JOHNSON HEALTH TECH. Matrix T101-05 User manual

TREADMILL BELT SPEED
TROUBLESHOOTING GUIDE
FOR
T101-05, T101-07, TR5, TR3 TREADMILLS
JOHNSON HEALTH TECH -TCMT
8/1/2022
V1

TABLE OF CONTENTS
Belt Speed Troubleshooting
2
Troubleshooting Guide
INTRODUCTION ....................................................................................................................... 3
INITIAL C HECKLIST ............................................................................................................................................................ 3
FLOWCHART ............................................................................................................................ 5
ROOT CAUSES .......................................................................................................................... 7
MIS-ADJUSTED OR FAULTY BELT SPEED SENSOR ..................................................................................................................... 8
HIGH BELT/DECK FRICTION TRIGGERING OVERCURRENT PROTECTION .......................................................................................... 9
CELL PHONE OR OTHER RF CAUSING CONSOLE GLITCHES ........................................................................................................ 10
WORN OR DAMAGED MOTOR COMMUTATOR/BRUSHES OR OTHER MOTOR FAILURE .................................................................... 11
MOTOR CONTROL BOARD (MCB) FAILURE ........................................................................................................................ 13
DAMAGED CONSOLE CABLE/CONSOLE CABLE TOO SHORT (AFTER INCLINE)................................................................................. 14
LOOSE WIRE CONNECTION .............................................................................................................................................. 15
INTERMITTENT EMERGENCY STOP CONNECTION .................................................................................................................. 16
DAMAGE TO REAR ROLLER .............................................................................................................................................. 16
LOW TENSION ALLOWING BELT SLIPPAGE OR DRIVE BELT DAMAGE ........................................................................................... 16
TREADMILL OR PANEL OVERCURRENT BREAKER OPENING ....................................................................................................... 17
INTERMITTENT STUCK KEY ON CONSOLE ............................................................................................................................. 19
TREADMILL ERROR CODES ............................................................................................................................................... 19
E-1 ERROR CODE .............................................................................................................................................................................................. 19
E-2 ERROR CODE .............................................................................................................................................................................................. 20
E-B ERROR CODE........................................................................................................................................................... 20
UPDATING CONSOLE SOFTWARE ........................................................................................... 20
CALIBRATING THE SPEED SENSOR ...........................................................................................20
INSPECTING AND CLEANING THE MOTOR (TECHNICIAN ONLY) .............................................. 21

FLOWCHART
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Belt Speed Troubleshooting
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Troubleshooting Guide
INTRODUCTION
There are many possible root causes of belt speed control issues on Retail/IPO treadmill models. This
document will help diagnose those issues and suggest possible corrective actions – settings,
adjustments, or part replacement.
Initial Checklist
Before concluding hardware failure is the root cause, rule out the following.
1. Check that the software is up to date. Software download files and instructions are available
here: https://support.horizonfitness.com/hc/en-us/articles/5149009125005-Software-and-
Firmware-Updates
2. The treadmill must be
connected to a ‘dedicated 15-
amp circuit’ by itself. – no other
appliances or devices should be
powered from the same
breaker the treadmill is
powered from. Confirm that
the outlet is not a GFCI or AFCI
outlet.
3. Treadmills should not be
connected to power with an extension cord, power strip, surge protector, or any other device.
Remove any of these and plug the treadmill directly into the wall power outlet before
proceeding. If an extension cord must be used, it must be as short as practicable, and the
conductors should be 14 gauge or better (a lower gauge number is better). Do not use any
extension cord over 25’ long.
4. Remove the Safety Key/Emergency Stop and confirm that the metal tab & magnets are clean.
Orient it correctly and re-insert into the socket. It should remain seated in place, with minimal
free-play or looseness.
5. The belt & deck must be lubricated after first time set-up and periodically lubricated every 3
months/150 miles. If this hasn’t been done routinely, suspect High belt/deck friction triggering
overcurrent protection.
6. Some workouts include automatic speed changes. When these workouts end the belt may stop,
possibly without obvious notification. Confirm that when the speed issue occurs, the workout
itself isn’t the cause.
7. A pinched or damaged console cable can cause erratic and difficult-to-diagnose behavior.
Always check the console cable thoroughly, especially at the top and bottom of the mast where
it can be kinked, crushed, or partially cut during final assembly. See additional detail in
Damaged console cable/console cable too short (after incline)
8. If the treadmill feels like it’s not running at the correct speed consistently, it may need to be
calibrated. See instructions for how to do that see here (T101, TR5, TR3 only).

