Horizon Treadmill Series
Contents
1. i At EDO 1 cose HoT 45 Lower Board LED Diagnosis LED 1 Transfer indicators When the power switch is turned on LED 1 amp 2 light up meaning that power is supplied to the lower board These LED s should remain on while operating the drive motor and elevation motor If the LED s are not lit check the AC service from the wall outlet LED 2 AC power indicator When the power switch is turned on LED 4 it will be lit meaning that power is supplied to the lower board This LED should remain on while operating the drive motor and elevation motor but while shut off if an error message E 1 E 2 is shown on the upper board If this LED is not lit and there is not an error message displayed on the upper board verify that all wire connections have been properly attached If the problem persists check the AC service from the wall outlet LED 3 amp 4 Motor indicator The LED goes on when the drive motor is operating Ifthe LED is not lit voltage is not being supplied to the motor and the lower board may need to be replaced LED 5 amp 6 Incline Motor Indicator When the upper board is commanding the incline motor to move UP or DOWN the LEDs go on LED 5 is for the UP function and LED 6 is for the DOWN function If there 1s no elevation follow the steps below e Inspect the console cable for pinches and make sure that console cable connections are secure replace if necessary e Remove the mo2. 2 With the Philips head screwdriver remove the speed sensor Press your finger against the drive belt and guide it towards the left until it is released from the front roller Loosen rear roller with appropriate sized Allen wrench 3 With the 6mm Allen wrench remove the front roller and replace it with a new one It is a good idea to note the position of the front roller before removing For best results place two removable marks on the left and right side of the deck and the running belt When reinstalling match up the marks for proper tension 4 Reassemble the front roller and the drive belt Tighten rear roller to previous tension Install the motor cover Rear roller 1 With a Philips head screwdriver remove the motor cover 2 With the appropriate size Allen wrench remove the rear roller and replace it with a new one It is a good idea to note the position of the rear roller before removing 3 Start the treadmill and run it to ensure proper belt tension and side to side belt tracking If is a problem with the belt tension or tracking adjust the rear roller position 60 Motor Replacement 1 1T 2 1T 5 1T Tools required Philips screwdriver Socket wrench 13mm Box wrench 8mm Allen wrench 6mm Procedure 1 Turn off the power to the treadmill and remove the power cord from the wall outlet 2 With a Philips head screwdriver remove the motor cover 3 Unplug the motor wires from t
3. 5 Remove the overlay 301 Make sure all and the adhesive is removed from the plastic console piece 6 Replace the keypad and plug it into the console 7 Install the overlay 8 Install the console panel N07 7A Air Shock Replacement Tools required Wrench 13mm Procedure 1 Fold treadmill to locking position 2 Use a 13mm wrench to loosen the nut that secures the top screws of the air shock to the frame 3 Unscrew the air shock from the bottom screw 4 Remove air shock and replace it with a new one screwing the new air shock into the bottom screw and then securing the top of the air shock with the 13 mm nut 75
4. If no voltage is present unplug the treadmill and visually inspect the motor brushes and springs to make sure they are installed properly Repeat voltage reading if necessary e f problem persists replace the lower board 40 Treadmill Will Stop and Reset e Check voltage of wall outlet Warning Hazardous voltages will be tested in the following procedure Exercise extreme caution when performing these procedures Do not connect or disconnect any wiring connectors or other components with the power applied to the treadmill e Disconnect the treadmill power cord from the wall outlet Using an AC voltmeter verify that the proper AC voltage is present at the wall outlet Nominal 120 Vac may vary between approximately 105 Vac and 135 Vac If the AC voltage is missing or incorrect check the AC service or consult an electrician e Make sure that the treadmill is connected to a dedicated 20amp circuit with out the use of an extension cord e Verify all wire connections for proper connection including power cord e Inadequate lubrication on deck and belt Refer to treadmill lubrication procedures 41 Running Speed Is Not Stable erratic speeds e Verify that the running belt and drive belt tensions are adequate preventing belts from slipping e Check voltage of wall outlet Warning Hazardous voltages will be tested in the following procedure Exercise extreme caution when performing these procedures Do
5. 0 should be displayed once in the Engineering Mode Menu 2 1 3 1T 4 1T 5 1T Power on the treadmill and have the safety key in position on the console Press and hold the elevation A and speed v for about 5 seconds to enter the Engineering Mode Menu The console should beep three times and Eng 0 should be displayed once in the Engineering Mode Menu Important Note For all Engineering modes press and hold Stop to exit 25 Eng0 Display and Button Check 1 1T a While in the Engineering Mode Menu press Speed or b Press Start to select Eng0 c Press Start button to verify all LED s 217 347 a While in the Engineering Mode Menu press Speed or b Press Start to select Engo c Press Start button to verify all LED s 4 1T 5 1T a While in the Engineering Mode menu press Speed A or b Press Select to select Eng0 c Press Start button to verify all LED s until EngO appears in the display v until EngO appears in the display v until Eng appears in the display 26 Eng1 Hardware Test Manual Calibration Important Note Use to check running belt speed and manually calibrate machine 1 1T a While in the Engineering Mode menu press Speed or until Engl appears in the display b Press Start to select Engl and Start again to get the belt started c The readout in the speed window will indicate t
6. This product must be grounded If a treadmill should malfunction or breakdown grounding provide a path of least resistance for electrical current to reduce the risk of electrical shock This product is equipped with a cord having an equipment grounding conductor and a grounding plug The plug must be plugged into an appropriate outlet that is properly installed and grounded in accordance with local codes and ordinances DANGER Improper connection of the equipment grounding conductor can result in a risk of electric shock Check with a qualified electrician of serviceman if you are in doubt as to whether the product is properly grounded Do not modify the plug provided with the product if it will not fit in the outlet have a proper outlet installed by a qualified electrician GROUNDED OUTLET ADAPTER GROUNDED GROUNDING SCREW DUTLET BOX GROUNDING PIN SAFETY TIPS e Never use the treadmill before securing the safety tether clip to your clothing e Ifyou experience chest pains nausea dizziness or shortness of breath stop exercising immediately and consult your physician before continuing e Do not wear clothes that might catch on any part of the treadmill e Keep power cord away from heated surfaces e Keep children off of treadmill at all times e Do not use treadmill outdoors e Unplug treadmill before moving it e Do not remove the treadmill motor covers or roller covers An authorized Horizon Fitness servi
