My Proform 545S treadmill powers on but won't start. Incline is stuck in higher position, but calibration mode doesn't work. I replaced motor control board but nothing changed.

All icon models are the same. The easiest way to incline calibration is to start the treadmill, push the incline up button and then after you release the button, remove the safety key. Replace the safety key and the treadmill should calibrate.
If that doesn't work, press the stop and speed up buttons and hold, then place the safety key in place. This will bring you to the speed/incline calibration. Press stop again. now press incline up. This will run the incline calibration.
You may need to remove the hood and manually with a drill lower the motor. Using a slot screwdriver bit, lower the motor a bout 50 turns and then try the procedure above again if necessary.

Run the software calibration for easy diagnostic and fix it. God bless you

RUN inmediately the software calibration for diagnose, troubleshooting and fix it easy.

God bless you

1) i recommend that you lube very well deck belt + rollers bearing

2) see the videos.

3) see the block

4) Try to RUN the software calibration, for troubleshooting.

5) measure the input voltage motor, if there are the motor need repair.
6) Measure the output voltage board, for input voltage board, if there are NOT, the board is faulty.

Run the software calibration for easy diagnose, troubleshooting, and fix it.
God bless you

It sounds a lot like it might be your Motor Control Board. You can find one used on varios websites (ebay if you're lucky). I found one for $149.00 on the following website:

http://www.treadmilldoctor.com/PROFORM-545S-TREADMILL-Motor-Control-Board

I hope you got a good deal on it because it seems to be quite an expensive part.

Thanks and good luck!

ICON CALIBRATION INSTRUCTIONS- INCLINE
1) Press the Stop and the Speed Up keys down while inserting the safety key.
2) Press the Stop key one time. The Time window should read EP:2P. Some newer models may also say FP, Pass, or the like. This means that it passes the EPROM test.
3) Press either incline key and the incline will calibrate automatically.
4) THIS IS A VERY IMPORTANT STEP BECAUSE YOU WILL GET AN ERROR MESSAGE IF THIS STEP IS SKIPPED.After completing calibration of incline, press the Stop key and then remove the safety key.



If the incline moves but you it will not operate normally nor calibrate, check the wiring from the incline sensor to the power board. If all looks normal, put it back in calibration and see if you see a blinking “- -” symbol in the incline window when you are calibrating. If not, the incline sensor is bad.

If the incline moves but only just a bit, it could be a problem as simple as the gearbox on the motor being jammed. We remove the motor from the treadmill, reconnect the wiring, and then try to run the incline motor outside the treadmill. Many times, this will unjam it if that is the problem and then reinstalling it in the treadmill will get it to work. If you have the same problem or it doesn’t run outside the machine and you can hear it try to work, you need to replace the incline motor.

If the incline motor does not move, we need to figure out if the motor is getting voltage. Use a simple multi-meter and set it to AC volts. When you put it into calibration, it tries to calibrate the directions one at a time. Measure across the white and black wires first, then measure across the white and red wires second. If the motor is getting voltage you will read 120VAC (or
thereabouts) one one of the measurements. If you have voltage but the motor won't move, you need to replace the motor.
4.
If the incline motor does not move and you have done the voltage test and you do not have any voltage present, there is a problem in the electronics board that supplies the power. If the console is powering the drive motor as normal, you can bet it is getting an incline signal and the power board needs to be replaced (some models have an integrated power board/controller) so if there is only a single board the whole board has to be replaced. It is possible the console is not giving the proper signal but we've never seen it happen in thousands of treadmills.

If the incline is stuck, it could be a problem as simple as the gearbox on the motor being jammed. Unplug the treadmill remove the motor shroud then remove the incline motor from the treadmill, reconnect the wiring, plug in the treadmill and then try to run the incline motor outside the treadmill. Many times, this will unjam it if that is the problem and then reinstalling it in the treadmill will get it to work. If you have the same problem or it doesn’t run outside the machine and you can hear it try to work, you need to replace the incline motor.
If the incline motor does not move, we need to figure out if the motor is getting voltage. Use a simple multi-meter and set it to AC volts. When you put it into calibration, it tries to calibrate the directions one at a time. Measure across the white and black wires first, then measure across the white and red wires second. If the motor is getting voltage you will read 120VAC (or thereabouts) one one of the measurements. If you have voltage but the motor won't move, you need to replace the motor. . If the incline motor does not move and you have done the voltage test and you do not have any voltage present, there is a problem in the electronics board that supplies the power, you need to replace the board.

Under the motor shroud their is a instruction mini manual it will have a how to calibrate the incline motor, if that does not fix it then you may have to manually adjust the incline motor and sometimes it will take awhile to realign . If that does not work replacing the motor maybe the only option

Although it is fairly rare the incline motor can jam up into the highest position and get stuck there. To fix this take off the plastic hood that covers the incline motor and depending on the motor you should be able to wind it with your hand out of the highest position. When it is out of the highest position run the calibration as described in the owner's manual and it should go all the way up and all the way down. If it is not this type of motor that can be wound by hand then the first and last thing to do is to try calibration of the incline as described in your manual. If this does not work then a new incline motor is needed.