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Belt Speed Troubleshooting
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Troubleshooting Guide
9. When the STOP button is pressed, the treadmill may enter a PAUSE state. Pressing START again
can cause the belt to return to whatever speed it was set to when STOP was first pressed.
10. When starting the running belt from a stopped/paused state, stand on the siderails until the belt
reaches a steady speed. The belt can fail to start with a heavy load, or ‘overshoot’ the
commanded speed when accelerating with a load.
With these factors ruled out, use the following flowchart to narrow down the possible root causes of the
belt speed control issue.

FLOWCHART
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Belt Speed Troubleshooting
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Troubleshooting Guide
Belt speed control
issue reported
Does the
console power
on at all?
Yes
Update the console
software to the
latest version.
No
• See Power or Console
troubleshooting
• MCB Fault/failure
• Damaged console cable
• Loose wire connection
• Failed MCB power circuit component
What does the
console do
when the belt
Belt fully stopped
on its own
stops?
“Stop” button or
Click here Emergency Stop
When the speed
issue occurs, how
best do you safely
stop the treadmill
belt?
Turns off
completely
Continues
counting
Time/distance
“Stop” button or
Emergency Stop didn’t stop belt;
Have to switch off power
or pull power cord
‘Ticking’ or
repetitive clicking
from the motor
compartment?
Yes
No
Inspect the console
cable for damage.
Inspect the console
cable connections.
• High belt/deck friction triggering
overcurrent protection
• Cell phone or other RF causing
console glitches
• Worn or damaged motor
commutator or brushes/Other motor
failure
• Damaged console cable
• Damage to rear roller
• Cell phone or other RF causing
console glitches
• Intentional or Intermittent E-stop
disconnection
• Loose wire connection
• Damaged console cable
• Cell phone or other RF causing
console glitches
• MCB Fault/failure
• Worn or damaged motor
commutator or brushes/Other
motor failure
• Damaged console cable
• Intermittent stuck key on
console
• Cell phone or other RF causing
console glitches
• Worn or damaged motor
commutator or brushes/Other motor
failure
• Console cable too short (after incline)
• MCB/motor fault or belt friction
causing breaker to open (15A
dedicated circuit?)
• Loose wire connection
• Damaged console cable
Flowchart
Resets to idle/P1 or
Dashes on display or
E# error displayed
workout includes
Other possible causes of speed issues to consider:
• Belt speed calibration incorrect/not done
• Stop operates as PAUSE when pressed once –
resumes at earlier speed
• Belt 'overshoots' expected speed when
accelerating/starting from Pause – this is
common & normal, especially with no user on
belt
• End of workout/workout includes automatic
speed changes
• End of workout/
automatic speed changes
• Intentional or Intermittent E-stop
disconnection
• Errors from UCB software
• Belt stop after detecting other fault
(Error code?)
• End of workout/workout includes
automatic speed changes

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Troubleshooting Guide
Is the speed issue ‘random’/
’erratic’/’difficult to reproduce’?
No
Record any details the Owner can provide about the belt speed control
issue:
• How to cause it to occur
• How to stop the belt
• How to restore normal function
• What did the console do when the speed issue occurs
• Did the commanded speed on the console change
• What speed was the belt moving at, and what did it change to
• How many minutes & miles into the workout when the speed issue occurred
• Mis-adjusted or faulty belt speed sensor
• High belt/deck friction triggering overcurrent
protection
• Cell phone or other RF causing console glitches
• Loose wire connection
• Damaged console cable
• Intermittent e-stop connection
• Intermittent stuck key on console
Yes
No
Yes
No
Yes
Continue from here
Does the belt appear to slow down/stall with a
user footfall?
Does the user have to command a high speed
to get the belt moving faster than ~3mph?
• Mis-adjusted or faulty belt speed sensor
• Mis-adjusted or faulty belt speed sensor
• Low tension allowing belt slippage
• Drive belt damage or tension
• Damage to rear roller

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Belt Speed Troubleshooting
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Troubleshooting Guide
Root Causes
All known possible root causes of belt speed control faults, in order of frequency:
1. Mis-adjusted or faulty belt speed sensor
2. High belt/deck friction triggering overcurrent protection
3. Cell phone or other RF causing console glitches
4. Worn or damaged motor commutator/brushes or other motor failure
5. Motor Control Board (MCB) failure
6. Damaged console cable/Console cable too short (after incline)
7. Loose wire connection
8. Intermittent Emergency Stop connection
9. Damage to rear roller
10. Low tension allowing belt slippage or Drive belt damage or tension
11. Treadmill or panel overcurrent breaker opening
12. Intermittent stuck key on console
13. Treadmill error codes

