Horizon Fitness E51 User manual

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

TABLE OF CONTENTS
Warranty 3
Safety 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

Horizon Series Elliptical Home Warranty
Models: E51, E52, E53, E54hr, E6050, 30150
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.
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 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.
LABOR – ONE YEAR
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 long as the
device remains in the possession of the original owner.
3

Models: 2.1E, 3.1E, 4.1E
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.
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 two
years from the date of purchase, so long as the device remains in the
possession of the original owner.
LABOR – ONE YEAR
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 long as the
device remains in the possession of the original owner.
4

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 exercise
equipment 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 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. 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.
5

Important Safety Instructions
Warning statements indicate a particularly dangerous activity. Please read
the following warnings before using, repairing or maintaining your exercise
equipment:
• Never drop or insert any object into any opening.
• Do not remove the exercise equipment’s side covers. Service should
be performed only by an authorized Horizon Fitness service provider
• Never operate the exercise equipment if it is not working properly, if
it has been damaged, or immersed in water.
• Visually check the machine 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
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 equipment. Use the
handrails whenever possible.
• Do not rock the unit. Do not stand or climb on the handrails,
electronic console, or side covers.
• If you experience chest pains, nausea, dizziness or shortness of breath,
stop exercising immediately and consult your physician before
continuing.
CHILDREN
• Keep children off of your exercise equipment at all times.
• When the exercise equipment is in use, young children and pets
should be kept at least 10 feet away.
6

Basic Troubleshooting Tips
When using this service guide for troubleshooting problems on a Horizon
Fitness bike or elliptical, follow the step-by-step procedures listed in the
troubleshooting section. The step-by-step procedures start with the most
basic checkpoints to more extensive checkpoints. However, 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, serial number and a
very detailed description of the defect (i.e. when does problem occur, how
often, etc.).
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
Flat-head screwdrivers
Digital multi-meter
Allen wrench set (Metric)
Open-end wrenches of assorted sizes (Metric)
½” 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

Preventative Maintenance Procedures
Cleanliness of your Horizon Fitness exercise equipment 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
• 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 equipment to its previous position.
Every Month
• Inspect all assembly bolts of the machine for proper tightness.
9

CONSOLE TROUBLESHOOTING
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

No Display on Console
Possible causes:
1. Weak batteries (Manual Resistance).
2. Loose connection between power supply and power jack (Programmable
Resistance).
3. Loose connection between console cable and console (Programmable
Resistance).
4. Defective power supply (Programmable Resistance).
5. Defective IC board (Programmable Resistance).
6. Pinched or cut console cable (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 proper amount of voltage is coming from the power
supply. Reference the power supply voltage checkpoint in the table of
contents (Programmable Resistance).
11

5. Verify voltage going to IC board (see IC board voltage checkpoint in
table of contents). Replace if necessary (Programmable Resistance).
6. 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

Partial LCD Display on Console
Possible causes:
1. Weak batteries (Manual Resistance).
2. Console subjected to cold temperatures (all models).
3. Defective console (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

Only Time Works On Console
(No workload, distance, etc.)
Possible causes:
1. Poor connection between sensor wire and console (all models).
2. Missing rpm magnet on crank assembly (all models).
3. Defective sensor wire (all models).
4. Defective console (all models).
Fix:
1. Verify proper connection between sensor 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 checkpoint in table of contents). Replace
if defective.
4. If problem persists, replace console.
14

Console Resets Intermittently
Possible causes:
1. Poor connection between sensor wire and console (all models).
2. Weak batteries in console (Manual Resistance).
3. Loose connection between the power jack and power supply
(Programmable Resistance).
4. Sensor wire is pinched or cut (all models).
5. Defective console (all models).
Fix:
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 wire for damage. Check continuity of rpm sensor wire.
Replace if defective.
5. If problem persists, replace console.
15

Erratic or No Heart Rate Readout
Possible causes:
1. Improper hand placement.
2. Verify that console display 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

Switching the Console from MPH to KM
E51
Once you insert the batteries into the back of the console, the console will be
set to mph. To switch from mph to km, press and hold the select button for
three seconds. While holding the select button down, the time on the
console will begin to increase. Once the select button is held for three
seconds, the time will reset to zero. Continue to hold the select button for
two additional seconds. Again the time will begin to increase but will reset
to zero once the select button is held for two seconds. The console is now
set for km. To switch back to mph, simply remove the batteries and replace.
Note: To verify speed setting, upon powering up console, look for a 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 for a 0 or 1
in the upper right hand corner of display. 0 represents Miles and 1
represents KM.
4.1E
Press Resistance +/- buttons simultaneously for a few seconds to get into
Engineering Mode. Press Select to change Engineering Mode to ENG4.
Press Start to enter ENG4. Once in this mode, press select to toggle between
Miles and KM. Once correct speed setting is selected, press and hold Stop
to exit ENG4.
Note: To verify speed setting, upon powering up console, look for MI or KM
to flash briefly on display.
17

RESISTANCE TROUBLESHOOTING
CONTENTS
Noresistancechange 19
Inconsistent resistance change 20
Resistance is too hard or too weak 22
18

No Resistance Change
Possible causes:
1. Tension cable is not connected to tension knob (Manual Resistance).
2. Tension cable is not connected to the brake (all models).
3. Tension cable is defective (Manual Resistance).
4. IC board is defective (Programmable Resistance).
5. Servomotor is defective (Programmable Resistance).
6. Console cable is defective (Programmable Resistance).
7. Console is defective (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
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 in
table of contents) to verify proper function of photo sensor board,
servomotor, and console cable. Replace parts if defective
(Programmable Resistance).
5. If problem persists, replace the console (Programmable Resistance).
19

Erratic or Continuous Resistance Change
Possible causes:
1. Incorrect adapter voltage (see Power Supply Voltage Check on pg.
35).
2. Tension cable is not connected properly to the tension knob (Manual
Resistance).
3. Tension cable is not connected properly to the brake (all models).
4. Tension cable is binding or is crimped (Manual Resistance).
5. Tension cable is defective (Manual Resistance).
6. Zero switch is not positioned properly (Programmable Resistance).
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
securely to the brake (all models).
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
20