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2006 Treadmill Service Manual

1. 1 While in the Engineering Mode Menu press the Speed or button until Eng6 appears in the display 2 Press Enter to select 3 Press Enter to toggle between Miles and KM software versions 0 Miles 1 KM Press and hold Start for 3 5 seconds until the console beeps 3 times The value has now been properly saved E s SAFEIT WARRANTY INSTRUCTIONS RECOMMENDED TOOLS PROPER MAINTENANCE HEART REATE USAGE 5 STEP DIAGNOSTIC PROCESS VOLTAGE CHECKS WIRING DIAGRAMS AND SCHEMATICS ss w AND LED DIAGNOSIS MODE TROUBLESHOOTING SPARE PARTS REPLACEMENT Safety Key Reed Switch Troubleshooting AINVUUVM Symptom Possible Cause Test Procedure Console only displays Safely key or reed switch Verify that the safety key Replace safety key dashes in the display is positioned incorrectly or is in position and that it is If plastic tab is broken window Slot style key safety key has failed Secure replace console shell Manually adjust the position of the reed switch trigger and or the plastic tab on the console shell Reference Upper Board Reed Switch Replacement in Spare Parts Replace ment section 1001 SNOILINYLSNI OI0NINNOIIY ALIAS 39NVN31NIVMA Failed reed switch Short the switch connector If the upper board still dis on the upper board by using plays dashes then replace a flat blade sc
2. 5 5 ES AN3H33V 1434 1YVd 34 45 5 Membrane Key Pad Overlay Troubleshooting Symptom Possible Cause All or some of the keys on Ribbon cables connecting the console will not work Unit starts as soon as safety key is in place or console will reset itself after a few seconds of USE the membrane keypad to upper board are not seated properly or are disconnected Membrane keypad defective Upper board defective Overlay defective or sticking Overlay defective or stick ing or membrane keypad defective Test Procedure Verify the ribbon cables are connected securely into the upper board Keys are pressed some of the buttons may function but there are no correspond ing beeps Keys are pressed and there are corresponding beeps but console does not respond Sometime the key will not beep until it is released Remove overlay and press keypad for proper function Peel up overlay and reposi tioning it Remove and reseat cables Replace membrane keypad Reference Membrane Keypad EL Paper Overlay Replacement in Spare Parts Replacement section Replace upper board Refer ence Upper Board Reed Switch Replacement in Spare Parts Replacement section Replace overlay Refer ence Membrane Keypad EL Paper Overlay Replacement in Spare Parts Replacement section Massage buttons on keypad Replace overlay and mem to make sure that none are stuck Rem
3. 3 Remove the speed sensor bracket WIRING DIAGRAMS AND SCHEMATICS 4 Remove the front roller bolt A on drive belt side Figure 38 5 On the opposite side of front roller remove front roller bolt B Figure 38 6 Press against the drive belt and guide it towards the left until it is released from the front and remove front roller ENGINEERING MODE 7 Reinstall the front roller Put Drive Belt on roller before reattaching bolts 8 Reattach drive belt to front roller and motor pulleys 9 Reattach rear roller TROUBLESHOOTING 10 Start the treadmill and run it to ensure proper belt tension and side to side belt tracking If there is a problem with the belt tension or tracking adjust the rear roller position Reference Tensioning and Aligning the Running Belt in Maintenance section w S SNOILINYLSNI 81001 G30N3 N033H AI34VS 39NVNINIVI 39751 21 4 1UV3H 14044 5532084 5150 9 10 9315 5 SISUNSVIG 037 NV 39V110A SOILVNFHIS SWV4SVIC 3NIHIM 100 INIYFINIINI 00853140041 5 Bm Running Belt Deck Replacement Tools Required Philips Screwdriver e 4mm 5mm 6mm 8mm Allen Wrenches e 13mm Socket and Combination Wrench Procedure Figure 35 Figure 36 Motor Cover Grip Tape Rear Guide Rail Front Guide Rail End Caps 1 Remove the motor cover rear roller end caps and guide rai
4. Console Upper Board Troubleshooting Continued AINVUUVM Symptom Possible Cause Test Procedure Running belt stops Safety key or reed switch Verify that the safety key Replace safety key console resets during is positioned incorrectly 1 in position and that it is If plastic tab is broken workout Safety key is damaged secure replace console shell Manually adjust the Slot style safety key position of the reed switch only trigger and or the plastic tab on the console shell Slot style safety key only SNOILINYLSNI ALIAS 1001 U30N3 AW0J34 Inadequate power Check for dedicated cir If the AC voltage is miss cuit 20 amp is ideal and ing or incorrect check the check wall outlet voltage AC service or consult an 120 VAC electrician Make sure machine is not on extension cord or surge protector 39NVN31NIVIAI 19 50 21 8 LUV3H Damaged or improper Verify there are no pinch Replace parts as needed 5512044 8180 8 10 4315 5 wiring es or cuts in the power cord power wires motor wires or console cable Verify the connections of above wires and cords SISONSVIG 031 723 2 39V110A Inadequate lubrication on hand underneath Apply silicone Reference deck and running belt running belt and feel for Maintenance section adequate silicone applica tion 521 25 NI SHWV89VI0 INIYIM 3000 3NIU31NI9N3 E
5. IRESE las 543 WHITE __ 5 __ Optic Speed Sensor RED BLUE GND BLACK GND I SD N Speed Sensor Incli ncline Motor i o on 7 GREEN wa Drive Motor 0 90 VDC Power Cord 110 120 VAC lt 6 B PROPER STEP VOLTAGE CHECKS WIRING DIAGRAMS WARRANTY WE RECOMMENDED MAINTENANCE HEART RATE i ps IS AND AND ENGINEERING TROUBLESHOOTING SPARE PARTS INSTRUCTIONS TOOLS MODE REPLACEMENT USAGE PROCESS LED DIAGNOSIS SCHEMATICS Power Source Wiring Diagram SOCKET A Socket wire to breaker or on off switch Ground C Socket wire to breaker or on off switch D On Off switch to motor control board E On Off switch to motor control board F On Off switch to breaker Figure 21 ON OFF SWITCH BREAKER Wire length will determine connection point Wire length will determine connection point SAFETY WARRANTY INSTRUCTIONS RECOMMENDED TOOLS MAINTENANCE PROPER HEART REATE USAGE 5 STEP DIAGNOSTIC PROCESS t ES ENGINEERING VOLTAGE CHECKS Ni LED DIAGNOSIS SCHEMATICS MODE TROUBLESHOOTING SPARE PARTS REPLACEMENT Upper Board Configurations AINVUUVM Figure 22 SNOLLINYLSNI ALIAS 1001 G3N32N033H Console Cable 39NVNINIVI Safety Key Elevation membrane key
6. SAFETY INSTRUCTIONS RECOMMENDED TOOLS MAINTENANCE PROPER HEART REATE USAGE Spin motor flywheel to produce voltage 5 STEP DIAGNOSTIC PROCESS AC Wire Voltage Check Figure 18 LED DIAGNOSIS z WIRING DIAGRAMS AND SCHEMATICS A ES E N B li AC Wi Y Ires ENGINEERING MODE TROUBLESHOOTING SPARE PARTS REPLACEMENT lt AINVUUVM SNOILINYLSNI AI34VS 1001 G3N32N033H 39NVNINIVI 19 50 21 4 1UV3H 14044 5532084 5150 9 10 9315 5 SISONSYIG 037 5 5 a SOILVNFHIS SWV4SVIC 3NIHIM 300N INIYFINIINI INILOOHSITANOUL ANINFIVTdIY 51 34 45 E S Lower Board LED Diagnosis Figure 19 a LED 1 Transfer indicators When the power switch is turned on LED 1 lights up meaning that power is sup plied to the lower board This LED 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 amp 3 Motor indicator The LED 3 will come on if the motor starts to run The motor control board will begin detecting the status of the motor and if everything is OK then LED 2 will turn on in 1 or 2 seconds LED 4 amp 5 Incline Motor Indicator When the upper board is commanding the incline motor to move UP or DOWN the LED s go on LED 4 is for the U
7. 161 amp 19 50 21 4 1UV3H 5512044 5150 9 10 9315 5 Figure 23 SISUNSVIO 031 any 5 39VL10A 5 gt 1521 Console Cable 100 INIYFINIINI INILOOHSIT9NOUL Speed membrane key Elevation membrane key Flevation HD cle irer ININIIVIdIY 18Vd 18 45 Upper Board Configurations WARRANTY Figure 24 SAFETY INSTRUCTIONS Polar Receiver RECOMMENDED TOOLS Console Cable Safety Key MAINTENANCE HR Grip Receiver Fan Speed membrane key Elevation membrane key PROPER HEART REATE USAGE Speed HP Quick key Elevation HP Quick key 5 STEP DIAGNOSTIC PROCESS VOLTAGE CHECKS AND LED DIAGNOSIS Figure 25 SCHEMATICS S 8 ENGINEERING MODE Grip Receiver Console Cable Safety Key TROUBLESHOOTING Speed membrane key Elevation membrane key SPARE PARTS REPLACEMENT Upper Board Configurations AINVUUVM Figure 26 SNOLLINYLSNI ALIAS 1001 G3N32N033H Grip Receiver Console Cable 39NVNINIVI Safety Key Elevation membrane key 19 50 21 4 1UV3H Speed membrane key DT850 55320844 5150 9 10 4315 6 SISONSVIO 031 any 5 39VL10A Figure 27 gt 8 SWYYSYIO INIYIM 300N INIYFINIINI 000000 4 HELLE
8. B nn nnnnn 0000000 4 Grip Receiver TY 8300 INILOOHSTIANOYL Speed membrane key C I 3 5 Elevation membrane key ININIIVIdIA 51874 18 45 Upper Board Configurations WARRANTY Figure 28 SAFETY INSTRUCTIONS Elevation membrane key Speed membrane key RECOMMENDED TOOLS HR Grip Receiver MAINTENANCE PROPER HEART REATE USAGE Console Cable Safety Key 5 STEP DIAGNOSTIC PROCESS VOLTAGE CHECKS AND LED DIAGNOSIS Figure 29 Speed membrane key Elevation membrane key El Paper SCHEMATICS a ss Ez JDYUDIUT o Miss dass ENGINEERING MODE WE n Console Cable ir Em ER TROUBLESHOOTING ze ME Control key Program Quick key PST6 SPARE PARTS REPLACEMENT Upper Board Configurations AINVUUVM Figure 30 SNOLLINALSNI ALIAS 1001 G3N32N033H usiIqei 0921 al 1 mi ER Y gt a gt eee m n 3 zT Mi E du mox 55 8 gt S 8 553120844 5150 9 10 4315 6 SISUNSVIO 031 any 5 39VL10A Figure 31 Polar Receiver vn gt E 1527 SWYYSYIO INIYIM Console Cable 100 INIYFINIINI HR Grip Receiver Safety key INILOOHSITANOAL Elevation membrane key ININ
