Horizon Fitness T61 Service Manual
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Horizon Fitness T61 Service Manual

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See also: User Manual
Ho r i zo n F it ness
Models
T61, T62, T63, T64,
CST 3.5, CST 4.5,
DT650, DT850, WT950,
PST 6, PST 8,
1.2T, 2.2T, 3.2T, 4.2T,
5.2T
2 0 0 6
Tr e ad m i ll S e r v ic e M a n u a l

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Summary of Contents for Horizon Fitness T61

  • Page 1 Ho r i zo n F it ness Models T61, T62, T63, T64, CST 3.5, CST 4.5, DT650, DT850, WT950, PST 6, PST 8, 1.2T, 2.2T, 3.2T, 4.2T, 5.2T 2 0 0 6 Tr e ad m i ll S e r v ic e M a n u a l...
  • Page 2 Table of C on ten ts Warranty Safety Instructions Recommended Tools Maintenance Proper Heart Rate Usage Horizon Fitness “5-Step” Diagnostic Process Voltage Checks and LED Diagnosis Wiring Diagrams and Schematics Engineering Mode Troubleshooting Spare Parts Replacement R EFER TO TH E S U P P L E M E N TA L S H E E T O N TH E L A S T P A GE OF T HE S E RV I CE M ANU AL...

  • Page 3: Warranty

    Horizon Fitness shall cover the labor cost for the repair of the device for the above warranty periods, so long as the device remains in the possession of the original owner.
  • Page 4 Im por tant Safety I ns t r u c t i o n s Warning statements indicate a particularly dangerous activity. You should be extremely cautious when doing the following: • Removing power from the treadmill, or removing the power cord from the wall outlet. Always en- sure 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 5 Connect this appliance to a properly grounded, dedicated 0-amp outlet only. WARNING See grounding Instructions. GROUNDING INSTRUCTIONS This product must be grounded. If a treadmill should malfunction or breakdown, grounding provide a path of least resistance for electrical current to reduce the risk of electrical shock. This product is equipped with a cord having an equipment-grounding conductor and a grounding plug.
  • Page 6 • Cable ties • Motor commutator stone • Needle nose pliers • Damp cloth • Rubber mallet • Drop cloth • Ruler • Snap ring pliers • Wire cutters Note: The motor commutator stone can be ordered from Horizon Fitness.
  • Page 7 Preve nta tiv e Mai ntenance Pr oc e d u r e s 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.
  • Page 8 Te ns i oni ng the Ru nnin g Be l t If you can feel a slipping sensation when running on the treadmill, the running belt must be tight- ened. In most cases, the belt has stretched from use, causing the belt to slip. This is a normal and common adjustment.
  • Page 9 Aligining th e R unni ng B el t 1) 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.
  • Page 10 Tens i oni ng the D r iv e Be lt ( Model s: T6 1, T62, T63, T6 4 , C S T 3 . 5 , C S T 4 . 5 , D T 6 5 0 , 1 . 2 T, 2 . 2 T, 3 . 2 T, 4 . 2 T, D T 85 0 , W T 9 5 0 ) Fi gur e 5 F igure 6 Procedure:...
  • Page 11 Tensioning the Dr i v e B el t ( Mod el s: PST6, PST 8, 5. 2 T) F igure 7 Procedure: 1) Turn off the power to the treadmill and remove the power cord from the wall outlet. ) Remove the motor cover.
  • Page 12 Stoni ng the M otor C om m u t a t o r 1) Unplug the power cord from the wall outlet. Do not plu g in t he pow er cord and do not turn on the treadmi l l w he n the motor br u sh es a r e r em oved f rom the dri ve motor.
  • Page 13 W he n re in st al li ng , ma tc h up the marks for prop er tension. b. Take a small amount of silicon oil (0 cc squeeze bottle provided by Horizon Fitness) and apply it to the entire top surface of the running deck.
  • Page 14 Pr oper Hear t R ate Us a g e HAND GRIPS Place the palm of you hands directly on the grip pulse handlebars. Both hands must grip the bars for your heart rate to register. It takes 5 consecutive heartbeats (15-0 seconds) for your heart rate to register accuratly. When gripping the pulse handle- bars, do not grip tightly.
