True Fitness 350-750 User Manual

True Fitness Service

Manual

Treadmills

Models 350-750

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

Page 2

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .

 No Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 12

 Circuit Breaker Trips at Start Up . . . . . . . . . . . . . .. . Page 13

 Soft Select Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . Page 14, 15

 Calibration Procedures . . . . . . . . . . . . . . . . . . . . . . . . Page 16

 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Page 17

Page 11

Symptom Probable Cause Corrective Action Recommended Tools

ERROR

MESSAGES:

S1 L LUBE

S2 C CLEAN

S3 M MOTOR

E5 S SPEED

E1 S STALL

E1 I INCLINE

E1 R RANGE

SENSOR

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 thickness­replace 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

Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: [phone]

Page 3

Symptom Probable Cause Corrective Action Recommended Tools

E2 O

ERROR

MESSAGES:

(cont’d)

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
Perform Belt / Deck Wear Test – Page 24.

Calibrate Treadmill – Page 16.
See appropriate Symptom Guide – pages 10-11.

Restart Treadmill, if error persists- replace
control panel.

Recalibrate Treadmill – Page 16.
(If unit loses programs- replace control panel)

20.

Multi-meter
Phillips head
screwdriver

Page 4

Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: [phone]

Symptom Probable Cause Corrective Action Recommended Tools

MOVEMENT

NO BELT

Treadmill in need of
calibration.

Missing command to
PWM.

Missing/incorrect
voltage to motor.

Damaged motor.

• Run calibration. (page 16)

--------

• 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 16)

• 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

Note:

All trouble
shooting should
be performed in
calibration
mode.
Page 16

Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: [phone]

Page 5

Symptom Probable Cause Corrective Action Recommended Tools

NO BELT

MOVEMENT

(cont’d)

Motor turns but belt

does not.

• 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.

Note:

All trouble
shooting should
be performed in
calibration
mode.
Page 16

Belt cannot be

moved manually-

foreign object under

belt.

--------

• Remove foreign object.

Perform the Amp Draw Test (page 20) to check

for excessive amp draw damage

Page 6

Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: [phone]

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 24).

• Perform Amp Draw Test (page 20).

• 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 22)

• 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 16

Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: [phone]

Page 7

Symptom Probable Cause Corrective Action Recommended Tools

•

NOT

HEART RATE

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 16

Page 8

Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: [phone]

Symptom Probable Cause Corrective Action Recommended Tools

•

ELEVATION

FUNCTIONAL

( E1 ERROR)

NOT

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 16)

• 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 16

Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: [phone]

Page 9

Symptom Probable Cause Corrective Action Recommended Tools

g

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 24)

• Perform Amp Draw Test (page 20)

--------

• 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 21)

--------

• 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 shootin
should be
performed in
Calibration
Mode:
See SG-12

Page 10

Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: [phone]

Symptom Probable Cause Corrective Action Recommended Tools

SPEED

FLUCTUATION

S4: Sensor
E5: Speed Sensor

E3: EPROM Error

E2: Overspeed

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 16)

• 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 21).

• 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

22)

• Perform speed sensor test (page 21) If

speed sensor fails adjust gap, if still
fails-replace speed sensor.

• Perform belt / deck wear test (page 24)

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 16

Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: [phone]

Page 11

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 23-30)

• 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 23-30). 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 16). If voltage is
present check voltage at PWM. If
voltage is present at PWM replace
pedestal wire harness.
replace PWM and recalibrate (page 16).

If 0 VDC

not

Allen Key set.

Phillips head
screwdriver.

Multi-meter.

Note:

All trouble
shooting should
be performed in
calibration
mode.
Page 16

Page 12

Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: [phone]

Symptom Probable Cause Corrective Action Recommended Tools

Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: [phone]

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 22).

• 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

• Check for correct tension adjustment

(page 22)

• Check for obstruction- remove

obstruction.

• Perform AC Amp Draw Test (page 20)

at circuit breaker.

• If draw is less than 15 amps

continuously - replace breaker.

• Perform Amp Draw test (page 20) If

Amp draw is higher than recommended

try push test (page 24) procedure.

trip- replace PWM.

--------

--------

Allen Key set

Needle nose pliers

Socket set

Multi-meter

Note:

All trouble
shooting should
be performed in
calibration
mode.
Page 16

Page 13

Symptom Probable Cause Corrective Action

Soft Select

Malfunctions

Control Panel Issues

Mechanical Issues

Incorrect/ Missing
Count Values

Defective Motor/
Start Capacitor

• Enter calibration mode

• Is there a count value displayed in the distance window? If No

replace control panel. If yes- continue to next step.

--------

• Press and hold the softer button, release. Press and hold the firmer

button to detect carriage movement in both directions. If the carriage
cannot go full range from –220 and consistently stops in the same
place, check for mechanical binding. Inspect the under pan for
damage or areas that cause mechanical binding. Also inspect the
carriage track in the side frame for binding. If the carriage cannot
move to its full range and back in the time limit, check for
mechanical binding.

• If the carriage is not

screws holding the drive shaft to the motor shaft.

• Threaded shaft turns when commanded but the pulse count does not

display/ or does not change. Physically check the hex cam located at
the front of the shaft and on the motor shaft. Hex cam should be
firmly attached. If hex cam slides freely super gluing it back onto the
shaft can repair it.

• Hex cam moves but counter does not register. Ensure that the micro

switch is properly adjusted and the switch is being made when the
hex cam points press against the roller.

• Disconnect the cable at J4 and check for continuity on cable. Cable

should have continuity if the switch roller is in a flat area of hex cam.
If no continuity- replace cable. If good continuity, place cable back
on J4 and continue

• While in calibration mode place the multi-meter leads on J4 and

check for 5 Volts. If no 5 Volts- replace board.

