Horizon Fitness EX-44 Service User manual

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Ws rra flty
Safety Instructions
Required Tools
Preventative Maintenance
Voltage Checks
Elliptical Troubleshooting
Part Replacement
5
6
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FRAMEoLIFETIME
HorizonFitness warrants the frame
against defects in workmanship
and materials for the fifefime of the,
original owner.
EX-22:BRAKEo 7 YEARS
Horizon Fitness warrants the brake
against defects Jnworkmansblpand
materials for the period of seven
years of the original owner.
EX-33:BRAKE_ ,10YEARS
Horizon Fitness warrants the brake
against defects in workmanshipand
materials for the period of tenyears
of the original owner.
EX-44:BRAKE_12 YEARS
Horizon Fitness warrants"the brake
against defects in worknTansblpand
materials for the period of twetve
years of the original owner.
ELECTRONICS& PARTS, i YEAR
HorJzonF/tnesswarrantstheelectronic
componentsand aft original parts for
aperiod of one year from the,date
of original pumhase,so long as the
device remains Jnthe possession of
the original owner.
EXCLUSIONSANDLiMtTATtONS
W,@is covered..
TheoNg/na/ownerandis not transferable.
WhatiS covered..
oRepairor replacement eta defective rnotor,ebctron/c component, or defective
part and is the sm_remedyof the warTanty
WhattSNOTcovered:
Normal wearand tea,_improper assemblyor maintenance, or installation of parts
or accessoriesnet originally intended or compatible with the equipment assold.
oDamageor failure due to accident, abuse,corrosion, disco/orationof paint or
plastic, ne_,tect,theft, vandalism, fire, flood, wind,/_htning, froezL:_g,or other
natural disasters of any kind, powerreduction, fluctuation or failure &ore whatever
cause,unusual atmospheric condfi/ons, collision, introduction of fem/gn objects
into the coveredunit, or modifications h_atam unauthorizedor not recommendedby
HerizonFitness.
oincidental or consequential damages.HorizonFitness is net responsible or liable
for indirect, special or consequential damages, economicloss, loss ofproperty,or
profits, less of en_yment or use,or oh@rconsequential damages of whatsoever
nature in connection with the pumhase, use, repair or maintenance of the product.
Equipment used for commercial purposesor any use other than a single family or
Household,unless endorsedby HorizonFitness forcoverage.
Equipment owneror operatedoutside the USand Canada.
De/iver_assembiy, installation, setup for or/ginat or replacement units or labor or
other costs associated with removal or replacement of the coveredunit.
oAny attempt to repair this equipmentcreates a Nskof/njurjz HoNzenFitness is
not responsibleor liable forany damage, lossor ftabifity arising from any per_enat
injury incurred during the course ell or as a result of any repair or attempted repair
ofyour fitness equipmentby other than an authorized service technician. Aft
repairs attempted byyou onyour fitness equipment am undertakenAT YOUROWN
RiSKand HorizonFitnessshaft have no liability for any injury to the personor prop-
ertyarising from such repairs.
LABORoiYEAR
HorizonFitness shaft cover the,labor
cost for the,repair of the devicefor a
period of oneyear from the date of
the orig/nai purchase,solong as the,
device remains in the possession of
the original owner.
SERViCE/flETURNS
In-home serviceis avai/abb om'ywithin 150 miles of the nearest autheNzefi
mpa/,*center:
oAft returns must be pm-aut,@rizedbyBeHzonFitness.
HorizonFitness' obligation under ibis warTantyis fl_nitedtorap/acing or repairing,
at HerizonFitness' option, theproduct at one of its authorizedservice centers.
A HerizonFitnessauh@rizedservicecenter must receiveaft products for which a
warrantyclaim is made. Theseproducts must bereceived with aft freight and other
transportation cha,*_esprepaid, accompanied bysufficient proof of purchase.
oParts andelectronic componentsreconditioned to As NewCondition by Horizon
Fitness or its vendersmay sometimesbe supplied as warTantyreplacement pa,*fs
andconstitute fu/f)_qmentof warrantyterms.
Thiswarranty_/ves youspecific/_a/r/_hts, and your r/_hts /flay vary from state
testate.

