Horizon Fitness 3.1E, Service Manual

Page 1: ...Horizon Fitness 2005 Elliptical Service Manual E51 E52 E53 E54hr 2 1E 3 1E 4 1E CSE2 CSE3 E6050 and 30150 If you have any questions please call the Horizon Fitness Service Hotline at 1 800 244 4192 ...

Page 2: ...ety Instructions 6 Basic Troubleshooting Tips 7 Required Tools 8 Preventive Maintenance 9 Console Troubleshooting 10 Resistance Troubleshooting 18 Drive Train Troubleshooting 23 Voltage Checkpoints 33 Elliptical Part Replacement 38 2 ...

Page 3: ...s it remains in the possession of the original owner BRAKE E51 E6050 5 Years E52 7 Years E53 30150 10 Years E54hr 12Years Horizon Fitness warrants the frame against defects in workmanship and materials for the above specified term so long as it remains in the possession of the original owner ELECTRONICS PARTS ONE YEAR Horizon Fitness warrants the electronic components and all original parts agains...

Page 4: ...it remains in the possession of the original owner BRAKE LIFETIME Horizon Fitness warrants the frame against defects in workmanship and materials for the above specified term so long as it 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 ...

Page 5: ...orized 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 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 s...

Page 6: ...while operating and checking the exercise equipment Do not use outdoors Do not wear clothing that might catch on any part of the exercise equipment Use this exercise product for its intended use as described in the Owner s guide Do not use attachments not recommended by the manufacture Fold and securely latch your exercise equipment before moving it Use care when getting on of off the exercise equ...

Page 7: ... it is still extremely important to follow the step by step procedures from start to finish to ensure that the proper steps are taken to resolve all issues It is also helpful to have a known good component to verify the defective part to eliminate troubleshooting errors When calling for service assistance or technical support be sure to gather as much information as possible such as the model name...

Page 8: ... Digital multi meter Allen wrench set Metric Open end wrenches of assorted sizes Metric drive ratchet and sockets of assorted sizes Bearing loctite Cable ties Needle nose pliers Damp cloth Rubber mallet Drop cloth to protect floor surfaces Ruler Snap ring pliers Wire cutters Drive belt tension gauge Crank Puller Bearing Extractor Available through Horizon Fitness at cost 8 ...

Page 9: ...e Wipe down the console handlebars and side covers with a damp cloth Never use solvents as they can cause damage to the exercise equipment Every Week Clean underneath the exercise equipment following these steps Move the exercise equipment to a remote location Wipe or vacuum any dust particles or other objects that may have accumulated underneath the exercise equipment Return the exercise equipmen...

Page 10: ...UBLESHOOTING CONTENTS No display on console 11 Partial LCD display on console 13 No RPM speed or watts readout 14 Console resets intermittently 15 Erratic or no heart rate readout 16 Switching from mph to km 17 10 ...

Page 11: ...ble Programmable Resistance 7 Defective console all models Fix 1 Check voltage on batteries or replace with known good batteries Manual Resistance 2 Check connection between power supply and power jack Programmable Resistance 3 Remove the console by removing the four attachment screws and verify that the console cable is properly attached to the console Programmable Resistance 4 Verify that the pr...

Page 12: ... Perform a physical check on the console cable to verify that it is not pinched or cut Verify that proper voltage is present at the end of the console cable which plugs into the console see console cable voltage chart in table of contents Replaced if necessary Programmable Resistance 7 If problem persists replace console all models 12 ...

Page 13: ...all models Fix 1 Check voltage on batteries or replace with known good batteries Manual Resistance 2 Allow console to warm to room temperature It may be necessary to gently massage the LCD crystal with your hand to allow for full display Pressing against the LCD crystal with excessive force may damage the crystal 3 If problem persists replace console 13 ...

Page 14: ...sor wire and console by removing console and snapping console wire and sensor wires together firmly Manual Resistance For all other models remove the side cover and verify that the sensor wire is properly connected to the console cable connection 2 Verify that magnet is installed in crank assembly 3 Inspect sensor wire for damage Check continuity of rpm sensor wire see sensor wire continuity check...

