True Fitness 455 Pediatric, Service Manual

Page 1: ...erve 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 ...

Page 2: ...ould 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 ...

Page 3: ...True Fitness Treadmill Service Manual START Symptom guide Calibration Procedures Diagnostic Procedures Test Procedures Wiring Diagrams Part Manuals Page 1 ...

Page 4: ...ing 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 ...

Page 5: ...out 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 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 brush...

Page 6: ...rtup 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 Support Services 800 883 8783 Mon Fr...

Page 7: ...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 con...

Page 8: ...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 Support Services 800 883 8783 Mon Fri 8 30am 5 00pm Central Time Zone Fax 636 272 7148 Page 6 ...

Page 9: ... 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 ...

Page 10: ...sure 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 Inv...

Page 11: ...tor 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...

Page 12: ...omer 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 inch Multi meter Socket Set Silicone Lubrication Packet Silicone Lubrication Applicator Note All trouble shooting should be performed in Cali...

Page 13: ... 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 per...

Page 14: ...sary 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 prese...

Page 15: ... 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 re...

Page 16: ...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 Support Services 800 88...

Page 17: ...fety 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 ...

Page 18: ...nsor Test Page 18 Voltage to Drive Motor Test Page 18 Drive Motor Test Page 19 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 ...

Page 19: ...es 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 ...

Page 20: ...ressing 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 MT...

Page 21: ... 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 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 t...

Page 22: ...nal to panel As the unit inclines during calibration watch the numbers in the Distance window if they do not increase by at least 60 from the zero value an E1 Minimum error will result Then the zero value may need to be reset to a lower 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 Thi...

Page 23: ... any abrasions or scratches are found replace the deck Push Off Test Place the machine in Calibration mode elevate to the highest elevation 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 I...

Page 24: ...Page 22 Page 22 455 Wiring Diagram ...

Page 25: ...LE DRV MTR 44lbs 70325900 3HP DRIVE MOTOR 10 MPH8 mph DRV BELT 70006300 210J10 POLY V DRIVE BELT ELEVATION MTR 10lbs 70113200 INCLINE MOTOR ELEVATION 70115500 3 8 X 1 1 2 CLEVIS PIN HARDWARE 70116700 1 16 DIA X 1 5 16 COTTER PIN 70118900 TORQUE ARM SWIVEL PIN 70183200 START CAPACITOR FOR INCLINE MOTOR 70013500 SCREW FOR START CAPACITOR LLS 70121000 LOWER LIMIT SWITCH 70125700 LLS SCREW 10X 1 4 701...

Page 26: ...R 70158900 ROLLER BOLT 70159000 5 16 INTERNAL TOOTH LOCK WASHER STRADDLE COVERS 70162101 LT RT STRADDLE COVERS 70030900 3 8 X 1 16 X 108 FT DBL STICK TAPE 70243400 BLUE TAPE 1 2 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 LUBRICATIO...

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