2006 Elliptical Service Manual
Contents
1. All Models Except 1 2E 1 Turn your multi meter setting to Ohms 2 Remove console and disconnect console cable 3 Put one lead into the purple pin P1 and the other on the yellow pin P7 Please refer to the Console Cable Voltage Check on page 16 Turn crank to produced an rpm in order to get continuity through the sensor wire TROUBLESHOOTING PARTS REPLACEMENT a Console Troubleshooting VuuvM AIN Symptom Possible Cause Test Procedure Repair No display on console Failed batteries 1 2E only Replace batteries Verify the connections between Connect wires correctly or the power supply and the power replace parts as needed jack Verify the connections between console cable and console Verify power supply is not pinched or damaged Failed or improper power supply Perform voltage check on Replace power supply power supply Reference Power Supply Voltage Check in Voltage Checks section Verify the power supply and make sure the adapter is the correct voltage Reference Power Supply Voltage Check in Voltage Checks section Failed console cable Verify console cable is not Replace console cable Refer pinched or damaged ence Console Cable Replace Perform voltage check on con ment in Parts Replacement sole cable Reference Console section cable Voltage Check in Voltage Checks section Failed console Replace console Failed batteries 12. 29151 IVY LUV3H 3JNVN31NIVM 39054 SWIIHI 39VIT0A E S e S INIWIIV1dI4 5149 El Side Cover Replacement EX 22 EX 33 EX 44 CSE 3 5 USE 4 5 EG5 Tools Required e Phillips Screwdriver e 13mm 17mm Socket and Combination Wrenches e 4mm 5mm Allen Wrenches Procedure 1 For Models EX 44 CSE 4 5 Only Remove lower link arm elbow covers Figure 15 Figure 19 SIDE ELBOW COVER LOWER HANDLEBAR OUTSIDE ELBOW COVER SCREW L LOWER LINK ARM 2 Remove bolt A and nut B holding link arm to lower handlebar Figure Below Figure 20 m LOWER HANDLEBAR LOWER LINK ARM TEFLON WASHERS F PROPER VOLTAGE REQUIRED SAFETY CHECKS ien MAIMTENAREE TOOLS INSTRUCTIONS TROUBLESHOOTING lt i Cg lt lt m Side Cover Replacement Continued EX 22 EX 33 EX 44 USE 3 5 CSE 4 5 EG5 Figure 21 AINVUUVM TOP SIDE COVERS EX 22 SNUHJIWISNI A133VS TOP SIDE COVERS 1001 0341030 SIDE COVER 3 Remove accessory trays and top side covers Figure Above 4 Remove AC Adaptor receptacle from side cover if applicable Figures Below 5 Remove side covers 3J9NVN31NIVM Figure 23 29151 IVY LUV3H 34054 193H9 39VI10A AC Adapter Recepticle AC Adapter Receptacle Side Cover INILOOHSITENOUL m gt Ii o Sensor Wire Replacement EX 22 EX 33 EX 44
3. REQUIRED TOOLS 2 Remove crank disk and side covers Reference Crank Disk Side Cover Crank Arm Replacement 1 2E amp 2 2E or 3 2E amp 4 2 3 Disconnect console cable from the speed sensor and servomotor MAINTENANCE PROPER HEART REAT USAGE Old Console Cable 4 Remove the console from the console mast 5 Unplug the console cable from the console and attach the new console cable to the old console cable in order to fish the cable through the console mast VOLTAGE CHECKS Figure 58 CONSOLE TROUBLESHOOTING CONSOLE MAST I IMPORTANT h You may need to unscrew the water bottle bracket screws in order to fish the console cable easily PARTS REPLACEMENT Servomotor Replacement 2 2E 3 2E 4 2E Tools Required e Phillips Screwdriver e 14mm 15mm 17mm Socket and Combination Wrenches e 5mm Allen Wrench e Crank Puller Procedure 1 Turn power on and press start on console 2 Set resistance level to highest position and turn off console 3 Unplug power supply from elliptical 4 Remove crank disk and side covers Reference Crank Disk Side Cover Crank Arm Replacement 1 2E amp 2 2E or 3 2E amp 4 2 5 Disconnect console cable from servomotor Figure 60 DC Motor Tension Wire Servomotor Replacement 2 2E 3 2E 4 2E Continued Figure 61 6 Remove the brake cable from the servomotor 7 Remove Servomotor PROPER VOLTAGE REQUI
4. 2E only Replace batteries Console was subjected to cold Verify proper connections be Allow machine to warm to room temperatures tween sensor wire and console temperature It may be neces by removing console and snap sary to gently massage the LCD ping console wire and sensor crystal with your hand to allow wires firmly together 1 2E only for full display Important Note Pressing against the LCD crystal with excessive force may damage the crystal Failed console Replace console Console Troubleshooting WARRANTY Symptom Possible Cause Test Procedure onsole Resets Intermittently Poor connection between console Verify proper connections be and sensor wire 1 2E only tween sensor wire and console by removing console and snap ping console wire and sensor wires firmly together 1 2E INSTRUCTIONS Weak batteries in console 1 2E Replace batteries only Poor connection between power Verify that the power supply is supply and power jack securely inserted into the power jack REQUIRED Failed power supply Perform voltage check on Replace power supply power supply Reference Power Supply Voltage Check in Voltage Checks section MAINTENANCE Failed console cable Verify console cable is not Replace console cable Refer pinched or damaged ence Console Cable Replace Perform voltage check on con ment in Parts Replacement sole cable Reference Console section cable Voltage C
5. MAINTENANCE 5 Insert new pedal axle set and bearings PROPER HEART REAT USAGE h Make sure there is thread lock applied to both the inner and outer diameters of the bearings before installing It is recommended to allow the thread lock to adhere for k 24 hours before using the machine VOLTAGE TROUBLESHOOTING CHECKS PARTS REPLACEMENT Ei Flywheel Drive Belt Replacement 1 2 2 2E 3 2E 4 2E Tools Required e Phillips Screwdriver e 13mm 14mm 17mm Socket and Combination Wrenches e 5mm Allen Wrench e Crank Puller Procedure 1 Turn power on and press start on console 2 Set resistance level to highest position and turn off console 3 Unplug power supply from elliptical m 4 Remove crank disk and side covers Reference Crank Disk Side Cover Crank Arm Replacement 1 2E amp 22E or 3 2E amp 4 2E 5 For 1 2E 3 2E and 4 2E only Remove tension cable from flywheel assembly Figure 66 Tension Cable Flywheel Drive Belt Replacement 1 2E 2 2E 3 2E 4 2E Continued Figure 67 Figure 68 TENSION BOLT TENSION BOLT 6 Remove both nuts A which hold the flywheel to frame 7 Remove the nuts B holding the tensioning bolts into position on both sides of the flywheel and remove the belt tensioning bolts 8 Remove drive belt from crank pulley 9 Place new flywheel into position and attach drive belt onto crank pulley 10 Slide belt te