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Warning statements indicate a particularly dangerous activity, P/ease read the following warnings before us-
ing, repairing or maintaining your exercise equipment:
oNever drop or insert any object into any opening.
oNeveroperate the exercise equipment if it is not working properly, if it has been damaged, or immersed in
water.
oVisually check the machine before beginning service or maintenance operations./f it is not completely as-
sembled or is damaged in any way,exercise extreme caution while operating and checking the exere/seequip-
ment.
eDonot use outdoors.
eDonot wear clothing that might catch on any part of the exere/seequipment.
eUse tbis exercise product for its intended use as described in the Owner'sguide. Donot use attachments not
recommended bythe manufacture.
eFoldand secure_vlatch your exercise equipment before moving it.
eUsecare when getting on of off the exercise equipment. Use the handrails whenever possible.
eDonot rock the unit. Donot stand or climb on the handrails, electronic console, or side covers.
eIfyou experience chest pair,s, nausea, dizziness or shortness of breath, stop exercising immediately and
consult your physician before continuing.
CHILDREIV
"Keep children off ofyour exercise equipment at all times.
oWhentbe exercise equipment is in use, young children and pets should be kept at least 10 feet away,
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Thefollowing list is a summary of the t_ols and equipment required bj' the aro_eflures in this manual
Tooisare not sup_hed by Horizon Fitness,
oPhi/tipsscrewdrivers
Flat-head screwdrivers
Right angle screwdriver
o Digital multi-meter
oAlien wrench set (Metric)
oOpen-end wrenches of assorted sizes (Metric)
o Y2" drive ratchet and sockets of assorted sizes
oBearing thread iock
oCable ties
o/Veefl/e nosepriers
oDamp cloth
oRubber mafiet
oDrop cloth (to protect floor surfaces)
oRuler
oSnap ring priers
oWirecutters
oDrive belt tension gauge _
oCrank Puffer (Park ToolCCP-2,22ram) _
oBeating Extractor _
*AvariablethroughHor_=onFitnessat cost,
_ _%1_,¸
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i i i i WHtITKllvDOFROUTINEMAllvTEIVAIVCEISREQb'IRED.}
Weusesealedbearingsthroughoutourellipticals solubrication is notneeded,Themostimportant maintenance
stepis to simply wipeyour perspirationoff tf,,etrainer after eachuse,
flOWDOI CLEAlvMYELLIPTICAL.}
Cleanwith soapand watercleanersonly,lveverusesolventsonplastic parts,
Cleanliness of your efiiptical and its operating environment will keep maintenance problems and
service cads to a minimum, Forthis reason, Hon_=onFitness recommends that tbe fo/lewing preventive
maintenance schedule be fo/lewefl,
AFTEREACHUSE(DAILY)
Tureoff the efliptica/ by unp/uggir,,g the power cord from the waft outlet
oWipe down tbe elliptical witb adamp clotb, lvever use solvents, as tbey can cause damage to tf,,e
elliptical
o Inspect the power cord, If the power cord is damaged, contact Horizon ,Fitness,
o Make sure the power cord is not unfl'emeath the elliptical or m any other area where it can become
pinched or cut,
Toremovepowerfromtheelliptica!, tbe powercordmust bedisconnectedfrom
the wallouflet.
WEEKLY
Clean underneath the efllpticaL following these ste_s:
Turnoff the elflptical
Move the elliptical to a remote location,
oWipe or vacuum any dust particles or other objects that may have accumulated undereeath the
elliptical
Refute the el//ot/cal to its mrevlous _os/t/on,
EVERYMOIVTH
,Inspect all assembly bolts and pedals on the machine for proper tightness,
,Clean any debris off of the _eda/arm wheels and guide rails,

ToolsRequired:
Phillips Screwdriver
o 11ram,19ramSocketand CombinationWrenches
Procedure:
I, Remove top cap or top side covers,
2. Checkthe tensionof the drivebelt
A
avai!able,thedrivebe!tShouldhaveabout0,25'_deflectionwhenpressingdo_;=_
firmlyonthedrivebe!t,
Flywheel
B
3. Loosenbothnuts _), whichhold thefly_,l_eelto frame.
4. Tightenor loosenthenuts (B)holdingthe tensioningboltsintoposition onbothsidesof the flywheel
toadjust the tensionof the drivebelt. 5'mportantNote_- Makesurethat both boltsaretightenedequallyso
that flywheelsits straight in frameand both thefly wheeland crankpulleyareproperlyaligned.
5.Oncethebelttensionis set properly,tighten the nuts_) onbothsidesof tbe flywheel.

