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Horizon Fitness CST 3.5, Service Manual, Page: 2 / 67

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Horizon Fitness CST 3.5 Service Manual Download Page 2

Warranty 

Safety Instructions 

Recommended Tools

Maintenance 

Proper Heart Rate Usage

Horizon Fitness “5-Step” Diagnostic Process 

Voltage Checks and LED Diagnosis

Wiring Diagrams and Schematics

Engineering Mode

Troubleshooting 

Spare Parts Replacement 

Table of Contents

3

4

6

7

14

16

18

31

34

46

REFER TO THE SUPPLEMENTAL SHEET ON THE LAST PAGE OF THE SERVICE MANUAL 

FOR THE MID SEASON PRODUCTION CHANGE ON THE LOWER CONTROL BOARD.

Summary of Contents for CST 3.5

Page 1: ...2006 Treadmill Service Manual Horizon Fitness Models T61 T62 T63 T64 CST 3 5 CST 4 5 DT650 DT850 WT950 PST 6 PST 8 1 2T 2 2T 3 2T 4 2T 5 2T...

Page 2: ...tic Process Voltage Checks and LED Diagnosis Wiring Diagrams and Schematics Engineering Mode Troubleshooting Spare Parts Replacement Table of Contents 3 4 6 7 14 16 18 22 31 34 46 REFER TO THE SUPPLEM...

Page 3: ...osion 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 Fitne...

Page 4: ...ll by the front Safety guidelines you should know and follow include Read the owner s manual and follow all operation instructions Operate the treadmill on a solid level surface Locate the rear of the...

Page 5: ...FUBM 4DSFX SPVOEFE 0VUMFU PY 5 4 PS SPVOEJOH 4DSFX SAFETY TIPS Never use the treadmill before securing the safety tether clip to your clothing If you experience chest pains nausea dizziness or shortn...

Page 6: ...by Horizon Fitness 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 wre...

Page 7: ...h the treadmill or in any other area where it can become pinched or cut Check the tension and alignment of the running belt Make sure that the treadmill belt will not damage any other components on th...

Page 8: ...In most cases the belt has stretched from use causing the belt to slip This is a normal and common adjustment Make sure that the unit is turned off and not running To eliminate this slipping tension...

Page 9: ...g 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...

Page 10: ...increase tension on drive belt Figures 5 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 6 7 Tighten...

Page 11: ...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 8 Tighten the two motor bracket atta...

Page 12: ...otor so that it makes contact with commutator PNNVUBUPS 4UPOF PNNVUBUPS Figure 49 4 Spin the motor flywheel by hand until any abnormal marks are removed and the commutator has a shiny copper finish 5...

Page 13: ...k 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 tre...

Page 14: ...derground 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 Gr...

Page 15: ...MAINTENANCE RECOMMENDED TOOLS SAFETY INSTRUCTIONS WARRANTY 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...

Page 16: ...t 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 Five Step Diagnosis Process...

Page 17: ...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...

Page 18: ...GUFS TUBSUFE FMMPX O B HSPVOE 1JOL WED CFGPSF TUBSUFE WED XIJMF JODMJOJOH SFFO 8IFO TQFFE TFOTPS BMJHOFE UP NBHOFU TIPSU WED XIJMF EFDMJOJOH 7PMUBHF DPOTUBOU XIJMF JODMJOJOH EFDMJOJOH WED 8IFO TFOTPS...

Page 19: ...KS AND LED DIAGNOSIS 5 STEP DIAGNOSTIC PROCESS PROPER HEART REATE USAGE MAINTENANCE RECOMMENDED TOOLS SAFETY INSTRUCTIONS WARRANTY 7 8JSFT 7 Motor Voltage Check AC Wire Voltage Check Figure 17 Figure...

Page 20: ...C16 R12 C17 R13 SJED08043EE R19 LED2 LED3 LED4 LED5 WJ28 025T 04 08 2 LED 5 LED 4 LED 3 LED 2 LED 1 Figure 19 a LED 1 Transfer indicators When the power switch is turned on LED 1 lights up meaning th...

Page 21: ...REV f 05 05 12 JOHNSONFITNESS D18 R27 R28 GND_S C26 R13 C30 R14 R4 D4 D17 7 D10 D7 R9 D9 R12 R2 R33 R34 DW UP D14 D8 D16 C3 D2 C24 R1 NTC1 C28 R26 USE JP2 C25 TZR1 NTC1 AC1 AC2 MT0302038 WJ28025T 05 0...