7. Will Incline Up or Down Without Command Possible causes e Verify that all wire connections are properly attached Pay close attention to the console cable connection in the upper right hand corner underneath the console e Inspect console cable for damage e Check voltage of console cable Determine defective part by using console cable chart e Verify Engineering LED s on lower board Reference Engineering LED chart for possible causes e Replace console cable e f problem persists replace elevation motor 51 Incline Does Not Reach Minimum or Maximum Settings Possible causes e Incline motor is not installed properly e Verify elevation motor shaft position The elevation motor shaft should be flush with the bottom of the motor housing If the position of the shaft is too close to the bottom motor housing the shaft may have become jammed correct this remove the bottom bolt from the elevation motor and spin the shaft manually Ifthe elevation shaft has become jammed and cannot be spun free to the proper position replace the elevation motor 52 DRIVE MOTOR AND ROLLER TROUBLESHOOTING CONTENTS Noises generating from under motor _________ 54 Cleaning the ettet tentent tette treten testet stets ssp SS Noises generating from rear of treadmill 56 53 Noises Generating From Und
8. a loose cupping grip while pressing your palms against the heart rate handlebars e Ifthe problem persists replace the heart rate receiver and the heart rate handlebars e Improper grounding of upper board or running belt Add grounding kit and or replace running belt 37 Static Shocks from Upper Board Heart Rate Grips Possible causes e Improper grounding of upper board Contact Horizon Fitness for grounding kit and instruction e Lubrication on running deck and running belt inadequate Contact Horizon Fitness for lubrication application e Defective grounding fibers in running belt Replace running belt Note Improper grounding of the upper board or running belt may also cause other symptoms like erratic speed scrambled reading of the upper board resetting of the treadmill or erratic or non responsive heart rate function 38 LOWER BOARD TROUBLESHOOTING CONTENTS Treadmill will not start Running speed is not stable Wiring diagram Lower board LED diagnosis Manual Speed Calibration 40 41 42 43 45 47 39 Treadmill Motor Will Not Start Possible causes e Verify that all wire connections are properly connected e Follow the auto calibration instructions reference auto calibration in table of contents e Verify the Engineering LED s on the lower board Reference Engineering LED chart for possible causes e Measure voltage from motor reference voltage checkpoints in table contents
9. blade screwdriver 4 Check the surface of the motor brush If the surface of carbon brush is pitted rough or has burn marks replace the motor brush 5 Insert old new motor brush making sure that the brush slides in and out easily 6 Stone the surface of the motor commutator and blow out particles inside motor with an air compressor 7 Install the motor brush and the motor brush cover 8 Plug in the treadmill and let the treadmill run for about 1 hour at 5mph to allow the proper seating of the brush 65 Lower Board Replacement Tools required Philips head screwdriver Procedure 1 Turn off the power to the treadmill and unplug the power cord from the wall outlet 2 With a Philips head screwdriver remove the motor cover 3 Verify that LED MTR is not lit on the lower board If this LED is lit please wait approximately 1 minute until the light is out This is an indication that the stored power has left the board 4 Unplug all the wires and cables from the lower board It is a good idea to note the position of all wiring before removing 5 With a Philips head screwdriver remove the lower board and replace it with a new one 6 Reconnect all the wires to the lower board Please refer to lower control board wiring diagram 7 Install the motor cover 8 Re plug the power cord and turn power on 66 Console Cable Replacement 2 1 T 5 1T 4 1T 5 1 T Models Tools required
10. every 6 months This is necessary to ensure the longevity of the treadmill 2 BELT REPLACEMENT When lubrication is added to a treadmill deck at the factory it is impregnated into the filament backing of the running belt providing a low friction long lasting coat When replacing the original belt on a treadmill this new belt will not be properly coated Always add lubrication when replacing the belt 3 BREAKER TRIPS With time the lubrication between the running deck and running belt of the treadmill will wear down The lack of lubrication between the deck and belt will cause a high amount of friction when running on the treadmill This in turn will cause the treadmill breaker to trip If this happens lubrication should be added These three applications should be the only times lubrication is ever added to a Horizon Fitness treadmill Please contact the Horizon Fitness service department to obtain the proper lubrication for reapplication PROCEDURES 1 For optimal results the running deck and belt should be warm before reapplication of lubrication It is recommended to run the treadmill at 5mph for 10 15 minutes before proceeding 2 With the appropriate sized Allen wrench loosen the rear roller bolts on both the left and right side It is a good idea to note the position of the roller to reassemble properly For best results place two removable marks on the left and right side of the deck and the running belt When reinstal
11. on the treadmill when the motor brushes are removed from the drive motor e With the brushes removed inspect the motor commutator for any unusual wear or burn marks If there is any abnormal marks or wear stone the motor commutator Make sure to blow any dust or particles from the motor commutator when finished e After you replace a motor brush make sure the brush is seated securely and makes full contact with the commutator before you plug in the power cord and turn on the treadmill e Run the treadmill for 15 minutes at 3 5 mph to seat the brushes properly Inspect the motor commutator again for any unusual wear Repeat stoning process if necessary 55 Noises Generating From the Rear of the Treadmill Possible causes e Ifthis problem is being experienced on a new treadmill let the treadmill run for about 30 minutes without load to break the treadmill in e Verify proper tension of the running belt over tightened running belt may create excessive noise e Verify that there is proper clearance between the rear roller and the bottom deck cover and frame e If problem persists replaced the rear roller 56 Upper Board Keypad Membrane Key Air Shock SPARE PARTS REPLACEMENT CONTENTS S8 60 61 65 66 67 71 72 74 75 57 Running Belt Deck Replacement Procedure Tools required Philips screwdriver e T handle Allen wrench Smm 6mm 8mm Procedure 1 Wi