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Belt Speed Troubleshooting
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Troubleshooting Guide
Mis-adjusted or faulty belt speed sensor
T101-05, T101-07, TR5, TR3
The position of the magnetic speed sensor is extremely sensitive on the models listed above. Being too
close or too far away from the magnet on the front roller can cause several possible indications:
• ‘Jerky’ or ‘surging’ belt speed
• Must command high speed (~6-8mph) before belt will move faster than moderate (~2-3mph)
speed
• Error codes
• After calibration, the unit may function better but will show hesitation again after cycling power
To diagnose & correct this issue:
1. Disconnect power and remove the motor cover. Inspect the speed sensor, located adjacent to
the front roller on the operator’s left side. There should be approx. 5mm/0.2” gap between the
sensor face and magnet on the front roller/pulley. The magnet on the roller should pass as near
as possible to the center of the sensor. Adjust the sensor as necessary to meet this spec.
See the service bulletin Erratic Treadmill Speed on the T101, TR3, or TR5 product page.
2. Confirm that the speed sensor is firmly connected to the MCB: 3-wire cable adjacent to the 9-
wire console cable, on top of the MCB. Check the cable routing and that there is no damage to
the cable.
3. Reinstall the motor cover and restore power. Complete the following steps to confirm the
speed sensor is working properly:
a. With the treadmill idle, hold Speed Down and Incline Up for ~3 seconds to access
Engineering Mode.
b. Use the Speed Up or Down buttons to navigate to ENG1 and press Enter.
c. Step onto the running belt and place one hand on each side of the handlebars. Lean
forward in a sled push stance. Push one foot backwards at a time to rotate the running

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Belt Speed Troubleshooting
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Troubleshooting Guide
belt. The right display should show a number that increases as you push faster and 0
when the belt is stopped—this is the output of the speed sensor.
d. While standing on the side rails, press Speed Up to increase the number in the left
display—this is the commanded speed signal. Press Start and the belt will start moving
slowly. By setting the left display to the following values, the right display should read
as indicated in the chart below:
Belt speed should change accordingly with the commanded
speed. The right display should read out within 10% of these
values and remain steady when the speed is not changing—
remaining at 0 or fluctuating as little 10 points up or down could
indicate that the speed sensor is out of adjustment, disconnected,
or faulty.
*These values were measured on T101-05s with console software version 1.xx. Values may be different
in different console software versions.
High belt/deck friction triggering overcurrent protection
T101-05, T101-07, TR5, TR3
The MCB measures the motor current and triggers self-protection when the motor is drawing too much
current. When this occurs, the belt will come to a stop but the console will continue operating the
workout – counting time & distance and appearing to respond to user controls. Cycling power (switch
on the front base or disconnecting the power cord) is necessary to restore normal function.
This issue can be difficult to diagnose because it may happen sporadically, depending on user weight,
speed, incline, temperature, distance/time into workout, and many other factors.
To diagnose & correct this issue:
1. When the issue occurs, remove the motor cover, and examine the MCB without disconnecting
power or turning the power switch off. If there is a RED LED illuminated on it, the MCB is in
overcurrent self-protection. Reinstall the motor cover and cycle power. Note: This LED will
reset when power is cycled. Confirm that the power remains on after the belt stop issue
occurred when making this check.
2. Lubricate the belt & deck according to the instructions included in the treadmill Owner’s
Manual.
3. If the issue re-occurs, the belt & deck are likely worn beyond lubrication resolving. Replace the
belt & deck.
4. If the issue continues to re-occur, the motor or MCB have likely been stressed to failure.
Replace the motor first. If issues continue to occur, replace the MCB.
TR5, TR3
TM1013, TM1012
T101-05*
TM486, TM743
Left
Right
Left
Right
1000
60
1000
81
2000
195
2000
217
3000
315
3000
342
4000
437
4000
466
5000
559
5000
591

