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Horizon Fitness T101-04 Service Manual Download Page 5

 

5 

 

CHAPTER 6: PART REPLACEMENT GUIDE

 

6.1    Motor Cover Replacement

 .................................................................................................................. 36 

6.2    Rear Roller Replacement

 .................................................................................................................... 37 

6.3    Side Rail Replacement

 ........................................................................................................................ 38 

6.4    Running Deck Replacement

 ................................................................................................................ 39 

6.5    Front Roller Replacement

 ................................................................................................................... 40 

6.6    Running Belt Replacement

 .................................................................................................................. 41 

6.7    Motor Control Board (MCB) Replacement

 .......................................................................................... 42 

6.8    Motor Replacement

 ............................................................................................................................. 43 

6.9    Drive Belt Replacement

 ....................................................................................................................... 44 

6.10    Incline Motor Replacement

 ................................................................................................................ 45 

6.11    Console Replacement

 ....................................................................................................................... 46 

6.12    Heart Rate Board Service

 ................................................................................................................. 47 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Summary of Contents for T101-04

Page 1: ...1 T101 04 T202 03 Service Manual ...

Page 2: ...2 ...

Page 3: ...3 ...

Page 4: ...orkout 15 3 4 Program Information 16 CHAPTER 4 ENGINEERING MODE 4 1 Engineering Mode 20 4 2 Engineering Mode Overview 21 CHAPTER 5 TROUBLESHOTING 5 1 Electrical Diagram 23 5 2 MCB Wiring Instructions 25 5 3 1 Troubleshooting No Power To The Console 27 5 3 2 Troubleshooting No Function For Safety Key 28 5 3 3 Troubleshooting No Response For Machine Console Motor 29 5 3 4 Troubleshooting Incline Mot...

Page 5: ...Rail Replacement 38 6 4 Running Deck Replacement 39 6 5 Front Roller Replacement 40 6 6 Running Belt Replacement 41 6 7 Motor Control Board MCB Replacement 42 6 8 Motor Replacement 43 6 9 Drive Belt Replacement 44 6 10 Incline Motor Replacement 45 6 11 Console Replacement 46 6 12 Heart Rate Board Service 47 ...

Page 6: ...6 CHAPTER 1 Serial Number Location 1 1 1 SERIAL NUMBER LOCATION 1 1 1 T101 04 ...

Page 7: ...7 CHAPTER 1 Serial Number Location 1 1 1 2 T202 03 ...

Page 8: ...lt Make sure that the treadmill belt will not damage any other components on the treadmill by being misaligned If any labels are damaged or illegible contact Customer Technical Support for replacements EVERY WEEK WEEKLY Clean underneath the treadmill following these steps Turn off the treadmill with the ON OFF switch then unplug the power cord at the wall outlet Fold the treadmill into the upright...

Page 9: ...tions Turn off the treadmill with the on off switch then unplug the power cord at the wall outlet Loosen both the rear roller bolts For best results place two removable marks on both sides of the frame and note roller position Once the belt is loosened take the bottle of lubricant and apply it to the entire top surface of the running deck Tighten both rear roller bolts matching up the marks for pr...

Page 10: ...ted at the factory before it was shipped At times the belt can move off center during shipment Before operating the treadmill make sure the belt is centered and remains centered to maintain smooth operation If the running belt is too far to the right side With the treadmill running at 1 mph turn the left adjustment bolt counter clockwise turn at a time using the supplied Allen wrench Check the bel...

Page 11: ... in jack plug your media player into the console using the included audio adaptor cable G Volume used to adjust volume up or down H Fan key press to turn fan on and off I Incline quick keys used to reach desired incline quickly J Incline keys used to adjust incline level K Speed quick keys used to reach desired speed quickly L Speed keys used to adjust speed level M Reading rack holds reading mate...

Page 12: ... LCD DISPLAY WINDOW time distance speed calories incline and heart rate B PROGRAMMING KEYS Used to cycle through programs and user setup C ENTER used to confirm selection D PROGRAM KEYS press to select workout E GOAL CENTER press to set or view your goal See page 22 for more information F AUDIO IN JACK plug your media player into the console using the included audio adaptor cable G VOLUME used to ...

Page 13: ...time remaining or the time elapsed in your workout DISTANCE Shown as km Indicates distance traveled or distance remaining during your workout CALORIES Total calories burned or remaining for your workout INCLINE Shown as percent Indicates the incline level of the running surface SPEED Shown as km h Indicates how fast the belt is moving HEART RATE Shown as BPM beats per minute Used to monitor your h...

Page 14: ...evel of the running surface SPEED Shown as km h Indicates how fast the belt is moving HEART RATE Shown as BPM beats per minute Used to monitor your heart rate displayed when contact is made with both pulse grips PROGRAM PROFILES Represents the profile of the program being used speed during speed based programs and incline during incline based programs FAN Indicates fan setting low medium high TRAC...