9. e Snap ring pliers 100 INIYFINIINI e Wire cutters Note INILOOHSITANOAL The motor commutator stone can be ordered from Horizon Fitness ININIIVIdIY 51 34 45 Preventative Maintenance Procedures WARRANTY 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 SAFETY INSTRUCTIONS After Each Use e Jurn off the treadmill with the on off switch and unplug the power cord from the wall outlet h To remove power from the treadmill the power cord must be disconect x A WARNIN ed from wall outlet e Wipe down the running belt deck motor cover and console casing with a damp cloth Never use RECOMMENDED TOOLS MAINTENANCE solvents as they can cause damage to the treadmill e Inspect the power cord If the power cord is damaged contact Horizon Fitness PROPER HEART REATE USAGE 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 5 STEP DIAGNOSTIC PROCESS Every Week Clean underneath the treadmill following these steps e Turn off the treadmill with the on
10. 5150 9 10 9315 5 SISONSVIU 031 ON 5 39V110A DR M SJIILYWIHIS NI SWV4IVIC INIYIM 100 INIYFINIINI Tensioning The Running belt INILOOHSITANOUL ININFIVTdIY 51 34 45 Aligining the Running Belt 1 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 2 If the running belt is not tracking properly follow the procedures below e f the running belt tracks to the left turn the left roller bolt clockwise 14 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 the running belt tracks to the right turn the right roller bolt clockwise 14 of a turn keeping the belt ten sion in mind Over tightening the running belt may cause damage to the running belt and roller bearings Figure 4 Belt is too far to the left side Belt is too far to the right side SAFETT WARRANTY INSTRUCTIONS RECOMMENDED TOOLS PROPER MAINTENANCE HEART REATE USAGE VOLTAGE CHECKS 5 WIRING DIAGRAMS DIAGNOSTIC PROCESS AND SCHEMATICS ENGINEERING AND LED DIAG
11. Enter to select 3 Press Enter to change software version Each time the select button is pressed a number will change in the upper right hand corner ex 1 10 This number represents the number of programs for that software version The settings are as follows until Eng3 appears in the display 1 10 T64 1 8 T63 er You can only change software ver 1 6 767 sion for the 161 164 Models 1 4 161 4 Press Start to change the distance parameters between miles and kilometers This number is shown in the upper left hand corner of the display 0 represents miles and I represents kilometers Eng4 Historical Information pees he historical information is stored in the upper control board If the upper VEE board is ever replaced all current information will be lost and reset to zero u n un 1 While in the Engineering Mode Menu press Speed or 2 Press Enter to select 3 Press Speed or buttons to view accumulated time distance This includes time spent at each speed in hours as well as distance in miles This number is shown in the upper right hand corner of the display until Eng4 appears in the display SAFEIT WARRANTY INSTRUCTIONS RECOMMENDED TOOLS 5 STEP PROPER HEART REATE MAINTENANCE USAGE DIAGNOSTIC PROCESS WIRING DIAGRAMS AND SCHEMATICS ss t VOLTAGE CHECKS LED DIAGNOSIS TROUBLESHOOTING SPARE
12. Keep a loose cupping hold You may experience an erratic readout if consistently holding the grip pulse handlebars Make sure to clean the pulse sensors to ensure proper contact can be maintained WIRELESS CHEST TRANSMITTER 164 amp 4 2 Chest strap sold separately PST 8 5 2T Prior to wearing the wireless chest transmitter moisten the two rubber electrodes with water Center the chest strap just below the breast or pectoral muscles directly over your sternum with the logo facing out Ne em chest strap must be tight and properly placed to receive an accurate and consis tal readout If the chest strap is too loose or positioned improperly you may receive erratic or inconsistent heart rate readout rq w w he heart rate function is not a medical device Various factors may affect the accu racy of your heart rate reading The heart rate reading is intended only as an exercise DC ald Figure 9 Figure 10 BACKSIDE OF CHEST TRANSMITTER TROUBLESHOOTING HEART RATE Check your exercise environment for sources of interference such as fluorescent lights computers underground fencing home security systems or appliances containing large motors These items may cause erratic heart rate read outs You may experience an erratic readout under the following conditions e Gripping the heart rate handlebars too tight Try to maintain moderate pressure while holding onto the he
13. Make sure power switch is turned on Failed power cord Take voltage check of power Replace power cord Check all wiring coming in from the power switch to the motor control board and to the upper board Refer ence Wiring Diagrams and Schematics section Verify LED s on motor con trol board Reference Voltage Checks and LED Diagnosis section If LED s are not lit on motor control board perform voltage check on AC wires Reference Voltage Checks and LED Diagnosis section If LED s on motor control board are present Check console cable voltages at B7 B8 Reference Voltage Checks and LED Diagnosis section Improper wiring or AC wires have failed Failed Console cable Failed Upper board of console cable Refer ence Voltage Checks and LED Diagnosis section Repair Reset breaker Replace power switch if necessary Connect wires correctly or replace as needed Replace console cable Reference Console Cable Replacement in Spare Parts Replacement section Check voltage and continuity Replace upper board Reference Upper Board Reed Switch Replacement in Spare Parts Replacement section SAFETY WARRANTY INSTRUCTIONS RECOMMENDED TOOLS 5 STEP PROPER WIRING DIAGRAMS DIAGNOSTIC HEART REATE MAINTENANCE PROCESS USAGE AND SCHEMATICS ENGINEERING SPARE PARTS VOLTAGE CHECKS ES 8 5 LED DIAGNOSIS MODE REPLACEMENT
14. PARTS REPLACEMENT SNOILINYLSNI 81001 30N3WW0938 AI34VS 39NVNINIVI 19 50 21 4 1UV3H 14044 5532084 5150 9 10 9315 5 SISUNSVIG 031 NV 723 2 39V110A SOILVNFHIS SHWV89VI0 3NIHIM m 5 5 D INILOOHSTIANOYL IN3HI33VTd 3H 51 4 34 45 Engineering Mode Models 1 271 2 21 3 2T 4 21 5 2T Entering Engineering Mode Press and hold Stop to exit all engineering modes 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 Eng0 should be displayed once in the Engineering Mode Menu TECHS ANG The 1 27 uses the Select button and not the Enter button to select the engineering mode on the screen Eng Display and Button Check 1 While in the Engineering Mode menu press Speed or display 2 Press Enter to select Engo 3 Press Start button to verify all LED s until Eng appears in the Eng1 Hardware Test 1 While in the Engineering Mode menu press Speed or display 2 Press Enter to select Engl and Start to get the belt started 3 Press Start button to verify belt movement sensor wire and elevation function until Engl appears in the Eng2 Auto Calibration 1 While in the Engineering Mode Menu pres
15. e Needle nose Pliers Procedure 1 Turn off the power to the treadmill and unplug the power cord from the wall outlet 2 For Models 161 T64 CST 3 5 amp 4 5 07620 amp 850 WT950 1 2T Only Remove the motor cover 3 For Models T61 T64 CST 3 5 amp 4 5 DT650 amp 850 WT950 1 2T Only Disconnect the console cable from the lower control board 4 For Models PST 6 amp 8 2 2T 5 2T Only Lift up right side console mast boot or remove right side cover Figures 59 60 Figure 59 Figure 60 Console Mast Boot Side Covers 5 For Models PST 6 amp 8 2 21 5 2T Only Remove screws holding console mast to base frame Fig ure 61 62 6 For Models PST 6 amp 8 2 21 5 2T Only Disconnect console cable on base of the machine near the console mast Figure 61 62 Figure 61 Figure 62 Console Mast Cable Replacement 7 Remove bolts holding console assembly onto console masts Figures 63 64 65 WARRANTY 8 Disconnect console cable in the upper left hand corner of the console and secure cable so that it does not fall down console mast Figures 63 64 65 Figure 63 Figure 64 RECOMMENDED SAFETY SUE TOOLS INSTRUCTIONS PROPER HEART REATE USAGE lt Console Cable 9 Attach the new console cable to the exIsting cable at the bottom of the con sole mast and fish the new cable up through the console mast Figure 66 5 DIAGNOSTIC PROCESS Console