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Cell phone or other RF causing console glitches
T101
Modern 4G & 5G cell phones can transmit with enough power to potentially cause console software
glitches. Additionally, other transmitters have been observed to cause intermittent issues.
Commonly, this will cause console display glitches – flickering, blinking, or displays off. Causing the
running belt to stop completely, slow down/stop and then attempt to return to the expected speed, or
speed up from the expected speed to some higher speed momentarily has also been observed.
Additionally, the Stop button & speed controls on the console may not respond as expected.
This issue is difficult to diagnose with certainty, and frequently occurs intermittently or sporadically.
Best practices to prevent issues include:
1. Update to the latest available software version
2. Install the EMI Protection kit (ZMS4011056), following instructions in the EMI Shielding Kit for
Speed Issues service bulletin (available on the T101-5 product page).
3. Ensure any cell phones near the console are in airplane mode.
4. Don’t place a cell phone on the lower rack of the console – the upper reading rack is safer if your
console has one.
Very similar symptoms can be found with an Emergency stop key making intermittent connection. See
further details here.

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Worn or damaged motor commutator/brushes or other motor failure
T101-05, T101-07, TR5, TR3
With the electrical power present in and many moving parts that make up the belt drive motor, normal
wear can cause it to fail. This wear is accelerated by many factors including user weight, speed, incline,
belt & deck friction, drive belt alignment, and lack of routine cleaning. Additionally, there are brushes
within the motor that will wear out, and the commutator may need to be cleaned.
If the belt does not start moving due to a motor failure, the console may display an E-1 error code.
To diagnose & correct this issue:
1. Disconnect power and remove the motor cover. Stand on a siderail and use your foot to rotate
the belt in the normal forward direction. Listen to the motor – any grinding, rubbing, or scraping
noises from the motor are indicators of a motor issue.
a. Consider that noises from other areas of the treadmill (drive belt, rollers, belt edges,
etc.) may indicate adjustments may need to be made, such as running belt tension &
centering, drive belt tracking, etc.
2. Inspect the motor leads (red, black, and green wires connected to the motor) for any signs of
damage. Replace the motor if any damage is found.
3. If a multimeter is available: Conduct the following tests.
a. Disconnect the red & black motor leads from the MCB and connect the leads to the
multimeter. Polarity isn’t important for this test.
b. With the multimeter set to measure resistance, the motor should have a resistance of
0.9-1.6 ohms. Moving the belt slightly will cause this measurement to change
dramatically – do not take this measurement while standing on or moving the belt, as
any disturbance to the motor will cause this measurement to be unstable and could
damage your meter.
c. With the multimeter set to measure DC volts, turn the motor flywheel or move the belt
(no faster than a walking pace on the belt). Turning the motor one direction should
cause a positive voltage reading; turning the motor the other direction should cause a
negative voltage reading. Both DC voltage readings should increase in magnitude when
the motor is turned faster – specific readings cannot be noted without a repeatable way
to measure/control how fast the motor is being turned.
If either of these measurements fail these checks, the motor will need to be serviced or
replaced. Refer to Inspecting and cleaning the motor for additional service information.
If both tests pass, suspect the MCB.
4. If no multimeter is available: Conduct the following tests.
a. Disconnect the red & black motor leads from the MCB.
b. Acquire a battery, nominally 9-20 volts (for example 9 volt cell, cordless tool battery, car
battery). Connecting the motor leads to the battery terminals, the motor should turn
slowly (1-4 MPH). Do not stand on the belt for this test. Note – some cordless tool
batteries have multiple terminals; confirm that the motor leads are connected to
terminals where battery voltage is present.
c. Have a helper turn the motor by hand, either directly by the motor flywheel or by
pushing the belt. Touch & hold the metal spade connectors on the motor leads
together while turning the motor is being turned - there should be a noticeable ‘braking’
force with the motor being harder to turn when the spade connectors are touching.

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Troubleshooting Guide
If the motor does not move when a battery is connected and no ‘braking’ force is felt connecting
the leads to one another, the motor will need to be serviced or replaced. Refer to Inspecting
and cleaning the motor for additional information.
If both of these tests pass, suspect the MCB.
5. See this addendum for additional details regarding inspection of the motor commutator and
brushes.