12. position Remove the top bolt from the incline motor Remove the incline motor from the machine 6 When installing the new incline motor make sure the elevation shaft is flush with the motor casing See diagram below 7 Install the top bolt to the incline motor 8 Install the bottom bolt to the incline shaft 9 Reconnect the incline motor wires to the lower control board 10 Attach the motor cover 71 Upper Board Replacement Tools required Philips screwdriver Procedure Diagram on following page 1 Turn off the power to the treadmill and unplug the power cord from the wall outlet 2 Remove console skirt N09 3 With a Philips head screwdriver loosen the screws N06 from the console panel N07 4 Unplug all the cables connecting to the upper board 5 Remove the console panel from the console assembly N08 6 With a screwdriver remove the console board from the console panel and replace with new console board 7 Reconnect the console cables and reinstall the console panel N07 8 Install the back console panel and tighten all screws 72 Upper Board Replacement Continued 73 Keypad Replacement Tools required Philips screwdriver Procedure 1 Turn off the power to the treadmill and unplug the power cord from the wall outlet 2 Remove console skirt N09 3 Remove screws N06 from the console panel N07 4 Disconnect the keypads N02 N03 from the console
13. Horizon Fitness 2005 Elite Treadmill Service Manual Treadmill Models 1 1T 2 1T 3 1T 4 1T 5 1T If you have any questions ple on Fitness Service Hotline at ase call the Horiz 1 800 244 4192 TABLE OF CONTENTS Warranty Safety Instructions Recommended Tools Maintenance Upper Board Troubleshooting Lower Board Troubleshooting Incline Motor Troubleshooting Drive Motor and Roller Troubleshooting Spare Parts Replacement 21 39 49 53 57 Treadmill Home Warranty Elite Series Treadmills LIMITED HOME USE WARRANTY Horizon Fitness extends the following exclusive limited warranty which shall apply to the use of the device in the home for residential non commercial purposes only Any other use shall void this warranty Horizon Fitness hereby extends the following limited warranties for the following components of the device for the time period indicated FRAME LIFETIME Horizon Fitness warrants the frame against defects in workmanship and materials for the life of the product so long as it remains in the possession of the original owner DRIVE MOTOR TWENTY FIVE YEARS Horizon Fitness warrants the drive motor against defects in workmanship and materials for a period of twenty five years from the date of purchase so long as the device remains in the possession of the original owner ELEVATION MOTOR TWENTY FIVE YEARS Horizon Fitness warrants the elevation motor against defects in workm
14. Philips screwdriver Allen wrench 5mm Procedure Diagram on following page 1 Turn off the power to the treadmill and unplug the power cord from the wall outlet 2 With a Philip head screwdriver remove the motor cover and disconnect the console cable from the lower control board 3 With a Philip head screwdriver remove the back panel for the upper board and unplug the console cable from the connectors 4 Fold up the deck and remove the wire protective cover N08 and remove the cable ties attaching the cable to the incline frame 5 Attach the new console control cable to the old one with a solid string at the bottom of the cable 6 Pull the old cable continuously until the new cable comes out of the top of the right support 7 Reconnect the console cable and install the protective wire cover Attach cable ties to the cable securing it to the incline frame 8 Install the motor cover and the back console panel 67 68 Console Cable Replacement I I T Model Tools required Philips screwdriver Allen wrench 5mm 13 mm wrench Needle nose pliers Procedure 1 Turn off the power to the treadmill and unplug the power cord from the wall outlet 2 With a Philip head screwdriver remove the motor cover and disconnect the console cable from the lower control board 3 With a Philip head screwdriver remove the back panel for the upper board and unplug the console cable from the c
15. achment screws and position sensor bracket closer to front roller pulley if the distance is greater than 2 4 mm Verify that the sensor wire is attached to the sensor bracket properly The proper position would be so that the sensor wire is protruding from the left hand side of the sensor and sensor bracket while facing the treadmill Verify that the rpm magnet is positioned in the front roller pulley Verify that the lower control board is outputting the proper voltage 5 volts DC See Voltage checkpoints in table of contents for voltage measurement instructions Verify that the sensor wire is functioning properly in Engineering Mode For directions on entering and using the Engineering Mode please refer to Engineering Mode starting on page 25 FIVE STEP DIAGNOSIS PROCESS Continued 4 Proper Speed Calibration Press Start Verify that the treadmill motor begins moving within 1 second If the treadmill motor begins hesitates and starts moving after 1 second follow the auto calibration instructions listed in the table of contents Verify that the treadmill motor turns smoothly There should not be any jerky or choppy movement of the motor If there is please adjust the torque cube on the lower board by referencing page 25 It may also be necessary to stand on the belt at a slow speed and ride the treadmill belt from the front roller to the rear roller to verify that the treadmill motor and running belt are traveling smoothl
16. admill e Inspect the power cord If the power cord is damaged contact Horizon Fitness e Make sure the power cord is not underneath the treadmill or in any other area where it can become pinched or cut e Check the tension and alignment of the running belt Make sure that the treadmill belt will not damage any other components on the treadmill by being misaligned Every Week Clean underneath the treadmill following these steps e Turn off the treadmill with the on off switch and then unplug the power cord at the wall outlet e Fold the treadmill into the upright position making sure that the lock latch is secure e Move the treadmill to a remote location e Wipe or vacuum any dust particles or other objects that may have accumulated underneath the treadmill e Return the treadmill to its previous position Every Month e Inspect all assembly bolts of the machine for proper tightness e Remove the motor cover and clean the motor and lower board area to eliminate any lint or dust particles that may have accumulated Failure to do so may result in premature failure of key electrical components Each 6 months e Add lubrication to deck and running belt Use lubrication provided by Horizon Fitness only e Lubricate the air shocks with a Teflon based spray Tensioning or Aligning the Running Belt Tensioning the Running Belt If you can feel a slipping sensation when running on the treadmill the running belt must be tightened In most case