16. from the machine Figure 69 Figure 69 7 Reinstall the top bolt to the elevation motor When installing the new incline motor make sure the elevation shaft is flush with the amp G amp G motor casing See diagram below If the position of the shaft is too close to the bottom motor housing the shaft may have become jammed To correct this remove the bottom bolt from the eleva tion motor press the Start button let the shaft spin out and then spin the shaft manually so there is almost one thread visible Figure 70 Figure 70 Proper Zero Shaft Position E sg 6 Reinstall the bottom bolt to the incline shaft SAFEIY WARRANTY INSTRUCTIONS RECOMMENDED TOOLS PROPER MAINTENANCE HEART REATE USAGE VOLTAGE CHECKS 5 STEP DIAGNOSTIC PROCESS WIRING DIAGRAMS ENGINEERING AND LED DIAGNOSIS AND SCHEMATICS MODE TROUBLESHOOTING 2 ES REPLACEMENT AINVUUVM SNOILINYLSNI AI34VS SISONSVIU 031 5532084 19 50 lt 1001 0 0 5150 9 10 21 4 1UV3H 39NVNINIVI 30N3WW0938 SOILVNFHIS SWV4SVIC 3NIHIM 9315 5 39V110A 300 INIYFINIINI INILOOHSIT9NOUL SS 5 Sm mr Upper Board Reed Switch Replacement Tools required e Philips Screwdriver Procedure 1 Turn off the power to the treadmill and unplug the power cord from the wall outlet 2 Remove screws connecting faceplate to consol
17. mast AND LED DIAGNOSIS Lock Washers VOLTAGE CHECKS Figure 66 10 Once the new console cable is installed through the console mast connect the plugs to the motor control pr board and upper boards WIRING DIAGRAMS AND SCHEMATICS ENGINEERING MODE 11 Attach the motor cover en suring that the console cable is not being pinched TROUBLESHOOTING 5 SNOILINYLSNI 81001 30N3WW0938 AI34VS 39NVNINIVI 19 50 21 4 1UV3H 14044 5532084 5150 9 10 9315 5 SISUNSVIG 031 NV 723 2 39V110A SOILVNFHIS SWV4IVIC INIYIM 300N INIYFINIINI INILOOHSITINOUL 3 Bm EE TA ELLEN Elevation Motor Replacement Tools Required e Philips Screwdriver e 17mm Socket and Combination Wrenches Qty 2 Procedure 1 Turn off the power to the treadmill and unplug the power cord from the wall outlet 2 Remove the motor cover 3 Disconnect the elevation motor wires from the motor control board and ground wires from motor control board bracket Figure 67 4 Lock treadmill into folding position 5 Remove the bottom bolt attaching the incline motor shaft to the main frame Figure 68 Figure 58 17 mm Nut 17 mm Bolt asss Elevation Motor Replacement 6 Fold the treadmill down to the running position and remove the top bolt from the elevation motor and remove the motor
18. to 75 Ibs If a 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 Tensioning the Drive Belt Models PST6 PST 8 5 2T WARRANTY Procedure SAFETY INSTRUCTIONS 1 Turn off the power to the treadmill and remove the power cord from the wall outlet RECOMMENDED TOOLS 2 Remove the motor cover 3 Unplug the motor wires from the mo MAINTENANCE tor control board MA Before continuing it is a good NN idea to weigh down the OG NNN nil deck to prevent the treadmill from springing up Removing the weight of the motor will sig PROPER HEART REATE USAGE nificantly reduce the weight in the front end of the treadmill 4 Loosen the attachment nuts A holding the motor bracket to the frame Figure 7 5 STEP DIAGNOSTIC PROCESS 5 Loosen Bolt B Figure 7 VOLTAGE CHECKS AND LED DIAGNOSIS 6 Tighten bolt C to increase tension on drive belt Figure 7 7 Tighten or loosen bolt D to straighten motor bracket and ensure that the pulleys on the motor and front roller are properly aligned Figure 7 WIRING DIAGRAMS AND SCHEMATICS 8 Tighten the two motor bracket attachment nuts A and bolt B when finished Figure 7 ENGINEERING MODE 9 Verify the proper tension on the drive belt Using a timing be
19. 0 9315 5 Overlays Faceplate 8180 9 10 031 NV 723 2 39V110A SIILYWIHIS SWV4IVIC INIYIM 100 INIYFINIINI 1 Turn off the power to the treadmill and unplug the power cord from the wall outlet 2 Remove screws from the back console faceplate 3 Disconnect the membrane keypad ribbon and or EL paper ribbon cables from the upper board Reference Upper Board Configurations in Wiring Diagrams and Schematics section INILOOHSTTANOAL SES 5 Sm Membrane Keypad EL Paper Overlay Replacement 4 Remove the overlay and keypad from faceplate Figures 80 81 82 Figure 80 Figure 81 L Paper Membrane EG Make sure all the adhesive is removed from the plastic console faceplate 5 Replace the keypad and connect ribbon cables to back of upper board 6 Install new overlay SAFEIY WARRANTY INSTRUCTIONS RECOMMENDED TOOLS PROPER MAINTENANCE HEART REATE USAGE VOLTAGE CHECKS 5 STEP DIAGNOSTIC PROCESS WIRING DIAGRAMS ENGINEERING AND LED DIAGNOSIS AND SCHEMATICS MODE TROUBLESHOOTING e x amp REPLACEMENT Air Shock Replacement Tools Required AINVUUVM e 12mm Socket and Combination Wrench e 13mm Socket and Combination Wrench e 17mm Socket and Combination Wrench SNOILINYLSNI AI34VS Procedure 1 Fold treadmill to locking position 1001 G3N3 N033H 2 Remove nut that secures the top scre
20. 3 5 seconds to return to the Engineering Menu button until Eng3 appears in the display until the display shows P1 Engineering Mode Continued Models 1 27 2 27 3 27 4 27 5 2T Eng4 Roller Diameter Check 3 It is important to verify proper roller values as WW WE mproper values can create inaccurate speeds 1 While in the Engineering Mode Menu press the Speed or button until Eng4 appears in the display 2 Press Enter to select 3 Press Speed or until proper value is reached Please refer to the following chart for value 4 Press and hold Start for 3 5 seconds until the console beeps 3 times The value has now been properly saved Roller Values Elite 1 2T 1481 Elite 2 2T 1481 Elite 3 2T 1481 Elite 4 2T 1952 Elite 5 2T 1972 Eng5 Software Change 4 2T and 5 2T Only 1 While in the Engineering Mode Menu press the Speed or button until Eng5 appears in the display 2 Press Enter to select 3 Press Enter to toggle between 4 2T and 5 2T software versions 4 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 21 4 2T 5 2T Models Only 4 Change 1 27 from miles to KM remove B jumper on back of upper control board A
21. 5 SWV4SVIC 3NIHIM INILOOHSITANOAL ININIIVIdIY 51 34 45 Connect this appliance to a properly grounded dedicated 20 amp outlet only AWARNING See S See grounding Instructions WARRANTY GROUNDING INSTRUCTIONS 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 Ke 5 ES 5 RECOMMENDED TOOLS h Improper connection of the equipment grounding conductor can result a risk of electric A WARNIN shock Check with a qualified electrician if you doubt as to whether the product is prop erly 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 MAINTENANCE Grounded Outlet Figure 1 PROPER HEART REATE USAGE Adapter Metal Screw 5 STEP DIAGNOSTIC PROCESS VOLTAGE CHECKS LED DIAGNOSIS Grounding Pin Grounded Outlet Box Grounding Screw WIRING DIAGRAMS AND SCHEMATICS SAFETY TIPS e Never use the treadmill before securing the safety tether clip to your clothing e f you e
22. 64 CST 3 5 amp 4 5 DT650 amp 850 WT950 Only Bring the deck back down into the horizontal position 6 For Models 161 T64 CST 3 5 amp 4 5 DT650 amp 850 WT950 Only Plug in and turn on the machine 7 For Models T61 T64 CST 3 5 amp 4 5 DT650 amp 850 WT950 Only Raise the deck to the highest elevation and turn off power to the unit 8 For Models 161 T64 CST 3 5 amp 4 5 DT650 amp 850 WT950 Only Remove the remaining screws from the front of the bottom motor cover Optical Disk Digital Sensor Drive Motor Replacement 9 Unplug the power cord from the wall outlet 10 Unplug motor and optic sensor wires from the motor control board Also remove the green ground wire that is attached to the bracket next to the motor control board 11 Remove the bolts A and holding the motor to the motor bracket Figure 41 Figure 41 12 Remove protective shield optic disk and optic sensor from the drive motor Figure 42 If new Motor has these pieces already preassembled then skip to step 14 Optic Sensor Figure 42 Protective Shield Optic Disk 13 Install optic sensor optic disk and the protective shield to the new motor 14 Reinsert the bolts A and washers B amp C holding the motor to the motor bracket but do not tighten Figure 41 15 Place the drive belt on the drive motor 16 Position motor so that the motor pulley is aligned with the front roller pulley 17 Tighten dow
23. ALIAS 39NVN31NIVMA 39751 31 8 LUV3H 5512044 8180 8 10 4315 5 SISONSVIG 031 ONY 723 2 39V110A 521 25 SHWV89VI0 INIYIM 3000 3NIU31NI9N3 E 5 8 E 5 AN3H33V 1434 51 34 48 Auto Calibration Troubleshooting Symptom Possible Cause Test Procedure Failed Auto Calibration Failed RPM sensor Put machine into Engl and Replace RPM sensor Belt runs for a few sec check for slight fluctuation onds and then stops and E1 of speed in speed window of message on console display Speed should not fluctuate more than a few hundredths RPM sensor misaligned Adjust sensor bracket to correct Reference Roller Replace ment in Spare Parts Replace Failed console cable Check voltage and continuity of Replace console cable Refer console cable Reference Volt ence Console Cable Replace age Checks and LED Diagnosis ment in Spare Parts Replace ment section section Magnet missing in front roller pulley Replace magnet Failed Auto Calibration Belt never runs and E1 See troubleshooting section for message on console no motor movement on page 38 Failed Auto Calibration RPM sensor not aligned properly Verify positioning of sensor Board never sets speeds has failed wire Wire coming from RPM Replace RPM sensor Belt will continue to run and sensor points toward the front not stop of the unit sensor is as close as pos