  • Page 15 Lubricating the Ai r Shock Procedure: 1) Fold the treadmill to the upright position; making sure the treadmill is locked securely. ) 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 Fi gur e 1 1...
  • Page 16 • Make sure the treadmill is on a dedicated circuit. Horizon Fitness recommends a 0 amp dedicated circuit, but a 15 amp dedicated circuit may be sufficient.
  • Page 17 Five -Ste p D i agnos i s Pr oces s 3. Proper Motor Function • Verify that the treadmill is properly lubricated (Reference Maintenance Section) and drive motor is operating at the proper amperage rating. To verify the current draw, place a clamp meter around the red motor wire.
  • Page 18 Co ns ol e C abl e Volt ag e Ch a r t ( D C V o lt s) F i g u r e 15 C onso le C a b l e V o l t a g e Ch e c k Fi gur e 16 To check the voltage of a specific function (i.e.
  • Page 19 M otor/AC W i r e Vol tage C heck Motor Vo lta g e C h e c k Figure 17 Spin motor flywheel to produce voltage AC Wi r e V olt a g e Ch e c k Figure 18...
  • Page 20 Low er Boar d L ED Dia gn o s is Fi gur e 19 a LED 5 LED 4 LED 3 LED 2 LED 1 LED 1: Transfer indicators - When the power switch is turned on, LED 1 lights up, meaning that power is sup- plied to the lower board.
  • Page 21 Lower Boar d L ED D i agnos is Fi gur e 1 9 b LED 4 LED 5 LED 2 LED 3 LED 1 LED 1: DC Voltage Indicator - When the power switch is turned on, LED 1 dimly lights up. If the belt begins to run LED1 will remain.
  • Page 22 Digi tal D ri v e Wi r i ng D ia g r a m F i g u r e 2 0...
  • Page 23 Power S our c e Wi ri ng D iagra m Fi g ur e 2 1 Wi r e l e n g t h w i l l d e te r m i n e c o n n e c t i o n p o i n t . A –...
  • Page 24 Up per B oar d Config ur a t io n s Figu r e 22 T6 1 & T 6 2 Figu r e 23 T 6 3...
  • Page 25 Upper Boar d C onfi gur ati ons F igu re 24 T 64 F igu re 25 D T6 50...
  • Page 26 Up per B oar d Conf ig ur a t io n s Figu r e 26 DT 8 5 0 Figu r e 27 CS T 3 .5...
  • Page 27 Upper Boar d C onfi gur ati ons F igu re 28 C ST 4 . 5 F igu re 29 PS T6...
  • Page 28 Up per Boar d Conf igu r a t i o n s Fi gur e 30 P S T 8 Fi gur e 31 1 . 2 T...
  • Page 29 Upper Boar d C onfi gur ati ons Fi gur e 32 2 .2T Fi gur e 33 3 .2T...
  • Page 30 Up per Boar d Conf igu r a t i o n s Figu r e 34 4 .2 T & 5 .2 T...
  • Page 31 Enginee rin g Mode (Mo dels : T61, T62, T6 3, T64 , CS T 3. 5 , CS T 4. 5, D T6 50 , DT 850 , WT950 , P ST 6, PS T 8) Entering Engineering Mode Press and hold “Stop”...
  • Page 32 En gi neeri ng M ode ( M odel s 1 . 2T, 2.2 T, 3. 2T, 4. 2 T, 5 . 2 T ) Entering Engineering Mode Press and hold “Stop” to exit all engineering modes. 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.
  • Page 33 Enginee rin g Mode C onti nued ( M odels 1.2T, 2.2T, 3 .2 T, 4. 2T, 5. 2 T) Eng4 – Roller Diameter Check It is important to verify proper roller values as improper values can create inaccurate speeds. 1.
  • Page 34 Safety Key /Reed Switc h Tr o u b le s h o o t i n g P o s sib le C a u se Te s t P r o ce d u r e R e pa i r S y mp to m Console only displays Safety key or reed switch...
  • Page 35 Console/Up per Boar d Tr ouble sh o o t i n g P o s s ib l e C a us e Te st Pr o c e du r e R e pa i r Sy mp t om No display on the console Circuit breaker in home has Check for dedicated circuit...
  • Page 36 Con sol e/U pper Boa r d Tr o u b le sh o o t i n g Co n t in u e d P o s sib le C a u se Te s t P r o ce d u r e R e pa i r S y mp to m Running belt stops,...
  • Page 37 M embrane Key P ad/Ov er l ay Tr ou b le s h o o t i n g P o s s ib l e C a us e Te st Pr o c e du r e R e pa i r Sy mp t om All or some of the keys on...

