Horizon Fitness RST 5.6 User manual

2007 Sears
Treadmill Service Manual
Horizon Fitness
Models
RST 5.6
RCT 7.6

Elevation Troubleshooting
No Motor Movement Troubleshooting
Erratic Speed Troubleshooting
Auto Calibration Troubleshooting
Console/Upper Board Troubleshooting
Membrane Keypad Overlay Troubleshooting
Safety Key/Reed Switch Troubleshooting
Heart Rate Troubleshooting
Circuit Breaker Troubleshooting
Engineering Mode
Digital Drive Wiring
RST 5.6 Upper Board
RCT 7.6 Upper Board
Power Source Wiring Diagram
No Motor Movement Voltage Check Points
Cut Console Cable Voltage Chart
Incline Wire Voltage Chart
Reseting The Incline Motor
Lubrication Procedure
3
4
5
7
8
10
11
12
14
15
17
18
19
20
21
23
25
26
27
Table Of Contents

rst 5.6 & rct 7.6 service manual 2007_rev1.0 | 3
RST5.6 & RCT 7.6 Sears Service Manual 2007
No Motot Movement TroubleshootingElevation Troubleshooting
Elevation motor starts
running as soon as the power is
turned on. Constant down.
Elevation motor bobs up and down
with command.
Elevation motor does not reach
minimum or maximum settings.
Elevation is stuck down and does
not function. Console is responsive
to the buttons being pressed.
Elevation is stuck at the highest
position and is will not come down.
Console is responsive to the but-
tons being pressed.
Elevation inclines to the high-
est position as soon as power is
applied.
The incline will go up, but not
down. (very rare)
Failed lower board.
Failed elevation motor.
Failed elevation motor.
Failed console cable.
Failed elevation motor.
Failed upper board
Failed upper board, lower board
(very rare for models made after
2003), console cable, and elevation
motor.
Failed lower board
Failed lower board
-Turn on power. Do not press start.
Wait 30-60 seconds and see if
motor is hot. Use caution. Motor can
get very hot.
Referance Incline Voltage Chart.
(p. 25)
-Verify there are no pinches or cuts
on the elevation wires.
-Verify the connections of above
wires.
Referance Incline WVoltage Chart.
(p. 25)
-Verify console cable connections.
Verify there are no pinches or cuts
in the cable.
Referance Console Cable Voltage
Chart. (p. 26)
-Put machine in hardware test
(Eng1) and press start. Eleva-
tion doesn’t respond buttons are
pressed. (You may see a value for
elevation that reads 255 or 1023.
That value will not change when the
buttons are pressed).
Referance Incline Voltage Chart.
(p. 25)
-Put machine in hardware test
(Eng1) and press start. Incline will
work in hardware test only.
Reference Engineering Modes (p.15)
-Verify all wire connections.
-If the incline went into the
highest position without start being
pressed.
-The incline will act normally
when going up, but when the down
incline is pressed there is no
movement.
Replace lower board.
Replace elevation motor.
-Recalibrate elevation motor by
hand. Referance Resetting the
Incline Motor. (p. 25)
-Replace elevation motor.
Replace console cable.
Replace elevation motor.
Replace upper board.
Replace upper board, console
cable, and elevation motor.
Replace lower board.
Replace lower board.
It’s recommended to send console cables for elevation repairs on all models using
sectional console cables.
Symptom Possible Cause Test Procedure Repair

4| rst 5.6 & rct 7.6 service manual 2007_rev1.0
RST5.6 & RCT 7.6 Sears Service Manual 2007
No Motor Movement Troubleshooting
4| rst 5.6 & rct 7.6 service manual 2007_rev1.0
RST5.6 & RCT 7.6 Sears Service Manual 2007
No Motor Movement Troubleshooting
Symptom Possible Cause Test Procedure Repair
If the AC voltage is missing
or incorrect, check the AC
service or consult an
electrician.
Replace parts as needed.
Replace MCB.
Replace drive motor.
Replace optic sensor.
No Motor Movement - Upon
pressing start, console
responds normally, keys
respond normally, and
elevation works but no belt
movement.
Inadequate power.
Damaged or improper
wiring.
Failed motor control board
(MCB).
Failed drive motor.
Failed optic sensor.
-Check for dedicated circuit
(20 amp is ideal) and check
wall outlet voltage (120 VAC)
Reference Power Source
Wiring Diagram. (p. 20)
-Make sure machine is not
on extension cord or surge
protector.
Reference No Motor
Movement Voltage
Checkpoints. (p. 21)
-Verify there are no pinches or
cuts in the power cord, power
wires motor wires, or console
cable.
-Verify the connections of
above wires and cords.
Reference No Motor
Movement Voltage
Checkpoints. (p. 21)
-Verify power to MCB
Reference No Motor
Movement Voltage
Checkpoints. (p. 21)
-Measure voltage output from
motor.
Reference No Motor
Movement Voltage
Checkpoints. (p. 21)
Reference No Motor
Movement Voltage
Checkpoints. (p. 21)

rst 5.6 & rct 7.6 service manual 2007_rev1.0 | 5
RST5.6 & RCT 7.6 Sears Service Manual 2007
Erratic Speed Troubleshooting
Symptom Possible Cause Test Procedure Repair
Erratic speeds - Upon pressing
start, belt speed increases rapidly
and then comes to a complete
stop quickly.
Erratic speeds - Upon pressing
start, belt speed increases rapidly
and does not stop.
Erratic speeds - Running belt
speed is not stable.
Failed optic sensor.
Failed motor control board (MCB).
Machine not calibrated properly.
-Running belt is too loose or too
tight.
-Drive belt is too loose or too
tight.
Inadequate power.
Failed or improper wiring.
Inadequate lubrication on deck
and running belt.
Failed motor control board (MCB).
Reference No Motor Movement
Voltage Checkpoints. (p. 21)
-Run auto calibration.
Reference Engineering Mode.
(p. 15 & p. 16)
-The running belt should not slip
at all when customer is using the
machine
-The drive belt should have
approximately 3/8 of inch
deflection.
-Check for dedicated circuit (20
amp is ideal) and check wall out-
let voltage (120 VAC). Reference
Power Source Wiring Diagram.
(p. 20)
-Make sure machine is not on
extension cord or surge protector.
-Verify there are no pinches or
cuts in the power cord, power
wires motor wires, or console
cable.
-Verify the connections of above
wires and cords.
Reference Cut Console Cable
Voltage Chart. (p. 23 & 24)
-Place hand underneath running
belt and feel for adequate silicone
application.
Reference No Motor Movement
Voltage Check Points. (p. 21)
Replace optic sensor.
Replace MCB.
If unit fails to auto calibrate,
refer to auto calibration
troubleshooting.
-Tighten running belt. Reference
Owners Manual. (p. 14)
-Tighten drive belt
If the AC voltage is missing or
incorrect, check the AC service or
consult an electrician.
Replace parts as needed.
Apply silicone.
Reference Lubrication
Procedure. (p. 27)
Replace MCB.