6. USE 3 5 CSE 4 5 EG5 Tools Required e Phillips Screwdriver e Right Angle Screwdriver e 13mm 17mm Socket and Combination Wrenches e 4mm 5mm Allen Wrenches Procedure 1 Remove side covers Reference Side Cover Replacement for this section 2 Remove the sensor wire bracket Figure 24 Figure 25 Sensor Bracket 3 Remove the old sensor wire from the sensor wire bracket 4 Disconnect sensor wire from console cable l c I s SE RSS c FFso o O O Figure 26 p PROPER VOLTAGE REQUIRED SAFETY CHECKS ie MAIMTENAREE TOOLS INSTRUCTIONS TROUBLESHOOTING Lu ez o aS m Sensor Wire Replacement Continued EX 22 EX 33 EX 44 CSE 3 5 CSE 4 5 EG5 AINVUUVM 5 Attach the new sensor wire to the sensor wire bracket 6 Attach bracket to the frame and position correctly SNUHJIWISNI A133VS Figure 27 RPM JW Sensor 1001 0341030 3JNVN31NIVM Frame 29151 IVY LUV3H 39054 P Turn crank by hand to make sure that there is a RPM reading on the console SWIIHI 2961107 3NHO0HSTISR0UI m 5 Ii E o Console Cable Replacement EX 22 EX 33 EX 44 CSE 3 5 USE 4 5 EG5 WARRANTY Tools Required e Phillips Screwdriver e 13mm 17mm Socket and Combination Wrenches e 4mm 5mm Allen Wrenches SAFETY INSTRUCTIONS Procedure 1 Unplug power s
7. axle 11 Loosely thread bolts A onto the flywheel axle 12 Tighten the nuts B to adjust the tension of the drive belt Hale n ib ne y p M flywheel sits straight in frame and 13 Check the tension of the drive belt The correct belt tension tolerance is 120 140 Ibs If a belt tension gauge is not available hel r Ww NM the drive belt should have about 0 25 deflection when pressing down firmly on the drive b pelt 14 Once the belt tension is set properly tighten the nuts A on both sides of the flywheel Crank Disk Side Cover Crank Arm Replacement 1 2E amp 2 2E Tools Required e Phillips Screwdriver e 14mm 15mm 17mm Socket and Combination Wrenches e 4mm 5mm Allen Wrenches e Crank Puller 1 1 2E Only Remove handle bar covers 2 1 2E Only Remove set screws holding lower handle bar 3 1 2E Only Remove bolt A holding link arm to pedal arm bracket Figure 37 HANDLEBAR COVER BOLT A PROPER VOLTAGE REQUIRED SAFETY TROUBLESHOOTING CHECKS ip cid MAINTENANCE TOOLS INSTRUCTIONS WARRANTY PARTS REPLACEMENT Crank Disk Side Cover Crank Arm Replacement Continued 1 2E amp 2 2E 4 2 2E Only Remove bolt A and nut B holding link arm to lower handlebar AINVUUVM SNUHJIWISNI A133VS NUT B BOLT A 1001 0341030 3J9NVN31NIVM 5 Remove pedal arm cover Figure 39 29151 IVY LUV3H 39054 SWIIHI 39VI10A PEDAL ARM 3NHOUH
8. of the covered unit e Any attempt to repair this equipment creates a risk of injury Horizon Fitness is not responsible or liable for any damage loss or liability arising from any personal injury incurred during the course of or as a result of any repair or attempted repair of your fitness equipment by other than an authorized service technician All repairs attempted by you on your fitness equipment are undertaken AT YOUR OWN RISK and Horizon Fitness shall have no liability for any injury to the person or prop erty arising from such repairs SERVICE RETURNS e In home service is available only within 150 miles of the nearest authorized repair center e All returns must be pre authorized by Horizon Fitness e 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 e A Horizon Fitness 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 e 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 e This warranty gives you specific legal rights and your rights may vary from state to state SAFETY INSTRUCTIONS REQ
9. step is to simply wipe your perspiration off the trainer after each use HOW DO CLEAN MY ELLIPTICAL Clean with soap and water cleaners only Never use solvents on plastic parts Cleanliness of your elliptical 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 DAILY Turn off the elliptical by unplugging the power cord from the wall outlet e Wipe down the elliptical with a damp cloth Never use solvents as they can cause damage to the elliptical e Inspect the power cord If the power cord is damaged contact Horizon Fitness e Make sure the power cord is not underneath the elliptical or in any other area where it can become pinched or cut m To remove power from the elliptical the power cord must be disconnected from AWARNING the wall outlet h WEEKLY Clean underneath the elliptical following these steps e Turn off the elliptical e Move the elliptical to a remote location e Wipe or vacuum any dust particles or other objects that may have accumulated underneath the elliptical e Return the elliptical to its previous position EVERY MONTH e Inspect all assembly bolts and pedals on the machine for proper tightness e Clean any debris off of the pedal arm wheels and guide rails Tensioning the Drive Belt EX 22 EX 33 EX 44 CSE 3 5 4 5 EG5 Tools