Page 22: ...BLACK BLACK RED WHITE BLACK WHITE GREEN Power Cord 110 120 VAC GREEN 2 5vdc EL Vcc 2 5v EL Pot Gnd Digital Ground RPM Power Voltage 15V Power Voltage 15V Speed Command pwr RELAY DOWN Incline UP Incli...

Page 23: ...S SAFETY INSTRUCTIONS WARRANTY Power Source Wiring Diagram 40 5 0 0 48 5 3 3 A Socket wire to breaker or on off switch B Ground C Socket wire to breaker or on off switch D On Off switch to motor contr...

Page 24: ...PROPER HEART RATE USAGE 5 STEP DIAGNOSIS PROCESS VOLTAGE CHECKS AND LED DIAGNOSIS WIRING DIAGRAMS AND SCHEMATICS ENGINEERING MODE TROUBLESHOOTING SPARE PARTS REPLACEMENT Upper Board Configurations Fi...

Page 25: ...IRING DIAGRAMS AND SCHEMATICS VOLTAGE CHECKS AND LED DIAGNOSIS 5 STEP DIAGNOSTIC PROCESS PROPER HEART REATE USAGE MAINTENANCE RECOMMENDED TOOLS SAFETY INSTRUCTIONS WARRANTY Upper Board Configurations...

Page 26: ...PROPER HEART RATE USAGE 5 STEP DIAGNOSIS PROCESS VOLTAGE CHECKS AND LED DIAGNOSIS WIRING DIAGRAMS AND SCHEMATICS ENGINEERING MODE TROUBLESHOOTING SPARE PARTS REPLACEMENT Upper Board Configurations Fig...

Page 27: ...RING DIAGRAMS AND SCHEMATICS VOLTAGE CHECKS AND LED DIAGNOSIS 5 STEP DIAGNOSTIC PROCESS PROPER HEART REATE USAGE MAINTENANCE RECOMMENDED TOOLS SAFETY INSTRUCTIONS WARRANTY Upper Board Configurations F...

Page 28: ...E PROPER HEART RATE USAGE 5 STEP DIAGNOSIS PROCESS VOLTAGE CHECKS AND LED DIAGNOSIS WIRING DIAGRAMS AND SCHEMATICS ENGINEERING MODE TROUBLESHOOTING SPARE PARTS REPLACEMENT Upper Board Configurations F...

Page 29: ...IRING DIAGRAMS AND SCHEMATICS VOLTAGE CHECKS AND LED DIAGNOSIS 5 STEP DIAGNOSTIC PROCESS PROPER HEART REATE USAGE MAINTENANCE RECOMMENDED TOOLS SAFETY INSTRUCTIONS WARRANTY Upper Board Configurations...

Page 30: ...ENANCE PROPER HEART RATE USAGE 5 STEP DIAGNOSIS PROCESS VOLTAGE CHECKS AND LED DIAGNOSIS WIRING DIAGRAMS AND SCHEMATICS ENGINEERING MODE TROUBLESHOOTING SPARE PARTS REPLACEMENT Upper Board Configurati...

Page 31: ...it will automatically exit Engineering Mode and will return you to the original screen Eng3 Software Setup 1 While in the Engineering Mode Menu press Speed or until Eng3 appears in the display 2 Pres...

Page 32: ...libration 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 s...

Page 33: ...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 an...

Page 34: ...le shell Reference Upper Board Reed Switch Replacement in Spare Parts Replace ment section Short the switch connector on the upper board by using a flat blade screwdriver or by placing a jumper switch...

Page 35: ...oltage check of 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 co...

Page 36: ...nd that it is secure Manually adjust the position of the reed switch trigger and or the plastic tab on the console shell Slot style safety key only Check for dedicated cir cuit 20 amp is ideal and che...

Page 37: ...o 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 k...

Page 38: ...rt Rate Usage section 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 Flor...

Page 39: ...humidity in air Apply silicone lubrication Reference Treadmill Deck Procedures lube in Maintenance section Reattach grounding wire If it is rough or worn in tex ture replace running belt and lubricat...

Page 40: ...ce Optical Disk Digital Sensor Drive Motor Replacement in Spare Parts Replacement section No motor movement Upon pressing start console responds normally keys respond normally and eleva tion works but...

Page 41: ...inch deflection Check for dedicated circuit 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 pinches or cuts in...

Page 42: ...w hundredths Adjust sensor bracket to correct position Check voltage and continuity of console cable Reference Volt age Checks and LED Diagnosis section Verify positioning of sensor wire Wire coming f...

Page 43: ...re 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 fee...

