Horizon Fitness Elite T4000 User manual

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2013 Elite T4000 (TM461C)
Service Manual

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TABLE OF CONTENTS
CHAPTER 1: SERIAL NUMBER LOCATION……………………………………………..………….3
CHAPTER 2: PREVENTATIVE MAINTENANCE
2.1 Preventative Maintenance……………………………………………………………….…………………4
2.2 Tension and Centering the Running Belt…………………………………………………….…………...6
CHAPTER 3: ENGINEERING MODE
3.1 Engineering Mode…………………………………….………………………………………….….……...7
3.2 Engineering Mode Overview…………………………………………….…………………………..……..8
CHAPTER 4: TROUBLESHOOTING
4.1 Electrical Diagram……………………………………………………………………………….…….….….9
4.2 Troubleshooting - No Power to the Console……………………………………………….………….....10
4.3 Troubleshooting - No Console Response………………………………………………….…....…….….12
4.4 Troubleshooting - Speed Response Inaccurate… …………………………………………..……….....13
4.5 Troubleshooting - Noise Issues……………………………………………………………..…….…….…14
4.6 Troubleshooting - Speaker / Audio Issues………………………………………………..…….………...16

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CHAPTER 1: Serial Number Location 1
1-1 Serial Number Location

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CHAPTER 2: Preventative Maintenance
2.1 PREVENTATIVE MAINTENANCE
Preventative maintenance is the key to smoothly operating equipment, as well as keeping the user’s liability to a minimum.
Equipment needs to be inspected at regular intervals. Defective components must be replaced immediately. Improperly
working equipment must be kept out of use until it is repaired. Ensure that any person(s) making adjustments or
performing maintenance or repair of any kind is qualified to do so.
AFTER EACH USE(DAILY)
Clean and inspect, following these steps:
• Turn off the treadmill with the ON / OFF switch, then unplug the power cord at 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 Customer Technical Support.
• 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.
• If any labels are damaged or illegible, contact Customer Technical Support for replacements.
EVERY WEEK (WEEKLY)
Clean underneath the treadmill following these steps:
• Turn off the treadmill with the ON / OFF switch, then unplug the power cord at the wall outlet.
• Fold the treadmill into the upright position, making sure that the lock latch is secured.
• 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 - IMPORTANT!
• Turn off the treadmill with the ON / OFF switch, then unplug the power cord at the wall outlet.
• Inspect all assembly bolts of the machine for proper tightness.
• Remove the motor cover. Wait until ALL display screens turn off.
• 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.
• Vacuum and wipe down the belt with a damp cloth. Vacuum any black / white particles that may accumulate around
the unit. These particles may accumulate from normal treadmill use.

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CHAPTER 2: Preventative Maintenance
2.1 PREVENTATIVE MAINTENANCE
EVERY 6 MONTHS OR 150 MILES
It is necessary to lubricate your treadmill running deck every
six months or 150 miles (240 kilometers) to maintain optimal
performance. Once the treadmill reaches 150 miles (240
kilometers), the console will display the message “LUBE” or
“LUBE BELT”. The treadmill will not operate while the
message is showing. Hold ‘STOP’ for 5 seconds to suspend
message for 5 miles.
Your treadmill came with a bottle of lubricant which can be
used for two applications.
●Turn off the treadmill with the on/off switch, then unplug the
power cord at the wall outlet.
●Loosen both the rear roller bolts. (for best results, place two
removable marks on both sides of the frame and note roller
position). Once the belt is loosened, take the bottle of
lubricant and apply it to the entire top surface of the
running deck. Tighten both rear roller bolts (matching up the marks for proper position) to original position. After you
have applied lubricant, plug in the power cord, insert the safety key, start the treadmill and walk on the belt for two
minutes to spread the lubricant.
●Lubricate the air shocks with Teflon based spray.
●Once lubrication is complete, reset the console by pressing and holding ‘STOP’ and ‘SPEED +’ buttons for 5 seconds.

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CHAPTER 2: Preventative Maintenance
2.2 TENSIONING & CENTERING 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,
turn the treadmill off and tension both the rear roller bolts using the supplied Allen wrench, turning them ¼ turn to the right
as shown. Turn the treadmill on and check for slipping. Repeat if necessary, but never turn the roller bolts more than ¼
turn at a time. Belt is properly tensioned when the slipping sensation is gone.
The running belt has been properly adjusted at the factory before it was shipped. At times the belt can move off-center
during shipment. Before operating the treadmill, make sure the belt is centered and remains centered to maintain smooth
operation.
If the running belt is too far to the right side: With the treadmill
running at 1 mph, turn the left adjustment bolt counter-clockwise
¼ turn at a time (using the supplied Allen wrench). Check the belt
alignment. Allow belt to run a full cycle to gauge if more
adjustment is needed. Repeat if necessary, until the belt remains
centered during use.
If the running belt is too far to the left side: With the treadmill
running at 1 mph, turn the right adjustment bolt counter-clockwise
¼ turn at a time (using the supplied Allen wrench). Check the belt
alignment. Allow belt to run a full cycle to gauge if more
adjustment is needed. Repeat if necessary, until the belt remains
centered during use.