10. x 4 Loosen the short nut A and adjust the long nut B clockwise to reduce the brake resistance and counterclockwise to increase the brake resistance m E IMBORTANT The correct position for the flywheel brake assembly is 1 2mm from the flywheel at the highest resistance level PROPER HEART REAT USAGE Figure 5 VOLTAGE CHECKS TROUBLESHOOTING PARTS REPLACEMENT JINUNIINIVN Adjusting the Magnetic Brake 2 2E Tools Required e Phillips Screwdriver e 12mm 13mm 14mm 17mm Socket and Combination Wrenches e 5mm Allen Wrench e Crank Puller Procedure 1 Turn on unit and Press start 2 Set resistance highest level and power off unit 3 Remove crank disk and side covers Reference Crank Disk Side Cover Crank Arm Replacement in Parts Replacement section 4 Adjust the nut on the magnetic brake spring clockwise to reduce the brake resistance and counter clockwise to increase the brake resistance ra m IMPORTANT The Correct position for the flywheel brake assembly is 2 3mm from the flywheel at s the highest resistance level 5 It may be necessary to also adjust the top half of the magnetic brake To do this loosen the two 5mm bolts that attach the magnetic brake to the frame Adjust the position of the magnetic brake closer or further from the flywheel Figure 6 Flywheel Magnetic S
11. 5mm Allen Wrenches SAFETY INSTRUCTIONS Procedure 1 Turn power on and press start on console 2 Set resistance level to highest position and turn off console REQUIRED TOOLS 3 Unplug power supply from elliptical 4 Remove side covers Reference Side Cover Replacement for this section 5 Disconnect console cable from servomotor MAINTENANCE Figure 32 Servo Motor Console Cable VOLTAGE HEART USAGE TROUBLESHOOTING PARTS 7 Remove Servomotor Lu X zi ui c Pedal Axle Set Replacement EX 22 EX 33 EX 44 CSE 3 5 CSE 4 5 EG5 Tools Required e Phillips Screwdriver e 13mm 14mm 17mm Socket and Combination Wrenches e 4mm 5mm Allen Wrenches e Snap ring Pliers e Rubber Mallet e Thread Lock Procedure 1 Remove side covers Reference Side Cover Replacement for this section 2 Remove the left and right crank arm bolts o The crank arms are pressed in place so it may be necessary to hit the ends of the IMPORTAN T crank arms with a rubber mallet N 2 Preassembled Pedal Axle Set 3 Remove the c clip on the right hand side of the pedal axle set 4 Tap the pedal axle set from the frame pounding on the right hand side towards the left 5 Once the pedal axle set and the bearings are removed from the frame make sure to remove all dirt or grease from the frame bearing housing 6 Insert new ped
12. Horizon Fitness 2006 Elliptical Service Manual TNES Designed for life IABLE OF CONTENTS Warranty j Safety Instructions 4 Required Tools 5 Preventative Maintenance 6 Voltage Checks 15 Elliptical Troubleshooting 20 Part Replacement 27 Limited Home Use Warranty FRAME e LIFETIME Horizon Fitness warrants the frame against defects in workmanship and materials for the lifetime of the original owner EX 22 BRAKE 7 YEARS Horizon Fitness warrants the brake against defects in workmanship and materials for the period of seven years of the original owner EX 33 BRAKE e 10 YEARS Horizon Fitness warrants the brake against defects in workmanship and materials for the period of ten years of the original owner EX 44 BRAKE 12 YEARS Horizon Fitness warrants the brake against defects in workmanship and materials for the period of twelve years of the original owner ELECTRONICS amp PARTS 1 YEAR Horizon Fitness warrants theelectronic components and all original parts for a period of one year from the date of original purchase so long as the device remains in the possession of the original owner LABOR e 1 YEAR Horizon Fitness shall cover the labor cost for the repair of the device for a period of one year from the date of the original purchase so long as the device remains in the possession of the original owner EXCLUSIONS AND LIMITATIONS Who is covered e Th
13. NYLON NUT C PEDAL ARM COVER 3 Remove pedal arm cover PROPER VOLTAGE REQUIRED SAFETY TROUBLESHOOTING CHECKS ip cid MAINTENANCE TOOLS INSTRUCTIONS WARRANTY PARTS REPLACEMENT Crank Disk Side Cover Crank Arm Replacement 3 2E amp 4 2E Continued 4 Remove nut C holding pedal arm to crank arm and remove pedal arm 2 5 Remove the crank cap from the center of the crank disk lt om Figure 47 1001 0341030 3J9NVN31NIVM Crank Puller 29151 IVY LUV3H 39054 SWIFHI 2961107 Crank Arm Nut 6 Remove the crank arm nut 3NHOOUHSTISR0UI Thread the crank puller onto the crank axle and remove the crank arm and crank disk from the crank axle IN3 3JVTd3H 5100 Crank Disk Side Cover Crank Arm Replacement 3 2E amp 4 2E Continued 8 Remove top cap or top side covers TOP SIDE COVER F g ure 4 9 SIDE COVER CRANK ARM CRANK ARM NUT CRANK CAP 9 Remove side covers 10 Remove bolts A and remove crank arm from crank disk PROPER VOLTAGE REQUIRED SAFETY TROUBLESHOOTING CHECKS ip cid MAINTENANCE TOOLS INSTRUCTIONS WARRANTY PARTS REPLACEMENT RPM Sensor Replacement 1 2E 2 2E 3 2E 4 2E Tools Required e Phillips Screwdriver e Right Angle Screwdriver e 14mm 15mm 17mm Socket and Combination Wrenches e 4mm 5mm Allen Wrenches e Crank Puller Procedure 1 Remove crank disk and side covers Reference Crank Disk Side Cover Cra
14. RED SAFETY TROUBLESHOOTING CHECKS ip cid MAINTENANCE TOOLS INSTRUCTIONS WARRANTY PARTS REPLACEMENT E co 29151 193H9 1001 SNUHJIWISNI 3NHO0HSTISR0UI 39ULT0A dt 3JNVN31NIVM ALANS AINVUUVM 1 3 2307934 5149 Cable Replacement 1 2E Tools Required e Phillips Screwdriver e 13mm 14mm 17mm Socket and Combination Wrenches e 5mm Allen Wrench e Needle Nose Pliers e Crank Puller Procedure 1 Turn the tension knob to the highest resistance level 2 Remove the bolt that attaches the tension knob to the console mast 3 Remove the tension knob from the tension cable by pulling up on the tension knob Figure 62 PRE INSTALLED RESISTANCE KEY HOLE BOLT amp WASHER KNOB BOTTOM KEY HOLE TENSION CABLE TENSION WIRE RESISTANCE KNOB BRACKET Tension Cable Replacement 1 2E Continued 4 Remove crank disk and side covers Reference Crank Disk Side Cover Crank Arm Replacement 1 2E amp 2 2E 5 Disconnect the tension cable from the flywheel brake assembly Figure 63 Tension Cable 6 Disconnect the nut that attaches the tension cable to the main frame 7 Fish the new tension cable through the console mast 8 Make sure that the tension knob is still set to the highest resistance level and attach the tension knob to the tension cable and secure to the console mast with screw 9 Connect tension cable to the flywheel brake assembly and adjust so that magnetic
