Horizon Fitness T40 Service Manual
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Horizon Fitness T40 Service Manual

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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

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Summary of Contents for Horizon Fitness T40

  • Page 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...

  • Page 2: Table Of Contents

    5 – 7 Recommended Tools Maintenance Tensioning or Aligning the Running Belt 10-11 Tensioning the Drive Belt Lubricating Procedures Horizon Fitness “5-Step” Diagnostic Process Console Cable Voltage Chart Upper Board Configuration Auto-Calibration Instructions Upper Board Troubleshooting E-1 Error Message E-2 Error Message...

  • Page 3: Warranty

    FRAME – LIFETIME Horizon Fitness warrants the frame against defects in workmanship and materials for the life of the product, so long as it remains in the possession of the original owner.
  • Page 4 LABOR – ONE YEAR (90 days for T20 model only) 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 possession of the original owner.

  • Page 5: 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 • Unplug treadmill before moving it. • Do not remove the treadmill motor covers or roller covers. Service should be performed by an authorized Horizon Fitness service provider only. • Treadmill should be plugged into a dedicated 20amp circuit for optimal performance.

  • Page 8: Recommended Tools

    Required 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 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.
  • Page 11 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

    Tensioning the Drive Belt 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. Before continuing, it is a good idea to weight down the treadmill deck to prevent the treadmill from springing up.

  • Page 13: Lubricating Procedures

    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 Note – Only use the wax provided by Horizon Fitness. Do not try to apply other manufacture’s wax 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: Horizon Fitness "5-Step" Diagnostic Process

    - 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 FIVE-STEP DIAGNOSIS PROCESS – Sensor Wire Function - 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 Diagnostics Mode. To enter Diagnostics Mode, follow the directions below: Diagnostic Mode Instructions - With the treadmill power on and the safety key in position on the console,...
  • 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/Diagnostic LED’s. Verify that the lower board is functioning properly by referencing the Diagnostic LED’s located on the lower control board. A complete description for each Diagnostic LED can be found by referencing the lower control board Diagnostic LED chart in the table of contents.
  • Page 21 UPPER BOARD TROUBLESHOOTING CONTENTS Console Cable Voltage Chart Upper board configuration Auto-Calibration procedures No display on console All or some of the keys on console will not work Error-message "E1 or E2" on console Diagnostics Mode Heart-rate-control function does not work Static shocks from upper board/heart rate grips……………………………….36...

  • Page 22: Console Cable Voltage Chart

    Console Cable Voltage Chart (DC volts) - Elevation - Elevation - Speed control - Ground - Ground - RPM (pulse) Power to console - Power to console - 0 volts - PWM - Elevation Down - Elevation Up CORRECT VOLTAGE FOR WIRE HARNESS: Blue 12 - 16 volts Brown 5 volts Dark Green 12 - 16 volts...

  • Page 23: Upper Board Configuration

    Upper Board Configuration – T40 Model 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...
  • Page 24 Upper Board Configuration – T30 Model 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 configuration are shown in black below).
  • Page 25 Upper Board Configuration – 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 shown in black below).

  • Page 26: Auto-Calibration Instructions

    Auto-Calibration Procedures The T40, T30, and T20 models have a built-in auto-calibration sequence into the software programming. This will allow the rpm sensor reading to be detected and stored in the upper board. This process is performed at the factory and will not need to be repeated unless replacing the upper board or lower board in your Horizon Series treadmill.
  • Page 27 Roller Values: T20 - 1481 T30 - 1481 T40 - 1930 Press Incline “+” or “-“to change the roller value. Once the correct value is selected, press and hold the “Start” button for 3-5 seconds until the console beeps three times. The roller value has now been properly saved.

  • Page 28: Upper Board Troubleshooting

    No Display on Console If the console only displays dashes in the display window, follow the possible causes below: Possible causes: • Adjust the position of the safety key. Manually rotate the safety key to see if the reed switch is in proper alignment. •...
  • Page 29 • Breaker is damaged. Inspect the circuit breaker to see if it has tripped off. (If it is tripped off--like diagram A, reset the breaker.) • 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 switch is not lit, check the power cord connection and function.

  • Page 30: All Or Some Of The Keys On Console Will Not Work

    All or Some of the Keys on Console Will not Work Possible causes: • Keypad connecting plug (N02) is not fit-in properly into the upper control board. Verify the keypad connection. • The upper control board is not configured properly. There should be a jumper switch on pin A (miles) and pin B (keypad).

  • Page 31: Error Message

    E-1 Error-message on the Upper Board If there is belt movement upon start up of the treadmill, and an E-1 message occurs, follow the possible causes below: Possible cause: • Check all wire connections. • Verify that the sensor magnet is positioned in the front roller pulley. •...