Page 15: ...rkout goal level or program using and press ENTER 3 Set workout program information using see program information for necessary settings and press ENTER after each selection 4 Press START to begin workout NOTE You can adjust the speed and incline during your workout FINISHING YOUR WORKOUT When your workout is complete the console will display workout complete and beep Your workout information will...

Page 16: ... workout complete and beep Your workout information will stay displayed on the console for 30 seconds and then reset TO RESET THE CONSOLE Hold STOP key for 3 seconds 3 4 PROGRAM INFORMATION T101 04 MANUAL Adjust your speed and incline manually during your workout User sets time starting speed and incline STEPS Promotes healthy activity with 2 step based workouts calculated using average stride len...

Page 17: ...ust your speed and incline manually during your workout User sets time starting speed and incline STEPS Promotes healthy activity with 10 step based workouts calculated using average stride length Choose from 1000 2000 3000 4000 5000 6000 7000 8000 9000 and 10 000 step workouts User sets starting speed and incline ...

Page 18: ...om 1 mile 2 miles 5k 5 miles 10k 8 miles 15k 10 miles 20k and half marathon goals User sets starting speed and incline INTERVALS An effective fat burning workout that helps you get improve your fitness level Choose from Speed Intervals Peak Intervals and Endurance Intervals workouts User sets time and starting level USING YOUR MEDIA PLAYER 1 Connect the included audio adaptor cable to the audio in...

Page 19: ...ergy by disabling most power to the machine until a key is pressed on the console This feature can be turned on or off in the engineering menu To enter the engineering menu press and hold the INCLINE key and SPEED key for 3 5 seconds Use the keys to navigate through the menu to ENG 3 Press ENTER to select Press ENTER to navigate to P5 in the ENG3 menu Use the keys to select ENRGY SVE ON or OFF Pre...

Page 20: ...20 CHAPTER 4 Engineering Mode 4 1 ENGINEERING MODE ...

Page 21: ...21 CHAPTER 4 Engineering Mode 4 2 ENGINEERING MODE OVERVIEW T101 04 ...

Page 22: ...22 CHAPTER 4 Engineering Mode T202 03 ...

Page 23: ...23 CHAPTER 5 Troubleshooting 5 1 ELECTRIC DIAGRAM T101 04 ...

Page 24: ...24 CHAPTER 5 Troubleshooting T202 03 ...

Page 25: ...leshooting 5 2 TROUBLESHOOTING MCB WIRING INSTRUCTIONS T101 04 MCB wiring instructions CN1 AC motor cable socket CN2 AC power cable socket CN3 Elevation motor cable socket CN4 Console set cable socket CN5 Transfer board ...

Page 26: ...hooting T202 03 MCB wiring instructions CN1 Power light CN2 AC power cable socket CN3 Elevation motor cable socket CN4 Speed sensor cable socket CN5 Error light near the chip CN6 Console set cable socket CN7 Transfer board ...

Page 27: ...the connection of the power wiring from the power receptacle to the MCB Use a multi meter to measure AC1 AC2 AC voltage shall be same as local s standard voltage 110V 240V If AC voltage value is standard replace the MCB as it shall be defective e If the MCB does have power check the connection of the console cable wire at the MCB and UCB Remove the console cable from MCB and use a multi meter to m...

Page 28: ...ow still shows safety key off 2 SOLUTION a Check if the safety key totally inserted in the console If no take off and insert again b Check if the safety key oxidized or not which will affect the conduction If yes please change a new one c If the safety key is function check the safety key sensor wires in console Suggest to re connect the wires or to change new wires ...

Page 29: ...anged the console is ok If not replace the PCB c Turn off the power switch and open the motor upper cover Remove the red black wires of motor from the MCB and use a multi meter to measure the resistance of drive motor If the resistance is bigger than 10 Ω the drive motor is defective Replace the drive motor If the resistance is lower than 10 Ω the drive motor is ok Then Check the connection of the...

Page 30: ...to ENG 1 Hardware Test Press the key ENTER first and then the key START Press the key INCLINE If can hear beeps from two relays at the MCB the MCB is ok Then check the connection of the elevation motor at the MCB first try to unplug and re plug these two pins If cannot resolve the issue replace the elevation motor If there is no beeps from these two relays MCB is defective and replace the MCB ...

Page 31: ...and tensioned correctly Remove and clean the rollers if needed Replace the rollers or running belt as needed b This sound is likely a moving component Remove the motor cover and check the drive belt for alignment and make sure it is not slipping or is frayed cut in any way Replace the drive belt if needed Make sure the optic disk on the motor is not rubbing the speed sensor Turn the motor by hand ...

Page 32: ...f needed Check to see if the air shock is making this noise lubricate or replace if needed f This sound is likely due to the air shock Lubricate or replace the air shock as needed g This sound is likely from the incline motor Check that the incline motor connection points include Teflon washers Lubricate the incline motor worm screw and connection points with grease Replace the incline motor C ...