15. Required e Phillips Screwdriver e 11 19mm Socket and Combination Wrenches Procedure 1 Remove top cap or top side covers Figure 1 TOP SIDE COVERS evel SIDE COVERS The correct belt tension tolerance is 120 140 Ibs If a belt tension gauge is not available the drive belt should have about 0 25 deflection when pressing down L firmly on the drive belt Figure 2 Flywheel 3 Loosen both nuts A which hold the flywheel to frame 4 Tighten or loosen the nuts B holding the tensioning bolts into position on both sides of the flywheel to adjust the tension of the drive belt gt IMPORTANT Important Note Make sure that both bolts are tightened equally so that flywheel sits straight in frame and both the fly wheel and crank pulley are properly aligned 5 Once the belt tension is set properly tighten the nuts A on both sides of the flywheel SAFETY INSTRUCTIONS WARRANTY REQUIRED TOOLS Lu S VOLTAGE CHECKS HEART REAT USAGE TROUBLESHOOTING PARTS REPLACEMENT Tensioning the Drive Belt 1 2 4 2E Tools Required e Phillips Screwdriver e 11 13mm 15mm 17mm 19mm Socket and Combination Wrenches e 5mm Allen Wrench e Crank Puller Procedure Es 1 Remove crank disk and side covers Reference Crank Disk Side Cover Crank Arm Replacement SE 2E amp 22Eor32E amp 4 2E on pp 2 Check the tens
16. STISR0UI 6 Remove nut C holding pedal arm to crank arm and remove pedal arm Remove the crank cap from the center of the crank disk INIWIIV1dI4 5149 Crank Disk Side Cover Crank Arm Replacement Continued 1 2E amp 2 2E 6 Remove the crank arm nut 9 Thread the crank puller onto the crank axle and remove the crank arm and crank disk from the crank axle Figure 40 Figure 41 Crank Puller 10 Lift console mast boot Figure 42 CONSOLE MAST BOOT ACCENT PLATE 11 Remove the accent piece by gently lifting up at the bottom of the accent piece and lifting towards the front of the machine 12 Remove side covers PROPER VOLTAGE REQUIRED SAFETY TROUBLESHOOTING CHECKS ii cid MAINTENANCE TOOLS INSTRUCTIONS WARRANTY PARTS REPLACEMENT 29151 SWIIHI 1001 SNOILINALSNI 3NHOUHSTISR0UI 39ULT0A n dt 3J9NVN31NIVM 3UlQD3u ALANS AINVUUVM INIWIIV1dI4 5149 Crank Disk Side Cover Crank Arm Replacement 1 2E amp 2 2E Continued AC Adapter Recepticle Figure 44 AC Adapter Receptacle Side Cover 13 Remove crank arm from crank disk Crank Disk Side Cover Crank Arm Replacement 3 2E amp 4 2E Tools Required e Phillips Screwdriver e 14mm 15mm 17mm Socket and Combination Wrenches e 4mm 5mm Allen Wrenches e Crank Puller 1 Remove inside and outside elbow covers Figure 45 LOWER HANDLEBAR OUTSIDE ELBOW COVER Figure 46 CRANK ARM
17. UIRED TOOLS MAINTENANCE PROPER HEART REAT USAGE VOLTAGE CHECKS TROUBLESHOOTING PARTS REPLACEMENT AINVUUVM IEE AY E S 5 29151 NI100HS3180041 IN IVY LUV3H TINYNILNI VN S 2961107 0 0341030 1 3 2307934 5149 s Safely Instruction Warning statements indicate a particularly dangerous activity Please read the following warnings before us ing repairing or maintaining your exercise equipment e Never drop or insert any object into any opening e Never operate the exercise equipment If it is not working properly if it has been damaged or immersed in water e Visually check the machine before beginning service or maintenance operations If it is not completely as sembled or is damaged in any way exercise extreme caution while operating and checking the exercise equip ment e Do not use outdoors e o not wear clothing that might catch on any part of the exercise equipment e Use this exercise product for its intended use as described in the Owner s guide Do not use attachments not recommended by the manufacture e Fold and securely latch your exercise equipment before moving it e Use care when getting on of off the exercise equipment Use the handrails whenever possible e Do not rock the unit Do not stand or climb on the handrails electronic console or side covers e f you experience chest pains nausea dizziness or shortness of breath stop exer
18. al axle set and bearings rq Make sure there is thread lock applied to both the inner and outer diameters of the bearings Wm before installing It is recommended to allow the thread lock to adhere for 24 hours before m using the machine Flywheel Drive Belt Replacement EX 22 EX 33 EX 44 CSE 3 5 CSE 4 5 EG 5 Tools Required e Phillips Screwdriver elimm 13mm 17mm 19mm Socket and Combination Wrenches e 4mm 5mm Allen Wrenches Procedure 1 Turn power on and press start on console 2 Set resistance level to highest position and turn off console 3 Unplug power supply from elliptical 4 Remove side covers Reference Side Cover Replacement for this section 5 Remove tension cable from flywheel assembly Figure 3b SQU L 4 a KS ANM W SN uu Y cl S Tension Cable PROPER REQUIRED SAFETY MAINTENANCE TOOLS INSTRUCTIONS WARRANTY HEART REAT USAGE VOLTAGE CHECKS TROUBLESHOOTING PARTS REPLACEMENT Flywheel Drive Belt Replacement Continued EX 22 EX 33 EX 44 CSE 3 5 CSE 4 5 EG 5 6 Remove both nuts A which hold the flywheel to frame 7 Remove the nuts B holding the tensioning bolts into position on both sides of the flywheel and S remove the belt tensioning bolts 8 Remove drive belt from crank pulley 9 Place new flywheel into position and attach drive belt onto crank pulley 10 Slide belt tensioning bolts onto the flywheel