  • Page 38: Proper Heart Rate Usage

    H ear t Rate Tr oubles ho o t i n g P o s sib le C a u se Te s t P r o ce d u r e R e pa i r S y mp to m (Reference Proper Heart Heart rate erratic or User error.
  • Page 39 Sta tic Trou bl es hooting P o s s ib l e C a us e Te st Pr o c e du r e R e pa i r Sy mp t om Static shocks when Machine on carpet. Place a rubber mat under touching machine machine to reduce static...

  • Page 40: Voltage Checks And Led Diagnosis

    No Motor Movemen t Tr o u b le sh o o t i n g P o s sib le C a u se Te s t P r o ce d u r e R e pa i r S y mp to m No motor movement Inadequate power.

  • Page 41: Troubleshooting

    Erra tic Spe ed Tr oubl eshoot in g P o s s ib l e C a us e Te st Pr o c e du r e R e pa i r Sy mp t om Erratic speeds - Upon Failed optic sensor.
  • Page 42 Auto C al i brati on Tr o ub le sh o o t i n g P o s sib le C a u se Te s t P r o ce d u r e R e pa i r S y mp to m Failed Auto Calibration Failed RPM sensor.
  • Page 43 Circ uit Bre aker Tr oubl es ho ot in g P o s s ib l e C a us e Te st Pr o c e du r e R e pa i r Sy mp t om Machine will trip home Inadequate power.
  • Page 44 El ev ati on Tr oubl es ho o t i n g P o s sib le C a u se Te s t P r o ce d u r e R e pa i r S y mp to m Elevation motor will incline Failed elevation motor.
  • Page 45 Noise Troubl es hooti ng P o s s ib l e C a us e Te st Pr o c e du r e R e pa i r Sy mp t om Thumping sound when New treadmill. Let the treadmill run for running belt is engaged.
  • Page 46 Spare Parts Repl acement Roller Running Belt/Deck Opticaln Disk/Digital Sensor/Drive Motor Motor Brush Motor Control Board Upper Board Console Cable Console Mast Cable Elevation Motor Upper Board/Reed Switch Membrane Keypad/EL Paper/Overlay Air Shock To Remove the motor cover on the PST6, PST8, and .-5. models, the machine must be elevated to at least level 6 or both side covers need to be removed to gain access to all 4 motor cover screws.

