR TEST This test is utilized in conditions of No Incline Movement Incline Fluctuation or El Minimum Set voltmeter to AC volts To access incline plug PWM screws may need to be removed Place voltmeter leads across White and Black while pushing UP button 10 VAC indicates normal PWM output 0 VAC signals no output Place voltmeter leads across Red and White while pushing Down button 110 VAC indicates normal PWM output 0 VAC signals no output Page 20 TEST PROCEDURES Belt 7 Deck VVear Test This is a simple physical test to gauge the general level of friction present between the deck and belt While the treadmill is not running inspect the condition of the underside of the tread belt The fabric should be soft and porous If the belt appears glazed replace the belt While the treadmill is not running slide your hand under the belt and feel the surface of the deck The deck should feel smooth with no abrasions or scratches If any abrasions or scratches are found replace the deck Push Off Test Place the machine in Calibration mode elevate to the highest elevation
18. ote All trouble shooting should be performed in calibration mode Page 14 Symptom Probable Cause NO DISPLAY No povver at the 110 VAC outlet No power to the treadmill No power to the control panel Corrective Action Check home circuit breaker Reset as necessary Test for 110 VAC at outlet Identify if outlet is a GFI Note Some brands of GFI outlets are too sensitive for treadmill use Call the help line if encountering GFI issues Check for AC light on PWM See diagram pages 23 Check for 110 VAC at power cord Replace if no power If Yes Check for 110 VAC at tread power switch Replace if no power If Yes Check for 110 VAC at tread circuit breaker Replace reset if necessary If Yes Check for 110 VAC at PWM across ACI AC2 If Yes Replace PWM Check status LED 11 VDC on PWM See diagram pages 23 If not remove fuses and check continuity as replace as needed If Yes Check wire harness connections at PWM and Control Panel Reconnect as needed If Yes Check voltage on harness at panel Refer to wiring diagram for your machine type in wiring diagram section If voltage is present replace panel and recalibrate page 14 If voltage is not present check voltage at PWM If voltage is present at PWM replace pedestal wire harness If 0 VDC replace PWM and recalibrate page 14 Recommended Tools Allen Key set Phillips head screwdriver Multi meter Note All
19. uctuation Note All trouble shooting should be performed in Bad Data Feedback Verify tach feedback accuracy through Calibration out the speed range Mode If inaccurate perform speed sensor test See Page 14 Incorrect Speed Verify correct Speed sensor Gap Sensor Gap Gap should be equal to the thickness of 3 credit cards pressed together approximately 1 8 to Va inch Symptom Probable Cause SPEED FLUCTUATION No Belt Movement S4 Sensor E5 Speed Sensor E2 Overspeed E3 EPROM Error No Intermittent Tach Feedback Overspeed Error E3 EPROM Error Software error during treadmill startup Corrective Action Go to page 5 6 Enter Calibration mode page 14 Verify speed feedback in speed display through out the speed range Speed display should never show 0 mph when belt is moving If no tach feedback is available perform speed sensor test page 18 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 20 Perform speed sensor test page 18 If speed sensor fails adjust gap if still fails replace speed sensor Perform belt deck wear test page 21 If badly worn replace belt and deck Replace PWM Restart unit if error persists replace control panel Recommended Tools Multi meter Socket Set Silicone Lubrication Packet Silicone Lubrication Applicator N
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