24. ED DIAGNOSIS 16 Tighten rear roller to proper position 17 Start the treadmill and run it to ensure proper belt tension and side to side belt tracking If there is a problem with the belt tension or tracking adjust the rear roller position Reference Tensioning and Aligning the Running Belt in Maintenance section ENGINEERING WIRING DIAGRAMS MODE AND SCHEMATICS TROUBLESHOOTING AINVUUVM SNOILINYLSNI AI34VS SISONSVIU 031 5532084 19 50 lt 1001 21 4 1UV3H 30N3WW0938 14044 SOILVNFHIS 39NVNINIVI 5150 9 10 39V110A 9315 5 SWV4SVIC 3NIHIM 300N INIYFINIINI 8 I INILOOHSITINOUL YL ELI EN Optical Disk Digital Sensor Drive Motor Replacement Tools Required 13 mm Socket e Philips Screwdriver e Right Angle Philips Screwdriver e 6mm Allen Wrench DOGG 3 m IMPORTANT For Optical Disk Replacement Only f you have a right angle Philips screw diver then you should be able to remove the optical disk after removing the motor cover Procedure 1 Remove the motor cover 2 For Models PST 6 amp 8 1 2T 5 2T Only Remove the screws attaching bottom motor cover to main frame 3 Put the deck into storage position 4 Remove the screws from the bottom motor cover Figure 39 amp 40 Figure 39 Figure 40 Bottom Motor Cover Bottom Motor Cover Screws Screws 5 For Models 161 T
25. Horizon Fitness oR Zo 4 2006 TENER Treadmill Service Manual Designed for life Table of Contents Warranty 3 Safety Instructions 4 Recommended Tools 6 Maintenance 7 Proper Heart Rate Usage 14 Horizon Fitness 5 Step Diagnostic Process 16 Voltage Checks and LED Diagnosis 18 Wiring Diagrams and Schematics 22 Engineering Mode 31 Troubleshooting 34 Spare Parts Replacement 46 REFER THE SUPPLEMENTAL SHEET ON THE LAST PAGE OF THE SERVICE MANUAL FOR THE MID SEASON PRODUCTION CHANGE ON THE LOWER CONTROL BOARD 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 offers the following limited warranties for the following components of the device for the time period indicated Model _ Labor rc Elevation Frame 161 _ Year Lifetime 162 0 Lifetime 163 Years 12 Years Lifetime T64 Lifetime DT650 lYear 1 7 Years 7 Years Lifetime 01850 10 Years 10 Years Lifetime 05725 12 Years 12 Years Lifetime CST 4 5 15 Years 15 Years Lifetime PST 6 _ 2 Years 20 Years _ Lifetime PST8 Lifetime 127 Lifetime 22r Lifetime 3A Lifetime 427 Lifetime oF Lifetime WT950 Year 11 Year Lifetime Horizon Fitness warranties the frame electronics and parts a
26. IIVIdIA 51874 18 45 Upper Board Configurations WARRANTY Figure 32 SAFETY INSTRUCTIONS RECOMMENDED TOOLS 65 ale a ge r Console Cable E 5 ra 5 HR Grip Receiver 6 gt 6 1144 MAINTENANCE Safety Key PROPER HEART REATE USAGE Speed membrane key 2 2 T Elevation membrane key 5 DIAGNOSTIC PROCESS VOLTAGE CHECKS AND LED DIAGNOSIS Figure 33 SCHEMATICS lt S ENGINEERING MODE Console Cable TROUBLESHOOTING Quick Program Key Speed membrane key Elevation membrane key 3 27 SPARE PARTS REPLACEMENT Upper Board Configurations WARRANTY SAFETY INSTRUCTIONS Led Panel HE Grip Receiver 5 gt t p 4 zn 5 M 8 8 p A E M ui 5 ta gt 5 2 Ta PROPER 5 STEP VOLTAGE CHECKS WIRING DIAGRAMS RECOMMENDED ENGINEERING SPARE PARTS MAINTENANCE HEART RATE DIAGNOSIS AND AND MODE TROUBLESHOOTING REPLACEMENT TOUS USAGE PROCESS LED DIAGNOSIS SCHEMATICS Engineering Mode Models T61 T62 T63 164 CST 3 5 CST 4 5 DT850 DT850 WT950 PST 6 PST 8 Entering Engineering Mode 4 IMPORTANT Press and hold Stop to exit all engineering modes AN Power on t
27. NG DIAGRAMS AND SCHEMATICS ENGINEERING MODE S E 5 SPARE PARTS REPLACEMENT A 5 Spare Parts Replacement Roller 47 Running Belt Deck 48 Opticaln Disk Digital Sensor Drive Motor 50 Motor Brush 52 Motor Control Board 54 Upper Board Console Cable 55 Console Mast Cable 56 Elevation Motor 58 Upper Board Reed Switch 60 Membrane Keypad EL Paper Overlay 62 Air Shock 64 To Remove the motor cover on the PST6 PST8 and 2 2 5 2 models the machine must be elevated to at least level 6 or both side covers need to be removed to gain access to all 4 motor cover screws Roller Replacement Tools Required WARRANTY Philips Screwdriver e4mm 6mm 8mm Allen Wrenches e13mm 14mm Socket and combination wrenches Procedure Front Roller 1 Remove the motor cover and rear roller end caps ATT PNI SAFETY INSTRUCTIONS RECOMMENDED TOOLS GOJ EE SER SES e 3 EL 5 STEP DIAGNOSTIC PROCESS Figure 38 2 Remove tension bolts and remove the rear roller VOLTAGE CHECKS LED DIAGNOSIS A BS SDS BW risa good idea to note the position of the rear roller before removing For best results place two removable WU marks on the left and right side of the deck and the running belt When reinstalling match up the marks for proper tension
28. NOSIS MODE TROUBLESHOOTING SPARE PARTS REPLACEMENT 1001 SNOILINYLSNI OI0NINWOIFY JINYNILNIYW AI34VS 19 50 21 4 LUV3H 14044 5532084 5150 9 10 9315 5 SISONSVIU 031 NV 723 2 39V110A INILOOHSITANOAL ae SWV4IVIC INIYIM IN3H33VTd34 51 34 45 Tensioning the Drive Belt Models T61 T62 T63 T64 CST 3 5 CST 4 5 DT650 1 2T 2 2T 3 21 4 2T DT850 WT950 Figure 6 Procedure 1 Turn off the power to the treadmill and remove the power cord from the wall outlet 2 Remove the motor cover 3 Unplug the motor wires from the motor control board ra wa Ww Before continuing it is a good idea to weigh down the treadmill deck to pre Nag vent the treadmill from springing up Removing the weight of the motor will wh GA We AL significantly reduce the weight in the front end of the treadmill 4 Loosen the attachment nuts A holding the motor bracket to the frame Figures 5 amp 6 5 Tighten bolt B to increase tension on drive belt Figures 5 amp 6 6 Tighten or loosen bolt C to straighten motor bracket and ensure that the pulleys on the motor and front roller are properly aligned Figures 5 amp 6 7 Tighten the two motor bracket attachment nuts A when finished Figures 5 amp 6 8 Verify the proper tension on the drive belt Using a timing belt tension gauge the proper tension should be between 65
29. P function and LED 5 is for the DOWN function Lower Board LED Diagnosis Figure 19 b ws 0 20 5 OG gg INL 55 vro M 4 CT 4 90 0302038 WJ28025T 05 LED 1 DC Voltage Indicator When the power switch is turned on LED 1 dimly lights up If the belt begins to run LED will remain Power is stored in the board do not touch LED 2 amp 3 Motor indicator The LED 3 will come on if the motor starts to run The motor control board will begin detecting the status of the motor and if everything is OK then LED 2 will turn on in 1 or 2 seconds LED 4 amp 5 Incline Motor Indicator When the upper board is commanding the incline motor to move UP or DOWN the LED s go on LED 4 is for the UP function and LED 5 is for the DOWN function WARRANTY INSTRUCTIONS RECOMMENDED TOOLS PROPER MAINTENANCE HEART REATE USAGE 5 STEP WIRING DIAGRAMS DIAGNOSTIC PROCESS AND SCHEMATICS ENGINEERING 2 5 lt amp Q a MODE TROUBLESHOOTING SPARE PARTS REPLACEMENT 2 SA TE
30. Replace drive motor Reference Optical Disk Digital Sensor Drive Motor Replacement in Spare Parts Replacement section Replace MCB Refer ence Motor Control Board replacemment 53 Replace circuit breaker A a PROPER HEART REATE 5 STEP DIAGNOSTIC VOLTAGE CHECKS SAFETY INSTRUCTIONS RECOMMENDED WIRING DIAGRAMS WARRANTY MAINTENANCE ENGINEERING 5 8 5 5 TOOLS AND SCHEMATICS REPLACEMENT PROCESS USAGE LED DIAGNOSIS MODE Elevation Troubleshooting AINVUUVM Symptom Possible Cause Test Procedure Elevation motor will incline Failed elevation motor Verify there are no pinches or Replace elevation motor and decline without com cuts on the elevation wires Reference Elevation Motor mand Verify the connections of Replacement in Spare Parts above wires Replacement section SNOILINYLSNI ALIAS Elevation motor starts run Failed motor control board Turn power on Do not press Replace MCB Reference ning as soon as the power is MCB start Wait 30 60 seconds and Motor Control Board Replace turned on Constant down see if motor is hot Use caution ment in Spare Parts Replace Motor can get very hot ment section 1001 U30N3 AW0J34 Elevation motor does not Elevation motor is not calibrated Verify elevation motor shaft Replace elevation motor Reach minimum or maxi correctly or failed incline motor positi
31. Wire is attached 5 STEP DIAGNOSTIC PROCESS Defective grounding fibers Feel underside of running If it is rough or worn in tex in running belt belt It should have a ture replace running belt smooth cottony feel to it lubricate VOLTAGE CHECKS 0 LED DIAGNOSIS WIRING DIAGRAMS AND SCHEMATICS ENGINEERING MODE 8 5 ES SPARE PARTS REPLACEMENT SNOILINYLSNI 51001 0234 ALIAS 39NVN31NIVMA 39751 21 8 LUV3H 5512044 8180 8 10 4315 5 30M 3NIU31NI9N3 AN3H33V 1434 1YVd 34 45 SISUNSVIG 031 723 2 39V110A 2 SHWV89VI 3NIHIM 3 5 A i No Motor Movement Troubleshooting Symptom Possible Cause Test Procedure No motor movement Upon pressing start console responds normally keys respond normally and eleva tion works but no belt movement Inadequate power Damaged or improper wir ing Failed motor contro board MCB Failed drive motor Failed optic sensor Check for dedicated cir cuit 20 amp is ideal and check wall outlet voltage 120 VAC Make sure machine is not on extension cord or surge protector Verify there are no pinch es or cuts in the power cord power wires motor wires or console cable Verify the connections of above wires and cords Verify power to MCB Ref erence Voltage Checks and LED Diagnosis sec t