Page 44: ...ce Voltage Checks and LED Diagnosis section Press start and check to see if the down LED is constantly lit on MCB Enter engineer ing mode Eng1 and press start Repeatedly increase the incline Reference...

Page 45: ...load to break new tread mill running belt in Remove motor cover and verify alignment of drive belt Inspect for debris on drive motor pulley front roller pulley or on drive belt Inspect motor brushes...

Page 46: ...Cable Elevation Motor Upper Board Reed Switch Membrane Keypad EL Paper Overlay Air Shock Spare Parts Replacement 47 48 50 52 54 55 56 58 60 62 64 To Remove the motor cover on the PST6 PST8 and 2 2 5...

Page 47: ...ove 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 7 Reinstall the front roller Put Drive Belt o...

Page 48: ...r rear roller end caps and guide rails Figures 35 36 2 For Models T61 T64 CST 3 5 4 5 DT650 850 WT950 Only Peel off grip tape stickers on front guide rail to expose the two screws underneath Remove sc...

Page 49: ...r deck 10 Tighten the deck bolts 11 Place Drive Belt around the front roller 12 Reinstall the front roller 13 Reattach drive belt to front roller and motor pulleys 14 Reattach the rear roller but do n...

Page 50: ...ve the screws from the bottom motor cover Figure 39 40 4DSFXT 4DSFXT PUUPN PUPS PWFS PUUPN PUPS PWFS 4DSFXT Figure 39 Figure 40 5 For Models T61 T64 CST 3 5 4 5 DT650 850 WT950 Only Bring the deck bac...

Page 51: ...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 0QUJD 4...

Page 52: ...or 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 Brush Covers Figures 43 44 SVTI PWFS...

Page 53: ...rface of the motor brush Figures 48 6 Stone the surface of the motor commutator and blow out particles inside motor with an air com pressor 7 Install the motor brush and the motor brush cover 8 Insert...

Page 54: ...e 6 Reconnect all the wires to the motor control board Figure 50 LED 1 NTC C1 30A 120 240VAC JQX 15FS A COIL 12VDC C US CQC CHINA 30A 120 240VAC JQX 15FS A COIL 12VDC C US CQC CHINA DLS2 D1 NTC D6 C8...

Page 55: ...aceplate to console shell Figures 51 52 53 3 Disconnect console cable from upper board Figure 53 CONSOLE CABLE ZIP TIE CONSOLE FRAME 4 Remove screws holding console shell to handle bar frame Figures 5...

Page 56: ...y Remove the motor cover 3 For Models T61 T64 CST 3 5 4 5 DT650 850 WT950 1 2T Only Disconnect the console cable from the lower control board 4 For Models PST 6 8 2 2T 5 2T Only Lift up right side con...

Page 57: ...that it does not fall down console mast Figures 63 64 65 POTPMF BCMF Console Mast Console Cable Bolt POTPMF SBDLFUT MBU 8BTIFST PDL 8BTIFST PMUT POTPMF NBTU POTPMF BCMF POTPMF BTU 0ME POTPMF BCMF FX P...

Page 58: ...crewdriver 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...

Page 59: ...or Replacement Figure 69 7 Reinstall the top bolt to the elevation motor 1SPQFS FSP 4IBGU 1PTJUJPO 8 Reinstall the bottom bolt to the incline shaft Figure 70 When installing the new incline motor make...

Page 60: ...off the power to the treadmill and unplug the power cord from the wall outlet 2 Remove screws connecting faceplate to console shell 3 For Models T61 T64 CST 3 5 4 5 DT650 850 WT950 Only Unplug and rem...

Page 61: ...RECOMMENDED TOOLS SAFETY INSTRUCTIONS WARRANTY Upper Board Reed Switch Replacement 5 Unplug all the cables to the upper board 6 Remove screws holding upper board to faceplate and replace old upper bo...

Page 62: ...ewdriver Flat Blade Screwdriver Procedure 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...

Page 63: ...OOLS SAFETY INSTRUCTIONS WARRANTY Membrane Keypad EL Paper Overlay Replacement 4 Remove the overlay and keypad from faceplate Figures 80 81 82 Figure 80 Figure 81 Figure 82 Make sure all the adhesive...

Page 64: ...cket and Combination Wrench Procedure 1 Fold treadmill to locking position 2 Remove nut that secures the top screw of the air shock to the frame and remove top portion of shock Figures 83 84 3 Leave b...

Page 65: ...65 Notes...

Page 66: ...ve 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 comments horizonfitness com Websi...

Page 67: ...d 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 A wiring diagram was not included for the new style mo...

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