  • Page 32: Error Message

    E-2 Error-message on the Upper Board If there is belt movement upon start up of the treadmill, and an E-2 message occurs, follow the possible causes below: Possible cause: • Check voltage of wall outlet. Warning! Hazardous voltages will be tested in the following procedure. Exercise extreme caution when performing these procedures.

  • Page 33: Diagnostics Mode

    Diagnostics Mode With the treadmill power 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 should be displayed once in the Engineering Mode Menu.
  • Page 34 • To begin testing the treadmill’s functions in diagnostics mode, press start. • The treadmill belt should begin moving and a value should appear in the Speed/Pulse window, indicating the speed of the treadmill, which correlates with the start speed in program P1 (0.5 mph). •...

  • Page 35: Heart Rate Troubleshooting

    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 36: 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 37 LOWER BOARD TROUBLESHOOTING CONTENTS Treadmill will not start Treadmill will reset Running speed is not stable Wiring diagram Lower board LED diagnosis Speed Calibration...

  • Page 38: Treadmill Motor 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 diagnostic LED’s on the lower board. Reference diagnostic LED chart for possible causes.

  • Page 39: Treadmill Resets

    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 40: Running Speed Is Not Stable (Erratic)

    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 41: Wiring Diagrams

    Lower Control Board Wiring Diagram Transformer Console cable Elevation motor (green) sensor wire Elevation motor (black) Elevation motor (red) Elevation motor (white) Motor (from on/off switch) (Red) Motor (from on/off (black) switch) Transformer Transformer (red) (red)
  • Page 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)

  • Page 43: Lower Control Board Diagnostic Led Chart

    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...
  • Page 44 Lower Board LED Diagnosis LED 1 & 2: 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.

  • Page 45: Manual Speed Calibration

    Manual Speed Calibration There are two ways to verify that the treadmill speed is set properly. 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 Alpine and Advance 500 treadmill and 4.5 revolutions per minute for the Paragon II, Quantum II, Omega II, Advance 400, 300, &...
  • Page 46 Manual Speed Calibration To adjust the speed setting of the treadmill, turn the speed dial clockwise (to increase speed) or counterclockwise (to decrease speed). IR Comp Speed Adjustment Calibration The IR comp dial should only need to be adjusted if the treadmill belt is running in a jerky or choppy motion.
  • Page 47 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 48: Incline Motor Troubleshooting

    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 diagnostic LED’s on lower board. Reference Diagnostic LED chart for possible causes.
  • Page 49 Treadmill Will Incline Up or Down Without Command 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 diagnostic LED’s on lower board. Reference Diagnostic LED chart for possible causes.
  • Page 50 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 to close to the bottom motor housing, the shaft may have become jammed.

  • Page 51: Drive Motor And Roller Troubleshooting

    DRIVE MOTOR AND ROLLER TROUBLESHOOTING CONTENTS Thumping noises generating from under motor cover Cleaning the motor Thumping noises generating from rear of treadmill...
  • Page 52 Noises Generating From Under Motor Cover Possible causes: • Verify proper tension of the running belt. Excessive noise may be created by an over-tightened running belt. • Remove motor cover and verify alignment of drive belt. • Inspect for debris on drive motor pulley, front roller pulley, or on drive belt •...
  • Page 53 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 54 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. Excessive noise may be created by an over-tightened running belt.
  • Page 55 SPARE PARTS REPLACEMENT CONTENTS Running Belt / Deck Roller Motor Motor Brush Lower Board Console Cable Incline Motor Console Keypad (Membrane Key) Air Shock...

  • Page 56: Running Belt And Deck Replacement

    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, 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 57 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.

  • Page 58: Roller Replacement

    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 59: Motor Replacement

    Motor Replacement 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. Unplug the motor wires from the lower board.
  • Page 60 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 61: Motor Brush Replacement

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

  • Page 62: Lower Control Board Replacement

    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 63: Console Cable Replacement

    Console Cable Replacement – T40 & T30 Models Tools required: Philips screwdriver Allen wrench (5mm) 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 64 5. Attach the new console control cable to the old one with a solid string at the bottom of the cable. 6. Pull the old cable continuously until the new cable comes out of the top of the right support. 7.
  • Page 65 Console Cable Replacement – T20 Models 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 66 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).

  • Page 67: Incline Motor Replacement

    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 68: Upper Board Replacement

    Upper Board Replacement Tools required: Philips 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, loosen the screws (N06) from the back console panel (N10). 3.

  • Page 69: Keypad Replacement

    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 screws (N06) from the back console panel (N10). 3. Disconnect the keypad (N02) from the console (N03). 4.

  • Page 70: Air Shock Replacement

    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.

This manual is also suitable for:

T30T20

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