32. art rate handlebars e Constant movement and vibration due to constantly holding the heart rate handlebars while exercising If you are receiving erratic heart rate readouts try to only hold the grips long enough to monitor your heart rate e When you are breathing heavily during a workout e When your hands are constricted by wearing a ring e When your hands are dry or cold Try to moisten your palms by rubbing them together to warm them e Anyone with heavy arrhythmia e Anyone with arteriosclerosis or peripheral circulation disorder e Anyone whose skin on the measuring palm is especially thick Lubricating the Air Shock Procedure 1 Fold the treadmill to the upright position making sure the treadmill is locked securely 2 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 Figure 11 Air Shock WARRANTY SAFETY INSTRUCTIONS 5 STEP PROPER HEART REATE aa USAGE DIAGNOSTIC PROCESS VOLTAGE CHECKS MAINTENANCE AND LED DIAGNOSIS WIRING DIAGRAMS AND SCHEMATICS ENGINEERING MODE TROUBLESHOOTING SPARE PARTS REPLACEMENT Five Step Diagnosis Process AINVUUVM e following steps are provided as routine checkpoints when diagnosing prob idel ag V NN ens on a Horizon Fitness treadmill If followed correctly these checkpoints h G soud help dia
33. ce lower board highest position as soon as highest position as soon as power is applied power was applied without start being pressed E s m ES 8 5 AN3H33V 1434 51 34 45 Noise Troubleshooting L Symptom Possible Cause Test Procedure Thumping sound when New treadmill Let the treadmill run for unning belt is engaged about 30 minutes without load to break new tread mill running belt in WARRANTY SAFETY INSTRUCTIONS Failed roller Replace front or rear roller as needed Reference Roller Replacement in Spare Parts Replacement section RECOMMENDED TOOLS MAINTENANCE ubbing or grinding Misaligned drive belt Remove motor cover and Align drive belt and or ound from underneath verify alignment of drive replace drive belt Ref belt erence Tensioning the Inspect for debris on Drive Belt in Maintenance drive motor pulley front section roller pulley or on drive belt PROPER HEART REATE USAGE 5 STEP DIAGNOSTIC PROCESS Failed drive motor bear Replace drive motor ings Reference Optical Disk Digital Sensor Drive Motor Replacement in Spare Parts Replacement section VOLTAGE CHECKS D LED DIAGNOSIS Motor brushes are not Inspect motor brushes Replace motor brushes seated properly and commutator for and or stone commutator abnormal wear Reference Motor Brush Replacement page 50 and Stoning the Com mutator in Spare Parts Replacement section WIRI
34. cedures There are three different situations where you would be required to add lubrication to a Horizon Fitness treadmill 1 MAINTENANCE Silicone needs to be applied to a Horizon Fitness treadmill regularly Horizon Fitness recommends that lubrication be applied every three to six months depending on the number of users and the frequency of use Running Belt Running Deck Silicone Oil Application 2 BELT REPLACEMENT When lubrication is added to a treadmill deck at the factory it is infused 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 lubri cation 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 a With the 6mm Allen wrench loosen the bolts that hold the rear roller in place It is not necessary to take off the roller just loosen it enough so that you can fit your hands underneath the belt comfortably NA OG Gi isa good idea to note the position of the rear roller before removing For best al results place two removable marks on the left and right side of the deck and
35. e of carbon brush is pitted rough or has burn marks replace the motor brush 6 Stone the surface of the motor commutator and blow out particles inside motor with an air com pressor ENGINEERING MODE 7 Install the motor brush and the motor brush cover 8 Insert old new motor brush making sure that the brush slides in and out easily TROUBLESHOOTING 9 Plug in the treadmill and let the treadmill run for about 1 hour at 5 mph to allow the proper seat ing of the brush E AINVUUVM SNOILINYLSNI AI34VS 5522094 39050 m 51509010 OFONINNODTY SISONSVIU 031 NV SOILVNFHIS 39V110A 9315 5 SWV4SVIC 3NIHIM 300N INIYFINIINI INILOOHSIT9NOUL 8 E 5 Motor Control Board Replacement Tools Required e Philips Screwdriver Procedure 1 Turn off the power to the treadmill and unplug the power cord from the wall outlet 2 Remove the motor cover 3 Verify that LED MTR is not lit on the motor control board AUN IMPORTANT h f this LED is lit please wait approximately 1 minute until the light is out This is an indication that the Ww Stored power has left the board 4 Unplug motor optic sensor elevation speed sensor and AC wires from the motor control board 5 Remove the motor control board and replace it with a new one 6 Reconnect all the w
36. e shell If not replacing reed switch skip to step 5 3 For Models T61 T64 CST 3 5 amp 4 5 DT650 amp 850 WT950 Only Unplug and remove reed switch from small plastic knobs Figures 71 amp 72 Figure 7 1 Figure 72 EF Q AAA TT 4 For Models PST 6 amp 8 1 27 5 2 Unplug reed switch and remove switch from fixing plate Figure 73 You will need an adhesive when reinstalling new switch Figure 73 Reed Switch Upper Board Reed Switch Replacement 5 Unplug all the cables to the upper board WARRANTY 6 Remove screws holding upper board to faceplate and replace old upper board with new one Figures 74 75 76 Figure 4 SAFETY INSTRUCTIONS Faceplate RECOMMENDED TOOLS MAINTENANCE Console Shell PROPER HEART REATE USAGE Figure 75 Upper Board Console Shell 5 STEP DIAGNOSTIC PROCESS VOLTAGE CHECKS ND LED DIAGNOSIS WIRING DIAGRAMS AND SCHEMATICS Figure 76 ENGINEERING MODE TROUBLESHOOTING pr Console gt zo w S Membrane Keypad EL Paper Overlay Replacement Tools Required AINVUUVM e Philips Screwdriver e Flat Blade Screwdriver Procedure SNOILINYLSNI AI34VS Figure 77 Figure 78 1001 G3N32N033H Faceplate EL Paper 7 Overlay Membrane Keys 39NVNINIVI 19 50 21 4 14044 Membrane Keys 5532084 5150 9 1
37. gainst defects in workmanship and materials for the above warranty periods so long as it remains in the possession of the original owner Horizon Fitness shall cover the labor cost for the repair of the device for the above warranty periods so long 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 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 discol oration 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 at Horizon Fitness option the product at one of its authorized service centers A Horizon autho rized 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 of purchase Parts and electronic components reconditi
38. gnos the majority of problems that may be encountered SNOILINYLSNI AI34VS 1 Proper supplying power to treadmill e Make sure the treadmill is not on an extension cord or surge protector Extension cords and surge protectors create energy loss which prevents proper voltage from being supplied to the treadmill 1001 G3N32N033H e 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 e Make sure that proper voltage is being supplied from the wall outlet 39NVNINIVI Hazardous voltages will be tested in the following procedure AWARNING Exercise extreme caution when performing these procedures Do not connect or hemme De any wiring connectors or other components with the power applied to the readmill 19 50 21 4 14044 e Disconnect the treadmill power cord from the wall outlet Using an AC voltmeter verify that the proper 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 Figure 12 SOILVNFHIS SISUNSVIG 031 NV SHWV89VI0 3NIHIM 5 39V110A 300N INIYFINIINI 2 Proper Wiring INILOOHSIT9NOUL Verify that all wires are secure and attached in the correct position Reference Wi
39. he hood removed remove jewelry especially from ears and neck tie up long hair remove neckties and do not wear loose clothing e 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 e 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 e Exercise caution when touching any wire or electrical component during treadmill operation e When it is necessary to lift the treadmill ensure that the treadmill has adequate support Do not lift amp 5 1001 39NVNINIVI G30NINNOIIY 19 50 21 4 1UV3H 14044 the treadmill by the front Safety guidelines you should know and follow include 5532084 5150 9 10 9315 5 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 com pletely assembled or is damaged in any way exercise extreme caution while operating and checking the treadmill e When opera