Page 15: ... 1 Verify proper connection between sensor wire and console by removing console and snapping console wire and sensor wire together firmly 2 Verify battery voltage or replace with known good batteries Manual Resistance 3 Verify that the power supply is securely inserted into the power jack Replace power supply and or power jack if there is a loose connection Programmable Resistance 4 Inspect sensor...

Page 16: ...is on pulse screen E51 3 Defective console Fix 1 Make sure that both hands are holding the grip pulse handlebars It is important to use a loose cupping hold when using the grip pulse 2 Press the select button until a P is displayed on the console screen E51 3 If the problem persists replace the console 16 ...

Page 17: ...0 or 1 in the upper right hand corner of display 0 represents Miles and 1 represents KM Programmable Resistance Except 4 1E 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 Note To verify speed setting upon powering up console look ...

Page 18: ...RESISTANCE TROUBLESHOOTING CONTENTS No resistance change 19 Inconsistent resistance change 20 Resistance is too hard or too weak 22 18 ...

Page 19: ...ove 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 cable Manual Resistance 2 Remove the side covers and verify that the tension cable is connected to the brake all models 3 If problem persists replace the tension cable Manual Resistance 4 Check voltages of console cable see console cable voltage chart i...

Page 20: ...ce 7 Defective IC board Programmable Resistance 8 Defective console cable Programmable Resistance 9 Defective console Programmable Resistance Fix 1 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 cable Manual Resistance 2 Remove the side covers and verify that the tension cable is connected secure...

Page 21: ...e switch that should come in contact with the servomotor shaft when at resistance level 0 If the zero switch does not come into connect with the servomotor the resistance will continuously cycle back and forth To resolve adjust the position of the zero switch by loosening the two attach screws and reposition Programmable Resistance 6 Check voltages of console cable see console cable voltage chart ...

Page 22: ...n the keyhole located on the tension cable 2 Remove the side covers and verify that the tension cable is connected securely to the brake 3 Remove side covers and inspect for any binding or crimping in the tension cable Keep in mind that the tension cable has an outer plastic sleeve with a small wire running internally If the small internal wire is binding or is crimped slightly it will not move sm...

Page 23: ...M TROUBLESHOOTING CONTENTS Noise while pedaling 24 Internal noise while pedaling at high resistance levels only 26 Rough feel while pedaling 27 Alignment issues with the pedal arms 29 Crank arms loosen during use 32 23 ...

Page 24: ...ank disk from the elliptical Remove the crank disk from the crank arm by removing the attachment screws Insert additional washers between the crank arm and crank disk in the area where the disk was rubbing against the side cover If problem persists replace crank arm 2 Remove the side covers and verify that the crank arms are tight There should not be any side to side play in the crank arms if tigh...

Page 25: ... the flywheel bearings To verify whether the crank or flywheel bearings are defective remove the side covers and accent piece Carefully turn the crank arms Take caution to avoid pinching fingers Once the flywheel is spinning at a fairly fast rpm listen carefully to both sets of bearings crank and flywheel bearings If it is still not apparent which set of bearings are defective place your hand on t...

Page 26: ... wheel and the side of the brake assembly If the crank pulley wheel is rubbing against the brake assembly manually push the brake assembly in the appropriate direction Verify that the proper gap has been achieved 2 Remove the side covers and verify that there is approximately a 3mm gap between the entire magnet surface of the brake assembly and the flywheel If the brake assembly is rubbing against...

Page 27: ...roperly Tighten if necessary If problems persist replace the crank axle nut with updated nut Contact Horizon Fitness for update kit 2 Remove the lower connecting arm from the pedal arm to determine whether an improper weld on the lower connecting arm causes the alignment issue If the alignment issue is corrected by removing the lower connecting arm replace the connecting arm IF the alignment issue...

Page 28: ... or the flywheel bearings To verify whether the crank or flywheel bearings are defective remove the side covers and accent piece Carefully turn the crank arms Take caution to avoid pinching fingers Once the flywheel is spinning at a fairly fast rpm listen carefully to both sets of bearings crank and flywheel bearings If it is still not apparent which set of bearings are defective place your hand o...

