Horizon Fitness 1.1T, 3.1T, 4.1T, 2.1T, 1.1T 2.1T Service Manual

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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

TABLE OF CONTENTS

Warranty 3

Safety Instructions

Recommended Tools

Maintenance

Upper Board Troubleshooting

Lower Board Troubleshooting

Incline Motor Troubleshooting

Drive Motor and Roller Troubleshooting

Spare Parts Replacement

Treadmill Home Warranty

Elite Series Treadmills

LIMITED HOME USE WARRANTY

Horizon Fitness extends the following exclusive, limited warranty, which shall apply to the use of the device in the home, for residential, non-commercial purposes only. Any other use shall void this warranty.

Horizon Fitness hereby extends the following limited warranties for the following components of the device, for the time period indicated:

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.

DRIVE MOTOR – TWENTY-FIVE YEARS

Horizon Fitness warrants the drive motor against defects in workmanship and materials for a period of twenty-five years from the date of purchase, so long as the device remains in the possession of the original owner.

ELEVATION MOTOR – TWENTY-FIVE YEARS

Horizon Fitness warrants the elevation motor against defects in workmanship and materials for a period of twenty-five years from the date of purchase, so long as the device remains in the possession of the original owner.

ELECTRONICS & PARTS – TWO YEARS Horizon Fitness warrants the electronic components and all original parts against defects in workmanship and materials for a period of two years from the date of purchase, so long as the device remains in the possession of the original owner.

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 possession of the original owner.

EXCLUSIONS AND LIMITATIONS

This warranty applies only to the original owner and is not transferable. This warranty is expressly limited to the repair or replacement of a defective frame, electronic component, or defective part and is the sole remedy of the warranty. The warranty does not cover normal wear and tear, improper assembly or maintenance, or installation of parts or accessories not originally intended or compatible with the treadmill as sold. The warranty does not apply to damage or failure due to accident, abuse, corrosion, discoloration of paint or plastic, 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 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. These products must be received with all freight and other transportation charges prepaid, accompanied by sufficient proof of purchase. Parts and electronic components reconditioned to As New Condition by Horizon Fitness or its vendors may sometimes be supplied as warranty replacement parts and constitute fulfillment of warranty terms. This warranty gives you specific legal rights, and your rights may vary from state to state.

WARRANTY REGISTRATION

Your warranty card must be completed and sent to Horizon Fitness or register on line at www.horizonfitness.com

, before a warranty claim can be processed.

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.

• Removing the motor cover exposes high voltage components and potentially

dangerous machinery. Exercise extreme caution when you perform maintenance procedures with the hood removed.

• During service operations you will be very close to moving machinery and high

voltage components. When you perform maintenance procedures with the hood removed, remove jewelry (especially from ears and neck), tie up long hair, remove neckties, and do not wear loose clothing.

• When the treadmill is operating, the capacitor will hold a lethal amount of charge.

Do not touch the capacitor as serious injury or death might result.

• When the treadmill is turned off and the power cord is removed from the wall outlet,

the capacitor will hold voltage for 30-60 seconds. Allow the capacitor to discharge for a period of one minute before you touch or work near the capacitor. Do not attempt to discharge the capacitor by any other means.

• Exercise caution when touching any wire or electrical component during treadmill

operation.

• When it is necessary to lift the treadmill, ensure that the treadmill has adequate

support. Do not lift the treadmill by the front.

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.

• Visually check the treadmill before beginning service or maintenance operations. If

it is not completely assembled or is damaged in any way, exercise extreme caution while operating and checking the treadmill.

• When operation the treadmill, do not wear loose clothing. Do not wear shoes with

heels or leather soles. Check the soles of your shoes and remove and embedded stones. Tie long hair back.

• Use care when getting on of off the treadmill. Use the handrails whenever possible.

Do not get on or off the treadmill when the running belt is 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 off the running belt.

• Do not rock the unit. Do not stand or climb on the handrails, electronic console, or

hood.