40. he 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 should be displayed once in the Engineering Mode Menu Eng Display and Button Check 1 While in the Engineering Mode Menu press Speed or 2 Press Enter to select Engo 3 Press Start button to verify all LED s until appears in the display Eng1 Hardware Test 1 While in the Engineering Mode Menu press Speed or 2 Press Enter to select Engl 3 Press Start button to verify belt movement sensor wire and elevation function un until Engl appears in the display Eng2 Auto Calibration 1 While in the Engineering Mode Menu press Speed or 2 Press Enter to select 3 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 until Eng2 appears in the display Eng3 Software Setup Using incorrect software settings will result in erratic speeds w incorrect button function elc un 1 While in the Engineering Mode Menu press Speed or 2 Press
41. ion Measure voltage output from motor Reference Voltage Checks and LED Diagnosis section If the AC voltage is miss ing or incorrect check the AC service or consult an electrician Replace parts as needed Replace MCB Reference Motor Control Board Re placement in Spare Parts Replacement section Replace drive motor Reference Optical Disk Digital Sensor Drive Motor Replacement in Spare Parts Replacement section Replace optic sensor Reference Optical Disk Digital Sensor Drive Motor Replacement in Spare Parts Replacement section Erratic Speed Troubleshooting Symptom rratic speeds Upon pressing start belt speed increases rapidly and then omes to a complete stop quickly pressing start belt speed increases rapidly and does ot stop rratic speeds Running belt speed is not stable Possible Cause Test Procedure Failed optic sensor Failed motor control board MCB Machine not calibrated properly Running belt is too loose or too tight Drive belt is too loose or too tight Inadequate power Failed or improper wiring Run auto calibration Refer ence Engineering Mode section The running belt should not slip at all when customer is using the machine The drive belt should have approximately 3 8 of inch deflection Check for dedicated circuit 20 amp is ideal and check wall outlet voltage 120 VAC Make sure machine is not on extensi
42. ires to the motor control board Figure 50 Figure 50 Wire from On Off Switch Wire from On Off Switch Black Motor Wire Upper Board Console Cable Replacement Tools required Philips Screwdriver eWire Cutters eZip Ties TE Procedure 2 1 Turn off the power to the treadmill and unplug the power cord from the wall outlet 2 Remove screws connecting faceplate to console shell Figures 51 52 53 3 Disconnect console cable from upper board Faceplate RECOMMENDED TOOLS MAINTENANCE onsole Shell 5 STEP PROPER DIAGNOSTIC HEART REATE PROCESS USAGE VOLTAGE CHECKS Ni LED DIAGNOSIS 5 Disconnect console cable in the upper left hand corner of the console and secure cable so that it does not fall down console mast 6 Cut zip ties that hold console cable the handle bar frame Figure 57 7 Install new console cable Figure 58 and secure it to the handle bar frame WIRING DIAGRAMS AND SCHEMATICS ENGINEERING MODE TROUBLESHOOTING EE Ea AINVUUVM SNOILINYLSNI AI34VS 1001 G3N32N033H 19 50 21 4 1UV3H 434044 5512044 100 INIYFINIINI m 9 B 5 SISONSVIU 031 SOILVNFHIS SWV4IVIC 3NIHIM 5150 9 10 39NVNINIVI 9315 5 39V110A INILOOHSTIANOYL Console Mast Cable Replacement Tools Required e Philips Screwdriver e 5mm Allen Wrench
43. is erratic or the belt speed does not correspond to what is displayed on the console Reference Engineering Mode Section 5 Voltage Checkpoints Diagnostic LED s e Verify that the motor control board is functioning properly by referencing the Diagnostic LED s located on the lower control board Reference Voltage Checks amp LED Diagnosis Section e Verify that proper voltage is being transferred through the console cable DOGG 7 If the techniques described in the five step diagnostic process did not resolve the problem reference the ww symptoms in the table of contents and review other possible causes in the troubleshooting section SAFEIY WARRANTY INSTRUCTIONS RECOMMENDED TOOLS 5 STEP PROPER WIRING DIAGRAMS HEART REATE MAINTENANCE USAGE AND SCHEMATICS ENGINEERING MODE lt i S ES VOLTAGE CHECKS 5 8 amp LED DIAGNOSIS TROUBLESHOOTING SPARE PARTS REPLACEMENT Console Cable Voltage Chart DC Volts AINVUUVM Figure 15 O B1 Incline VCC O B2 Incline Pot Incline GND B4 Digital GND B5 Digital GND B6 RPM IO B7 Power Voltage to UCB B8 Power Voltage to UCB B9 Speed Command PWM P B10 Drive Motor Relay SNOILINYLSNI AI34VS B11 Incline Down B12 Incline Up CORRECT VOLTAGE FOR WIRE HARNESS 1001 G3N32N033H B1 Black 2 5 vdc constant B7 Blue 15 vdc consta
44. ls Figures 35 amp 36 2 For Models T61 T64 CST 3 5 amp 4 5 DT650 amp 850 WT950 Only Peel off grip tape stickers on front guide rail to expose the two screws underneath Remove screws and remove front guide rail Bolt B Front Roller Bolt A Motor Pulles 4 Deck Bolt A Drive d Front Roller Figure 37 Rear Rolle 3 Remove tension bolts and remove the rear roller Figure 37 Running Belt Deck Replacement 4 Remove the speed sensor bracket WARRANTY 5 Loosen or remove the front roller bolt A on drive belt side 6 On the opposite side of the front roller remove front roller bolt B SAFETY INSTRUCTIONS 7 Press against the drive belt and guide it towards the left until it is released from the front roller and remove front roller 8 Remove deck bolts RECOMMENDED TOOLS ha Q D S IMPORTANT If you are only replacing the belt then it is not necessary to remove all the deck w bolts Only remove the left hand or right hand bolts and slide the running belt MAINTENANCE 9 Replace running belt and or deck 10 Tighten the deck bolts PROPER HEART REATE USAGE 11 Place Drive Belt around the front roller 12 Reinstall the front roller 5 STEP DIAGNOSTIC PROCESS 13 Reattach drive belt to front roller and motor pulleys 14 Reattach the rear roller but do not tighten completely 15 Add silicon oil lubrication to deck VOLTAGE CHECKS AND L
45. lt tension gauge the proper tension should be between 65 to 75 185 If a 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 TROUBLESHOOTING adjust SPARE PARTS REPLACEMENT Stoning the Motor Commutator 1 Unplug the power cord from the wall outlet AINVUUVM AA A A 4 IMPORTANT Do not plug in the power cord and do not turn on the treadmill when the motor R NNE brushes are removed from the drive motor SNOILINYLSNI AI34VS 2 Remove the brush covers on the drive motor 3 Gently insert commutator stone into motor so that it makes contact with commutator 1001 Figure 49 Commutator 19 50 21 4 LUV3H JINVNILNIVW 14044 5532084 5150 9 10 9315 5 Commutator Stone 4 Spin the motor flywheel by hand until any abnormal marks are removed and the commutator has a shiny copper finish SISONSVIU 031 NV 723 2 39V110A 5 Blow any dust and particles with compressed air from the motor commutator when finished 6 Run the treadmill for 15 minutes at 3 5 mph to seat the brushes properly SJIILYWIHIS SWV4IVIC INIYIM 7 Inspect the motor commutator again for any unusual wear 8 Repeat stoning process if necessary 100 INILOOHSTIANOYL ANINIINIDNT ININIIVIdIY 51 34 45 Ls Treadmill Deck Pro
46. n bolts A SAFETT WARRANTY INSTRUCTIONS RECOMMENDED TOOLS MAINTENANCE 5 DIAGNOSTIC PROCESS PROPER HEART REATE USAGE WIRING DIAGRAMS CHECKS AND LED DIAGNOSIS AND SCHEMATICS ENGINEERING MODE TROUBLESHOOTING e 5 REPLACEMENT Motor Brush Replacement Tools Required AINVUUVM e Flat Blade Screwdriver Procedure SNOILINYLSNI AI34VS 1 Turn off the power to the treadmill and unplug the power cord from the wall outlet 2 Remove Brush Covers Figures 43 amp 44 1001 G3N32N033H Figure 43 Figure 44 19 50 21 4 1UV3H 39NVNINIVI 14044 5532084 5150 9 10 9315 5 3 For Models T61 T62 C 13 5 DT650 amp 850 WT950 1 2T 2 2T Only Remove clip and spring hold ing motor brush remove motor brush Figures 45 amp 46 SISUNSVIG 031 N 723 2 39V110A SOILVNFHIS SWV4IVIC 3NIHIM Figure 45 Figure 46 100 INIYFINIINI INILOOHSITINOUL 58 Sm Motor Brush Replacement 4 For Models T63 T64 C 14 5 3 27 5 2T Only Remove brushes Figure 47 WARRANTY Figure 47 RECOMMENDED SAFETY TOOLS INSTRUCTIONS PROPER HEART REATE USAGE 5 Check the surface of the motor brush Figures 48 Figure 48 Burned Pitted 5 STEP DIAGNOSTIC PROCESS Smooth VOLTAGE CHECKS AND LED DIAGNOSIS WIRING DIAGRAMS AND SCHEMATICS If the surfac
47. nt Range 15 0 to 17 0 vddc B2 Brown 2 5 vdc at 0 0 incline 0 5 vdc at max incline B8 Purple 15 vdc constant Range 15 0 to 17 0 vdc Voltage changes with each change in incline B9 Grey 0 0 vdc before started 0 5 vdc at 0 5 mph 4 vdc at 10 mph B3 Brown n a ground Voltage changes as speed changes 4 Orange n a ground B10 White 1 6 vdc before started 0 0 vdc after started gt B5 Yellow n a ground B11 Pink 0 0 vdc before started 0 0 vdc while inclining m B6 Green When speed sensor aligned to magnet short 41 9 vdc while declining Voltage constant while inclining declining E 0 0 vdc When sensor not aligned open 5 0 vdc B12 Lt Blue 0 0 vdc before started 1 9 vdc while inclinig 0 0 vdc S while declining Voltage constant while inclining declining mox 558 cg m Console Cable Voltage Check L TE F 16 5858 igure AAD AG m SISONSVIG 077 SOILVNFHIS SWV89VI0 3NIHIM 300N INIYFINIINI check the voltage of specific function i e elevation motor control etc place the negative lead of your multi meter on pin B3 B4 or B5 and place the positive lead on the desired pin Follow the voltage chart above for the correct voltages INILOOHSITANOUL Wire colors are subject to change IN3H33VTd34 51 34 45 Motor AC Wire Voltage Check WARRANTY Motor Voltage Check Figure 17