17. anship and materials for a period of twenty five years from the date of purchase so long as the device remains in the possession of the original owner ELECTRONICS amp PARTS TWO YEARS Horizon Fitness warrants the electronic components and all original parts against defects in workmanship and materials for a period of two years from the date of purchase so long as the device remains in the possession of the original owner LABOR ONE YEAR Horizon Fitness shall cover the labor cost for the repair of the device for a period of one year from the date of original purchase so lone as the device remains in the possession of the original owner EXCLUSIONS AND LIMITATIONS This warranty applies only to the original owner and is not transferable This warranty is expressly limited to the repair or replacement of a defective frame electronic component or defective part and is the sole remedy of the warranty The warranty does not cover normal wear and tear improper assembly or maintenance or installation of parts or accessories not originally intended or compatible with the treadmill as sold The warranty does not apply to damage or failure due to accident abuse corrosion discoloration of paint or plastic or neglect Horizon Fitness shall not be responsible for incidental or consequential damages All returns must be pre authorized by Horizon Fitness Horizon Fitness obligation under this warranty is limited to replacing or repairing
18. at Horizon Fitness option the product at one of its authorized service centers A Horizon authorized service center must receive all products for which a warranty claim is made These products must be received with all freight and other transportation charges prepaid accompanied by sufficient proof ofpurchase Parts and electronic components reconditioned to As New Condition by Horizon Fitness or its vendors may sometimes be supplied as warranty replacement parts and constitute fulfillment of warranty terms This warranty gives you specific legal rights and your rights may vary from state to state WARRANTY REGISTRATION Your warranty card must be completed and sent to Horizon Fitness or register on line at www horizonfitness com before a warranty claim can be processed Important Safety Instructions Warning statements indicate a particularly dangerous activity You should be extremely cautious when doing the following Removing power from the treadmill the power cord being disconnected from the wall outlet Always ensure that the treadmill is unplugged from the wall outlet when you inspect or adjust the treadmill or when you isolate remove or replace a treadmill component Removing the motor cover exposes high voltage components and potentially dangerous machinery Exercise extreme caution when you perform maintenance procedures with the hood removed During service operations you will be very close to moving machinery and hi
19. ce provider should perform Service only e Treadmill should be plugged into a dedicated 20amp circuit for optimal performance Recommended Tools and Equipment The following list is a summary of the tools and equipment required by the procedures in this manual Phillips screwdrivers Anti static wrist strap when handling electronic parts Flat head screwdrivers Digital multi meter Drive belt tension gauge Allen wrench set Metric Open end wrenches of assorted sizes Metric Clamp on AC amp meter V drive ratchet and sockets of assorted sizes Blue loc tite Cable ties Motor commutator stone Needle nose pliers Damp cloth Rubber mallet Drop cloth Ruler Snap ring pliers Wire cutters Note Drive belt tension gauges and motor commutator stone can be ordered from Horizon Fitness PREVENTATIVE MAINTENANCE PROCEDURES Cleanliness of your Horizon Fitness treadmill and its operating environment will keep maintenance problems and service calls to a minimum For this reason Horizon Fitness recommends that the following preventive maintenance schedule be followed After Each Use e Turn off the treadmill with the on off switch and unplug the power cord from the wall outlet Warning To remove power from the treadmill the power cord must be disconnected from the wall outlet e Wipe down the running belt deck motor cover and console casing with a damp cloth Never use solvents as they can cause damage to the tre
20. does not have any display follow the possible causes below Possible causes e Check voltage of wall outlet Warning Hazardous voltages will be tested in the following procedure Exercise extreme caution when performing these procedures Do not connect or disconnect any wiring connectors or other components with the power applied to the treadmill 34 e Disconnect the treadmill power cord from the wall outlet Using an AC voltmeter verify that the proper AC voltage is present at the wall outlet Nominal 120 volts AC may vary between approximately 105 volts AC and 135 volts AC If the AC voltage is missing or incorrect check the AC service or consult an electrician e Breaker is damaged Inspect the circuit breaker to see if it has tripped off If it is tripped off like diagram A reset the breaker W 1 1 c T 2 1 e ON OFF switch is damaged Make sure the ON OFF switch is turned to the ON position and that the switch is lit If the switch is not lit check the power cord connection and function e Improper wiring Check all wiring coming in from the power switch to the lower board to the upper board Refer to wiring diagrams e Inspect Engineering LED s on lower board Determine defective part according to chart e Check voltage of console cable Determine defective part by using console cable chart 35 All or Some of the Keys on Console Will not Work Possible causes e fkeys are pre
21. elect C Press Start to begin 2 1T 3 1T a While in the Engineering Mode Menu press the Speed a or v button until Eng2 appears in the display b Press Start to select C Press Start to begin 4 1T 5 1T a While in the Engineering Mode Menu press the Speed button until Eng2 appears in the display b Press Select to select C Press Start to begin e The treadmill running belt will begin moving and will automatically begin the auto calibration sequence to properly set and store the speed values e Upon successful calibration there will be four beeps and it will automatically exit Engineering Mode and will return you to the original screen 29 Eng3 Manual Calibration Important Note Use to manually calibrate the running belt speed if auto calibration is unsuccessful 1 1T a b c d e 9 8 h i j k D While in the Engineering Mode Menu press Speed or until Eng3 appears in the display Press Start to select 66 should be displayed in the Distance Laps window if it is not press Speed or until it is displayed Press Start to begin The speed displayed is the actual speed of the running belt Press Speed or until the speed is 0 5 0 05 mph Press and hold the Start button for 3 5 seconds until the console beeps three times to save speed se
22. er Motor Cover Possible causes e Verify proper tension of the running belt An over tightened running belt may create excessive noise e Remove motor cover and verify alignment of drive belt e Inspect for debris on drive motor pulley front roller pulley or on drive belt e fthis problem is being experienced on a new treadmill let the treadmill run for about 30 minutes without load to break the treadmill in e Remove the brush covers on the drive motor and inspect the brushes and the motor commutator for any uneven wear Make sure the treadmill is turned off before doing this procedure e Ifthe surface of the motor brush is pitted rough or has burn marks replace the motor brush and stone the motor commutator e Do not plug in the power cord and do not turn on the treadmill when the motor brushes are removed from the drive motor e After you replace a motor brush make sure the brush is seated securely and makes full contact with the commutator before you plug in the power cord and turn on the treadmill e Ifthe problem persists replace the drive motor or front roller 54 Stoning the Motor Commutator e Unplug the power cord from the wall outlet e Remove the brush covers on the drive motor and inspect the brushes and the motor commutator for any uneven wear e Ifthe surface of the motor brush is pitted rough or has burn marks replace the motor brush e Do not plug in the power cord and do not turn
