True Fitness 455 Pediatric User manual

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 [phone].
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.
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)
Inspect the belt surfaces, topside should still have
texture for grip, bottom should be porous fabric-
not glazed, smooth or hard.
Inspect deck surface, should be free of scratches,
abrasions or blistering.
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.
Inspect/ adjust tracking of belt.
Vacuum out motor area, being careful not to
damage PWM.
Inspect drive belt for wear and cracking.
Wipe down machine- leave it in better condition
than you found it.

True Fitness
Treadmill Service
Manual
START
Symptom guide
Calibration Procedures
Diagnostic Procedures
Test Procedures
Wiring Diagrams
Part Manuals
Page 1

SYMPTOM GUIDE
Error Code Definitions . . . . . . . . . . . . . . . . . . . . . . . . Page 3, 4
No Belt Movement . . . . . . . . . . . . . . . . . . . . . . . . Page 5, 6
Tread Belt Stops During Workout . . . . . . . . . . . . . . . . Page 7
Heart Rate Not Working / Erratic Readings . . . . . . . . Page 8
Elevation Not Functional . . . . . . . . . . . . . . . . . . . . .. . Page 9
Speed Fluctuation: E2 Cal . . . . . . . . . . . . . . . . . . . . . . Page 10
Speed Fluctuation: S4, E5, E2
E3: EPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . Page 11
No Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 12
Circuit Breaker Trips at Start Up . . . . . . . . . . . . . .. . Page 13
Calibration Procedures . . . . . . . . . . . . . . . . . . . . . . . . Page 14
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Page 15
Page 2

Symptom Probable Cause Corrective Action Recommended Tools
ERROR
MESSAGES:
S1 L LUBE
S2 C CLEAN
S3 M MOTOR
E5 S SPEED
SENSOR
E1 S STALL
E1 I INCLINE
E1 R RANGE
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
•Lube deck with True Fitness liquid
silicone lubricant. Inspect wax bar
assembly on commercial models, if
worn to less that ¼ 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.
Liquid silicone single
use pack
Liquid Silicone
Applicator.
Vacuum
Shop towel
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Symptom Probable Cause Corrective Action Recommended Tools
ERROR
MESSAGES:
(cont’d)
E2 O
OVERSPEED
E2 C
CALIBRATE
E3 E EEPROM
E2 R
RECALIBRATE
Belt speed ramping
too fast.
Micro-controller
cannot adjust belt
speed to target.
Software error during
treadmill startup
diagnostics.
Treadmill has lost
calibration settings.
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)
Multi-meter
Phillips head
screwdriver
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Page 4

Symptom Probable Cause Corrective Action Recommended Tools
NO BELT
MOVEMENT
Treadmill in need of
calibration.
Missing command to
PWM.
Missing/incorrect
voltage to motor.
Damaged motor.
•Run calibration. (page 14)
--------
•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…
Multi-meter
PWM / Motor test
cables
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Note:
All trouble
shooting should
be performed in
calibration
mode.
Page 16

Symptom Probable Cause Corrective Action Recommended Tools
NO BELT
MOVEMENT
(cont’d)
Motor turns but belt
does not.
Belt cannot be
moved manually-
foreign object under
belt.
•Check belt tension.
•Set belt tension to 1/8-inch deflection or
correct tension can be verified by
twisting the belt almost to a 90-degree
position.
--------
•Remove foreign object.
Perform the Amp Draw Test (page 17) to check
for excessive amp draw damage
Note:
All trouble
shooting should
be performed in
calibration
mode.
Page 14
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Page 6

Symptom Probable Cause Corrective Action Recommended Tools
TREADBELT
STOPS
DURING
WORKOUT
Error Code
displays:
Go to page 3 &
Page 4.
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
•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 & 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
Liquid silicone
single use pack
Liquid silicone
Applicator
Multi-meter
Socket set
Note:
All trouble
shooting should
be performed in
calibration
mode.
Page 14
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Symptom Probable Cause Corrective Action Recommended Tools
HEART RATE
NOT
WORKING /
ERRATIC
READINGS
Incorrect power
source
Improper treadmill
grounding
Improper heart rate
receiver mount
Defective Chest
Strap
Defective receiver
Radio Frequency
Interference
•
Verify that the treadmill is connected to
a dedicated line, 15-amp circuit, and not
on an extension cord.
•Move to proper outlet.
•Test 110 VAC outlet for proper ground
--------
•Proper grounding is vitally important.
•Ensure that the pedestal wire harness
ground lead is secure
--------
•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.
Multi-meter
Double sided tape
Heart rate simulator
Note:
All trouble
shooting should
be performed in
calibration
mode.
Page 14
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Page 8