Page 29: ...rm pin is welded crooked 3 Crank arm is welded improperly Fix 1 Disconnect the right and left lower handlebars by removing the 13mm nut and associated bolt that connect the lower handlebar to the lower connecting arm Take caution when removing so the handlebars do not swing freely Remove the lower connecting arms by removing the 12 mm bolts and washers 29 ...

Page 30: ...efer to top diagram for non pivoting footpads and lower diagram for pivoting footpads With the pedal arms still attached ride the elliptical to check for proper alignment If the problem has been corrected the lower 30 ...

Page 31: ...ch side of the guide rail the pedal arm wheels are jumping off of the guide rail For example if the pedal arm wheels are jumping off of the inside of the guide rail in theory the pedal arm needs to be placed further away from the machine and if the pedal arm wheels are jumping off of the outside of the guide rail in theory the pedal arm needs to be placed closer to the machine Once this has been d...

Page 32: ...Crank Arms Loosen During Use Possible causes 1 Crank axle nut is defective Fix 1 Replace crank axle nut with updated nut Contact Horizon Fitness for update kit 32 ...

Page 33: ...VOLTAGE READINGS CONTENTS Console cable chart 34 Power supply voltage check 35 IC Board voltage check 36 RPM sensor continuity check 37 33 ...

Page 34: ... VOLTS DC P5 GREEN 46 VOLTS DC P6 WHITE 46 VOLTS DC P7 YELLOW 5 VOLTS DC P8 GREY 9 5 VOLTS DC P9 BLUE 0 VOLTS DC P10 RED 5 5 VOLTS DC P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 To check for voltages coming from a specific part i e sensor wire power supply DC motor place the negative lead of the multimeter in pin P9 ground and the positive lead in the desired pin Follow the pin voltages listed above to diagnos...

Page 35: ...n to the wall place the positive lead of your multimeter into the power supply jack and the negative lead on the outside of the power supply jack The voltage of the power supply should be between 7 5 11 5 volts DC CSE3 3 1E 10 12 volts DC 4 1E only 14 5 16 5 volts DC E52 E53 E54 E6050 35 ...

Page 36: ...ltage going to the IC board place the positive lead of your multimeter on the top soldered pin on the backside of the IC board and the negative lead on the second soldered pin on the backside of the IC board The voltage reading should be between 5 to 6 volts DC 36 ...

Page 37: ... wire jack There must be an rpm present in order to get continuity through the sensor wire Programmable Resistance To check for continuity on the sensor wire turn your multimeter setting to Ohms Place the positive lead of your multimeter into the tip of the sensor wire console cable connection and the negative lead into the other tip of the sensor wire console cable connection There must be an rpm...

Page 38: ...43 Replacing the console cable 44 Replacing the servomotor IC Board 46 Replacing the tension cable 48 Replacing the crank assembly 50 Replacing the flywheel drive belt 53 Adjusting the drive belt tension 55 Adjusting the magnetic brake 57 Replacing the side case 61 Replacing the pedal arm 63 38 ...

Page 39: ...le mast boot 9 Remove the accent piece by gently lifting up at the bottom of the accent piece and tilting towards the front of the machine 10 Remove the screws that attach the left side cover in place 11 Locate the sensor wire bracket Remove the screw from the sensor wire bracket 12 Remove the old sensor wire from the sensor wire bracket 13 Remove the console from the console mast Attach the new s...

Page 40: ...tach pedal arm onto crank arm Replace nut attaching pedal arm to crank arm using 17mm wrench 22 Replace pedal arm cap 23 Attach the lower handlebar to the pedal arm and secure with a 5mm nut and washers 24 Attach the lower handlebar to the lower link arm using the 13mm nut and associated bolt 25 Test ride elliptical to make sure it is working correctly 40 ...

Page 41: ...m Extract the crank arm and crank disk from the axle and remove 9 Lift console mast boot 10 Remove the accent piece by gently lifting up at the bottom of the accent piece and tilting towards the front of the machine 11 Remove the screws that attach the left side cover in place 12 Locate the sensor wire bracket Remove the screw from the sensor wire bracket 13 Remove the old sensor wire from the sen...

Page 42: ...ank arm Replace nut attaching pedal arm to crank arm using 17mm wrench 23 Replace pedal arm cap 24 Attach the lower handlebar to the pedal arm and secure with a 5mm nut and washers 25 Attach the lower handlebar to the lower link arm using the 13mm nut and associated bolt 26 Test ride elliptical to make sure it is working correctly 42 ...

Page 43: ...Magnet Crank pulley Magnet should pass evenly over the edge of the sensor wire The sensor wire should not cover the whole magnet Sensor Sensor bracket Proper sensor wire alignment guide 43 ...

Page 44: ...console mast boot 10 Remove the accent piece by gently lifting up at the bottom of the accent piece and tilting towards the front of the machine 11 Remove the screws that attach the left side cover in place 12 Unscrew the power jack from the frame 13 Unplug the console cable from the sensor wire and IC board 14 Unscrew the console from the console mast Unplug the console cable from the console and...

Page 45: ...crank arm to the crank axle Place black cap onto the center of the crank disk 23 Attach pedal arm onto crank arm Replace nut attaching pedal arm to crank arm using 17mm wrench 24 Replace pedal arm cap 25 Attach the lower handlebar to the pedal arm and secure with a 5mm nut and washers 26 Attach the lower handlebar to the lower link arm using the 13mm nut and associated bolt 27 Test ride elliptical...

Page 46: ...ank puller thread the puller onto the crank arm Extract the crank arm and crank disk from the axle and remove 9 Lift console mast boot 10 Remove the accent piece by gently lifting up at the bottom of the accent piece and tilting towards the front of the machine 11 Remove the screws that attach the left side cover in place 12 Unplug the console cable from the IC board 13 Remove the brake cable from...

Page 47: ... Place black cap onto the center of the crank disk 24 Attach pedal arm onto crank arm Replace nut attaching pedal arm to crank arm using 17mm wrench 25 Replace pedal arm cap 26 Attach the lower handlebar to the pedal arm and secure with a 5mm nut and washers 27 Attach the lower handlebar to the lower link arm using the 13mm nut and associated bolt 28 Test ride elliptical to make sure it is working...

Page 48: ...ack cap from the center of the crank disk 8 Remove the crank arm nut with a 14mm socket 9 Using a crank puller thread the puller onto the crank arm Extract the crank arm from the axle and remove 10 Lift console mast boot 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 the screws that attach the left side cover...

Page 49: ...l brake assembly 21 Attach the left side cover and secure with screws 22 Attach the accent piece placing the bottom tab into position first then placing the top tab into position 23 Slide console mast boot back into place 24 Attach the crank disk and crank arm to the crank axle Place black cap onto the center of the crank disk 25 Attach pedal arm onto crank arm Replace nut attaching pedal arm to c...

Page 50: ...a Phillips screwdriver 4 With a 17mm wrench remove the nut that attaches the right pedal arm to the crank axle Remove the pedal arm from the crank axle 5 Remove the black cap Q17 from the center of the crank disk 6 Remove the crank arm nut R11 with a 14mm socket 7 Thread a crank puller onto the crank arm AJ1 Extract appropriately and remove the crank arm and crank disk from the crank axle 8 Lift c...

Page 51: ...bearing and crank pulley first Once the right bearing and the crank pulley are in place carefully tap the left bearing into position It is best to let the loctite set for 24 hours before using the elliptical 16 Attach the c clip R34 in place on the crank assembly 17 Attach the right side cover crank arm crank disk and black cap in that order Attach the wood grain accent piece 18 Attach the left si...

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Page 53: ...d remove the crank arm and crank disk from the crank axle 8 Lift console mast boot 9 Remove the accent piece by gently lifting up at the bottom of the accent piece and lifting towards the front of the machine 10 Remove the screws that attach the left side cover in place 11 Repeat steps for right side 12 Loosen the 11mm nut R15 holding horizontal tensioning bolt R13 into position on both sides of t...

Page 54: ... Once the belt tension is set properly tighten the 17mm nuts on both sides of the flywheel 22 Attach the right and left side covers and secure with screws 23 Replace wood grain accent piece 24 Attach crank arms and crank disks and secure with 14mm nut Place black crank disk cap over 14mm nut 25 Slide console mast boot back into place 26 Attach pedal arms onto crank arms and secure with 17mm nut 27...

Page 55: ...ift console mast boot 9 Remove the accent piece by gently lifting up at the bottom of the accent piece and lifting towards the front of the machine 10 Remove the screws that attach the left side cover in place 11 Repeat steps for right side 12 Check belt tightness To measure the belt tension a timing belt tension gauge is required The correct belt tension tolerance is 120 140 lbs If a belt tension...

Page 56: ...arms Secure with 17mm nut and washers 22 Attach the crank arm covers to the pedal arms secure with screws 23 Attach the lower handlebars to the pedal arms and secure with washers and nuts 24 Attach the lower handlebar to the lower link arm using the 13mm nut and associated bolt 25 Test ride elliptical to make sure it is working correctly 56 ...

Page 57: ... and crank disk from the crank axle 9 Lift console mast boot 10 Remove the accent piece by gently lifting up at the bottom of the accent piece 11 Remove the screws that attach the left side cover in place 12 Locate the flywheel brake assembly 13 The correct position for the flywheel brake assembly is 2 3mm from the flywheel at the highest resistance level 14 Locate the 13mm nut attached to the mag...

Page 58: ...re with 17mm nut and washers 22 Attach the crank arm covers to the pedal arms secure with screws 23 Attach the lower handlebars to the pedal arms and secure with nuts and washers 24 Attach the lower handlebar to the lower link arm using the 13mm nut and associated bolt 25 Test ride elliptical to make sure it is working correctly 58 ...

Page 59: ...ller onto the crank arm Extract appropriately and remove the crank arm and crank disk from the crank axle 9 Lift console mast boot 10 Remove the accent piece by gently lifting up at the bottom of the accent piece 11 Remove the screws that attach the left side cover in place 12 Locate the flywheel brake assembly 13 The correct position for the flywheel brake assembly is 2 3mm from the flywheel at t...

Page 60: ...ank arm covers to the pedal arms secure with screws 22 Attach the lower handlebars to the pedal arms and secure with nuts and washers 23 Attach the lower handlebar to the lower link arm using the 13mm nut and associated bolt 24 Test ride elliptical to make sure it is working correctly 60 ...

Page 61: ...p Q17 from the center of the crank disk 6 Remove the crank arm nut R11 with a 14mm socket 7 Thread a crank puller onto the crank arm AJ1 Extract appropriately and remove the crank arm and crank disk from the crank axle 8 Lift console mast boot 9 Remove the accent piece Q16 by gently lifting up at the bottom of the accent piece 10 Remove the screws that attach the side cover in place 11 Attach the ...

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Page 63: ...y removing the three attachment bolts H11 and bracket H10 with a 5mm Allen wrench 3 Remove the nut E21 attaching pedal arm to the pivot tube AE2 using 17mm wrench Lift pedal arm off of crank arm 4 Attach new pedal arm onto crank arm Replace nut attaching pedal arm to crank arm and secure nut with a 17mm wrench 5 Attach the connecting arm to the pedal arm and lower handlebar 6 Test ride elliptical ...

Page 64: ...astic cover Q21 to expose the nut underneath Remove the nut E21 attaching pedal arm to the pivot tube using 17mm wrench Lift pedal arm off of crank arm 3 Attach new pedal arm onto crank arm Replace nut attaching pedal arm to crank arm and secure nut with a 17mm wrench 4 Attach the connecting arm to the pedal arm and lower handlebar 5 Test ride elliptical to make sure it is working correctly 64 ...

Page 65: ...Notes 65 ...