23. from being supplied to the treadmill Make sure the treadmill is on a dedicated circuit Horizon Fitness recommends a 20 amp dedicated circuit but a 15 amp dedicated circuit may be sufficient Make sure that proper voltage is being supplied from the wall outlet Warning Hazardous voltages will be tested in the following procedure Exercise extreme caution when performing these procedures Do not connect or disconnect any wiring connectors or other components with the power applied to the treadmill Disconnect the treadmill power cord from the wall outlet Using an AC voltmeter verify that the proper AC voltage is present at the wall outlet Nominal 120 volts AC may vary between approximately 105 volts AC and 135 volts AC Ifthe AC voltage is missing or incorrect check the AC service or consult an electrician FIVE STEP DIAGNOSIS PROCESS Continued 2 Proper Wiring Verify that all wires are secure and attached in the correct position reference wiring diagrams in table of contents Verify that there aren t any pinches or cuts in any of the wires especially the console cable connecting from the lower board to the upper board Replace and wires that are pinched or cut 3 Proper Sensor Wire Function Verify that the rpm sensor wire is positioned as close to the front roller pulley as possible The factory standard is a distance or 2 4 mm between the sensor wire and the front roller pulley Loosen the sensor bracket att
24. gh voltage components When you perform maintenance procedures with the hood removed remove jewelry especially from ears and neck tie up long hair remove neckties and do not wear loose clothing When the treadmill is operating the capacitor will hold a lethal amount of charge Do not touch the capacitor as serious injury or death might result When the treadmill is turned off and the power cord is removed from the wall outlet the capacitor will hold voltage for 30 60 seconds Allow the capacitor to discharge for a period of one minute before you touch or work near the capacitor Do not attempt to discharge the capacitor by any other means Exercise caution when touching any wire or electrical component during treadmill operation When it is necessary to lift the treadmill ensure that the treadmill has adequate support Do not lift the treadmill by the front Safety guidelines you should know and follow include e Read the owner s manual and follow all operation instructions e Operate the treadmill on a solid level surface Locate the rear of the treadmill at least four feet from walls or furniture Keep the area behind the treadmill clear e Visually check the treadmill before beginning service or maintenance operations If it is not completely assembled or is damaged in any way exercise extreme caution while operating and checking the treadmill e When operation the treadmill do not wear loose clothing Do not wear shoes
25. gs Tensioning the Drive Belt 1 1T 2 1T 5 1T Procedure 1 Turn off the power to the treadmill and remove the power cord from the wall outlet 2 With a Philips head screwdriver remove the motor cover 3 Unplug the motor wires from the lower board 4 Before continuing it is a good idea to weight down the treadmill deck to prevent the treadmill from springing up Removing the weight of the motor will significantly reduce the weight in the front end of the treadmill 5 With a 13mm wrench loosen the attachment nuts M08 and washers M09 holding the motor to the frame 6 With a 6mm Allen wrench loosen the two motor bracket attachment bolts M45 M46 and adjust to proper position 7 Tighten the two motor attach bolts M45 M46 with a 6mm Allen wrench 8 Verify the proper tension on the drive belt Using a timing belt tension gauge the proper tension should be between 65 to 75 lbs Ifa timing belt tension gauge is not available the drive belt should have approximately 3 8 of inch deflection If the drive belt tension is not set properly loosen the motor attachment bolts and adjust Treadmill Deck Lubrication Procedures There are three different applications in which you would be required to add lubrication to a Horizon Fitness treadmill 1 MAINTENANCE A Horizon Fitness treadmill does not need to be lubricated regularly However Horizon Fitness recommends that a 100 pure silicone lubricant be applied
26. he lower board and ground wire from machine 4 Before continuing it is a good idea to weight down the treadmill deck to prevent the treadmill from springing up Removing the weight of the motor will significantly reduce the weight in the front end of the treadmill 5 With a 13mm wrench remove the attachment nuts M08 and washers M09 holding the motor to the frame 61 With a 6mm Allen wrench loosen the two motor bracket attachment bolts M45 M46 With a 6mm Allen wrench remove the bolts M06 and washers M30 M25 holding the motor to the motor bracket and replace it with a new motor Put the new motor in place on the frame taking caution to properly align the motor flywheel pulley and the front roller pulley Tighten with a 13mm wrench Place the drive belt on the drive motor making sure that the motor pulley is aligned with the roller pulley Tighten the two motor attach bolts M45 M46 with a 6mm Allen wrench Verify the proper tension on the drive belt Using a timing belt tension gauge the proper tension should be between 65 to 75 lbs Ifa timing belt tension gauge is not available the drive belt should have approximately 3 8 of inch deflection If the drive belt tension is not set properly loosen the motor attachment bolts and adjust 62 Motor Replacement 4 1T 5 1T Tools required Philips screwdriver Socket wrench 13mm Box wrench 8mm Allen wrench 5mm 6mm Proced
27. he start speed of the treadmill which should be 0 5 mph or 05 mph Ifthe speed is not within the proper start speed range adjust the Speed Cube located on the board under the motor cover until the speed is approximately 0 5 mph or 05 mph in the Speed window Refer to diagram Speed Cube d Once the speed cube is set to the proper setting Press and hold the Stop for three seconds to return to the Engineering Mode Menu Important Note Steps c and d are the same for the 1 1T through the 5 1T 2 1T 3 1T a While in the Engineering Mode menu press Speed v until Engl appears in the display b Press Start to select Engl and Start again to get the belt started c Use steps c and d from 1 1T instructions 4 1T S 1T a While in the Engineering Mode menu press Speed A or v until Engl appears in the display b Press Select to select Engl and Start to get the belt started c Use steps c and d from 1 1T instructions The display window should reference the following values 3 1T 4 1T 5 1T models e Calories Elevation display window software version 27 Distance Laps display window elevation value Time display window speed value Speed Pulse display window RPM speed sensor signal 28 2 Auto Calibration 1 1T a While in the Engineering Mode Menu press Speed or until Eng2 appears in the display b Press Start to s
