Horizon Fitness Horizon T40 User manual

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

TABLE OF CONTENTS
Warranty 3 - 4
Safety Instructions 5 – 7
Recommended Tools 8
Maintenance 9
Tensioning or Aligning the Running Belt 10-11
Tensioning the Drive Belt 12
Lubricating Procedures 13
Horizon Fitness “5-Step” Diagnostic Process 16
Console Cable Voltage Chart 22
Upper Board Configuration 23
Auto-Calibration Instructions 26
Upper Board Troubleshooting 28
E-1 Error Message 31
E-2 Error Message 32
Diagnostics Mode 33
Heart Rate troubleshooting 35
Treadmill Motor will not start 38
Treadmill Resets 39
Running Speed is not Stable (Erratic) 40
Wiring Diagrams 41
Lower Control Board Diagnostic LED Chart 43
Manual Speed Calibration 45
Incline Motor Troubleshooting 48
Drive Motor and Roller Troubleshooting 51
Running Belt and Deck Replacement 56
Roller Replacement 58
Motor Replacement 59
Motor Brush Replacement 61
Lower Control Board Replacement 62
Console Cable Replacement 63
Incline Motor Replacement 67
Upper Board Replacement 68
Keypad Replacement 69
Air Shock Replacement 70
2

Treadmill Home Warranty
Horizon 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 – TEN YEARS
Horizon Fitness warrants the drive motor against defects in workmanship and
materials for a period of ten years from the date of purchase, so long as the device
remains in the possession of the original owner.
ELEVATION MOTOR – TEN YEARS
Horizon Fitness warrants the elevation motor against defects in workmanship and
materials for a period of ten years from the date of purchase, so long as the device
remains in the possession of the original owner.
ELECTRONICS & PARTS – ONE YEAR
Horizon Fitness warrants the electronic components and all original parts against
defects in workmanship and materials for a period of one year from the date of
purchase, so long as the device remains in the possession of the original owner.
3

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.
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.
4

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
neck ties, 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.
5

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.
6

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 provides 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. Service should be performed by an
authorized Horizon Fitness service provider only.
• Treadmill should be plugged into a dedicated 20amp circuit for optimal performance.
7

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” 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.
8

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, 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.
Each Year
• Add lubrication to deck and running belt. Use lubrication provided by Horizon Fitness
only!
• Lubricate the air shocks with a Teflon based spray
9

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.
10