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CHAPTER 3: Engineering Mode
3. ENGINEERING MODE
1) To enter Engineering Mode, press & hold the INCLINE UP “▲”and SPEED DOWN “▼” keys at the same time for
3-5 seconds until Engineering Menu appears on the display.
2) Use the INCLINE and SPEED UP and DOWN keys to select a parameter.
3) Press ENTER to enter a parameter setting.
4) Use the INCLINE and SPEED UP and DOWN keys to change the parameter.
5) Press the START key to save the change to the parameter.
6) Press and hold the STOP key to exit Engineering Mode and return to normal operation.

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CHAPTER 3: Engineering Mode
3.2 ENGINEERING MODE OVERVIEW
MODE FUNCTION DESCRIPTION
ENG 0 Display Test
Start Key – LCD/LED on
Stop Key – LCD/LED off
Any Other Key - Will show on the display window.
Hold the STOP key for 3 seconds to return to the Engineering Menu.
ENG 1 Hardware Test Motor & Incline Motor Test.
ENG 2 Auto Calibration There is no function for this model.
ENG 3 Switch Function
Use the INCLINE or SPEED UP and DOWN keys to switch DEMO
MODE off or on (Demo on=1 & Demo off=0 on DISTANCE
window).
Use the START key to select unit (1=KM & 0=Mile on TIME
window)
Use the “ENTER” key to select language. (English, German,
Dutch, French)
ENG 4 Information
Accumulated Time and Distance
Remarks: Unit of Time is Hour.
Unit of Distance is KM or Mile based on your set.
SECOND LEVEL
ENG 8
Test
(for factory or
technician use
only)
To Get to ENG 8 - Enter into ENG 3, the press and hold the INCLINE
UP and SPEED DOWN key at the same time for 3 seconds.
Press ENTER at P0 – PCB Software version.
Press ENTER at P1 – Accelerator (for factory only).
Press ENTER at P3 -- Hold the START key to clear accumulated Time
and Distance
Press ENTER at P4 – Burn Time (for factory only).
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※Energy Saver function must be on Demo off mode. When the treadmill no use over 15mins then
into Energy Saving mode. Touch any key to release.

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CHAPTER 4: Troubleshooting
4.1 Electrical Diagram
Energy Saver program is per-set. When the treadmill
no use over 15mins then into Energy Saving mode.
Touch any key to release.

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CHAPTER 4: Troubleshooting
4.2 TROUBLESHOOTING – NO POWER TO THE CONSOLE
NO POWER TO THE CONSOLE
1) SYMPTOM:
a. The power switch is in the on position, but the console will not turn on.
2) SOLUTION:
a. Check to see if the power switch is lit. If it is not, try a different outlet.
- If the power switch still does not light up with a known good outlet, replace the power switch.
b. Check to see if the MCB has power. There is a red power LED on the MCB that should be lit.
c. If the MCB does not have power, check the connection of the power wiring from the power receptacle to the MCB.
Use a multi-meter to measure AC1 & AC2, AC voltage shall be same as local’s standard voltage (110V-240V)
- If AC voltage value is standard, replace the MCB as it shall be defective.

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CHAPTER 4: Troubleshooting
4.2 TROUBLESHOOTING – NO POWER TO THE CONSOLE-CONTINUED
d. If the MCB does have power, check the connection of the console cable wire at the MCB and UCB.
- Remove the console cable from MCB, and use a multi-meter to measure the DC voltage between the “GND pin” (Pin
7&8) and the ” + 12V Pin” (Pin1 & 2)---see section 4.1. DC output is normally around DC 12V. If no output, replace the
MCB.
- If output is around DC 12V, check the console cable. If it is defective, replace the console cable.
- If the console cable connections are all good, replace the PCB.

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CHAPTER 4: Troubleshooting
4.3 TROUBLESHOOTING – NO CONSOLE RESPONSE
THE POWER IS ON, BUT MACHINE HAS NO RESPONSE
1) SYMPTOM:
a. The power is on and the console lights up, but the treadmill does not run when keys are pressed.
2) SOLUTION:
a. Check if the console beeps when all keys are pressed. If no, replace the keypads.
b. Enter Engineering Mode (See Section 4.1), and scroll to ENG 1 (Hardware Test).Press the key “ENTER” first and
then the key ”START”.
- When press the key “SPEED + / -“, if the data on windows “TIME” & “DISTANCE” is changed, the console is ok.
If not, replace the PCB.
c. Turn off the power switch, and open the motor upper cover. Remove the red & black wires of motor from the MCB,
and use a multi-meter to measure the resistance of drive motor.
If the resistance is bigger than 10 Ω, the drive motor is defective. Replace the drive motor.
If the resistance is lower than 10 Ω, the drive motor is ok. Then,
- Check the connection of the speed sensor (encoder disk group) at the MCB (Figure A).
- Remove the speed sensor (Figure B) from the motor and clean it, then re-test.
- If the speed sensor is clean and has a good connection but still will not operate, replace the speed sensor.
- Replace the MCB as the last step if machine does still not run after to take above actions.
FIGURE A FIGURE B