28. ill belt is running in a jerky or choppy motion To adjust the IR comp turn the dial clockwise to increase voltage to motor or counterclockwise to decrease voltage to motor To verify proper adjustment start the treadmill at 0 5 mph and ride the treadmill belt from the front to rear roller If the treadmill does not have any apparent jerky or choppy movement the IR comp is set properly 48 INCLINE MOTOR TROUBLESHOOTING Incline function does not work Treadmill will incline up or down without command Incline does not reach minimum or maximum settings CONTENTS 49 No Incline Function Possible Causes e Verify that all wire connections are properly attached e Inspect console cable for damage e Check voltage of console cable Determine defective part by using console cable chart e Verify Engineering LED s on lower board Reference Engineering LED chart for possible causes e Verify elevation motor shaft position The elevation motor shaft should be flush with the bottom of the motor housing If the position of the shaft is to close to the bottom motor housing the shaft may have become jammed To correct this remove the bottom bolt from the elevation motor and spin the shaft manually Ifthe elevation shaft has become jammed and cannot be spun free to the proper position replace the elevation motor e If problem persists replace the lower and upper boards 50 Treadmill
29. ling match up the marks for proper tension It is not necessary to take off the roller just loosen it enough so that you can fit your hands underneath the belt comfortably 13 Once the belt is loosened take a small amount of silicon oil 20 cc squeeze bottle provided by Horizon Fitness and apply it to the entire top surface of the running deck After the silicon oil has been applied to the top surface of the running deck the roller can be tightened to the proper position With a damp cloth wipe off any excessive silicon oil that may have seeped out from underneath the running belt Note Only use the lubrication provided by Horizon Fitness Do not try to apply other manufacture s lubrication to a Horizon Fitness deck 14 Lubricating the Air Shock Procedure 1 Fold the treadmill to the upright position making sure the treadmill is locked securely Add lubricating oil on the shaft of the air shock 3 Lift the frame up and down repeating this several times to allow the lubricating oil blend into air shock FIVE STEP DIAGNOSIS PROCESS The following steps are provided as routine checkpoints when diagnosing problems on a Horizon Fitness treadmill Iffollowed correctly these checkpoints should help diagnosis the majority of problems that may be encountered 1 Proper supplying power to treadmill Make sure the treadmill is not on an extension cord Extension cords create energy loss which prevents proper voltage
30. n console eee e stretto 34 All or some of the keys on console will not work 36 Heart rate control function does not work 37 Static shocks from upper board heart rate 38 21 Console Cable Voltage Chart DC volts Inputto Upper Board Elev ation Ground Ground Ground RPM Input to Upper Board Input ta Upper Board PM Motor Elev ation Dow n Elev ation Up P d P 4 P CORRECT VOLTAGE FOR WARE HARNESS B1 Black 2 5 Volts DC B2 Brown 2 4 Volts DC B3 Red 0 Volts DC B4 Orange 0 Volts DC B5 Yellow 0 Volts DC Green 5 Volts DC B7 Blue 16 16 5 Volts DC B8 Purple 16 16 5 Volts DC B8 Grey 0 Volts DC B10 White 1 6 Volts DC B11 Pink 0 Volts DC B12 Lt Blue 0 Volts DC To check the voltage of a specific function 1 6 elevation motor control etc place the negative lead of your multi meter on pin B4 or B5 and place the positive lead on the desired pin Follow the voltage chart above for the correct voltages Note Wire colors are subject to change 22 Upper Board Configuration Ex bai Engineering Mode Entering Engineering Mode 1 1T Power on the treadmill and have the safety key in position on the console Press and hold the elevation and speed for about 5 seconds to enter the Engineering Mode Menu The console should beep three times and Eng
31. not connect or disconnect any wiring connectors or other components with the power applied to the treadmill e Disconnect the treadmill power cord from the wall outlet Using an AC voltmeter verify that the proper AC voltage is present at the wall outlet Nominal 120 Vac may vary between approximately 105 Vac and 135 Vac If the AC voltage is missing or incorrect check the AC service or consult an electrician e Make sure that the treadmill is connected to a dedicated 20amp circuit with out the use of an extension cord e Verify that there are not any pinches or cuts in power cord motor wires or console cable Replace if necessary e Adjust IR Comp dial on lower board e Inadequate lubrication on deck and belt Refer to treadmill Lubrication procedures e f problem persists replace lower board 42 Lower Control Board Wiring Diagram TQEVR Console Cable Elevation 3 Wie Plug 77 SPDVR Speed Sensor Black Elevation AA oos mu x i AE z Wire U ee Te Rc M Y i V 22213 Red Elevation Wire II ateroo Y N E 1 10000180 100 White Elevation Wire On Off Switch On Off Switch 43 Wiring Diagram ON OFF SWITCH SOCKET A SOCKET WIRE TO ON OFF SWITCH E ON OFF SWITCH TO LOWER BOARD AC1 B GROUND F ON OFF SWITCH TO BREAKER C SOCKET WIRE TO BREAKER D ON OFF SWITCH TO LOWER BOARD AC2 44 Lower Board LED Diagnosis
32. onnectors 69 4 Remove the console assembly from the console mast 2 by removing the console mast covers on both the left and right side 5 Remove the rear closet to the back of the treadmill 45 mm bolt and 13 mm nut that attaches the console assembly to the console mast 1 6 Remove the console mast plug P30 from the console mast 7 Attach the new console cable to the existing cable and fish the new cable through the console mast 8 Once the new console cable is installed through the console mast connect the plugs to the lower board and upper boards 9 Attach the console assembly to the console masts with the 45 mm bolts and 13 mm nut and attach the console mast covers 10 Attach the back panel on the upper board 11 Attach the motor cover ensuring that the console cable is not being pinched 70 Incline Motor Replacement Tools required Philips screwdriver Oty2 wrenches 17mm Procedure 1 Turn off the power to the treadmill and unplug the power cord from the wall outlet 2 With a Philips head screwdriver remove the motor cover Disconnect the incline motor wires from the lower control board 3 Fold up the treadmill to the locking position 4 With two 17mm wrenches remove the bottom bolt attaching the motor shaft to the incline frame It may be helpful to tip the treadmill on its side to release pressure from the shaft bolt 5 Fold the treadmill down to the running
