How to Troubleshoot the Carl Lewis Treadmill


Carl Lewis fitness produces a line of magnetic and automatic treadmills. Magnetic resistance treadmills operate on foot power and have few internal components. Problems are most often associated with running belt adjustment or the magnetic flywheel. A treadmill technician should inspect the speed sensor and heart rate monitor. Automatic treadmills can develop problems with the internal electrical circuits, the main motor, incline motor and drive belt. A technician should inspect the hand-motion speed adjustment feature. Troubleshooting the Carl Lewis treadmill is done using a typical step-by-step procedure to identify problems.

Magnetic Treadmill

Use a box wrench to loosen the running belt adjustment bolts at the rear roller. Alternate turning each of the bolts counterclockwise until the running belt can be lifted to inspect the underside of the belt and the running deck. Clean any dust or debris from the surface of the deck with a clean rag.

Remove the bolts that hold the front cover in place. Rotate the front roller by hand. If the roller does not move freelyl there may be a problem resulting from overloading the running deck. Use an Allen wrench to remove the bolts that hold the left side cover to the treadmill frame. Remove the cover and set it aside.

Slide the running belt off the rollers. Remove the nuts at each end of the front roller. Lift the roller and disconnect the wire leads that run to the console. Replace the front roller and magnetic flywheel if necessary. Reattach the side piece and the front cover.

Adjust the running belt by turning each of the adjustment bolts alternately in a clockwise direction. Have an assistant run on the treadmill. Make additional adjustments to the running belt until it continues to track in the middle of the front and rear rollers.

Automatic Treadmill

Unplug the electrical power cord. Insert the safety key in the console. This closes the switch and activates the internal circuitry. Attach the leads of a voltage meter to the prongs on the power cord and check the continuity of the electronic circuits. If the meter shows a reading, check the electrical circuit breaker to make sure it is on. Have a technician troubleshoot the electronic circuits if the breaker is on and the voltage meter does not show a reading.

Loosen the running belt adjustment bolts and remove the motor cover. Inspect the main motor pulley and drive belt for damages or a loose belt. If the belt is loose, remove the motor mount bolts and turn the adjustment bolt to tighten the belt tension. Replace the belt if damage is noted. Adjust the belt tension to 1/4-inch deflection and reinstall the motor mount bolts.

Inspect the incline arm that attaches to the smaller incline motor. Remove any obstructions and clean the area of the motors with a vacuum or compressed air. Clean the underside of the running belt and running deck with a clean rag.

Trace the wire leads from the main motor to the nearby connectors. Disconnect the leads and check the continuity of the motor by connecting the voltage meter leads to the motor leads. If the meter shows a reading you can reconnect the leads. If not, remove the motor and have it tested by a technician.

Check the continuity of the incline motor in the same way. If the meter shows continuity and there is a problem with the incline feature, the incline sensor needs to be replaced. Trace the wire lead from the incline motor to the sensor, remove the lead and replace the sensor.

Remove the safety key from the console and plug the power cord into an outlet. Straddle the running belt and reinsert the safety key. Star the treadmill and select the slowest speed. Step off the treadmill and adjust the running belt until it continues to track in the center of the rollers. Contact a technician if programmable features do not operate normally.