• Do not set anything on the handrails, electronic console, or hood. Never place

liquids on any part of the treadmill.

• To prevent electrical shock, keep all electrical components, such as the drive motor,

power cord, and circuit breaker away from water and other liquids.

• Do not use accessory attachments that are not recommended by the

manufacturer-such attachments might case injuries.

• Turn off the treadmill when adjusting o working near the take-up roller. Do not

make any adjustments to the running belt when someone is standing on the machine.

• Keep all loose items away from the treadmill running surface. A treadmill running

belt will not stop immediately if an object becomes caught in the belt or rollers.

WARNING:

Connect this appliance to a properly grounded, dedicated 20-amp outlet only. 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. The plug must be plugged into an appropriate outlet that is properly installed and grounded in accordance with local codes and ordinances.

DANGER - Improper connection of the equipment-grounding conductor can result in a risk of

electric shock. Check with a qualified electrician of 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 qualified electrician.

SAFETY TIPS

• Never use the treadmill before securing the safety tether clip to your clothing.

• If you experience chest pains, nausea, dizziness, or shortness of breath, stop exercising

immediately and consult your physician before continuing.

• Do not wear clothes that might catch on any part of the treadmill.

• Keep power cord away from heated surfaces.

• Keep children off of treadmill at all times.

• 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.

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” drive ratchet and sockets of assorted sizes Blue loc-tite Cable ties Motor commutator stone Needle nose pliers Damp cloth Rubber mallet Drop cloth Ruler Snap ring pliers Wire cutters

Note:

Drive belt tension gauges and motor commutator stone can be ordered from Horizon Fitness.

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

• Turn off the treadmill with the on/off switch, and unplug the power cord from the wall outlet.

Warning! To remove power from the treadmill, the power cord must be disconnected from the wall outlet.

• Wipe down the running belt, deck, motor cover, and console casing with a damp cloth. Never use solvents, as they can cause damage to the treadmill.

• Inspect the power cord. If the power cord is damaged, contact Horizon Fitness.

• Make sure the 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 damage any other components on the treadmill by being misaligned

Every Week Clean underneath the treadmill, following these steps:

• Turn off the treadmill with the on/off switch, and then unplug the power cord at the wall outlet.

• Fold the treadmill into the upright position; making sure that the lock latch is secure.

• Move the treadmill to a remote location.

• Wipe or vacuum any dust particles or other objects that may have accumulated underneath

the treadmill.

• Return the treadmill to its previous position.

Every Month

• Inspect all assembly bolts of the machine for proper tightness.

• Remove the motor cover and clean the motor and lower board area to eliminate any lint or

dust particles that may have accumulated. Failure to do so may result in premature failure of key electrical components.

Each 6 months

• Add lubrication to deck and running belt. Use lubrication provided by Horizon Fitness only!

• Lubricate the air shocks with a Teflon based spray

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. 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. Try the treadmill again to check for slipping. Repeat if necessary, but NEVER TURN the roller bolts more than 1/4 turn at a time.

NOTE: The belt tension is set properly when the running belt is ¼ of an inch from the deck, towards the rear roller.

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.

If the running belt is not tracking properly follow the following procedures:

• If the running belt tracks to the left, turn the left roller bolt clockwise ¼ of a turn,

keeping the belt tension in mind. Over-tightening the running belt may cause damage to the running belt and roller bearings.

• If the running belt tracks to the right, turn the right roller bolt clockwise ¼ of a turn,

keeping the belt tension in mind. Over-tightening the running belt may cause damage to the running belt and roller bearings.

Tensioning the Drive Belt (1.1T, 2.1T, 3.1T)

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. 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 will significantly reduce the weight in the front end of 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 adjust to proper position.

7. Tighten the two motor attach bolts (M45, M46) with a 6mm Allen wrench.

8. Verify the proper tension on the drive belt. Using a timing belt tension gauge, the

proper tension should be between 65 to 75 lbs. If a timing belt tension gauge is not available, the drive belt should have approximately 3/8 of inch deflection. If the drive belt tension is not set properly, loosen the motor attachment bolts and adjust.