19. all specific engineering menu e Press and hold Start Stop again to completely exit engineering mode and return to standard operating mode Hardware Test e Indicates software version e Indicates whether console is set for Miles or KM e Indicates whether console is set for an elliptical or a stationary bike e Displays RPM s and heart rate similar to standard operating mode e Displays resistance as the number of turns the resistance motor has made LCD Test e Displays all LCD s at once or individually by pressing individual buttons Information 22E does not have this menu i e Displays the number of hours and mile the machine has logged rw If the console is ever changed this information will reset to 0 b Heart Rate Troubleshooting WARRANTY Problem There is no heart rate reading Solution Remove the console and verify that the heart rate cables are attached properly making sure that the cables are securely inserted into the console Check your exercise environment for sources of interference such as high power lines large motors etc SAFETY INSTRUCTIONS You may experience an erratic Heart Rate readout under the following conditions e Gripping the heart rate handlebars too tight Try to maintain moderate pressure while holding onto the heart rate handlebars e Constant movement and vibration due to constantly holding the heart rate grips while exercising e When you are breathing heav
20. and the negative lead on the outside of the power supply jack The voltage of the power supply should be as follows Unloaded voltages may be higher b MODEL Adapter DC Voltage Unloaded VDC loaded VDC EX22 EG5 xl 6 109 88 IE B zm EGG3 amp MICSES ER LS 2E RAE 14 16 INILOOHSITENOYL INIWIIV1dI4 5149 Servomotor Voltage Check All Models Except 1 2E 1 For Models EX 22 EX A4 CSE 3 5 amp 4 5 EG5 2 2E Only Remove plastic housing to access IC board pins WARRANTY EX 22 EX MV CSE 3 5 amp 4 5 EG5 2 2E Figure 15 SAFETY INSTRUCTIONS Console Cable REQUIRED TOOLS Servo Motor MAINTENANCE 2 Place the positive lead of your multi meter on the top soldered pin on the backside of the IC board 3 Place negative lead on the second soldered pin on the backside of the IC board PROPER HEART REAT USAGE VOLTAGE TROUBLESHOOTING PARTS REPLACEMENT Servomotor Voltage Check All Models Except 1 2E igure E 3 2 4 2E Red QO P1 Power to DC Motor IC Board VCC Black C P2 Ground From Motor Brown Optic Count From Motor Orange 7 PA Zero Switch Sensor Green C P5 Power To Resistance Up nm O P6 Power To Resistance Down CORRECT VOLTAGE FOR WIRE HARNESS P1 Red 45 0 VDC P4 Orange If zero switch engaged 5 0 VDC Any other resistance 0 0 VDC Short P2 B
21. brake is posi tion properly Reference Adjusting the Magnetic Brake in Maintenance in section 10 Adjust the tension knob from the lowest to highest resistance settings to ensure proper movement and position of the flywheel brake assembly El PROPER VOLTAGE REQUIRED SAFETY CHECKS ae MAIMTENAREE TOOLS INSTRUCTIONS TROUBLESHOOTING PARTS REPLACEMENT AINVUUVM SNOILINALSNI ALIAS JINUNIINIVN 3 ipie 74 29151 IVY LUV3H 39054 SWIFHI 39VIT0A NI100HS3180041 ININIIV1dI4 S1UWd Pedal Axle Set Replacement 1 2 2 2E 3 2E 4 2E Tools Required e Phillips Screwdriver e 13mm 14mm 17mmm Socket and Combination Wrenches e 4mm 5mm Allen Wrenches e Crank Puller e Snap Ring Pliers e Rubber Mallet e Thread Lock Procedure 1 Remove crank disk and side covers Reference Crank Disk Side Cover Crank Arm Replacement 1 2E amp 2 2E or 3 2E amp 4 2 2 Remove the c clip on the left hand side of the pedal axle set 3 Tap the pedal axle set from the frame pounding on the left hand side towards the right Figure 64 PREASSEMBLED PEDAL A BEARING Pedal Axle Set Replacement 1 2E 2 2E 3 2E 4 2E Continued WARRANTY Figure 65 PREASSEMBLED PEDAL AXPLE SET SAFETY INSTRUCTIONS REQUIRED TOOLS 4 Once the pedal axle set and the bearings are removed from the frame make sure to remove all dirt or grease from the frame bearing housing
22. cising immediately and consult your physician before continuing CHILDREN e Keep children off of your exercise equipment at all times e When the exercise equipment is in use young children and pets should be kept at least 10 feet away Required Tooles and Equipment WARRANTY The following list is a summary of the tools and equipment required by the procedures in this manual Tools are not supplied by Horizon Fitness e Phillips screwdrivers e Flat head screwdrivers e Right angle screwdriver e Digital multi meter e Allen wrench set Metric e Open end wrenches of assorted sizes Metric e 1 2 drive ratchet and sockets of assorted sizes e Bearing thread lock Cable ties e Needle nose pliers e Damp cloth e Rubber mallet e Drop cloth to protect floor surfaces e Ruler e Snap ring pliers e Wire cutters e Drive belt tension gauge e Crank Puller Park Tool CCP 2 22mm e Bearing Extractor SAFETY INSTRUCTIONS a s Se MAINTENANCE PROPER HEART REAT USAGE Available through Horizon Fitness at cost VOLTAGE TROUBLESHOOTING CHECKS PARTS REPLACEMENT ALIAS AINVUUVM SNOILINYLSNI 1001 0341030 m 29151 NI100HS3180041 iad IVY LUV3H 14044 ININIIV1dI4 5100 Preventative Maintenance Procedures WHAT KIND OF ROUTINE MAINTENANCE IS REQUIRED We use sealed bearings throughout our ellipticals so lubrication is not needed The most important maintenance
23. e original owner and is not transferable What IS covered Repair or replacement of a defective motor electronic component or defective part and is the sole remedy of the warranty What IS NOT covered e Normal wear and tear improper assembly or maintenance or installation of parts or accessories not originally intended or compatible with the equipment as sold e Damage or failure due to accident abuse corrosion discoloration of paint or plastic neglect theft vandalism fire flood wind lightning freezing or other natural disasters of any kind power reduction fluctuation or failure from whatever cause unusual atmospheric conditions collision introduction of foreign objects into the covered unit or modifications that are unauthorized or not recommended by Horizon Fitness e Incidental or consequential damages Horizon Fitness is not responsible or liable for indirect special or consequential damages economic loss loss of property or profits loss of enjoyment or use or other consequential damages of whatsoever nature in connection with the purchase use repair or maintenance of the product e Equipment used for commercial purposes or any use other than a single family or Household unless endorsed by Horizon Fitness for coverage e Equipment owner or operated outside the US and Canada e Delivery assembly installation setup for original or replacement units or labor or other costs associated with removal or replacement
24. ect position of magnetic brake Reference Adjusting the Magnetic Brake in Maintenance section Reattach cable Reference Tension Cable Replacement in Parts Replacement section Reattach cable Reference Tension Cable Replacement for 1 2E or Servomotor Re placement in Parts Replace ment section for all other models Reposition the magnetic brake Reference Adjusting the Mag netic Brake in Maintenance section Noise and Drive Train Troubleshooting WARRANTY Symptom Possible Cause Test Procedure Noise internally while Magnetic brake is rubbing Verify the correct position of Reposition the magnetic pedaling at higher resis against the flywheel magnetic brake Reference brake Reference Adjust tance levels only Adjusting the Magnetic ing the Magnetic Brake in Brake in Maintenance sec Maintenance section tion SAFETY INSTRUCTIONS Noise internally externally Machine may not be on level Verify surface is level Adjust levelers on machine while pedaling or rough Improper assembly or loose Verify assembly steps using lighten all bolts used for assembly bolts owner s guide assembly feel while pedaling Alignment issues with pedal Reference Alignment Issues arms due to improper assem with Pedal Arms Trouble bly or improper welds shooting REQUIRED TOOLS Access build up on or defec Wipe off roller wheels and Replace roller wheels tive roller wheels guide rails with da
25. heck in Voltage Checks section Failed console ee Replace console Only Time Works on Console Poor connection between console Verity proper connections be No workload distance etc and sensor wire 1 2E only tween sensor wire and console by removing console and snap ping console wire and sensor wires firmly together 1 2E only HEART REAT Failed sensor wire Perform RPM continuity check Replace sensor wire Refer Missing rpm magnet on crank Visually verify presence or Replace magnet and or reposi assembly or misaligned RPM magnet and alignment of RPM tion RPM sensor Reference sensor sensor RPM Sensor Replacement in Parts Replacement section TROUBLESHOOTING Failed console Replace console REPLACEMENT SNOILINALSNI AINYYYYM 1001 A133VS 0341030 3J3NVN3INIVIH 29151 IVY LUV3H 14044 421 2 191104 INIWIIV1dI4 E S e S 5100 Heart Rate Troubleshooting Symptom Possible Cause Test Procedure Erratic or no heart rate User Error Reference Proper Heart Rate Hand grips on or separate Usage section from console Failed heart rate grips Reference Proper Heart Rate If there is absolutely no heart Usage section response replace heart rate grips Reference Proper Heart Rate If proper heart rate instructions Usage section are followed and heart rate continues to be erratic replace Heart rate erratic or no heart User error Reference P
26. ily during a workout e When your hands are constricted by wearing a ring e When your hands are dry or cold Iry moistening your palms or rubbing them together to warm e Anyone with heavy arrhythmia e Anyone with arteriosclerosis or peripheral circulation disorder e Anyone whose skin on the measuring palms is especially thick REQUIRED TOOLS MAINTENANCE NOTE Outside interference sources such as computers motors and fluorescent lights may cause the heart rate reading to be erratic Handlebars Place the palm of your hands directly on the grip pulse handlebars Both hands must grip the bars for your heart rate to register It takes 5 consecutive heart beats 15 20 seconds for your heart rate to register When gripping the pulse handlebars do not grip tightly Holding the grips tightly may elevate your blood pressure Keep a loose cupping hold You may experience an erratic readout if consistently holding the grip pulse handlebars Make sure to clean the pulse sensors to ensure proper contact can be maintained Lu SES SS VOLTAGE TROUBLESHOOTING CHECKS PARTS REPLACEMENT A B Heart Rate Troubleshooting AINVUUVM Figure BACKSIDE OF CHEST TRANSMITTER SNOILINALSNI A133VS APPLY MOISTURE HERE 1001 0341030 WIRELESS CHEST TRANSMITTER CSE4 5 EX44 4 2E SOLD SEPARATELY Prior to wearing the wireless chest transmitter on your chest moisten the two rubber electrodes with water Ce
27. ion of the drive belt EN The correct belt tension tolerance is 120 140 Ibs If a belt tension gauge is not available the drive belt should have about 0 25 deflection when pressing down firmly on the drive belt JINUNIINIVN 3 Loosen both nuts A which hold the flywheel to frame Figure 3 Figure 4 A TENSION BOLT TENSION BOLT n 0dd 19151 31Vy LUV3H 1 14 O o 4s q e 66s TENSION BOLT A FLYWHEEL ow v FLYWHEEL 4 Tighten or loosen the nuts B holding the tensioning bolts into position on both sides of the flywheel to adjust the tension of the drive belt s Make sure that both bolts are tightened equally so that flywheel sits straight in frame and IMPORTANT WW ee both the fly wheel and crank pulley are properly aligned 5 Once the belt tension is set properly tighten the nuts A on both sides of the flywheel Adjusting the Magnetic Brake EX 22 EX 33 EX 44 CSE 3 5 4 5 EG5 1 2E 3 2E 4 2E WARRANTY Tools Required e Phillips Screwdriver e 8mm 13mm 17mm Socket and Combination Wrenches e 5mm Allen Wrench e Crank Puller SAFETY INSTRUCTIONS Procedure 1 1 2E only Adjust tension knob to highest setting REQUIRED TOOLS 2 Turn on unit and Press start 3 Set resistance highest level and power off unit 4 Remove side covers Reference side cover replacement in Parts Replacement section Lu
28. lack n a Ground P5 Green 0 0 to 0 4 VDC if motor idle 8 5 VDC if Brown 5 0 VDC if Slot in Optic Disk resistance increasing 0 6 to 2 0 VDC if resistance decreasing aligned with sensor 0 0 VDC P5 White 0 0 to 0 46 VDC if motor idle 8 5 VDC if resistance decreasing 0 6 to 2 0 VDC if resistance increasing Note 1 All voltages measured loaded with functioning console and resistance motor Note 2 All grounds same point once plugged into console with or without power on Note 3 If measured White to Green when resistance increasing 7 vdc if decreasing 7 7 vdc The above measurements for the Orange and Brown wires were using the ori gional serve motor 2 2E 3 2E 4 2E The new style servo motor voltage measurements are Ex22 Ex44 CSE3 5 amp 4 5 EG5 INIOdYIIHI EE MIU Orange 3 0 vdc if resistance at lowest 0 2 vdc if resistance at any position other than lowest Brown 3 0 vdc if optic sensor open 0 2 vdc as wheel passes through optic sensor RPM Sensor Continuity Check WARRANTY Figure 18 REQUIRED SAFETY TOOLS INSTRUCTIONS MAINTENANCE PROPER HEART REAT USAGE L2E 1 Turn your multi meter setting to Ohms 2 Place the positive lead of your multi meter on the tip of the sensor wire jack and the negative lead on the outside of the sensor wire jack 3 Turn crank to produced an rpm in order to get continuity through the sensor wire VOLTAGE
29. mp cloth Check roller wheels for any abnormal wear Roller wheels should have smooth texture If the rough feel seems to be on one side only try switching suspect roller wheel to opposite pedal arm MAINTENANCE PROPER HEART REAT Loose crank arms Tighten crank arms Ref erence Pedal Axel Set Replacement in Parts Replacement section Improper alignment of the Align drive belt and adjust to drive belt or improper tension proper tension Reference of the drive belt Tensioning the Drive Belt in Maintenance section TROUBLESHOOTING Defective flywheel or pedal Replace flywheel and or axle set pedal axle set Reference Flywheel or Pedal Axel Set Replacement in Parts Replacement section PARTS REPLACEMENT Alignment Issues with Pedal Arms Troubleshooting AINVUUVM Symptom Possible Cause Test Procedure Noise externally while Improper assembly or Verify assembly steps us Tighten all bolts used for pedaling rough feel loose assembly bolts ing owner s guide assembly while pedaling or SNUHJIWISNI A133VS ighten crank arms Reference Pedal Axel Set Replacement in Parts Replacement section Alignment issues with Disconnect appropri f the noise ceases or pedal arms due to im ate link arm from lower pedal does not jump off proper welds handle bar assembly and guide rail replace lower pedal unit link arm If there is no change replace lower handle bar pedal arm and crank
30. nk Arm Replacement 1 2E amp 2 2E or 3 2E amp 4 2E 2 Remove sensor wire bracket Figure 51 Sensor Bracket 3 Remove the old sensor wire from the sensor wire bracket 4 For Models 2 2E 4 2E Only Disconnect sensor wire from console cable Sensor Wire Console Cable RPM Sensor Replacement 1 2E 2 2E 3 2E 4 2E Continued 5 1 2E Only Disconnect console from console mast WARRANTY Figure 53 SAFETY INSTRUCTIONS REQUIRED TOOLS PRE ATTACHED MAINTENANCE 6 1 2E Only Unplug sensor from console 7 1 2E Only Attach the new sensor wire to the old sensor wire in order to fish the sensor through the console mast PROPER HEART REAT USAGE Figure 54 VOLTAGE CHECKS TROUBLESHOOTING PARTS REPLACEMENT RPM Sensor Replacement 1 2E 2 2E 3 2E 4 2E Continued 8 Attach the new sensor wire to the sensor wire bracket 9 Attach bracket to the frame and position correctly Figure 55 RPM Sensor MN Oy N Figure 56 Magnet RPM N 10 Turn crank by hand to make sure that there is a RPM reading on the console 4 Ke Console Cable Replacement 2 2E 3 2E 4 2E Tools Required WARRANTY e Phillips Screwdriver e 14mm 17mm Socket and Combination Wrenches e 5mm Allen Wrench e Crank Puller SAFETY INSTRUCTIONS Procedure 1 Unplug power supply from elliptical
31. nsioning bolts onto the flywheel axle 11 Loosely thread bolts A onto the flywheel axle 12 Tighten the nuts B to adjust the tension of the drive belt Make sure that both bolts are tightened equally so that flywheel sits straight in IMPORTANT frame and both fly wheel and crank pulley are properly aligned SA Cn EI PROPER VOLTAGE REQUIRED SAFETY CHECKS ae MAIMTENAREE TOOLS INSTRUCTIONS TROUBLESHOOTING PARTS REPLACEMENT CUSTOMER TECH SUPPORT 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 1 800 244 4192 Email comments horizonfitness com Website www horizonfitness com Customer Tech Support hours Monday Friday 8 am 5 pm CST excluding holidays
32. nter the chest strap just below the breast or pectoral muscles directly over your sternum with the logo facing out NOTE The chest strap must be tight and properly placed to receive an accurate and consistent readout If the chest strap is too loose or positioned improperly you may receive an erratic or inconsistent heart rate readout WARNING The heart rate function is not a medical device Various factors may affect the accuracy of your heart rate reading The heart rate reading is intended only as an exercise aid 3JNVN31NIVH CSE4 5 EX44 m lt 59 5 20 ER mag m POLAR RECEIVER SWIIHI 2961107 DRIVE BELT NI100HS3180041 1 3 2307934 5100 Console Cable Voltage Check All Models Except 1 2E WARRANTY Figure 13 ER ES O P1 Ground From RPM Sensor D O P2 Ground From Motor O Zero Switch Sensor O P4 Optic Count From Motor O P5 Power To Resistance Up Q P6 Power To Resistance Down QP7 RPM Sensor P8 Power To Console From Power Supply VDD O P9 Ground From Power Socket P10 Power To Console VCC CORRECT VOLTAGE FOR WIRE HARNESS P1 Purple n a ground P6 White 0 0 to 0 46 vdc if motor idle 8 5 vdc if resistance P2 Black n a ground decreasing 0 6 to 2 0 vdc if resistance increasing Voltage changes with each change in incline P7 Yellow If magnet aligned with rpm sensor 0 0 vdc short Orange If zero switch engaged lo
