Horizon Fitness
2003-2004 Treadmill
Service Manual
Horizon Series Treadmill Models – T40, T30, T20
If you have any questions, please call the Horizon Fitness Service Hotline at
1-888-993-3199
Страница 1: ...Horizon Fitness 2003 2004 Treadmill Service Manual Horizon Series Treadmill Models T40 T30 T20 If you have any questions please call the Horizon Fitness Service Hotline at 1 888 993 3199...
Страница 2: ...sage 32 Diagnostics Mode 33 Heart Rate troubleshooting 35 Treadmill Motor will not start 38 Treadmill Resets 39 Running Speed is not Stable Erratic 40 Wiring Diagrams 41 Lower Control Board Diagnostic...
Страница 3: ...possession of the original owner DRIVE MOTOR TEN YEARS Horizon Fitness warrants the drive motor against defects in workmanship and materials for a period of ten years from the date of purchase so long...
Страница 4: ...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 lim...
Страница 5: ...h voltage components When you perform maintenance procedures with the hood removed remove jewelry especially from ears and neck tie up long hair remove neck ties and do not wear loose clothing When th...
Страница 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...
Страница 7: ...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 qual...
Страница 8: ...wdrivers 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 tite...
Страница 9: ...power cord is not underneath 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 damag...
Страница 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...
Страница 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...
Страница 12: ...the treadmill 5 With a 13mm wrench loosen the attachment nuts M08 and washers M09 holding the motor to the frame 6 With a 6mm Allen wrench loosen the two motor bracket attachment bolts M45 M46 and ad...
Страница 13: ...will cause the treadmill breaker to trip If this happens lubrication should be added These three applications should be the only times lubrication is ever added to a Horizon Fitness treadmill Please c...
Страница 14: ...light coat has been applied to the entire underside of the belt the roller can be tightened to the proper position It is important to walk on the treadmill to properly impregnate the running belt with...
Страница 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...
Страница 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...
Страница 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...
Страница 18: ...peed keys for about 5 seconds to enter the Engineering Mode Menu The console should beep three times and Eng 0 should be displayed once in the Engineering Mode Menu While in the Engineering Mode Menu...
Страница 19: ...Engineering Mode Menu The console should beep three times and Eng 0 should be displayed once in the Engineering Mode Menu While in the Engineering Mode Menu press Speed or until Eng1 appears in the d...
Страница 20: ...ED can be found by referencing the lower control board Diagnostic LED chart in the table of contents Verify that proper voltage is being transferred through the console cable reference console cable v...
Страница 21: ...configuration 23 Auto Calibration procedures 26 No display on console 28 All or some of the keys on console will not work 30 Error message E1 or E2 on console 31 Diagnostics Mode 33 Heart rate control...
Страница 22: ...6 volts B9 Light Green 0 volts B10 Black 5 volts B11 Grey action 5 volts Normal 0 volts B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 Elevation Down Elevation Up B6 Purple 5 volts B12 White action 5 volts No...
Страница 23: ...el For proper function of the T40 treadmill the upper board must be calibration properly Please note that there should be a jumper on pins A B and on the HR Control pin pins with the properly configur...
Страница 24: ...el For proper function of the T30 treadmill the upper board must be calibration properly Please note that there should be a jumper on pins A B and on the 799 wheel pin pins with the properly configura...
Страница 25: ...ion T20 Model For proper function of the T20 treadmill the upper board must be calibration properly Please note that there should be a jumper on pins A B and pins with the properly configuration are s...
Страница 26: ...out 5 seconds to enter the Engineering Mode Menu The console should beep three times and Eng 0 should be displayed once in the Engineering Mode Menu Press Speed or until Eng1 appears in the display Pr...
Страница 27: ...speed appears to be inaccurate Verify that the proper roller values have been stored in the Engineering Mode Menu Verifying the Proper Roller Values With the treadmill power on and the safety key in p...
Страница 28: ...console does not have any display follow the possible causes below Possible causes Check voltage of wall outlet Warning Hazardous voltages will be tested in the following procedure Exercise extreme c...
Страница 29: ...position and that the switch is lit If the switch is not lit check the power cord connection and function Improper wiring Check all wiring coming in from the power switch to the lower board to the upp...
Страница 30: ...d properly There should be a jumper switch on pin A miles and pin B keypad Pins Eng_Mode_Test and Eng_Display_Test should be open Overlay is sticking or is damaged N01 Try peeling up overlay and repos...
Страница 31: ...table of contents Verify the signal of the RPM sensor by entering Diagnostics Mode If there is no signal present check the continuity of the RPM sensor wire If there is no continuity replace the sens...
Страница 32: ...disconnect any wiring connectors or other components with the power applied to the treadmill Disconnect the treadmill power cord from the wall outlet Using an AC voltmeter verify that the proper AC vo...
Страница 33: ...d or until Eng1 appears in the display Press and hold Start for three seconds to select Press Start to begin At this time the running belt should begin moving The readout in the speed window will indi...
Страница 34: ...ed dial on the lower board reference speed calibration in table of contents The speed of the treadmill can be increased or decreased by pressing the Speed Up or Down buttons which will change the valu...
Страница 35: ...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...
Страница 36: ...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...
Страница 37: ...LOWER BOARD TROUBLESHOOTING CONTENTS Treadmill will not start 38 Treadmill will reset 39 Running speed is not stable 40 Wiring diagram 41 Lower board LED diagnosis 43 Speed Calibration 45 37...
Страница 38: ...erify the diagnostic LED s on the lower board Reference diagnostic LED chart for possible causes Measure voltage from motor reference voltage checkpoints in table contents If no voltage is present unp...
Страница 39: ...cord from the wall outlet Using an AC voltmeter verify that the proper AC voltage is present at the wall outlet Nominal 120 Vac may vary between approximately 105 Vac and 135 Vac If the AC voltage is...
Страница 40: ...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...
Страница 41: ...m Motor Red RPM sensor wire Transformer green Console cable Elevation motor Elevation motor black Elevation motor red Elevation motor white Motor black AC1 from on off switch AC2 from on off switch Tr...
Страница 42: ...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 42...
Страница 43: ...Lower Board LED Diagnosis Top layer of lower control board LED 5 6 LED 1 LED 2 LED 4 LED 3 Bottom layer of lower control board LED 7 LED 8 43...
Страница 44: ...ists check the AC service from the wall outlet LED 5 6 Incline Motor Indicator When the upper board is commanding the incline motor to move UP or DOWN the LEDs go on LED 5 is for the UP function and L...
Страница 45: ...ower on and the safety key in position on the console press and hold the Incline and Speed keys for about 5 seconds to enter the Engineering Mode Menu The console should beep three times and Eng 0 sho...
Страница 46: ...need to be adjusted if the treadmill belt is running in a jerky or choppy motion To adjust the IR comp turn the dial clockwise to increase voltage to motor or counterclockwise to decrease voltage to m...
Страница 47: ...INCLINE MOTOR TROUBLESHOOTING CONTENTS Incline function does not work 48 Treadmill will incline up or down without command 49 Incline does not reach minimum or maximum settings 50 47...
Страница 48: ...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 sha...
Страница 49: ...properly attached Inspect console cable for damage Check voltage of console cable Determine defective part by using console cable chart Verify diagnostic LED s on lower board Reference Diagnostic LED...
Страница 50: ...ify elevation motor shaft position The elevation motor shaft should be flush with the bottom of the motor housing If the position of the shaft is to close to the bottom motor housing the shaft may hav...
Страница 51: ...DRIVE MOTOR AND ROLLER TROUBLESHOOTING CONTENTS Thumping noises generating from under motor cover 52 Cleaning the motor 53 Thumping noises generating from rear of treadmill 54 51...
Страница 52: ...ush 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 i...
Страница 53: ...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...
Страница 54: ...treadmill run for about 30 minutes without load to break the treadmill in Verify proper tension of the running belt Excessive noise may be created by an over tightened running belt Verify that there...
Страница 55: ...SPARE PARTS REPLACEMENT CONTENTS Running Belt Deck 56 Roller 58 Motor 59 Motor Brush 61 Lower Board 62 Console Cable 63 Incline Motor 67 Console 68 Keypad Membrane Key 69 Air Shock 70 55...
Страница 56: ...e the position of the rear roller before removing For best results place two removable marks on the left and right side of the deck and the running belt When reinstalling match up the marks for proper...
Страница 57: ...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...
Страница 58: ...ller before removing For best results place two removable marks on the left and right side of the deck and the running belt When reinstalling match up the marks for proper tension 4 Reassemble the fro...
Страница 59: ...over 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 w...
Страница 60: ...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 Allen wrench 11 Verify the proper tension on...
Страница 61: ...t blade screwdriver 3 Check the surface of the motor brush If the surface of carbon brush is pitted rough or has burn marks replace the motor brush 4 Stone the surface of the motor commutator and blow...
Страница 62: ...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...
Страница 63: ...ll outlet 2 With a Philip head screwdriver remove the motor cover and disconnect the console cable from the lower control board 3 With a Philip head screwdriver remove the back panel for the upper boa...
Страница 64: ...he cable 6 Pull the old cable continuously until the new cable comes out of the top of the right support 7 Reconnect the console cable and install the protective wire cover Attach cable ties to the ca...
Страница 65: ...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...
Страница 66: ...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...
Страница 67: ...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...
Страница 68: ...wall outlet 2 With a Philips head screwdriver loosen the screws N06 from the back console panel N10 3 Unplug all the cables connecting to the upper board N03 4 With the screwdriver loosen screws N05 r...
Страница 69: ...from the wall outlet 2 Remove screws N06 from the back console panel N10 3 Disconnect the keypad N02 from the console N03 4 Remove the overlay N01 Make sure all and the adhesive is removed from the pl...
Страница 70: ...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...