Treadmill Deck Lubrication Procedures

There are three different applications in which you would be required to add lubrication to a

Horizon Fitness treadmill.

1. MAINTENANCE

A Horizon Fitness treadmill does not need to be lubricated regularly. However, Horizon Fitness recommends that a 100% pure silicone lubricant be applied every 6 months. This is necessary to ensure the longevity of the treadmill.

2. BELT REPLACEMENT

When lubrication is added to a treadmill deck at the factory it is impregnated into the filament backing of the running belt, providing a low friction, long lasting coat. When replacing the original belt on a treadmill, this new belt will not be properly coated. Always add lubrication when replacing the belt.

3. BREAKER TRIPS

With time, the lubrication between the running deck and running belt of the treadmill will wear down. The lack of lubrication between the deck and belt will cause a high amount of friction when running on the treadmill. 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.

PROCEDURES

1. For optimal results, the running deck and belt should be warm before reapplication of

lubrication. It is recommended to run the treadmill at 5mph for 10–15 minutes before proceeding.

2. With the appropriate sized Allen wrench, loosen the rear roller bolts on both the left and right

side. It is a good idea to note the position of the roller to reassemble properly. 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. It is not necessary to take off the roller, just loosen it enough so that you can fit your hands underneath the belt comfortably.

3. Once the belt is loosened, take a small amount of silicon oil (20 cc squeeze bottle provided by

Horizon Fitness) and apply it to the entire top surface of the running deck.

After the silicon oil has been applied to the top surface of the running deck, the roller can be tightened to the proper position. 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.

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

FIVE-STEP DIAGNOSIS PROCESS

The following steps are provided as routine checkpoints when diagnosing problems on a Horizon Fitness treadmill. If followed correctly, these checkpoints should help diagnosis the majority of problems that may be encountered.

1. Proper supplying power to treadmill.

- 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.

- Make sure that proper voltage is being supplied from the 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.

- 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.

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. Replace and wires that are pinched or cut.

3. Proper Sensor Wire Function

- Verify that the rpm 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 attachment screws and position sensor bracket closer to front roller pulley if the distance is greater than 2-4 mm.

- Verify that the sensor wire is attached to the sensor bracket properly. The proper position would be so that the sensor wire is protruding from the left hand side of the sensor and sensor bracket while facing the treadmill.

- Verify that the rpm magnet is positioned in the front roller pulley.

- 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).

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. There should not be any

jerky or choppy movement of the motor. If there is please adjust the torque cube on the lower board by referencing page 25. It may also be necessary to stand on the belt at a slow speed and ride the treadmill belt from the front roller to the rear roller to verify that the treadmill motor and running belt are traveling smoothly.

- Verify start up speed (0.5 mph) in Engineering Mode. (For directions on entering and using the Engineering Mode please refer to Engineering Mode page 25).

- The start speed of the treadmill can also be determined by counting the revolutions/minute of the running belt. At 0.5 mph, the treadmill belt should make 4 revs/minute for the Elite 5.1T and 4.5 revs/minute for Elite 4.1T,

3.1T & 2.1T. If the belt revolutions are incorrect, adjust the speed dial located on the lower control board (see speed calibration in contents).

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.

Verify that proper voltage is being transferred through the console cable

(reference console cable voltage chart in the table of contents).

If the techniques described in the five-step Engineering process did not resolve the problem, reference the symptoms in the table of contents and review other possible causes in the troubleshooting section.

UPPER BOARD TROUBLESHOOTING

CONTENTS

Console Cable Voltage Chart 22

Upper Board Configuration

Engineering Mode (Inc. hardware test, auto-calibration, roller values, etc)

No display on console 34

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

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.

Upper Board Configuration

3.1T

4.1T

+ 52 hidden pages

Horizon Fitness 1.1T, 3.1T, 4.1T, 2.1T, 1.1T 2.1T Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual