Related Manuals for Horizon Fitness 1.1T
Summary of Contents for Horizon Fitness 1.1T
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Page 1: Service Manual
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: Table Of Contents
TABLE OF CONTENTS Warranty Safety Instructions Recommended Tools Maintenance Upper Board Troubleshooting Lower Board Troubleshooting Incline Motor Troubleshooting Drive Motor and Roller Troubleshooting Spare Parts Replacement... -
Page 3: Warranty
LABOR – ONE YEAR Horizon Fitness shall cover the labor cost for the repair of the device for a period of one year from the date of original purchase, so lone as the device remains in the... - Page 4 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 authorized service center must receive all products for which a warranty claim is made.
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Page 5: Important Safety Instructions
Important Safety Instructions Warning statements indicate a particularly dangerous activity. You should be extremely cautious when doing the following: • Removing power from the treadmill, the power cord being disconnected from the wall outlet. Always ensure 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. - Page 6 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 treadmill at least four feet from walls or furniture. Keep the area behind the treadmill clear. •...
- Page 7 • Do not use treadmill outdoors. • Unplug treadmill before moving it. • Do not remove the treadmill motor covers or roller covers. An authorized Horizon Fitness service provider should perform Service only. • Treadmill should be plugged into a dedicated 20amp circuit for optimal performance.
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Page 8: Recommended Tools
Recommended Tools and Equipment The following list is a summary of the tools and equipment required by the procedures in this manual. 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 wrenches of assorted sizes (Metric) Clamp-on AC amp meter ½”... -
Page 9: Maintenance
PREVENTATIVE MAINTENANCE PROCEDURES 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. After Each Use •... - Page 10 Tensioning or Aligning the Running Belt Tensioning the Running Belt: If you can feel a slipping sensation when running on the treadmill, the running belt must be tightened. In most cases, the belt has stretched from use, causing the belt to slip. This is a normal and common adjustment.
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Page 11: Aligning The Running Belt
Aligning the Running Belt: If the running belt moves rapidly to one side when performing the next step, press the Stop button immediately. • 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. - Page 12 Tensioning the Drive Belt (1.1T, 2.1T, 3.1T) Procedure: Turn off the power to the treadmill and remove the power cord from the wall outlet. With a Philips head screwdriver, remove the motor cover. Unplug the motor wires from the lower board.
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Page 13: Belt Replacement
This, in turn, 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 contact the Horizon Fitness service department to obtain the proper lubrication for reapplication. - Page 14 With a damp cloth, wipe off any excessive silicon oil that may have seeped out from underneath the running belt Note – Only use the lubrication provided by Horizon Fitness. Do not try to apply other manufacture’s lubrication to a Horizon Fitness deck.
- Page 15 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...
- Page 16 - Make sure the treadmill is not on an extension cord. Extension cords create energy loss, which prevents proper voltage from being supplied to the treadmill. - 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.
- Page 17 FIVE-STEP DIAGNOSIS PROCESS - Continued 2. Proper Wiring - Verify that all wires are secure and attached in the correct position (reference wiring diagrams in table of contents). - Verify that there aren’t any pinches or cuts in any of the wires, especially the console cable connecting from the lower board to the upper board.
- Page 18 - Verify that the lower control board is outputting the proper voltage (5 volts 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 the Engineering Mode please refer to Engineering Mode starting on page 25).
- Page 19 FIVE-STEP DIAGNOSIS PROCESS – Continued 4. Proper Speed Calibration. - Press Start. Verify that the treadmill motor begins moving within 1 second. If the treadmill motor begins hesitates and starts moving after 1 second, follow the auto-calibration instructions listed in the table of contents. Verify that the treadmill motor turns smoothly.
- Page 20 FIVE-STEP DIAGNOSIS PROCESS – Continued 5. Voltage Checkpoints/Engineering LED’s. Verify that the lower board is functioning properly by referencing the Engineering LED’s located on the lower control board. A complete description for each Engineering LED can be found by referencing the lower control board Engineering LED chart in the table of contents.