ToolsRequired:
,Phillips Screwdriver
11mm ]3mm. ISmm.17ram.19mmSocketand CombinationWrenches
e5ramA!len Wrench
oCrankPuller
Procedure:
!i:ii{:!ii_
L Removecrankdisk andsidecovers.,'ReferenceCrankDisk!SideCover/CrankArrnReplacement
-L2E &2.2Eor3.2E& 4.2EonPPd
2. Checkthe tensionof the drivebelt.
Thecorrectbelt tensiontoleranceis I20=J40 /bs. Ira belt tensiongaugeIs nor
available,the drivebeltshouldhaveabout0.25" deflectionwhenpressingdown
firmly on thedrivebelt.
3. Loosenbothnuts (A),whichhold the flywheelto frame.
37 02
12
R09
R20
R08
Rt2
4. Tightenorloosenthenuts (B)holding thetensioningboltsflTtopositiononbothsidesof theflywheel
to adjust the tensionof the drivebelt.
Makesure that bothboltsaretightenedequallysothat fi}w@ee!sits straight in frame and
both the fi_/wheel and CrankpulleyareproperlyalL,ned.
5. Oncethe belt tensionis setproperly,tighten thenuts (.4)onbothsidesof theflywheel

ToolsRequire_
oPhillips Screwdriver
o8mm,13ram,17ramSocketanfi CombinationWrenches
o5ramAdenWrench
oCrankPuller
Procedu;e:
I, 1,2Eonly-Mjust tension knob to highest setting,
2, Turnon unit anfi Press start,
3, Set rns/stance highest level anfi power off unit,
4, Removes/fie covers, (Reference side cover replacement in Parts Replacement section,)
4. Loosen the short nut (,4),and afijust the long nut (B) clockwise to reduce the brake resistance and
counterclockwise to/ncrnase the brake resistance,
Thecorrecf position for the flywtleel/brake assembly is i -2mm from the flywheel at
..? s_, _;S;"

TootsRequired-
Phillips Screwdriver
o12ram,13ram,14ram,17ramSocketanti CombinationWrenches
e5ramAllen Wrench
oCrankPuffer
Procedure:
]. Turnonunit and Pressstart.
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Z Setresistance highest level and power off unit,
3, Removecrank disk and side covers, (t_eferenceCrank 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.
Thecorrect position for the f/ywhee//brake assembly is 2-3ram from the flywheel at
5./t maybenecessarytoalsoadjust the topha/f of themagneticbrake.Todothis, loosenthetwo
5ramboltsthat attach themagneticbraketo the frame.Adjust tbe positionof the magnetic"brakecloseror
furtherfromthe h_v_;_,,eeL
Flywheel

All ModelsExcept 1.2E
Theback of the console features a smirch to convert the speed readout from mph to kin, Toconvert from mph
to kin, simply flip the switch, Please note that the console needs to be reset before the change will be detected,
*lmportaflt Note* -To/enfy speed setting, uoon powering uo console, look for Miles or KM to flash briefly on
display,
_44
_P _/LE:
$w2 SWI
SwitchUp _KR Bike
SwitchDown _ REP
®

/i!!i!
Using Engineering Mode
oPowerontheelliptical
_,Pressandholdtheresistance,,A,,and speed"v"for 3- 5secondsto entertheErdineeHngModeMenu.
Pressand boldresistance #2 and resistance #20 for tile 2.2E
oTheconsolewill beep2-3 times and HARDWARETESTwill bedisplayed.
oPress'_Enter"to movethroughthe differentmenusin engineeringmode.
oPress"Start" toenter desiredmenu.
o.Pressandhold "Start/Stop" toexit a//specific engineeringmenu.
oPressandhold "Start!Stop" again tocompletelyexit engineeringmodeand returntostandard operating
mode,
Hardware Test
Indicates software version,
oindicates _;_,,etherconsole is set for Miles or tfM,
o/ndioates w;_etherconsole is set for an e/liptioal or a stationary bike
oDisplays RPM'sand heart rate similar to standard operating mode.
eDisplays resistance as the number of turns the resistance motor has made,
LCDTest
oDisplaysaftLCD'sat onceorindividually bypressingmd/v/dualbuttons.
Information
Z2E doesnot dave tflis menu.
oDisplaysthenumberof hoursand milethemachinehaslogged.
If tile consoleis ever cflanged tflis reformation will reset to 0.

