Horizon Fitness ELITE 1.1T Page 65 Service Manual Download

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Motor Brush Replacement

Tools required:

Flat blade screwdriver

Procedure:

1. Turn off the power to the treadmill and unplug the power cord from the wall outlet.

2. Remove clip holding motor brush spring (1.1T only).

3. Remove the motor brush cover and the carbon brushes with a flat blade

screwdriver.

4. Check the surface of the motor brush.

If the surface of carbon brush is pitted, rough, or has burn marks, replace the
motor brush.

5. Insert old/new motor brush making sure that the brush slides in and out easily.

6. Stone the surface of the motor commutator and blow out particles inside motor

with an air compressor.

7. Install the motor brush and the motor brush cover.

8. Plug-in the treadmill, and let the treadmill run for about 1 hour at 5mph to allow

the proper seating of the brush.

Summary of Contents for ELITE 1.1T

Page 1: ...Horizon Fitness 2005 Elite Treadmill Service Manual Treadmill Models 1 1T 2 1T 3 1T 4 1T 5 1T If you have any questions please call the Horizon Fitness Service Hotline at 1 800 244 4192...

Page 2: ...y 3 Safety Instructions 5 Recommended Tools 8 Maintenance 9 Upper Board Troubleshooting 21 Lower Board Troubleshooting 39 Incline Motor Troubleshooting 49 Drive Motor and Roller Troubleshooting 53 Spa...

Page 3: ...manship and materials for a period of twenty five years from the date of purchase so long as the device remains in the possession of the original owner ELEVATION MOTOR TWENTY FIVE YEARS Horizon Fitnes...

Page 4: ...rized 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 au...

Page 5: ...gh voltage components When you perform maintenance procedures with the hood removed remove jewelry especially from ears and neck tie up long hair remove neckties and do not wear loose clothing When th...

Page 6: ...moving Before starting the running belt straddle the belt by placing your feet firmly on the sides of the treadmill You should also step off the belt and onto the sides of the treadmill after turning...

Page 7: ...of serviceman if you are in doubt as to whether the product is properly grounded Do not modify the plug provided with the product if it will not fit in the outlet have a proper outlet installed by a...

Page 8: ...ewdrivers Digital multi meter Drive belt tension gauge Allen wrench set Metric Open end wrenches of assorted sizes Metric Clamp on AC amp meter drive ratchet and sockets of assorted sizes Blue loc tit...

Page 9: ...e tension and alignment of the running belt Make sure that the treadmill belt will not damage any other components on the treadmill by being misaligned Every Week Clean underneath the treadmill follow...

Page 10: ...his is a normal and common adjustment To eliminate this slipping tension both the rear roller bolts with the appropriate sized Allen wrench turning both the left and right bolt 1 4 TURN as shown below...

Page 11: ...the other and that the belt is centered between the side rails If the running belt is not tracking properly follow the following procedures If the running belt tracks to the left turn the left roller...

Page 12: ...end of the treadmill 5 With a 13mm wrench loosen the attachment nuts M08 and washers M09 holding the motor to the frame 6 With a 6mm Allen wrench loosen the two motor bracket attachment bolts M45 M46...

Page 13: ...tween the deck and belt will cause a high amount of friction when running on the treadmill This in turn will cause the treadmill breaker to trip If this happens lubrication should be added These three...

Page 14: ...r the silicon oil has been applied to the top surface of the running deck the roller can be tightened to the proper position With a damp cloth wipe off any excessive silicon oil that may have seeped o...

Page 15: ...he 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...

Page 16: ...ecommends a 20 amp dedicated circuit but a 15 amp dedicated circuit may be sufficient Make sure that proper voltage is being supplied from the wall outlet Warning Hazardous voltages will be tested in...

Page 17: ...m sensor wire is positioned as close to the front roller pulley as possible The factory standard is a distance or 2 4 mm between the sensor wire and the front roller pulley Loosen the sensor bracket a...

Page 18: ...lts DC See Voltage checkpoints in table of contents for voltage measurement instructions Verify that the sensor wire is functioning properly in Engineering Mode For directions on entering and using th...

Page 19: ...sary to stand on the belt at a slow speed and ride the treadmill belt from the front roller to the rear roller to verify that the treadmill motor and running belt are traveling smoothly Verify start u...

Page 20: ...ED can be found by referencing the lower control board Engineering LED chart in the table of contents Verify that proper voltage is being transferred through the console cable reference console cable...

Page 21: ...Board Configuration 23 Engineering Mode Inc hardware test auto calibration roller values etc 25 No display on console 34 All or some of the keys on console will not work 36 Heart rate control functio...

Page 22: ...f a specific function i e elevation motor control etc place the negative lead of your multi meter on pin B4 or B5 and place the positive lead on the desired pin Follow the voltage chart above for the...

