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