33. press the Speed or v button until Eng5 appears in the display b Press Select to select c Press Select to toggle between 4 1T and 5 1T software versions d Press and hold Start for 3 5 seconds until the console beeps 3 times The value has now been properly saved Eng6 Change from Miles to KM 2 1T 4 1T 5 1T Models Only 99 a While in the Engineering Mode Menu press the Speed or v button until Eng6 appears in the display b Press Select to select c Press Select to toggle between Miles and KM software versions 0 Miles 1 KM d Press and hold Start for 3 5 seconds until the console beeps 3 times The value has now been properly saved Note To change from miles to KM on the 3 1T you must flip the switches on the back of the upper board to the following configuration Switch 1 UP Switch 2 DOWN Switch 3 UP 33 No Display on Console If the console only displays dashes in the display window follow the possible causes below Possible causes e Adjust the position of the safety key Manually rotate the safety key to see if the reed switch is in proper alignment 1 1T only e Reed switch is damaged By pass the reed switch Disconnect the reed switch N23 and place a flat blade screwdriver on the connection prongs If the console lights up replace the reed switch N23 e Replace the safety key NESS v NL If the console
34. s the belt has stretched from use causing the belt to slip This is a normal and common adjustment To eliminate this slipping tension both the rear roller bolts with the appropriate sized Allen wrench turning both the left and right bolt 1 4 TURN as shown below Try the treadmill again to check for shipping Repeat if necessary but NEVER TURN the roller bolts more than 1 4 turn at a time NOTE The belt tension is set properly when the running belt is of an inch from the deck towards the rear roller Aligning the Running Belt If the running belt moves rapidly to one side when performing the next step press the Stop button immediately e Turn on the treadmill With the treadmill speed between 6 8 mph stand behind the treadmill and watch the movement of the running belt As you watch the running belt make sure that the belt runs without moving from one side to the other and that the belt is centered between the side rails If the running belt is not tracking properly follow the following procedures e Ifthe running belt tracks to the left turn the left roller bolt clockwise 1 4 of a turn keeping the belt tension in mind Over tightening the running belt may cause damage to the running belt and roller bearings e Ifthe running belt tracks to the right turn the right roller bolt clockwise 1 4 of a turn keeping the belt tension in mind Over tightening the running belt may cause damage to the running belt and roller bearin
35. s important to verify proper roller values as improper values can create inaccurate speeds Roller Values Elite 1 1T 1481 Elite 2 1T 1481 Elite 3 1T 1481 Elite 4 1T 1952 Elite 5 1T 1191 1 1T a While in the Engineering Mode Menu press Speed or until Eng4 appears in the display b Press Start to select c Press Speed or until proper value is reached Please refer to chart above for value d Press and hold Start for 3 5 seconds until the console beeps 3 times The value has now been properly saved 2 1T 3 1T a While in the Engineering Mode Menu press the Speed a or v button until Eng4 appears in the display b Press Start to select c Press Speed until proper value is reached Please refer to chart above for value d Press and hold Start for 3 5 seconds until the console beeps 3 times The value has now been properly saved 4 1T 5 1T a While in the Engineering Mode Menu press the Speed or v button until Eng4 appears in the display b Press Select to select c Press Speed v until proper value is reached Please refer to chart above for value d Press and hold Start for 3 5 seconds until the console beeps 3 times The value has now been properly saved 32 Eng5 Software Change 4 1T 5 1T Models Only 4 1T 5 1 T a While in the Engineering Mode Menu
36. ssed and do not hear a corresponding beep the membrane key is likely defective e Ifkeys are pressed and there is a corresponding beep but the console does not respond then the upper board is likely defective e Keypad connecting plug N02 or N03 is not fit in properly into the upper control board Verify the keypad connection The upper control board is not configured properly Reference upper board configuration in the table of contents e Overlay is sticking or is damaged N01 Try peeling up overlay and repositioning it e Overlay is damaged N01 Remove overlay and press touch pad N02 or N03 for proper function If buttons of touch pad work replaced the overlay If the buttons of the touch pad do not work replace the touch pad 36 Heart Rate Control Function Does Not Work When holding the heart rate handlebars the display in the Pulse display window should register HR If this does not register follow the possible causes below Possible causes e Defective heart rate receiver heart rate grips e Improper grounding of upper board or running belt Add grounding kit and or running belt e Defective upper board When holding the heart rate handlebars the display in the Pulse display window should register HR If this registers but the actual heart rate reading does not register or is erratic follow the possible causes below Possible causes e Try standing off to the side of the treadmill and use
37. th a Philips head screwdriver remove the motor cover rear roller end caps bottom deck cover and left and right side rails 2 With the appropriate size Allen wrench remove the rear roller It is a good idea to note the position of the rear roller before removing For best results place two removable marks on the left and right side of the deck and the running belt When reinstalling match up the marks for proper tension 3 With the Philips screwdriver remove the speed sensor 4 With a 6mm Allen wrench remove the front roller It is a good idea to note the position of the rear roller before removing 5 Loosen the bolts that hold the deck to the frame and remove the running belt and deck Replace the deck and running belt with a new one 58 Running Belt Deck Replacement Procedure Continued Tighten the deck bolts Assemble the front roller first but do not tighten completely Then assemble the rear roller and drive belt idler Finish tightening the front roller Start the treadmill and run it to ensure proper belt tension and side to side belt tracking is a problem with the belt tension or tracking adjust the rear roller position Install the sensor side rails and all the covers 59 Roller Replacement Tools required Philips screwdriver handle Allen wrench 6mm 8mm Procedure Front roller 1 With a Philips head screwdriver remove the motor cover
38. tor cover e Locate the Elevation LED s LED 5 amp 6 e Press START e Ifneither of the LED s are illuminated the upper control board is the probable cause e Ifonly the down LED is illuminated press and hold STOP to reset e Enter Hardware Test Engl in Engineering Mode e Press START twice to begin e Repeatedly press Incline e Ifthe elevation increases the upper control board is the probable cause e Ifthe elevation does not increase the elevation motor is the probable cause 46 Manual Speed Calibration There are two ways to verify that the treadmill speed is set properly 1 The first way is to count the running belt revolutions per minute At 0 5 mph the treadmill belt should make 4 revolutions minute for the 5 1T treadmill and 4 5 revolutions per minute for 4 1T 3 1 T amp 2 1T 1 1T treadmills If the belt revolutions are incorrect adjust the speed dial located on the lower control board 2 The other way to verify that the treadmill speed is set properly is to enter Engineering Mode For directions on entering and using the Engineering Mode please refer to page 25 To adjust the speed setting of the treadmill turn the speed dial clockwise to increase speed or counterclockwise to decrease speed IR Comp Adjustment Speed Calibration 1 ooo 100 47 The IR comp dial should only need to be adjusted if the treadm