Problem: Thereis n_ heart rate reading.
Solution: Remove the console and verify that the heart rate cabies arc attached properly, making sure
that the cables are securcl}l inserted int_ the console.
Checkyour exercise environment for sources of interfercnce such as high oower fines, large motors, etc.
Youmay experience an erratic"Heart Rate readout under the fo//o_:ing conditions:
oGripping the heart rate handlebars too tight. Tryto maintain moderate orcssurc while holding onto the
heart rate handlebars.
oConstant movement and vibration due to constantly holding the heart rate grips while exercising.
oWhenyou arc brcathing heavily during a workout.
oWhenyour hands arc constricted by wearing a ring.
oWhenyour hands arc dry or cold. Trymoistening your palms or rubbing them together to warm.
oAnyone with heavy arrhythmia.
oAnyone with arteriosclerosis or peripheral circulation disorder
oAnyone whose skin on the measuring oa/ms fs especially thick.
NOTE:Outside interference sources such as comauters, motors and fluorescent lights may cause the heart rate
rcading to be erratic'.
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Handlebars
Place the palm of your hands directlyon the grip pulsehandlebars, Both hands must grip the bars for your
heart rate to register` It takes _consecutive heart beats ,_]5-20 seconds) for your heart rate to register, When
gripping the puHe handlebars, do not grip tlghtl_ Holding the grips tightly may elevate your blood pressure,
Keep a loose, cupping hold, Youmay experience an erratic readout if consistently holding the grip pulse
handlebars, Make sure to clean the oulse sensors to ensure DroDercontact can be maintained,
BACKSIBEOFCNES]TRANSMITTER f
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_'_'RELESSCHESTTRANSMITTER(EX-44 ONLY)
Prior to wearing the wireless chest transmitter onyour chest, moisten the two rubber electrodes with water,
Center the chest strap just belew the breast or pectoral muscles, directly overyour sternum, with the lego
facing out, NOTE:Thechest strap must be tight and properly placed to receive an accurate and consistent
readout, If the chest strap is too loose, or positioned irnpreper/_Kyou may receive an erratic or inconsistent
heart rate readout, W4RNING!Theheart rate function is not a medical device, Variousfactors may affect the
accuracy ofyour heart rate reading, Theheart rate reading is intended only as an exercise aid,

--_0 P1 Ground-From RPM Sensor
0 P2 Ground-From Motor
0 P3 Zero Switch Sensor
0 P4 Optic Count-From Motor
__JO P5 PowerTo Resistance Up
___0 P6 Power To Resistance Down
:-._!0 P7 RPM Sensor
_"jO P8: Power ToConsole-From Power Suppl! (VDD
_------'_0 P9: Ground-From Power Socket
NJfO PIO: PowerTo Console [VCC)
CORRECTVOLTAGE FORWIRE HARNESS
PI: Purple n/a ground P6: White +0.0 to 0.46 vdc f motor idle.+&5 vdc if resistance
P2: Black n/a ground decreasing +0.6 to 2.( vdc if resistance ncreasmg
vol[age ccanges wml eacl change in Reline. PT: Yellow If magne[ aligned wl[n rpm sensor: 0.0 Vat mor[
P3: Orange f zero switcl engaged owesr resls[ance level,: _ magnr nor augned wl[r rom sensor: 5.0 vdc een
+5.0vdc. ooen. Any omer resistance oosmon: 0.0 vdc snort. P8: Grey Decendant uoon cower supply
P4: Brown +5.0 vdc. f slot )Pile dISKaligned wml sensor P9: Blue n/a __round
0.0 vdc PIO: 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
NoteI: All voltagesmeasuredloaded,with functionbg consoleand resistancemotor,
Note2: All groundssamepoint oncepluggedinto consolewith orwithoutpoweron.
Note3:If measuredWhite(÷) to Green(-) whenresistanceincreasing= -7.7vdc,if decreasing= ÷7.7 vdc.
Thenew style servo motor voltage measurements are: (Ex22-Ex44/CSE3,5 &4,5/EG5)
Orange=3,0 vdcif resistanceat lowest,0.2 vdcif resistanceat anypositbn other thanlowesL
Bro_t;_÷3,0 vdcif optic"sensoropen,0,2 vdcas wheelpassesthroughoptic"sensor,