48. off switch e Unplug the power cord at the wall outlet VOLTAGE CHECKS AND LED DIAGNOSIS e Fold the treadmill into the upright position making sure that the foot lock latch is secure e Move the treadmill to a remote location WIRING DIAGRAMS AND SCHEMATICS 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 ENGINEERING MODE Every Month e Inspect all assembly bolts of the machine for proper tightness TROUBLESHOOTING Each 3 6 months e Add lubrication to deck and running belt Use lubrication provided by Horizon Fitness only e ubricate the air shocks with a Teflon based spray SPARE PARTS REPLACEMENT 5 Tensioning the Running Belt If you can feel a slipping sensation when running on the treadmill the running belt must be tight AINVUUVM ened In most cases the belt has stretched from use causing the belt to slip This is a normal and common SNOILINYLSNI AI34VS adjustment Make sure that the unit is turned off and not running 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 slipping Repeat if necessary but NEVER TURN the roller 1001 G30N34N033H bolts more than 1 4 turn at a time 19 50 21 4 1UV3H 14044 Figure 2 5532084
49. on Reference elevation Reference Elevation Motor mum settings motor replacement in Spare Replacement in Spare Parts Parts Replacement section Replacement section 39NVN31NIVMA gt 3 No elevation function Failed console cable Check voltage and continuity Replace console cable Refer MC of console cable Reference ence Console Mast Cable Voltage Checks and LED Replacement in Spare Parts Diagnosis section Replacement section gt 5 Failed elevation motor Press start and check to see If the up LED flashes but the RES if the down LED is constantly elevation does not increase lit on MCB Enter engineer replace elevation motor and ing mode Eng and press console cable Reference 5 start Repeatedly increase the Elevation Motor page 56 and incline Reference Voltage Console Mast Cable Replace 2 Checks and LED Diagnosis ment in Spare Parts Replace 8 section ment section Failed upper board Press start and check to see If the up LED flashes and the if the down LED is constantly elevation increases replace lit on MCB Enter engineer upper board Reference Upper ing mode Eng 1 and press board Reed switch Replace start Repeatedly increase the ment in Spare Parts Replace incline ment section Reference Voltage Checks and LED Diagnosis section 30M 3NIU31NI9N3 Elevation is stuck at the Failed lower board If the incline went into the Repla
50. on cord or surge protector Verify there are no pinches or cuts in the power cord power wires motor wires or console cable Verify the connections of above wires and cords Inadequate lubrication on deck Place hand underneath and running belt Failed motor control board MCB running belt and feel for adequate silicone application Replace optic sensor Refer ence Optical Disk Digital Sen sor Drive Motor Replacement on in Spare Parts Replace ment section Replace MCB Reference Mo tor Control Board Replace ment in Spare Parts Replace ment section If unit fails to auto calibrate refer to auto calibration troubleshooting on page Tighten running belt Refer ence Tensioning and Aligning the Running Belt in Mainte nance seciton Tighten drive belt Reference Tensioning the Drive Belt in Maintenance section If the AC voltage is missing or incorrect check the AC service or consult an electrician Replace parts as needed Apply silicone Reference Silicon Dil Application in Maintenance section Replace MCB Reference Motor Control Board Re placement in Spare Parts Replacement section SAFETY WARRANTY INSTRUCTIONS RECOMMENDED TOOLS 5 STEP PROPER ENGINEERING ee DIAGNOSTIC HEART REATE MAINTENANCE PROCESS USAGE SPARE PARTS REPLACEMENT VOLTAGE CHECKS 5 LED DIAGNOSIS MODE SNOILINYLSNI 51001 U30N3 AW0J34
51. oned 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 m EE WARRANTY INSTRUCTIONS RECOMMENDED TOOLS PROPER MAINTENANCE HEART REATE USAGE 5 STEP DIAGNOSTIC PROCESS WIRING DIAGRAMS ENGINEERING VOLTAGE CHECKS AND SCHEMATICS LED DIAGNOSIS MODE TROUBLESHOOTING SPARE PARTS REPLACEMENT Important Safety Instructions Warning statements indicate a particularly dangerous activity You should be extremely cautious when doing the following AINVUUVM e Removing power from the treadmill or removing the power cord from the wall outlet Always en sure 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 e Removing the motor cover exposes high voltage components and potentially dangerous machinery Exercise extreme caution when you perform maintenance procedures with the motor cover removed e During service operations you will be very close to moving machinery and high voltage components When you perform maintenance procedures with t
52. ove overlay and press keypad for proper function Peel up overlay and reposi tioning it brane keypad Reference Membrane Keypad EL Paper Overlay Replacement in Spare Parts Replacement section SAFETY WARRANTY INSTRUCTIONS RECOMMENDED TOOLS PROPER MAINTENANCE HEART REATE USAGE 5 STEP DIAGNOSTIC PROCESS WIRING DIAGRAMS AND SCHEMATICS ENGINEERING SPARE PARTS VOLTAGE CHECKS ES E 8 5 ES LED DIAGNOSIS MODE REPLACEMENT SNOILINYLSNI 51001 U30N3 AW0J34 AI34VS 39NVN31NIVMA 39751 414 LUV3H 5512044 8180 8 10 4315 5 SISONSVIG 031 ONY 723 2 39V110A 2 SHWV89VI 3NIHIM 3000 3NIU31NI9N3 AN3H33V 1434 E 5 3 I 5 51 34 45 Heart rate erratic or no heart rate function Hand Grips Heart rate erratic or no heart rate func tion Telemetric chest strap Failed heart rate grips Failed heart rate receiver Failed upper board User error Electromagnetic interfer ence Failed telemetric chest strap or polar receiver Heart Rate Troubleshooting Reference Proper Heart Rate Usage section Reference Proper Heart Rate Usage section Reference Proper Heart Rate Usage section Check immediate area for causes of interference Florescent lighting electric dog fences large electric motors etc Reference Proper Heart Rate U
53. production change involving the motor control board has occurred effective 11 01 05 Units with 2 75 HP Drive Motors will not be affected by this production change PST8 and 5 2T Please check the serial number Pictured Below to verify the production change YEAR OF PRODUCTION DATE 0511 165 05110001 MONTH OF PRODUCTION This change will affect the service guide in the following ways The old motor control board has five diagnostic LED s and the new has only one LED which is the equivalent to LED 1 Therefore a complete LED diagnostic cannot be completed wiring diagram was not included for the new style motor control board supplied with this supplement Instructions for the motor control board replacement were not included in this service guide supplied with this supplement All other information in the service guide should be valid for both the new and old motor contro boards
54. rewdriver or by upper board Otherwise placing a jumper switch on replace reed switch Refer the connector ence Upper Board Reed Engage reed switch manu Switch Replacement in ally to ensure its function Spare Parts Replacement section Console only displays Safety key is positioned incor Remove safety key and Replace safety key dashes in the display win rectly or has failed reapply dow Magnet style key Test magnet 39751 21 8 LUV3H 5512044 8180 8 10 4315 5 Failed reed switch Short the switch connector If the upper board still dis on the upper board by using plays dashes then replace a flat blade screwdriver or by upper board Otherwise placing a jumper switch on replace reed switch Refer the connector ence Upper Board Reed Switch Replacement in Spare Parts Replacement section SIILYWIHIS SISONSVIG 031 ONY SWV289VI INIYIM SHIFHI 39V110A 30M 9NIU31NI9N3 3 E 5 E 3 32 1438 1YVd 34 45 Console Upper Board Troubleshooting Symptom No display on the console and power switch on machine is dark No display on the console and power switch on machine is lit Possible Cause Test Procedure Check for dedicated circuit 20 amp is ideal and check Wall outlet voltage 120 VAC Circuit breaker in home has Breaker on machine has Reset breaker Replace breaker if necessary tripped or has failed Failed power switch