Page 23: ...Upper Board Configuration 3 1T 4 1T 23...

Page 24: ...5 1T 24...

Page 25: ...p three times and Eng 0 should be displayed once in the Engineering Mode Menu 2 1T 3 1T 4 1T 5 1T Power on the treadmill and have the safety key in position on the console Press and hold the elevation...

Page 26: ...button to verify all LED s 2 1T 3 1T a While in the Engineering Mode Menu press Speed or until Eng0 appears in the display b Press Start to select Eng0 c Press Start button to verify all LED s 4 1T 5...

Page 27: ...dow Refer to diagram Speed Cube d Once the speed cube is set to the proper setting Press and hold the Stop for three seconds to return to the Engineering Mode Menu Important Note Steps c and d are the...

Page 28: ...Distance Laps display window elevation value Time display window speed value Speed Pulse display window RPM speed sensor signal 28...

Page 29: ...to select c Press Start to begin 4 1T 5 1T a While in the Engineering Mode Menu press the Speed or button until Eng2 appears in the display b Press Select to select c Press Start to begin The treadmil...

Page 30: ...tton for 3 5 seconds until the console beeps three times to save speed setting o Press Select to continue p Press and hold Stop for three seconds to return to the Engineering Menu 2 1T 3 1T a While in...

Page 31: ...d hold Stop for 3 5 seconds until the console beeps 2 times h Press Speed until the display shows P2 i Repeat steps d g with the speed being adjusted to 2 4 mph j Press Speed until the display shows P...

Page 32: ...es The value has now been properly saved 2 1T 3 1T a While in the Engineering Mode Menu press the Speed or button until Eng4 appears in the disp lay b Press S tart to select c Press Speed or until pro...

Page 33: ...saved Eng6 Change from Miles to KM 2 1T 4 1T 5 1T Models Only a While in the Engineering Mode Menu press the Speed or button until Eng6 appears in the display b Press Select to select c Press Select t...

Page 34: ...the reed switch N23 and place a flat blade screwdriver on the connection prongs If the console lights up replace the reed switch N23 Replace the safety key If the console does not have any display fol...

Page 35: ...o see if it has tripped off If it is tripped off like diagram A reset the breaker A ON OFF switch is damaged Make sure the ON OFF switch is turned to the ON position and that the switch is lit If the...

Page 36: ...ng plug N02 or N03 is not fit in properly into the upper control board Verify the keypad connection The upper control board is not configured properly Reference upper board configuration in the table...

Page 37: ...pper board When holding the heart rate handlebars the display in the Pulse display window should register HR If this registers but the actual heart rate reading does not register or is erratic follow...

Page 38: ...ng deck and running belt inadequate Contact Horizon Fitness for lubrication application Defective grounding fibers in running belt Replace running belt Note Improper grounding of the upper board or ru...

Page 39: ...ER BOARD TROUBLESHOOTING CONTENTS Treadmill will not start 40 Treadmill will stop and reset 41 Running speed is not stable 42 Wiring diagram 43 Lower board LED diagnosis 45 Manual Speed Calibration 47...

Page 40: ...rify the Engineering LED s on the lower board Reference Engineering LED chart for possible causes Measure voltage from motor reference voltage checkpoints in table contents If no voltage is present un...

Page 41: ...rd from the wall outlet Using an AC voltmeter verify that the proper AC voltage is present at the wall outlet Nominal 120 Vac may vary between approximately 105 Vac and 135 Vac If the AC voltage is mi...

Page 42: ...from the wall outlet Using an AC voltmeter verify that the proper AC voltage is present at the wall outlet Nominal 120 Vac may vary between approximately 105 Vac and 135 Vac If the AC voltage is miss...

Page 43: ...Lower Control Board Wiring Diagram 43...

Page 44: ...Wiring Diagram A SOCKET WIRE TO ON OFF SWITCH E ON OFF SWITCH TO LOWER BOARD AC1 B GROUND F ON OFF SWITCH TO BREAKER C SOCKET WIRE TO BREAKER D ON OFF SWITCH TO LOWER BOARD AC2 44...

Page 45: ...Lower Board LED Diagnosis LED 5 LED 6 LED 1 LED 2 LED 3 LED 4 45...

Page 46: ...LED 3 4 Motor indicator The LED goes on when the drive motor is operating If the LED is not lit voltage is not being supplied to the motor and the lower board may need to be replaced LED 5 6 Incline M...

Page 47: ...or the 4 1T 3 1T 2 1T 1 1T treadmills If the belt revolutions are incorrect adjust the speed dial located on the lower control board 2 The other way to verify that the treadmill speed is set properly...

Page 48: ...R comp turn the dial clockwise to increase voltage to motor or counterclockwise to decrease voltage to motor To verify proper adjustment start the treadmill at 0 5 mph and ride the treadmill belt from...