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Motor Control Board (MCB) failure
T101-05, T101-07, TR5, TR3
The MCB takes electricity from the outlet and converts it to power for the console, as well as translates
control signals from the console to drive the belt & incline motors.
Issues caused by MCB faults can present in many ways, from belt speed control issues, incline issues,
console power issues, or causing the treadmill or electrical panel breaker to open.
To test the MCB output to the belt drive motor (multimeter required):
1. Disconnect power and remove the motor cover. Connect the leads of the multimeter to the red
& black leads from the motor, connected to the MCB (multimeter leads can be inserted into the
back of the plastic boot protecting the motor lead terminals). Set the meter to measure DC
volts (auto-ranging or 200 VDC range).
2. Reapply power to the treadmill and start a manual workout. Do not stand or walk on the belt
for this test – stand on the siderails or off the treadmill entirely. At the following commanded
speeds, the multimeter should read approximately (+- 10%) the voltage noted below.
Model
Commanded
speed (MPH)
Motor DC
volts
T101, TR5, TR3
0.5
3
6
10
8.5
34.7
65.8
107.3
Exact measurements will vary due to different calibration values and slight variations in motor
construction but should be close. If the MCB can produce these voltages to the motor and
speed control issues continue to appear, suspect the motor.
3. In some cases, it may not be possible to get the belt to move in a normal workout (E-1 error
appears on console during a workout, for example). Hardware test mode can be used to work
around possible issues.
a. With the treadmill idle, hold Speed Down and Incline Up for ~3 seconds to access
Engineering Mode.
b. Use the Speed Up or Down buttons to navigate to ENG1 and press Enter.
c. Press Go, and the belt may start moving slowly. Use the Speed Up keys to increase belt
speed and the commanded speed signal in the Left display.
Model
Commanded speed setting
(Left display)
Motor
DC volts
T101
1000
2000
3000
4000
5000
11.6
26.2
39.4
52.4
65.4
d. Cycle power to exit Hardware test mode.

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Troubleshooting Guide
Damaged console cable/console cable too short (after incline)
T101, TR5, TR3
The console cable is the link between the console and MCB, carrying console power and control signals
between the different parts of the treadmill.
The console cable can be damaged in numerous ways: pinched or crushed by incorrect routing, kinked
around sharp bends, or knicked when a fastener is tightened into it, for example. Damage to the console
cable can cause any number of faults, including speed control, incline, or power issues. This root cause
can be difficult to diagnose, as the symptoms may appear to change randomly or only appear
intermittently. Additionally, some treadmills are assembled in such a way that the console cable can pull
free from the MCB at high incline, immediately stopping the belt and powering off the console.
Fortunately, close physical examination of the cable is usually able to locate damage, and with a
replacement console cable, repair is straightforward.
T101 treadmill models use a 9-wire console cable. The following table describes the signal conducted on
each wire, and possible symptoms that may appear with intermittent or severed continuity of that wire.
Pin
Number
Signal
label
Function & Signal
direction
Symptom if cut/damaged
1 VCC DC 12V power supply
MCB to console
No console power
If intermittent, console may power down and
stop any ongoing workout
2 SGND
GROUND signal
MCB to console
No console power
If intermittent, console may power down and
stop any ongoing workout
Possible erratic speed or incline
3 COUNT Incline position sensor
MCB to console
Possible erratic incline movement
Incline motor may move deck down past the
limit switch, requiring maintenance to correct
4 UP
Incline up signal
Console to MCB Incline won't move up
5 ZERO Incline motor zero switch
MCB to console
Possibly no incline movement
Incline motor may move deck down past the
limit switch, requiring maintenance to correct
6 DOWN Incline down signal
Console to MCB Incline won't move down
7 RPM Belt speed sensor signal
MCB to console
Likely E-1 error code if enabled
Possibly 'ticking' sound from MCB
Possibly unexpected speed change or stop
8 MR_SW E-Stop signal
Console to MCB
No belt movement or unexpected stop
Likely E-1 error code if enabled
Possibly 'ticking' sound from MCB
9 UPPWM PWM (speed) signal
Console to MCB
No belt movement or unexpected stop
Likely E-1 error code if enabled