33. roper Heart Rate rate function Telemetric Usage section chest strap console Electromagnetic interference Check immediate area for causes of interference Flo rescent lighting electric dog fences large electric motors etc Failed telemetric chest strap or Reference Proper Heart Rate Replace chest strap and or po polar receiver Usage section lar receiver Reference Proper Heart Rate Usage section Resistance Troubleshooting Possible Cause Symptom Tension cable is not connected to tension knob 1 2E Only No resistance change or erratic or continuous resis tance change Tension cable is not connected to the brake or has failed Failed or improper power supply Failed console cable Failed servomotor Failed console Test Procedure Remove tension knob from the console mast Verify that the copper cable from the tension knob is seated properly in the keyhole located on the tension knob Verify that the tension cable is connected to the break or has not failed Perform voltage check on power supply Reference Power Supply Voltage Check in Voltage Checks section Verify the power supply and make sure the adapter is the correct voltage Reference Power Supply Voltage Check in Voltage Checks section Verify console cable is not pinched or damaged Perform voltage check on con Reattach cable Reference Tension Cable Replacement in Parts Replacemen
34. t section Reattach cable Reference Tension Cable Replacement fo 1 2 and Servomotor Replace ment in Parts Replacement section for all other models Replace power supply Replace console cable Refer ence Console Cable Replace ment in Parts Replacement sole cable Reference Console section cable Voltage Check in Voltage Checks section Perform voltage check on ser vomotor Reference Servomo tor Voltage Check in Voltage Checks section Replace servomotor Reference Servomotor Replacement in Parts Replacement section Replace console E WARRANTY INSTRUCTIONS REQUIRED TOOLS MAINTENANCE PROPER REAT USAGE CHECKS PARTS REPLACEMENT S S SNOILINALSNI ALNVUMVM 1001 A133VS 0341030 3JNVN31NIVM 29151 IVY LUV3H 14044 421 2 191104 INIWIIV1dI4 S e S 5149 Resistance Troubleshooting Continued Symptom Possible Cause Test Procedure Resistance is Too Hard or Too Tension cable is not connected to tension knob 1 2E Only Tension cable is not connected to the brake or has failed Magnetic brake is positioned improperly Remove tension knob from the console mast Verify that the copper cable from the tension knob is seated properly in the keyhole located on the tension knob Verify that the tension cable is connected to the break or has not failed Verify the corr
35. upply from elliptical 2 Remove side covers Reference Side Cover Replacement in Parts Replacement REQUIRED TOOLS 3 Disconnect console cable from the speed sensor and servomotor Figure 28 Servo Motor Figure 29 MAINTENANCE Console Cable Sensor Wire Console Cable PROPER HEART REAT USAGE VOLTAGE CHECKS Connection For Servo Motor Connection For lt RPM Sensor TROUBLESHOOTING Figure 30 AA AL Recepticle ER lt Sg ZI ccr Q ui Console Cable Replacement Continued EX 22 EX 33 EX 44 CSE 3 5 CSE 4 5 EG5 AINVUUVM 4 Remove the console from the console mast 5 Unplug the console cable from the console and attach the new console cable to the old console cable in order to fish the cable through the console mast D A IMPORTANT You may need to unscrew the water bottle bracket screws in order to fish the console cable easily SNUHJIWISNI ALIAS Figure 31 1001 0341030 CONSOLE P 4 CONSOLE WIRES CONSOLE MAST 3J9NVN31NIVM PRE ATTACHED 29151 IVY LUV3H 39054 193H9 2961107 6 Reconnect console cable to speed sensor and servomotor 3NHO0HSTISR0UI m 5 Ii E o Servomotor Replacement EX 22 EX 33 EX 44 USE 3 5 CSE 4 5 EG5 WARRANTY Tools Required e Phillips Screwdriver e 13mm 17mm Socket and Combination Wrenches e 4mm
36. west resistance level If magnt not aligned with rpm sensor 5 0 vdc open 5 Ovdc open Any other resistance position 0 0 vdc short P8 Grey Dependant upon power supply P4 Brown 5 0 vdc If slot in optic disk aligned with sensor P9 Blue n a Ground 0 0 vdc P10 Red 5 0 vdc P5 Green 0 0 to 0 4 vdc if motor idle 8 5 vdc if resistance increasing 0 6 to 2 0 vdc if resistance decreasing MAINTENANCE Note 1 All voltages measured loaded with functioning console and resistance motor Note 2 All grounds same point once plugged into console with or without power on Note 3 If measured White to Green when resistance increasing 7 7vdc if decreasing 4 7 vdc The above measurements for the Orange and Brown wires were using the ori gional serve motor 2 2E 3 2E 4 2E The new style servo motor voltage measurements are Ex22 Ex44 CSE3 5 amp 4 5 EG5 PROPER HEART REAT USAGE VOLTAGE Orange 3 0 vdc if resistance at lowest 0 2 vdc if resistance at any position other than lowest Brown 3 0 vdc if optic sensor open 0 2 vdc as wheel passes through optic sensor TROUBLESHOOTING PARTS REPLACEMENT Power Supply Voltage Check All Models Except 1 2E AINVUUVM Figure 14 1001 SNUHJIWISNI g3ult3u A133VS 3JNVN31NIVM 29151 IVY 1UV3H 14044 With the power supply plugged in to the wall place the positive lead of your multi meter into the power supply Jack
37. witching the Console from MPH to KM WARRANTY All Models Except 1 2E The back of the console features a switch to convert the speed readout from mph to km To convert from mph to km simply flip the switch Please note that the console needs to be reset before the change will be detected To verify speed setting upon powering up console look for Miles or KM to flash IMPORTANT x E briefly on display SAFETY INSTRUCTIONS REQUIRED TOOLS Lu S Figure 8 PROPER HEART REAT USAGE w2 SWI Switch Up KM Bike M VOLTAGE CHECKS TROUBLESHOOTING PARTS REPLACEMENT JINUNIINIYN Engineering Mode Using Engineering Mode e Power on the elliptical e Press and hold the resistance and resistance v for 3 5 seconds to enter the Engineering Mode Menu Press and hold resistance 2 and resistance 20 for the 2 2E e The console will beep 2 3 times and HARDWARE TEST will be displayed e Press Enter to move through the different menus in engineering mode e Press Start to enter desired menu e Press and hold Start Stop to exit
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