39. tting Press Select to continue Press Speed until P2 is displayed Press Speed or until the speed is 5 0 or 0 05 mph Press and hold the Start button for 3 5 seconds until the console beeps three times to save speed setting Press Select to continue Press Speed until P3 is displayed m Press Speed or until the speed is 10 0 or 0 05 mph n 0 p Press and hold the Start button for 3 5 seconds until the console beeps three times to save speed setting Press Select to continue Press and hold Stop for three seconds to return to the Engineering Menu 2 1T 3 1T a b c d e f g h i k 1 99 While in the Engineering Mode Menu press the Speed or v button until Eng3 appears in the display Press Start to select Press Speed v until the display shows P1 Press START to begin Press Speed v until the speed is approximately 0 5 mph Press and hold Start for 3 5 seconds until the console beeps 3 times Press and hold Stop for 3 5 seconds until the console beeps 2 times Press Speed until the display shows P2 Repeat steps d g with the speed being adjusted to 2 0 mph Press Speed until the display shows P3 Repeat steps d g with the speed being adjusted to 5 0 mph Press Speed
40. until the display shows P4 m Repeat steps d g with the speed being adjusted to 7 0 mph n 0 p Press Speed until the display shows P5 Repeat steps d g with the speed being adjusted to 10 0mph Press and hold Stop for 3 5 seconds until the console beeps 2 times At this point the 2 1T will exit the Engineering Menu the 3 1T will return to the Engineering Menu 30 4 1T 5 1T a While in the Engineering Mode Menu press the Speed a or v button until Eng3 appears in the display b Press Select to select c Press Speed A or v until the display shows d Press START to begin e Press Speed A or v until the speed is approximately 0 5 mph f Press and hold Start for 3 5 seconds until the console beeps 3 times g Press and hold Stop for 3 5 seconds until the console beeps 2 times h Press Speed a until the display shows P2 i Repeat steps d g with the speed being adjusted to 2 4 mph j Press Speed a until the display shows P3 k Repeat steps d g with the speed being adjusted to 6 0 mph 1 Press Speed A until the display shows P4 m Repeat steps d g with the speed being adjusted to 8 4 mph n Press Speed until the display shows P5 o Repeat steps d g with the speed being adjusted to 12 0mph p Press and hold Stop for 3 5 seconds to return to the Engineering Menu 31 Eng4 Roller Diameter Check Important Note It i
41. ure 1 Turn off the power to the treadmill and remove the power cord from the wall outlet 2 With a Philips head screwdriver remove the motor cover 3 Unplug the motor wires from the lower board 4 Before continuing it is a good idea to weight down the treadmill deck to prevent the treadmill from springing up Removing the weight of the motor will significantly reduce the weight in the front end of the treadmill 5 With a 5mm Allen wrench remove the attachment bolts for the idler tension wheel and remove the drive belt from the motor 6 With a 13mm wrench remove the attachment nuts M08 and washers M09 holding 63 the motor to the frame 7 With a 6mm Allen wrench remove the bolts M06 and washers M25 M30 attaching the motor to the bracket Attach the new motor to the bracket 8 Put the new motor in place on the frame taking caution to properly align the motor flywheel pulley and the front roller pulley Tighten with a 13mm wrench 9 Place the drive belt on the drive motor making sure that the motor pulley is aligned with the roller pulley 10 Secure the drive belt idler in place with a 5mm Allen wrench 64 Motor Brush Replacement Tools required Flat blade screwdriver Procedure 1 Turn off the power to the treadmill and unplug the power cord from the wall outlet 2 Remove clip holding motor brush spring 1 1T only 3 Remove the motor brush cover and the carbon brushes with a flat
42. with heels or leather soles Check the soles of your shoes and remove and embedded stones Tie long hair back e Use care when getting on of off the treadmill Use the handrails whenever possible Do not get on or off the treadmill when the running belt is moving e Before starting the running belt straddle the belt by placing your feet firmly on the sides of the treadmill You should also step off the belt and onto the sides of the treadmill after turning off the running belt e Do not rock the unit Do not stand or climb on the handrails electronic console or hood e Do not set anything on the handrails electronic console or hood Never place liquids on any part of the treadmill e To prevent electrical shock keep all electrical components such as the drive motor power cord and circuit breaker away from water and other liquids e Do not use accessory attachments that are not recommended by the manufacturer such attachments might case injuries e Turn off the treadmill when adjusting o working near take up roller Do not make any adjustments to the running belt when someone is standing on the machine e Keep all loose items away from the treadmill running surface A treadmill running belt will not stop immediately if an object becomes caught in the belt or rollers WARNING Connect this appliance to a properly grounded dedicated 20 amp outlet only See grounding Instructions GROUNDING INSTRUCTIONS
43. y Verify start up speed 0 5 mph in Engineering Mode For directions on entering and using the Engineering Mode please refer to Engineering Mode page 25 The start speed of the treadmill can also be determined by counting the revolutions minute of the running belt At 0 5 mph the treadmill belt should make 4 revs minute for the Elite 5 1T and 4 5 revs minute for Elite 4 1T 3 1 T amp 2 1T If the belt revolutions are incorrect adjust the speed dial located on the lower control board see speed calibration in contents FIVE STEP DIAGNOSIS PROCESS Continued S Voltage Checkpoints Engineering LED s Verify that the lower board is functioning properly by referencing the Engineering LED s located on the lower control board A complete description for each Engineering LED can be found by referencing the lower control board Engineering LED chart in the table of contents Verify that proper voltage is being transferred through the console cable reference console cable voltage chart in the table of contents If the techniques described in the five step Engineering process did not resolve the problem reference the symptoms in the table of contents and review other possible causes in the troubleshooting section 20 UPPER BOARD TROUBLESHOOTING CONTENTS Console Cable Voltage Chart 22 Upper Board Configuration 23 Engineering Mode Inc hardware test auto calibration roller values etc 25 No display o
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