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Troubleshooting Guide
To inspect the console cable:
1. Disconnect power and remove the motor cover. Locate the socket on the MCB where the
console cable connects and ensure that connection is secure.
2. Trace the console cable along its routing, paying special attention to any irregularities in the
shape or size of the cable. Common areas where damage occurs are the base of the mast where
the console leaves the motor compartment and turns up the mast, and the top of the mast
where console mount bolts thread in. Removing one of the upper mast shrouds may aid this
inspection.
3. Inspect any connectors where different sections of the console cable connect – typically there
may be one at the top and bottom of one of the masts. Pull these connectors apart (being
careful to open any locking tabs) and inspect that there are no bent pins (see image below) or
debris in a socket. Carefully reassemble each connector.
4. If a multimeter is available: Testing the console cable can also be done with a multimeter.
Disconnect the console cable from the MCB and UCB (opening the console may be required to
access the top end of the cable). Set the meter to measure continuity and test each conductor
of the console cable end to end and for continuity to one another. Each conductor should have
continuity, with no continuity between any of the conductors.
If any damage is found, replace the entire console cable. It can be challenging to properly route the
console cable during replacement – be especially mindful of where damage was found on the existing
console cable and consider routing options that avoid or prevent that damage in the future. A video of
how to inspect your T101 communication cable can be found here. A video showing how to replace the
communication cable in the T101 is also available.
Loose wire connection
Any treadmill model:
Electrical connectors can loosen and disconnect over time or with use. While a fully disconnected wire
will usually cause some portion of the treadmill to repeatably not work at all, a loose or intermittently
connected connector can cause unpredictable or erratic behavior.
Troubleshooting & diagnosing loose connectors frequently involves manually checking each connector.
Many connectors support multiple wires, so disconnecting the connector and inspecting each terminal
may be required.
Some connectors where substantial current is conducted may have visible signs that a good electrical
connection is not being made – for example, discoloration or pitting caused by arcing. Additionally,
loose connectors may emit a ‘burned plastic’ or ‘ozone’ smell as an early indicator.
If only one system of the treadmill is misbehaving intermittently, consider checking the connectors of
that system – for instance, with erratic belt speed is observed, check the connection of the motor leads
to the MCB.
If a connector is found to be loose or damaged, replace the cable or component with the damaged
connector.

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Troubleshooting Guide
Intermittent Emergency Stop connection
Any treadmill model:
If the Emergency Stop key isn’t making consistent electrical contact, several symptoms can appear. The
vibration & movement of the console while a user walks/runs on the belt can be enough to cause
intermittent e-stop connection problems.
Most obviously, the e-stop function may trigger unexpectedly, stopping the workout and requiring it to
be re-started by the user. In this case, the treadmill will behave the same as if the E-stop had
intentionally been engaged.
Some versions of console software will display the “Emergency Stop engaged” message appropriate for
that model for ~2 seconds after detecting the E-stop trigger. This behavior can help to diagnose an
intermittent connection of the E-stop key or wiring.
An intermittent connection can cause erratic belt speed, sometimes described as ‘the belt moves, stops
or slows, then resumes moving’. Finally, an intermittent connection can put the MCB into a state where
it ‘ticks’ or clicks repeatedly, with or without belt movement.
To investigate an intermittent E-stop connection:
1. Remove the E-stop key and inspect the metal tab. It should be clean and have no corrosion –
attempt to clean or replace if any found.
2. Look into the slot that the E-stop fits into. There shouldn’t be any debris visible; there should be
4 small metal ‘fingers’ that need to make contact with the metal tab on the key. Replace if the
tabs appear damaged.
3. Open the console and inspect the wire from the E-stop slot to the UCB. Confirm no damage,
and that the connector is properly seated in its socket on the UCB.
4. Inspect the Console Cable for any damage. See that topic here for further information.
Similar symptoms may be observed if the console is experiencing EMI from a cell phone or other source.
See further information here.
Damage to rear roller
Any treadmill model:
The rear roller can become bent or cracked during use. This may cause belt tensioning or centering
issues, or prevent the belt from rolling over the roller smoothly. In the worst case, damage to the roller
can prevent the belt from moving at all, eventually triggering overcurrent protection on the MCB,
damage to the motor, or another MCB fault.
Diagnosing a damaged roller can commonly be done by inspection. Any noticeable irregularity in the
roller (including under the belt), movement of some portion of the rear roller relative to the frame or
other portions of the roller, or any resistance to smooth turning can indicate a roller failure. Replace the
roller, being sure to tension & center the belt afterwards. See this video for further information on
tensioning & centering the belt.
Low tension allowing belt slippage or drive belt damage
Any treadmill model