55. ring Diagrams and Sce matics section e Verify that there aren t any pinches or cuts in any of the wires especially the console cable connecting from the motor control board to the upper board Replace any wires that are pinched or cut ININIIVIdIY 51 4 34 45 Five Step Diagnosis Process 3 Proper Motor Function Verify that the treadmill is properly lubricated Reference Maintenance Section and drive motor is operating at the proper amperage rating To verify the current draw place a clamp meter around the red motor wire If a clamp meter is not available an additional wire harness can be produced to measure amperage with a standard voltmeter Figure 14 e Remove the brush covers on the drive motor and inspect the brushes and the motor commutator for any uneven wear If the surface of the motor brush is pitted rough has burn marks or the commutator has a black residue on it replace the motor brush and stone the motor commutator Reference Motor Brush Replacement and Stoning the Commutator in Spare Parts Replacement Section 4 Proper Speed Calibration Jo ensure proper belt speed and proper calibration use engineering mode to verify that machine is running in MPH not KM all models and that the correct roller diameter is set 1 2T 5 2T only Reference Engineering Mode Section e Auto calibrate the machine from engineering mode if the belt speed
56. s the Speed or 2 Press Enter to select 3 Press Start to begin until Eng2 appears in the display The treadmill running belt will begin moving and will automatically begin the auto calibration sequence to properly set and store the speed values Upon successful calibration there will be four beeps and it will automatically exit Engineering Mode and will return you to the original screen Eng3 Manual Calibration Use to manually calibrate the running belt speed if auto calibration is unsuccessful un 1 While in the Engineering Mode Menu press the Speed or 2 Press Enter to select 3 Press Speed or 4 Press START to begin 5 Press Speed or until the speed is approximately 0 5 mph 6 Press and hold Start for 3 5 seconds until the console beeps 3 times 7 Press and hold Stop for 3 5 seconds until the console beeps 2 times 8 Press Speed until the display shows P2 9 Repeat steps 4 7 with the speed being adjusted to 2 4 mph 10 Press Speed until the display shows P3 11 Repeat steps 4 7 with the speed being adjusted to 6 0 mph 12 Press Speed until the display shows P4 13 Repeat steps 4 7 with the speed being adjusted to 8 4 mph 14 Press Speed until the display shows P5 15 Repeat steps 4 7 with the speed being adjusted to 12 0 mph 16 Press and hold Stop for
57. sage section Symptom Possible Cause Test Procedure Repair User error Reference Proper Heart Rate Usage section If there is absolutely no heart response replace heart rate grips If proper heart rate instructions are followed and heart rate continues to be erratic replace heart rate receiver Replace upper board Reference Upper Board Reed Switch Re placement in Spare Parts Replacement section Remove interference from vicinity of the unit Replace chest strap and or upper board Refer ence Upper Board Reed Switch Replacement in Spare Parts Replacement section E Static Troubleshooting WARRANTY Symptom Possible Cause Test Procedure Static shocks when Machine on carpet Place a rubber mat under touching machine machine to reduce static carried from carpet SAFETY INSTRUCTIONS Nylon clothing Wear cotton clothing to reduce static on the body or spray static guard on clothing prior to using machine Dry air in home Use humidifier to increase humidity in air Inadequate lubrication on Place hand underneath Apply silicone lubrication deck and running belt running belt and feel for Reference Treadmill adequate silicone appli Deck Procedures lube in cation Maintenance section RECOMMENDED MAINTENANCE TOOLS PROPER HEART REATE USAGE Improper grounding of Inspect heart rate receiver Reattach grounding wire heart rate receiver to insure that grounding
58. sible to the magnet in the pulley without touch ing and the sensor bracket 90 degree angle not bent in any way Put machine into Engl and check for slight fluctuation of speed in speed window of display Speed should not fluctuate more than a few hundredths Failed motor control board If other tests mentioned above are normal then replace MCB Replace MCB Reference Motor Control Board Replace ment in Spare Parts Replace ment section Circuit Breaker Troubleshooting Symptom Possible Cause Test Procedure circuit breaker Inadequate lubrication on deck and running belt Failed running belt Failed drive motor Failed motor control board MCB Machine breaker will Failed circuit breaker trip Check for dedicated cir If the AC voltage is miss cuit 20 amp is ideal and ing or incorrect check the check wall outlet voltage 120 VAC Make sure machine is not on extension cord or surge protector Place hand underneath running belt and feel for adequate silicone appli cation Feel underside of running belt It should have a smooth cottony feel to it Perform AMP draw test on motor Refer to 5 Step Diagnostic section AC service or consult an electrician Apply Silicon lubrica tion Reference Silicon Oil Application in Maintenance section Replace running belt Reference Running Belt Deck Replacement in Spare Parts Replace ment section
59. the run NG 3 h n ng belt When reinstalling match up the marks for proper tension b Take 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 C Tighten rear roller to proper position d Wipe off any excessive silicon oil that may have seeped out from underneath the running belt with a damp cloth Please contact the Horizon Fitness service department to obtain the proper lubrication for reapplication SAFETT WARRANTY INSTRUCTIONS RECOMMENDED TOOLS 5 PROPER WIRING DIAGRAMS DIAGNOSTIC HEART REATE MAINTENANCE PROCESS USAGE AND SCHEMATICS ENGINEERING VOLTAGE CHECKS Ni LED DIAGNOSIS MODE TROUBLESHOOTING SPARE PARTS REPLACEMENT SNOILINYLSNI 81001 30N3WW0938 AI34VS 39NVNINIVI 5 3 m 5532084 5150 9 10 9315 5 SISUNSVIG 031 NV 39V110A SOILVNFHIS Suv 3NIHIM 300N INIYFINIINI INILOOHSITANOUL ININIIVIdIY 5149 34 45 Proper Heart Rate Usage HAND GRIPS Place the palm of you hands directly on the grip pulse handlebars Both hands must grip the bars for your heart rate to register It takes 5 consecutive heartbeats 15 20 seconds for your heart rate to register accuratly When gripping the pulse handle bars do not grip tightly Holding the grips tightly may elevate your blood pressure
60. ting the treadmill do not wear loose clothing Do not wear shoes with heels or leather soles Check the soles of your shoes and remove any embedded stones Tie long hair back e Use care when getting on or 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 guiderails of the treadmill You should also step off the belt and onto the guiderails of the treadmill after turning off the run ning belt e Do not rock the unit Do not stand or climb on the handrails electronic console or motor cover e Do not set anything on the handrails electronic console or motor cover 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 attach ments might cause injuries e Turn off the treadmill when adjusting or working near the rear 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 SISUNSVIG 031 aN 19110 300N 82 T 9
61. w of the air shock to the frame and remove top portion of shock Figures 83 84 Figure 83 Figure 84 39NVNINIVI Top Screw Top Screw 39751 21 4 LUV3H 14044 ay A 5532084 5150 9 10 9315 5 Bottom Screw SISONSVIU 031 5 39V110A 0 3 Leave bottom screw and nut secure and unthread shock from bottom screw 4 Remove bottom screw from the new shock Figure 85 SOILVNFHIS SWV4SVIC 3NIHIM Figure 85 300N INIYFINIINI 00853140041 5 Thread the new shock into the bottom screw that is already attached to the fold frame DH 53 E gt 58 6 Reattach top screw and tighten nut Notes CUSTOMER TECH SUPPORT If you have any questions or comments you may contact one of our trained customer technicians via phone email or our website Customer Tech Support Hotline 1 800 244 4192 Email commentsQhorizonfitness com Website www horizonfitness com Customer Tech Support hours Monday Friday 8 am 5 pm CST excluding holidays oR 2o Designed for life NEW MOTOR CONTROL BOARD Optic Sensor Console Cable Elevation 2 Speed Sensor E C _ f Af 1 Q ao so 28000008 IL Je s Sa ai 80000 O Qu Og ap 0 44 em Motor Wires LED 1 A mid
62. xperience 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 Do not remove the treadmill motor cover or roller covers e Treadmill should be plugged into a dedicated 20 amp circuit for optimal performance ENGINEERING TROUBLESHOOTIN OUBLESHOOTING MODE SPARE PARTS REPLACEMENT Required Tools and Equipment The following list is a summary of the tools and equipment required by the procedures in this manual AINVUUVM Tools are not supplied by Horizon Fitness SNOILINYLSNI AI34VS e Phillips screwdrivers e Anti static wrist strap when handling electronic parts 8 5 e Flat head screwdrivers e Digital multi meter e Drive belt tension gauge 39NVNINIVI e Allen wrench set Metric e Open end wrenches of assorted sizes Metric 19 50 21 4 1UV3H 14044 e Clamp on amp meter e 1 2 drive ratchet and sockets of assorted sizes e Blue Thread Lock 5532084 5150 9 10 9315 5 e Cable ties e Motor commutator stone e Needle nose pliers SISUNSVIG 031 aN 723 2 39V110A Damp cloth Rubber mallet e Drop cloth SJIILYWIHIS NI SWV4IVIC INIYIM e Ruler

2006 Treadmill Service Manual

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