Page 33: ...ing from the amp board to the console Replace the speaker or amp boards and wiring Replace the speakers If the speaker board amp board wiring and speakers do not solve the issue replace the console b There is a bad connection between the headphones and the console Verify the connection of the music player to the dock or audio adaptor cable Verify the audio adaptor cable connection at the console R...

Page 34: ...iring is bad Check the speaker wire connections Switch the speaker connections from one speaker to the other to see if sound switches sides If the sound does not switch sides replace the speaker board If the sound does switch sides replace the speaker and speaker wires f Grounding issue Try a different set of headphones Check the grounding of the console ...

Page 35: ...he chest strap is damaged d The HR grips are damaged e Heart rate board damaged f The UCB is damaged 2 SOLUTION a Re center the chest strap below the user s pectoral muscle and check again b Replace the battery in the chest strap c Replace the chest strap d If there is no HR present replace the HR grips e If there is a HR present but it is much higher than normal replace the HR board f If replacin...

Page 36: ...ews holding the motor cover to the frame Figures A B 2 The cover is secured to the frame with velcro so you will have to pull up with some force F FIGURE A FIGURE B 3 Figure C shows the motor area with the motor cover removed FIGURE C 4 Reverse Steps 1 3 to install a new motor cover ...

Page 37: ...37 CHAPTER 6 Part Replacement Guide 6 2 REAR ROLLER REPLACEMENT 1 Remove the rear end caps Figure A 2 Remove both roller adjustment screws FIGURE A 3 Remove the roller Figure C FIGURE C ...

Page 38: ...he back of the treadmill Figures B FIGURE A FIGURE B 4 Reverse Steps 1 2 to install a new side rail NOTE After reinstalling the side rail make sure the rear end cap is on first before tightening the screws for proper gap spacing Be careful not to over tighten the screws or they will poke through the top of the side rail ...

Page 39: ...n Section 6 3 3 Remove the end cap 4 Remove the running deck screws Figure A F FFIGURE A FIGURE B 5 Remove the running deck from the running belt Figure B 6 Reverse Steps 1 4 to install a new running deck NOTE The running deck is waxed on both sides so the opposite side surface may be usable New deck surfaces must ALWAYS be matched to a new running belt ...

Page 40: ...6 1 2 Loosen both of the rear roller screws to remove tension from the running belt Figure A FIGURE A FIGURE B 4 Remove the spring from the drive belt tensioner The tensioner should now pivot away from the drive belt Figure B 5 Remove the drive belt from the front roller and remove the roller from the running belt ...

Page 41: ...d in Section 6 2 3 Remove the running deck as outlined in Section 6 4 4 Remove the front roller as outlined in Section 6 5 5 Remove the running belt Figures A FIGURE A 6 Reverse Steps 1 5 to install a new running belt NOTE New running belts should ALWAYS be installed on a new deck surface deck should either be flipped or replaced to gain a new surface ...

Page 42: ... machine 2 Remove the motor cover as outlined in Section 6 1 3 Disconnect the wire connectors at the MCB 4 Remove the 2 screws holding each side of the MCB to the frame Figures A FIGURE A FIGURE B 5 Remove the MCB Figure B 6 Reverse Steps 1 5 to install a new MCB Make sure that all wires removed during Step 3 are re connected ...

Page 43: ...e spring from the drive belt tensioner 4 Remove the drive belt tensioner 6 Disconnect the motor cable ground wire from the grounding post 7 Disconnect the motor cable from the MCB 8 Remove the 2 screws holding the motor to the frame Figure A FIGURE A 9 Remove the motor from the treadmill 10 Reverse Steps 1 9 to install a new motor NOTE Be sure that the motor isolator pad is in place prior to mount...

Page 44: ... The tensioner should now pivot away from the drive belt 5 With the tension on the drive belt relieved it can be walked off of the motor pulley 6 Loosen the rear roller screws to relieve tension on the running belt 7 Remove the two 8 mm screws from front roller 8 Lift the roller and remove the old drive belt 9 Reverse Steps 1 8 to install a new drive belt NOTE After installing a new belt check it ...

Page 45: ... so that the front wheels are off the floor or the unit may be tipped on its side 4 Remove the screws from the elevation rack Figure A FIGURE A FIGURE B 5 Disconnect the incline motor from the top mounting bracket Figure B 6 Reverse Steps 1 5 to install a new incline motor NOTE When installing a new incline motor make sure to replace the white nylon washers at the top and bottom connection points ...

Page 46: ...nnect the power cord 2 Remove the 2 screws holding the console from the console mast Figure A FIGURE A FIGURE B 3 Remove the 4 screws holding the back of console Figure B 4 Disconnect the wires connections from the console Figure C FIGURE C 5 Remove the console 6 Reverse Steps 1 5 to install a new console ...

Page 47: ...e treadmill and remove the power cord 2 Remove the console as outlined in Section 6 12 3 Loose the screws which fix the heart rate sensor Figure A FIGURE A 4 Disconnect the wires connections that go to the heart rate board Figure B FIGURE B 5 Reverse Steps 1 3 to install a new heart rate board ...

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