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Belt Speed Troubleshooting
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Troubleshooting Guide
To function properly, the running belt must be properly tensioned and centered. If it is not, it may cause
undue noise as it rubs to one side or may appear to ‘stall’ or ‘hesitate’ on each footfall. If the belt is very
loose, it may not move at all with a user on the running surface.
Additionally, the drive belt from the motor to the front roller must also be tensioned and aligned.
Similar symptoms can appear if this belt is not properly adjusted, although this drive belt is much less
susceptible to inadvertent adjustment or wear than the running belt.
To diagnose a loose running belt:
1. Start a manual workout and set the speed to a comfortable walking pace.
2. ‘Stomp’ on the belt. If it hesitates, stalls, or comes to a stop, the running belt is likely
inadequately tensioned.
3. Further diagnosis can be done by removing the motor cover and repeating the ‘stomp’ test
above, while observing the pulley on the front roller. If both the motor and front roller continue
turning at a steady speed and the belt doesn’t, the running belt is inadequately tensioned.
4. When the running belt is properly tensioned, you should only be able to place a finger between
the belt & deck up to the second knuckle. Do not do this test with power applied.
5. Refer to the “Treadmill Belt & Deck Guide” under General Maintenance or this video for detail
on how to tension and center the running belt.
To diagnose a drive belt:
1. Disconnect power and remove the motor cover. Inspect the drive belt from the motor to the
front roller pulley for cuts, abrasions, cracking, or any other sign of damage; replace if any
found.
2. Check the alignment of the motor to the front roller pulley – the motor rotor and front roller
should be on the same axis. Adjust the motor set bolts if necessary to correct.
3. Reapply power, start a manual workout, and set the belt speed to a walking pace. ‘Stomp’ on
the belt, and observe the drive belt. If it stalls, hesitates, or slips on the motor shaft or front
roller, the drive belt needs to be tensioned.
4. On models with a magnetic speed sensor (T101, TR5, TR3), a loose drive belt may cause an E-1
error to be displayed on the console, due to the belt not moving as expected.
Treadmill or panel overcurrent breaker opening
Any treadmill:
Some faults or high belt/deck friction can cause either the overcurrent breaker in the treadmill or the
owner’s electrical panel to open. Belt/Deck friction is typically the root cause, but a fault with the MCB,
belt drive, or incline motors could also be found.
If the treadmill breaker opens, the treadmill will immediately lose power until the breaker is reset. On
T101 models, there is a button on the lower front of the treadmill, adjacent to the power switch &
power cord. If this button is ‘popped out’, the treadmill breaker has opened. Press the button inwards
to reset the breaker.
To diagnose a treadmill that causes the unit breaker to open:

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Troubleshooting Guide
1. Consider whether the belt & deck have been properly lubricated or are worn. Review & follow
lubrication instructions included in the treadmill Owner’s Manual or Treadmill Belt & Deck
Guide. Replace the belt & deck of either show signs of wear or problems reoccur.
2. Consider what the treadmill is doing when the breaker opens:
a. If the breaker opens immediately when power is connected/switched on, the power
input components and MCB should be suspected.
b. If the breaker opens when an incline movement is commanded, the MCB or incline
motor should be suspected. When inspecting the incline motor, confirm that the
moving parts of the incline linkage all flex freely and are not seized or interfering with
another part.
c. If the breaker opens when the belt would normally start moving or during a workout,
the belt drive motor and MCB should be suspected. Also consider that high belt/deck
friction can cause this issue.
If the breaker in the electrical panel opens, the treadmill (and every other device on that circuit) will
immediately lose power until the breaker is reset. It is important to remember that breakers are
designed and installed to protect the wiring in the home/facility, not the devices powered by that
circuit. As such, consider if there are other devices on the same circuit (especially high-power devices
such as heaters, motors, pumps, computers): If both the treadmill and another device are drawing large
amounts of power at the same time, there may not actually be any fault with the treadmill at all – just
too much power being drawn through the breaker.
To diagnose a treadmill that’s causing the panel breaker to open:
1. Disconnect every other device that also lost power when the breaker opened, reset the breaker,
and test the treadmill again for any faulty behavior. Without the additional load on the breaker,
the treadmill may not exhibit any faults.
2. Consider whether the belt & deck have been properly lubricated or are worn. Review & follow
lubrication instructions included in the treadmill Owner’s Manual or Treadmill Belt & Deck Guide
(available under General Maintenance). Replace the belt & deck of either show signs of wear or
problems reoccur.
3. Consider what the treadmill is doing when the breaker opens:
a. If the breaker opens immediately when power is connected/switched on, the power
input components and MCB should be suspected.
b. If the breaker opens when an incline movement is commanded, the MCB or incline
motor should be suspected. When inspecting the incline motor, confirm that the
moving parts of the incline linkage all flex freely and are not seized or interfering with
another part.
c. If the breaker opens when the belt would normally start moving or during a workout,
the belt drive motor and MCB should be suspected. Also consider that high belt/deck
friction can cause this issue.