• If command and count data/voltage are present and Led 1 indicates

AC voltage is good but soft select motor does not respond. Set
probes on TP 8 and TP3, press soft command (with soft select limit
switch not activated) result should be 120 VAC. Set probes on TP8
and TP2 and press firm command (with soft select limit switch not
activated) result should be 120 VAC. If no 120 VAC on either test
point- replace soft select board. If voltage is correct- continue to next
step.

• In calibration mode, place red lead on the larger red wire and post on

the start capacitor of the soft select system and the black lead on the
common black lead, press firm- the result should be 120 VDC. Next
place the white lead on the larger white wire and post on the start
capacitor of the soft select system and the black lead on the common
black lead; press soft- the result should be 120 VDC. If voltage is
correct- replace the motor. If voltage is incorrect- replace the start
capacitor.

moving and the motor is turning, check the set

--------

--------

Page 14

Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: [phone]

Symptom Probable Cause Corrective Action

Soft Select
Malfunctions
(continued)

AC Power Issues

Wire Harness

• Is AC power LED D3 lit?

• No- check F1 fuse. If F1 is good check for AC voltage between TP1

and TP5. If fuse and voltage are good- replace the board.

--------

• Yes- While in calibration mode Press the Softer button- LED D1

should light, press the Firmer button- LED D2 should light. If the
lights respond to the button then command is being sent from the
upper board and received at the soft select board. If lights do not
respond check or replace 6-pin data cable, if cable is ok- replace
upper panel.

-------

SOFT SELECT BOARD

ILLUSTRATION

Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: [phone]

Page 15

SS 100 PWM (5-xxxxx to 6-79999 serial numbers)

Entering Engineering Mode:

With safety key in, power up unit while holding Grade Up and Grade Down keys.

Incline will reset to zero.

Mode 1: Max Speed

Press Select/Enter- 01 (C1 for 450) appears in Distance.
Adjust speed using Fast and Slow buttons until 10 or 12 mph

Verify speed by counting belt revolutions: 10mph= 102 Belt revs/per min. 12mph= 121 Belt revs/per min.

Press Start/Reset to save max speed, wait for belt to stop.

Mode 2: Speed Table

Press Select/Enter-02 (C2 for 450) appears in Distance
Press Start/Reset to set speed table. Treadmill will speed up and slow down on its own. Wait for belt to

stop.

Mode 3: Incline

Press Select/Enter- 03 (C3 for 450) appears in distance
Press Grade Up to upper incline limit, then back down slightly
Save upper limit by pressing Start/Reset

Turn treadmill off and then back on and check operation

SS90 Calibration (6-8xxxx serial numbers and after)

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.

Page 16

Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: [phone]

Calibration Procedures

(

)

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

Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: [phone]

DIAGNOSTICS

Available only in SS90 Machines

Page 17

Page 18

TEST PROCEDURES

 Grounded Outlet Test Page 20

 Amp Draw Test Page 20

 Speed Sensor Test Page 21

 Voltage to Drive Motor Test Page 21

 Drive Motor Test Page 22

 Drive Belt Tension Test Page 22

 Tread belt Tension Test Page 22

 Incline Potentiometer Calibration Test Page 23

 Voltage to Incline Motor Test Page 23

 Belt / Deck Wear Test (Push Off Test) Page 24

Page 19

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)

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

DC AMP DRAW PROCEDURE

Page 20

Place 1 lead in the ground plug
A properly grounded outlet will read 110 VAC

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

5.0 mph w/out load 3.5-4.0 AMPS AC

5.0 mph with load 5.0-7.0 AMPS AC

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

5.0 mph w/out load 5.0-5.5 AMPS DC

5.0 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.

Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: [phone]

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.

SS100 (Serial numbers 5-xxxx to 6-7999)

Set voltmeter to Volts DC. Treadmill power on speed and speed at 0mph
Attach voltmeter leads across outside 2 contacts at P2 on PWM
With magnet in front of sensor, 0 VDC
With no magnet in front of sensor, 3.0 VDC

SS90 (Serial numbers 6-8000 and above)

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

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.

Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: [phone]

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

TEST PROCEDURES

Page 21

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

DRIVE BELT TENSION TEST

This test is used in front roller replacement and in conditions of belt slipping.

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 to loose tread belt tension- check these
conditions before adjusting tread belt tension.

Turn treadmill on and adjust speed to 2 mph

If hesitation or slip is detected, tighten tread belt tension bolts ¼ turn

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.

Page 22

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

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

Walk heavily on the belt pulling slightly against belt movement

Repeat until no hesitation or slip is encountered. Check at higher speeds

Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: [phone]

TEST PROCEDURES

INCLINE POTENTIOMETER CALIBRATION TEST

This test can correct E1: Minimum conditions and aid in diagnosis of incline problems with finding zero or
target incline.

SS100 and SS90
Set voltmeter to Ohms (Ω) with treadmill unplugged from wall

SS90 Only: In calibration mode before pressing Start, the Distance window displays the incline number.

If incline potentiometer needs adjustment, remove swivel opines and twist incline motor shaft by hand for
SS100 or use Up and Down keys for SS90. (See diagram on T-6)

VOLTAGE TO INCLINE MOTOR TEST

This test is utilized in conditions of No Incline Movement, Incline Fluctuation, or E1: Minimum.

Set voltmeter to AC volts. To access incline plug, PWM screws may need to be removed.

Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: [phone]

Place 1 voltmeter lead on pin 3 (Blue) and 1 lead on pin 2 (Orange)
Check for 800 Ohms

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 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 rest to a lower value.

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

TEST PROCEDURES

Page 23