Symptom Probable Cause Corrective Action Recommended Tools
ELEVATION
NOT
FUNCTIONAL
( E1 ERROR)
Improper grounding
/ Calibration
(May cause unit to
drift up & down
without command)
Unit is stuck at full
incline
Defective Start
Capacitor
Defective PWM
•
Test 110VAC outlet for proper
grounding
•If unit has not been calibrated –
calibrate
•Ensure that incline cables are secure on
PWM
--------
•Verify the lower limit switch is properly
connected to the PWM
•Remove the LLS wire from the PWM
and short the two posts of the connector
together with an alligator clip. Cycle the
power. If the treadmill lowers itself
then replace the lower limit switch.
•Perform Incline potentiometer
calibration procedure (page 20)
•If incline nut is stripped- replace incline
nut
--------
•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.
Multi-meter
Alligator clip
Note:
All trouble
shooting should
be performed in
calibration
mode.
Page 14
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Symptom Probable Cause Corrective Action Recommended Tools
SPEED
FLUCTUATION
E2: CAL
Speed Fluctuation
(Due to high friction)
Speed Fluctuation
(Due to Voltage
fluctuation)
Bad Data Feedback
Incorrect Speed
Sensor Gap
•Perform Push Off Test (page 21)
•Perform Amp Draw Test (page 17)
--------
•Check Line voltage for fluctuations.
•Have customer take corrective action.
--------
•Verify tach feedback accuracy through
out the speed range.
•If inaccurate perform speed sensor test
(page 18)
--------
•Verify correct Speed sensor Gap.
•Gap should be equal to the thickness of
(3) credit cards pressed together
(approximately 1/8 to ¼ inch)
------
Multi-meter
Socket Set
Silicone Lubrication
Packet
Silicone Lubrication
Applicator
Note: All
trouble shooting
shou ld be
performed in
C alibration
M ode :
See Page 14
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Page 10

Symptom Probable Cause Corrective Action Recommended Tools
SPEED
FLUCTUATION
S4: Sensor
E5: Speed Sensor
E2: Overspeed
E3: EPROM Error
No Belt Movement
No/Intermittent
Tach Feedback
Overspeed Error
E3: EPROM Error
Software error
during treadmill
startup
•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.
Multi-meter
Socket Set
Silicone Lubrication
Packet
Silicone Lubrication
Applicator
Note:
All trouble
shooting should
be performed in
calibration
mode.
Page 14
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Symptom Probable Cause Corrective Action Recommended Tools
NO DISPLAY No power at the 110
VAC outlet.
No power to the
treadmill.
No power to the
control panel.
•
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 AC1 & 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).
Allen Key set.
Phillips head
screwdriver.
Multi-meter.
Note:
All trouble
shooting should
be performed in
calibration
mode.
Page 14
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Page 12

Symptom Probable Cause Corrective Action Recommended Tools
CIRCUIT
BREAKER
TRIPS
Possible short in
treadmill wiring.
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
•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.
Allen Key set
Needle nose pliers
Socket set
Multi-meter
Note:
All trouble
shooting should
be performed in
calibration
mode.
Page 14
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Page 14
Calibration Procedures
455 Calibration
Enter Calibration Mode by holding the Up and Down 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.
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Page 15
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
E1: Minimum
E2: Overspeed
E2: Cal
E3: EPROM
Remove Safety Key to exit Diagnostics

TEST PROCEDURES
Grounded Outlet Test Page 17
AmpDrawTest Page17
Speed Sensor Test Page 18
Voltage to Drive Motor Test Page 18
DriveMotorTest Page19
Drive Belt Tension Test Page 19
Tread belt Tension Test Page 19
Incline Potentiometer Calibration Test Page 20
Voltage to Incline Motor Test Page 20
Belt / Deck Wear Test (Push Off Test) Page 21
Page 16

TEST PROCEDURES
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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 will 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 from MTR1 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
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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 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