  • Page 47: Figure

    Roller Repl acement Tools Required: •Philips Screwdriver •4mm, 6mm, 8mm Allen Wrenches •13mm, 14mm Socket and combination wrenches Procedure: Front Roller 1) Remove the motor cover and rear roller end caps. F igu r e 3 8 ) Remove tension bolts and remove the rear roller. It is a good idea to note the position of the rear roller before removing.
  • Page 48 1) Remove the motor cover, rear roller end caps, and guide rails. (Figures 35 & 36) ) For Models T61 -T64/CST 3.5 & 4.5/DT650 & 850/WT950 Only - Peel off grip tape stickers on front guide rail to expose the two screws underneath. Remove screws and remove front guide rail.
  • Page 49 Running Bel t/Deck Repl acem en t 4) Remove the speed sensor bracket. 5) Loosen or remove the front roller bolt A on drive belt side. 6) On the opposite side of the front roller remove front roller bolt B. 7) Press against the drive belt and guide it towards the left until it is released from the front roller and remove front roller.
  • Page 50 5) For Models T61 -T64/CST 3.5 & 4.5/DT650 & 850/WT950 Only - Bring the deck back down into the horizontal position. 6) For Models T61 -T64/CST 3.5 & 4.5/DT650 & 850/WT950 Only - Plug in and turn on the machine.
  • Page 51 Optica l Dis k /Di gi tal Sensor /D r iv e M o t o r Re p l a c e m e n t 9) Unplug the power cord from the wall outlet. 10) Unplug motor and optic sensor wires from the motor control board. Also remove the green ground wire that is attached to the bracket next to the motor control board.
  • Page 52 ) Remove Brush Covers. (Figures 43 & 44) F i g u r e 4 4 Fi gur e 43 3) For Models T61-T62/CST3.5/DT650 & 850/WT950/1.2T-2.2T Only - Remove clip and spring hold- ing motor brush remove motor brush. (Figures 45 & 46) Fi gure 45...
  • Page 53 M otor Brush Repl acement 4) For Models T63-T64/CST4.5/3.2T-5.2T Only – Remove brushes. (Figure 47) Fi gure 47 5) Check the surface of the motor brush. (Figures 48) Fi gure 48 If the surface of carbon brush is pitted, rough, or has burn marks replace the motor brush. 6) Stone the surface of the motor commutator and blow out particles inside motor with an air com- pressor.
  • Page 54 M otor Contr ol B oa r d Re p la c e m e n t Tools Required: • Philips Screwdriver Procedure: 1) Turn off the power to the treadmill and unplug the power cord from the wall outlet. ) Remove the motor cover.
  • Page 55 Upper Boar d C onsol e C abl e Re p l a c e m e n t Tools required: •Philips Screwdriver •Wire Cutters •Zip Ties Procedure: 1)Turn off the power to the treadmill and unplug the power cord from the wall outlet. 2)Remove screws connecting faceplate to console shell (Figures 51, 52, 53) 3)Disconnect console cable from upper board.
  • Page 56 1) Turn off the power to the treadmill and unplug the power cord from the wall outlet. ) For Models T61 -T64/CST 3.5 & 4.5/DT650 & 850/WT950/1.2T Only - Remove the motor cover. 3) For Models T61 -T64/CST 3.5 & 4.5/DT650 & 850/WT950/1.2T Only - Disconnect the console cable from the lower control board.
  • Page 57 Console M a s t Cabl e Repl ace me n t 7) Remove bolts holding console assembly onto console masts. (Figures 63, 64, 65) 8) Disconnect console cable in the upper left hand corner of the console and secure cable so that it does not fall down console mast.
  • Page 58 El ev ati on Motor Re plac e m e n t Tools Required: • Philips Screwdriver • 17mm Socket and Combination Wrenches (Qty ) Procedure: 1) Turn off the power to the treadmill and unplug the power cord from the wall outlet. ) Remove the motor cover.
  • Page 59 Elevation M o tor Repl acemen t 6) Fold the treadmill down to the running position and remove the top bolt from the elevation motor, and remove the motor from the machine. (Figure 69) Fi gur e 6 9 7) Reinstall the top bolt to the elevation motor. When installing the new incline motor;...
  • Page 60 I f n o t re p l a c i n g re e d s w i t c h s k i p to s t e p 5 . 3) For Models T61 -T64/CST 3.5 & 4.5/DT650 & 850/WT950 Only – Unplug and remove reed switch from small plastic knobs.
  • Page 61 Upper Bo ar d/R eed Swi tch Re pla c e m e n t 5) Unplug all the cables to the upper board. 6) Remove screws holding upper board to faceplate and replace old upper board with new one. (Figures 74, 75, 76) F igure 74 Figure 75...
  • Page 62 M embr ane Key pad /E L Pa p e r / Ov e r l a y R e p l a c e m e nt Tools Required: • Philips Screwdriver • Flat-Blade Screwdriver Procedure: Fi gure 77 F ig u r e 7 8 F ig u r e 7 9 1) Turn off the power to the treadmill and unplug the power cord from the wall outlet.
  • Page 63 Membran e Key pad/EL P aper / Ov e r la y Re p la c e m e n t 4) Remove the overlay and keypad from faceplate. (Figures 80, 81, 8) Figu re 80 F ig u re 8 1 Fi gur e 8 2 Make sure all the adhesive is removed from the plastic console faceplate.
  • Page 64 Ai r Shock Repl acem e n t Tools Required: • 1mm Socket and Combination Wrench • 13mm Socket and Combination Wrench • 17mm Socket and Combination Wrench Procedure: 1) Fold treadmill to locking position. ) Remove nut that secures the top screw of the air shock to the frame and remove top portion of shock.
  • Page 65 N otes...
  • Page 66 C US T OMER TEC H SU P PO R T If you have any questions or comments, you may contact one of our trained customer technicians via phone, email or our website. Customer Tech Support Hotline: 1 - 8 0 0 - 2 4 4 - 4 1 9 2 Email: comments@horizonfitness.com Website: www.horizonfitness.com Customer Tech Support hours: Monday - Friday, 8 am - 5 pm CST (excluding holidays)
  • Page 67 LED 5 NEW M OT OR CON TR OL B OA RD Console Cable Optic Sensor Elevation Speed Sensor Power Motor Wires LED 1 A mid-production change involving the motor control board has occurred effective (11/01/05): Units with .75 HP Drive Motors will not be affected by this production change. (PST8 and 5.T) Please check the serial number (Pictured Below) to verify the production change.

This manual is also suitable for:

T62T63T64Cst 3.5Cst 4.5Dt650 ... Show all

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