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Troubleshooting Guide
Intermittent stuck key on console
Any treadmill:
One or more of the keys on the console can fail, intermittently responding as though it was pressed
without the user doing so. These issues can be very difficult to diagnose, since the fault can be so
sporadic and difficult to reliably reproduce.
Diagnosis largely relies on the user being noticing consistencies in how the treadmill misbehaves, and
then identifying which buttons detecting a press in error could cause that symptom. For example, if the
speed control issue is reported as “when it occurs, the speed always sets to 8 MPH” may indicate that a
key commanding that change could be stuck.
One common indicator of a stuck key is that when a key (other than the stuck key) is pressed, the
console will beep indicating that it acknowledged the key press, but will not respond to what the button
is commanding. Pressing the key that’s stuck causes no beep, and can be used to help diagnose which
key pad might be faulty. Further diagnosis can be done by opening the console, disconnecting all of the
wires/ribbon/cables that go to a keypad from the UCB, and connecting them back one by one, checking
for function each time a pad is reconnected. When the faulty behavior returns, a key on that pad is
likely stuck. Replace the keypad.
Also, some treadmill models allow the speed to be changed multiple different ways: Quick-keys, rollers
on grips, or Interval Keys. Confirm that the user isn’t inadvertently commanding the speed change
manually.
Treadmill error codes
T101-05, T101-07
Treadmills are able to detect some fault conditions and set an error code on the console, providing
some assistance in diagnosis. Depending on the error code and particular treadmill model, the causes
and solutions vary slightly.
E-1 error code
Error E-1 is displayed when the treadmill expects the running belt to be moving, but doesn’t detect any
movement signal from the speed sensor. There are multiple root causes or faults that can cause this
error.
To troubleshoot & diagnose an E-1 error:
1. Disconnect power and remove the motor cover. Manually check the console cable for damage.
2. Confirm that the speed sensor is connected to the MCB. Inspect the speed sensor wire for
damage or kinks.
a. T101, TR5, TR3: Inspect the location of the speed sensor, and adjust if necessary.
3. Inspect the motor leads (black and red wires connecting to the motor) for any damage. Confirm
that the motor leads are properly & firmly connected to the MCB.
4. Inspect the MCB for any signs of damaged or burned components.
5. Stand on the running belt; hold the handlebar and push the belt at a walking pace. The belt
should rotate freely, with no unusual noises or grinding. If anything abnormal is noted, consider

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Troubleshooting Guide
Worn or damaged motor commutator/brushes or other motor failure, Damage to rear roller, or
Low tension allowing belt slippage or Drive belt damage or tension.
E-2 error code
Error E-2 is displayed when the treadmill detects that the belt is moving slower than it is being
commanded to by the console.
The most common cause for this error is lack of lubrication between the belt & deck, with the increased
friction preventing the treadmill from being able to attain the commanded speed. Lubricate the belt &
deck, following the instructions included in the Owner’s Manual.
If the issue continues to occur, the console may be getting faulty data from the belt speed sensor. Refer
to the section Mis-adjusted or faulty belt speed sensor for details on how to inspect & adjust the speed
sensor. Replacing the speed sensor is sometimes needed, but getting it adjusted properly usually fixes
the problem.
E-b error code
Error E-b is displayed when the running belt speed signal from the speed sensor is higher than the
expected range for the commanded speed.
There are two common causes of this error code – User walking at high incline causing the belt to turn
faster than the console expects it to, and faulty data from the belt speed sensor.
Refer to the section Mis-adjusted or faulty belt speed sensor for details on how to inspect & adjust the
speed sensor. Replacing the speed sensor is sometimes needed, but getting it adjusted properly usually
fixes the problem.
If this error continues to appear after speed sensor adjustment or replacement, there is not much else
that can be done as a repair – the user just may not be able to operate the treadmill at the speed &
incline settings where the error occurs.
Updating console software
Updating the console software to the latest version is critical to ensuring the latest bug-fixes and
features of the treadmill are installed.
Software can be found for download at this web address.
Refer to the document in the “Additional Files” column for specific instructions on how to configure the
USB update and install it to the treadmill console.
Calibrating the speed sensor
Follow the procedure below to calibrate the speed sensor. Important: Do not stand on the treadmill
belt—stand on the side rails or the floor.
1. Hold Speed Down and Incline Up for about 3 seconds to access the Engineering Mode.
2. Use the Speed Up or Down buttons to navigate to ENG2.
3. Press Enter, and then press Start. The belt should begin moving automatically and increase
speed on its own.