Page 49: ...INCLINE MOTOR TROUBLESHOOTING CONTENTS Incline function does not work 50 Treadmill will incline up or down without command 51 Incline does not reach minimum or maximum settings 52 49...

Page 50: ...causes Verify elevation motor shaft position The elevation motor shaft should be flush with the bottom of the motor housing If the position of the shaft is to close to the bottom motor housing the sh...

Page 51: ...le cable connection in the upper right hand corner underneath the console Inspect console cable for damage Check voltage of console cable Determine defective part by using console cable chart Verify E...

Page 52: ...t should be flush with the bottom of the motor housing If the position of the shaft is too close to the bottom motor housing the shaft may have become jammed To correct this remove the bottom bolt fro...

Page 53: ...DRIVE MOTOR AND ROLLER TROUBLESHOOTING CONTENTS Noises generating from under motor cover 54 Cleaning the motor 55 Noises generating from rear of treadmill 56 53...

Page 54: ...covers on the drive motor and inspect the brushes and the motor commutator for any uneven wear Make sure the treadmill is turned off before doing this procedure If the surface of the motor brush is pi...

Page 55: ...ve motor With the brushes removed inspect the motor commutator for any unusual wear or burn marks If there is any abnormal marks or wear stone the motor commutator Make sure to blow any dust or partic...

Page 56: ...the treadmill run for about 30 minutes without load to break the treadmill in Verify proper tension of the running belt An over tightened running belt may create excessive noise Verify that there is...

Page 57: ...SPARE PARTS REPLACEMENT CONTENTS Running Belt Deck 58 Roller 60 Motor 61 Motor Brush 65 Lower Board 66 Console Cable 67 Incline Motor 71 Upper Board 72 Keypad Membrane Key 74 Air Shock 75 57...

Page 58: ...ea to note the position of the rear roller before removing For best results place two removable marks on the left and right side of the deck and the running belt When reinstalling match up the marks f...

Page 59: ...completely Then assemble the rear roller and drive belt idler Finish tightening the front roller Start the treadmill and run it to ensure proper belt tension and side to side belt tracking If there is...

Page 60: ...ront roller before removing For best results place two removable marks on the left and right side of the deck and the running belt When reinstalling match up the marks for proper tension 4 Reassemble...

Page 61: ...ad screwdriver remove the motor cover 3 Unplug the motor wires from the lower board and ground wire from machine 4 Before continuing it is a good idea to weight down the treadmill deck to prevent the...

Page 62: ...y Tighten with a 13mm wrench 9 Place the drive belt on the drive motor making sure that the motor pulley is aligned with the roller pulley 10 Tighten the two motor attach bolts M45 M46 with a 6mm Alle...

Page 63: ...r 3 Unplug the motor wires from the lower board 4 Before continuing it is a good idea to weight down the treadmill deck to prevent the treadmill from springing up Removing the weight of the motor will...

Page 64: ...o the bracket 8 Put the new motor in place on the frame taking caution to properly align the motor flywheel pulley and the front roller pulley Tighten with a 13mm wrench 9 Place the drive belt on the...

Page 65: ...iver 4 Check the surface of the motor brush If the surface of carbon brush is pitted rough or has burn marks replace the motor brush 5 Insert old new motor brush making sure that the brush slides in a...

Page 66: ...wait approximately 1 minute until the light is out This is an indication that the stored power has left the board 4 Unplug all the wires and cables from the lower board It is a good idea to note the...

Page 67: ...ck panel for the upper board and unplug the console cable from the connectors 4 Fold up the deck and remove the wire protective cover N08 and remove the cable ties attaching the cable to the incline f...

Page 68: ...68...

Page 69: ...1 Turn off the power to the treadmill and unplug the power cord from the wall outlet 2 With a Philip head screwdriver remove the motor cover and disconnect the console cable from the lower control bo...

Page 70: ...P30 from the console mast 7 Attach the new console cable to the existing cable and fish the new cable through the console mast 8 Once the new console cable is installed through the console mast connec...

Page 71: ...tom bolt attaching the motor shaft to the incline frame It may be helpful to tip the treadmill on its side to release pressure from the shaft bolt 5 Fold the treadmill down to the running position Rem...

Page 72: ...Philips head screwdriver loosen the screws N06 from the console panel N07 4 Unplug all the cables connecting to the upper board 5 Remove the console panel from the console assembly N08 6 With a screw...

Page 73: ...Upper Board Replacement Continued 73...

Page 74: ...ll outlet 2 Remove console skirt N09 3 Remove screws N06 from the console panel N07 4 Disconnect the keypads N02 N03 from the console 5 Remove the overlay N01 Make sure all and the adhesive is removed...

Page 75: ...e a 13mm wrench to loosen the nut that secures the top screws of the air shock to the frame 3 Unscrew the air shock from the bottom screw 4 Remove air shock and replace it with a new one screwing the...

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