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CHAPTER 4: Troubleshooting
4.4 TROUBLESHOOTING - SPEED FEEDBACK INACCURATE
SPEED FEEDBACK INACCURATE
1) SYMPTOM:
a. The treadmill speed is not stable and did not match the actual speed.
2) SOLUTION:
a. Check the speed sensor first.
- If the Speed Sensor is too dusty. Remove it from the motor and clean it, then re-install and test it if the speed can
be normal.
- If the speed sensor is clean and has a good connection but the speed is still not stable, replace the speed
sensor.
b. If the speed sensor is good, replace the MCB.
Remarks: Elite T5000 uses the digital-control MCB, so there is no necessary to perform the speed auto-calibration,
and the machine will auto-calibrate the speed when it is moving.

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CHAPTER 4: Troubleshooting
4.5 TROUBLESHOOTING - NOISE ISSUES
NOISE ISSUES
1) SYMPTOM:
a. Thumping noise twice per rotation on new machine.
b. Rubbing / grinding noise.
c. High pitched “bell-like” sound from under the motor cover.
d. Banging or clunking sound.
e. Slapping / thunking / squeaking sound with each footstep.
f. Rubbing sound underneath the treadmill.
g. Squeaking noise when raising / lowering the deck into storage positions.
h. Squeaking / grinding noise when using elevation.
2) SOLUTION:
a. This noise is from the roller or running belt.
- If this is a new unit, some noise is normal as the running belt forms around the rollers and the joint of the belt.
- Check that the belt is centered and tensioned correctly.
- Remove and clean the rollers if needed.
- Replace the rollers or running belt as needed.
b. This sound is likely a moving component.
- Remove the motor cover and check the drive belt for alignment and make sure it is not slipping or is frayed / cut
in any way. Replace the drive belt if needed.
- Make sure the optic disk on the motor is not rubbing the speed sensor.
- Turn the motor by hand to see if motor brushes or bearings are rubbing. Replace the motor
if needed.
- Check the front and rear rollers, replace if needed.
c. This sound is likely caused by the optic disk.
- Check that the optic disk is tight on the motor and not rubbing the speed sensor.
d. The sound is likely due to the unit not being level.
- Check that all levelers are touching the ground.
- Move the treadmill to another flat surface.

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CHAPTER 4: Troubleshooting
4.5 TROUBLESHOOTING - NOISE ISSUES-CONTINUED
e. This sound is from the running deck / belt.
- Check that the running deck is tightly attached to the frame.
- Check the deck shocks for detioration or crumbling. Replace if needed.
- Check to see if the air shock is making this noise, lubricate or replace if needed.
f. This sound is likely due to the air shock.
- Lubricate or replace the air shock as needed.
g. This sound is likely from the incline motor.
- Check that the incline motor connection points include Teflon washers.
- Lubricate the incline motor worm screw and connection points with grease.
- Replace the incline motor.
C

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CHAPTER 4: Troubleshooting
4.6 TROUBLESHOOTING - SPEAKER / AUDIO ISSUES
Speaker / Audio Issues
1) SYMPTOM:
a. No sound through the speakers but headphones work.
b. No sound through headphones but the speakers work.
c. No sound through speakers or headphones.
d. Speakers buzzing.
e. Sound from one speaker only.
f. Shock from headphones.
2) SOLUTION:
a. One of the speaker boards has a bad connection or is faulty.
- Check the connection of the wires going from the speakers to the speaker power board.
- Check the connection of the wires going from the speaker power board to the amp board.
- Check the connection of the wires going from the amp board to the console.
- Replace the speaker or amp boards and wiring.
- Replace the speakers.
- If the speaker board, amp board, wiring, and speakers do not solve the issue,
replace the console.
b. There is a bad connection between the headphones and the console.
- Verify the connection of the music player to the dock or audio adaptor cable.
- Verify the audio adaptor cable connection at the console.
- Replace the headphone jack.
- Replace the audio adaptor cable.
c. There is a bad connection between one of the audio boards and the console.
- Verify the connection of the music player to the dock or audio adaptor cable.
- Verify the audio adaptor cable connection at the console.
- Replace the audio adaptor cable.
- Replace the console.
d. Speakers are not getting a clear signal through the speaker wires.
- Check the speaker wire connections.
- Check for any kinks or cuts in the speaker wires.
- Replace the speaker wiring.
- Replace the speakers.

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CHAPTER 4: Troubleshooting
4.6 TROUBLESHOOTING - SPEAKER / AUDIO ISSUES-CONTINUED
e. The speaker or speaker wiring is bad.
- Check the speaker wire connections.
- Switch the speaker connections from one speaker to the other to see if sound switches sides.
- If the sound does not switch sides, replace the speaker board.
- If the sound does switch sides, replace the speaker and speaker wires.
f. Grounding issue.
- Try a different set of headphones.
- Check the grounding of the console.