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Page 21: Upper Board Troubleshooting
UPPER BOARD TROUBLESHOOTING CONTENTS Console Cable Voltage Chart Upper Board Configuration Engineering Mode (Inc. hardware test, auto-calibration, roller values, etc) No display on console All or some of the keys on console will not work Heart-rate-control function does not work Static shocks from upper board/heart rate grips... -
Page 22: Console Cable Voltage Chart
Console Cable Voltage Chart (DC volts) To check the voltage of 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 correct voltages. Note: Wire colors are subject to change. -
Page 23: Upper Board Configuration
Upper Board Configuration 3.1T 4.1T... - Page 24 5.1T...
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Page 25: Engineering Mode (Inc. Hardware Test, Auto-Calibration, Roller Values, Etc)
Engineering Mode Entering Engineering Mode 1.1T 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 Eng 0 should be displayed once in the Engineering Mode Menu. - Page 26 Eng0 – Display and Button Check 1.1T While in the Engineering Mode Menu, press Speed “+” or “- “ until Eng0 appears in the display. Press “Start” to select Eng0. Press “Start” button to verify all LED’s 2.1T, 3.1T While in the Engineering Mode Menu, press Speed “∧” or “∨ “ until Eng0 appears in the display.
- Page 27 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 same for the 1.1T through the 5.1T 2.1T, 3.1T While in the Engineering Mode menu, press Speed “∧”...
- Page 28 • Distance/Laps display window – elevation value • Time display window – speed value • Speed/Pulse display window – RPM speed sensor signal...
- Page 29 Eng2 - Auto Calibration 1.1T While in the Engineering Mode Menu, press Speed “+” or “-“ until Eng2 appears in the display. Press, “Start” to select. Press, “Start” to begin. 2.1T, 3.1T While in the Engineering Mode Menu, press the Speed “∧” or “∨ “ button until Eng2 appears in the display.
- Page 30 Eng3 – Manual Calibration Important Note: Use to manually calibrate the running belt speed if auto calibration is unsuccessful. 1.1T a) While in the Engineering Mode Menu, press Speed “+” or “-“ until Eng3 appears in the display. b) Press “Start” to select.
- Page 31 4.1T, 5.1T a) While in the Engineering Mode Menu, press the Speed “∧” or “∨ “ button until Eng3 appears in the display. b) Press, “Select” to select. c) Press Speed “∧” or “∨ “ until the display shows P1 d) Press “START”...
- Page 32 Eng4 – Roller Diameter Check Important Note: It is important to verify proper roller values as im prope r values can create inaccurate speeds. Roller V alues: Elite 1.1T = 1481 Elite 2.1T = 1481 Elite 3.1T = 1481 Elite 4.1T = 1952 Elite 5.1T = 1972...
- Page 33 Eng5 – Software Change (4.1T, 5.1T Models Only) 4.1T, 5.1.T While in the Engineering Mode Menu, press the Speed “∧” or “∨ “ button until Eng5 appears in the display. Press, “Select” to select. Press “Select” to toggle between 4.1T and 5.1T software versions. d) Press and hold “Start”...
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Page 34: No Display On Console
Possible causes: • Adjust the position of the safety key. Manually rotate the safety key to see if the reed switch is in proper alignment (1.1T only). • Reed switch is damaged. By-pass the reed switch. Disconnect the reed switch (N23), and place a flat blade screwdriver on the connection prongs. - Page 35 • Disconnect the treadmill power cord from the wall outlet. Using an AC voltmeter, verify that the proper AC 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.
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Page 36: All Or Some Of The Keys On Console Will Not Work
All or Some of the Keys on Console Will not Work Possible causes: • If keys are pressed and do not hear a corresponding beep, the membrane key is likely defective. • If keys are pressed and there is a corresponding beep but the console does not respond, then the upper board is likely defective. -
Page 37: Heart-Rate-Control Function Does Not Work
Heart-Rate Control Function Does Not Work When holding the heart rate handlebars, the display in the Pulse display window should register HR. If this does not register, follow the possible causes below. Possible causes: • Defective heart rate receiver/heart rate grips. •... -
Page 38: Static Shocks From Upper Board/Heart Rate Grips
Static Shocks from Upper Board/Heart Rate Grips Possible causes: • Improper grounding of upper board. Contact Horizon Fitness for grounding kit and instruction. • Lubrication on running deck and running belt inadequate. Contact Horizon Fitness for lubrication application. • Defective grounding fibers in running belt. Replace running belt. -
Page 39: Lower Board Troubleshooting
LOWER BOARD TROUBLESHOOTING CONTENTS Treadmill will not start Treadmill will stop and reset Running speed is not stable Wiring diagram Lower board LED diagnosis Manual Speed Calibration... -
Page 40: Treadmill Will Not Start
Treadmill Motor Will Not Start Possible causes: • Verify that all wire connections are properly connected. • Follow the auto-calibration instructions (reference auto-calibration in table of contents). • Verify the Engineering LED’s on the lower board. Reference Engineering LED chart for possible causes. •... -
Page 41: Treadmill Will Stop And Reset
Treadmill Will Stop and Reset • Check voltage of wall outlet. Warning! Hazardous voltages will be tested in the following procedure. Exercise extreme caution when performing these procedures. Do not connect or disconnect any wiring, connectors, or other components with the power applied to the treadmill. •... -
Page 42: Running Speed Is Not Stable
Running Speed Is Not Stable (erratic speeds) • Verify that the running belt and drive belt tensions are adequate, preventing belts from slipping. • Check voltage of wall outlet. Warning! Hazardous voltages will be tested in the following procedure. Exercise extreme caution when performing these procedures. - Page 43 Lower Control Board Wiring Diagram...
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Page 44: Wiring Diagram
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) -
Page 45: Lower Board Led Diagnosis
Lower Board LED Diagnosis LED 5 LED 6 LED 1 LED 2 LED 3 LED 4... - Page 46 Lower Board LED Diagnosis LED 1: Transfer indicators. When the power switch is turned on, LED 1 & 2 light up, meaning that power is supplied to the lower board. These LED’s should remain on while operating the drive motor and elevation motor.
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Page 47: Manual Speed Calibration
1. The first way is to count the running belt revolutions per minute. At 0.5 mph, the treadmill belt should make 4 revolutions/minute for the 5.1T treadmill and 4.5 revolutions per minute for 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. - Page 48 The IR comp dial should only 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 motor). To verify proper adjustment, start the treadmill at 0.5 mph and ride the treadmill belt from the front to rear roller.
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Page 49: Incline Motor Troubleshooting
INCLINE MOTOR TROUBLESHOOTING CONTENTS Incline function does not work Treadmill will incline up or down without command Incline does not reach minimum or maximum settings... - Page 50 No Incline Function Possible Causes: • Verify that all wire connections are properly attached. • Inspect console cable for damage. • Check voltage of console cable. Determine defective part by using console cable chart. • Verify Engineering LED’s on lower board. Reference Engineering LED chart for possible causes.
- Page 51 Treadmill Will Incline Up or Down Without Command Possible causes: • Verify that all wire connections are properly attached. Pay close attention to the console cable connection in the upper right hand corner underneath the console. • Inspect console cable for damage. •...
- Page 52 Incline Does Not Reach Minimum or Maximum Settings Possible causes: • Incline motor is not installed properly • 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 too close to the bottom motor housing, the shaft may have become jammed.
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Page 53: Drive Motor And Roller Troubleshooting
DRIVE MOTOR AND ROLLER TROUBLESHOOTING CONTENTS Noises generating from under motor cover Cleaning the motor Noises generating from rear of treadmill... - Page 54 Noises Generating From Under Motor Cover Possible causes: • Verify proper tension of the running belt. An over-tightened running belt may create excessive noise. • Remove motor cover and verify alignment of drive belt. • Inspect for debris on drive motor pulley, front roller pulley, or on drive belt •...
- Page 55 Stoning the Motor Commutator • Unplug the power cord from the wall outlet. • 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, or has burn marks, replace the motor brush.
- Page 56 Noises Generating From the Rear of the Treadmill Possible causes: • If this problem is being experienced on a new treadmill, let 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.
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Page 57: Spare Parts Replacement
SPARE PARTS REPLACEMENT CONTENTS Running Belt / Deck Roller Motor Motor Brush Lower Board Console Cable Incline Motor Upper Board Keypad (Membrane Key) Air Shock... -
Page 58: Running Belt / Deck
Running Belt/Deck Replacement Procedure Tools required: Philips screwdriver T-handle Allen wrench (5mm, 6mm, 8mm) Procedure: With a Philips head screwdriver, remove the motor cover, rear roller end caps, bottom deck cover and left and right side rails. With the appropriate size Allen wrench remove the rear roller. It is a good idea to note the position of the rear roller before removing. - Page 59 Running Belt/Deck Replacement Procedure - Continued Tighten the deck bolts. Assemble the front roller first, but do not tighten 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.
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Page 60: Roller
Roller Replacement Tools required: Philips screwdriver T-handle Allen wrench (6mm, 8mm) Procedure: Front roller 1. With a Philips head screwdriver, remove the motor cover. 2. With the Philips head screwdriver, remove the speed sensor. Press your finger against the drive belt and guide it towards the left until it is released from the front roller. -
Page 61: Motor
Motor Replacement (1.1T, 2.1T, 3.1T) Tools required: Philips screwdriver Socket wrench (13mm) Box wrench (8mm) Allen wrench (6mm) Procedure: Turn off the power to the treadmill and remove the power cord from the wall outlet. With a Philips head screwdriver, remove the motor cover. - Page 62 With a 6mm Allen wrench, loosen the two motor bracket attachment bolts (M45, M46). With a 6mm Allen wrench, remove the bolts (M06) and washers (M30, M25) holding the motor to the motor bracket, and replace it with a new motor. Put the new motor in place on the frame, taking caution to properly align the motor flywheel pulley and the front roller pulley.
- Page 63 Motor Replacement (4.1T, 5.1T) Tools required: Philips screwdriver Socket wrench (13mm) Box wrench (8mm) Allen wrench (5mm, 6mm) Procedure: 1. Turn off the power to the treadmill and remove the power cord from the wall outlet 2. With a Philips head screwdriver, remove the motor cover. 3.
- Page 64 the motor to the frame. 7. With a 6mm Allen wrench, remove the bolts (M06) and washers (M25, M30) attaching the motor to the bracket. Attach the new motor to 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.
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Page 65: Motor Brush
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. -
Page 66: Lower Board
Lower Board Replacement Tools required: Philips head screwdriver Procedure: 1. Turn off the power to the treadmill and unplug the power cord from the wall outlet. 2. With a Philips head screwdriver, remove the motor cover. 3. Verify that LED MTR is not lit on the lower board. If this LED is lit, please wait approximately 1 minute until the light is out. -
Page 67: Console Cable
Console Cable Replacement – 2.1T, 3.1T, 4.1T, 5.1T Models Tools required: Philips screwdriver Allen wrench (5mm) Procedure: (Diagram on following page) 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 board. - Page 69 Console Cable Replacement – 1.1T Model Tools required: Philips screwdriver Allen wrench (5mm) 13 mm wrench Needle nose pliers Procedure: 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 board.
- Page 70 4. Remove the console assembly from the console mast (AC02) by removing the console mast covers on both the left and right side. 5. Remove the rear (closet to the back of the treadmill) 45 mm bolt and 13 mm nut that attaches the console assembly to the console mast (AC01).
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Page 71: Incline Motor
Incline Motor Replacement Tools required: Philips screwdriver Qty 2 wrenches (17mm) Procedure: 1. Turn off the power to the treadmill and unplug the power cord from the wall outlet. 2. With a Philips head screwdriver, remove the motor cover. Disconnect the incline motor wires from the lower control board. -
Page 72: Upper Board
Upper Board Replacement Tools required: Philips screwdriver Procedure: (Diagram on following page) 1. Turn off the power to the treadmill and unplug the power cord from the wall outlet. 2. Remove console skirt (N09). 3. With a Philips head screwdriver, loosen the screws (N06) from the console panel (N07). - Page 73 Upper Board Replacement - Continued...
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Page 74: Keypad (Membrane Key)
Keypad Replacement Tools required: Philips screwdriver Procedure: 1. Turn off the power to the treadmill and unplug the power cord from the wall 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. -
Page 75: Air Shock
Air Shock Replacement Tools required: Wrench (13mm) Procedure: 1. Fold treadmill to locking position. 2. Use 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.