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Restart Treadmill, if error persists- replace
control panel.
Recalibrate Treadmill – Page 14.
(If unit loses programs- replace control panel)
17.
Multi-meter
Phillips head
screwdriver
Page 4
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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 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
Note:
All trouble
shooting should
be performed in
calibration
mode.
Page 16
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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.
Pa ge 14
Belt cannot be
moved manually-
foreign object under
belt.
--------
•Remove foreign object.
Perform the Amp Draw Test (page 17) to check
for excessive amp draw damage
Page 6
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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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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.
Pa ge 14
Page 8
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•
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 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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Page 9
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
Page 10
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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 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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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)
•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
present check voltage at PWM. If
voltage is present at PWM replace
pedestal wire harness.
replace PWM and recalibrate (page 14).
If 0 VDC
not
Allen Key set.
Phillips head
screwdriver.
Multi-meter.
Note:
All trouble
shooting should
be performed in
calibration
mode.
Pa ge 14
Page 12
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Symptom Probable Cause Corrective Action Recommended Tools
Support Services 800-883-8783 Mon-Fri 8:30am-5:00pm Central Time Zone Fax: 636-272-7148
CIRCUIT
BREAKER
TRIPS
Possible short in
treadmill wiring.
Motor issues.
Incline motor
drawing treadmill
down
Bad PWM
Too much tension
on belt or
obstruction
Weakened circuit
breaker or High
belt/deck friction
under
belt.
•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
•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.
trip- replace PWM.
--------
--------
Allen Key set
Needle nose pliers
Socket set
Multi-meter
Note:
All trouble
shooting should
be performed in
calibration
mode.
Page 14
Page 13
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.
Page 14
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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
Page 15
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DIAGNOSTICS
TEST PROCEDURES
Grounded Outlet Test Page 17
Amp Draw Test Page 17
Speed Sensor 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
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 17
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
4.0 mph w/out load 3.5-4.0 AMPS AC
4.0 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
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.
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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 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.
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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 18
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 19
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
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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.
Set voltmeter to Ohms (Ω) with treadmill unplugged from wall
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 E1: Minimum.
Set voltmeter to AC volts. To access incline plug, PWM screws may need to be removed.
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455:
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 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.
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 20
Belt / Deck Wear Test
1.
2.
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*. 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 ¾ of the distance of the deck due to higher tension on
the belt.
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.
TEST PROCEDURES
Page 21
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