Withthe powersupplypluggefi in to thewaft,place thepositive leaflofyourmulti-meter into thepowersupply
jack and thenegativeleafl ontheoutsideof thepowersupplyjack, Thevoltageofthe powersupp/yshouiflbe
as follows:
Unloaded vo!fagesmaybe higher
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I) ForModelsEX-22-EX-44/OSE3.5 &4.5/EGS/2.2EOnly- Removeplastic housingtoaccessIC boardpins,
Conso/eCab/e
ServoMotor
2) Placethe positivelead ofyour multi-meter onthe top solderedpin onthe backsideof theICboard,
3) Placenegativeleadonthe secondsolderedpin onthe backsideof tbe/Cboard,
\

Red 0 PI: Power to DC Motor IC Board (VCC)
Black0 P2: Ground-From Motor
Brown0 P3: Optic Count-From Motor
P4: Zero Switch Sensor
Green0 P5: Power To Resistance Up
White0 P6: Power To Resistance Down
CORRECTVOLTAGEFORWIRE HARNESS
PI: Red +5.0 VDC
P2: Black n/a Ground
P3: Brown +5.0 VDC. if Slot in Optic Disk
aligned with sensor O.OVDC
P4: Orange If zero switch engaged +5.0 VDC Any other resistance 0.0 VDC Short
PS: 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.
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
Note1:A/I vo/tagesmeasured/oaded with functioning conso/eandresistancemotor,
Note2:All groundssamepoint oncep/uggedintoconsolewith or withoutpoweron,
Note3: If measuredWhite(÷) to Green(_)l#len resistanceincreasing= -7,7vdc if decreasing= ÷7,7 vdc,
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gionalservemotor.(Z2E, 3.2E.4.2E)
_e newstyleservomotor vo/ta_emeasurementsare: (Ex22-Ex44/CSE3,5& 4,5/EG5)
Orange=3,0 vdcif resistanceat/owest,O,2vdcif resistanceat anypositionotherthan/owest,
Brown÷3,0 vdcif opticsensoropen,0,2 vdcas wheelpassesthroughoptic sensor,

/
/(\
I) Turnyour 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 had on the
outside of the sensor wirejack,
3) Turncrank to pro&ced an rpm in order to get continuity through the sensor wire,
A/IModelsExcept1.2E
I) Turnyour multi-meter setting to Ohms, "<:i
2) Removeconsole and disconnect console cable. _!i
3) Put one lead into the purple pin (Pl) anfl the other on theyefiow pin (PT). (Please referto the Console Cable
VoltageCheck on page 16) _
Turncrank to produced an rpm in order to get continuity through the sensor wire.

Nodisplay on console. _aiiedbatteries. (l.2E only)
Improperwiring.
rai/efiorimproperpowersupply
railedconsole,cable.
-Verifythe connectionsbetween
the powersupply and the power
ack.
-Verifythe connectionsbetween
consolecable and console.
-Verifypowersupply is not
_inchedor damaged.
railedconsole.
railedbatteries.(t.2Eonly)
_ensm'ewassubjectedtocm'd
!emperatums.
-PeAbrm voltagecheckon
powersuppl}<(Reference
Power Supply Voltage Checkin
Voltage Checkssection.)
-Verifythe powersupply and
makesure the adapter is the
correct vottage.(Reference
Power Supply Voltage Checkin
Voltage Checkssection.)
- l/erifyconsolecableis not
Anchedordamaged.
-Performvoltagecheckoncon-
solecable.(ReferenceConsole
cableVoltageCheckin Voltage
Checkssection.)
Replacebatteries.
Connectwires correctly or
replace parts as needed.
Replacepowersupply
,Replaceconsolecable.(Refer-
once Console Cable Replace-
meat in Parts Replacement
section.)
Replaceconsm'e.
Partial LCDDisplay on Replacebatteries.
Console.
_ailedconsole.
l/erifyproper connectionsbe-
tweensensor wireandconsole
byremoving consoleandsnap-
ping consolewireandsensor
wiresfirmly together (l.2E only)
Allow machine to warmtoroom
temperature,it may beneces-
sary togently rnassagethe LCD
crystal withyour band to allow
forfun display *important
Note* -Pressinga_ainst the
LCDcrystal wit,_excessiveforce
may damage the crystal
Replaceconsm'e.