!j
Ws rra flty
Safety Instructions
Required Tools
Preventative Maintenance
Voltage Checks
Elliptical Troubleshooting
Part Replacement
5
6
i5
20
27
FRAMEo LIFETIME
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 periodof 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
a period 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/ownerand is not transferable.
WhatiS covered..
o Repair or 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 orcompatible with the equipment as sold.
o Damageor failure due to accident, abuse,corrosion, disco/oration of paint or
plastic, ne_,tect,theft, vandalism, fire, flood, wind,/_htning, froezL:_g,or other
natural disasters of any kind, powerreduction, fluctuation orfailure &ore whatever
cause,unusual atmospheric condfi/ons, collision, introduction of fem/gn objects
into the coveredunit, or modifications h_atam unauthorizedornot recommendedby
HerizonFitness.
o incidental or consequential damages.HorizonFitness is net responsible or liable
forindirect, special or consequential damages,economicloss, loss of property,or
profits, less of en_yment or use,or oh@rconsequential damages of whatsoever
nature in connection with thepumhase, use, repair ormaintenance of theproduct.
Equipment usedfor commercial purposesor any use other than a single family or
Household,unless endorsedbyHorizonFitness for coverage.
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 equipment creates a Nsk of/njurjz HoNzenFitness is
not responsibleor liable forany damage, loss or ftabifity arising from any per_enat
injury incurredduring the course ell or as a result of any repair orattempted repair
ofyour fitness equipment by other than an authorized service technician. Aft
repairs attempted byyou onyour fitness equipment am undertakenAT YOUROWN
RiSKand HorizonFitnessshaft haveno liability for any injury to the personor prop-
ertyarising from such repairs.
LABORo i YEAR
HorizonFitness shaft cover the,labor
cost for the,repairof the devicefor a
period of oneyear from the date of
the orig/nai purchase,solong as the,
device remains in the possessionof
the original owner.
SERViCE/flETURNS
In-homeservice is avai/abb om'ywithin 150 miles of the nearest autheNzefi
mpa/,*center:
oAft returns must be pm-aut,@rizedby BeHzonFitness.
HorizonFitness' obligation under ibis warTantyis fl_nitedtorap/acing or repairing,
at HerizonFitness' option, theproduct at one of its authorizedservicecenters.
AHerizonFitnessauh@rizedservice center must receive aft products for which a
warrantyclaim is made. Theseproducts must bereceived with aft freight and other
transportation cha,*_esprepaid, accompanied bysufficient proof of purchase.
o Parts andelectronic componentsreconditioned to As NewCondition by Horizon
Fitness or its vendersmay sometimes be supplied as warTantyreplacementpa,*fs
andconstitute fu/f)_qmentof warranty terms.
Thiswarranty_/ves youspecific/_a/r/_hts, andyour r/_hts /flay varyfromstate
testate.
ii_ii_T_ ii_
ii i i i
_!iii:::iiii!
Warning statements indicate a particularly dangerous activity, P/easeread the following warnings before us-
ing, repairing or maintaining your exercise equipment:
o Neverdrop orinsert any object into any opening.
o Neveroperate the exercise equipment if it is not working properly, if it has been damaged, or immersed in
water.
o Visually 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/se equip-
ment.
e Donot use outdoors.
e Donot wear clothing that might catch on any part of the exere/seequipment.
e Usetbis exercise product for its intended use as described in the Owner'sguide. Donot use attachments not
recommended by the manufacture.
e Foldand secure_vlatch your exercise equipment before moving it.
e Usecare when getting on of off the exercise equipment. Use the handrails whenever possible.
e Donot rock the unit. Donot stand orclimb onthe handrails, electronic console, or side covers.
e Ifyou experience chest pair,s, nausea, dizziness or shortness of breath, stop exercising immediately and
consult your physician before continuing.
CHILDREIV
!iiiii::ii_
"Keep children off of your exercise equipment at all times.
o Whentbe exercise equipment is in use, young children and pets should be kept at least 10 feet away,
Thefollowing list is a summary of the t_ols and equipment required bj' the aro_eflures in this manual
Tooisare not sup_hed by HorizonFitness,
oPhi/tipsscrewdrivers
Flat-head screwdrivers
Right angle screwdriver
o Digital multi-meter
o Alien wrench set (Metric)
o Open-end wrenches of assorted sizes (Metric)
o Y2" drive ratchet and sockets of assorted sizes
o Bearing thread iock
o Cable ties
o/Veefl/e nosepriers
o Damp cloth
o Rubber mafiet
o Drop cloth (to protect floor surfaces)
o Ruler
o Snap ring priers
o Wirecutters
o Drive belt tension gauge _
o Crank Puffer (Park ToolCCP-2,22ram) _
o Beating Extractor _
*AvariablethroughHor_=onFitnessat cost,
_ _%1_,¸
.........i_iiii
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,lveverusesolventson plastic 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
o Wipe down tbe elliptical witb a damp 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 be disconnectedfrom
the wallouflet.
WEEKLY
Clean underneath the efllpticaL following these ste_s:
Turnoff the elflptical
Move the elliptical to a remote location,
o Wipe 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 thedrivebelt
avai!able,thedrivebe!tShouldhaveabout0,25'_deflectionwhenpressingdo_;=_
firmlyonthedrivebe!t,
A
3. Loosenbothnuts _), whichholdthefly_,l_eelto frame.
4. Tightenor loosenthenuts (B)holdingthe tensioningboltsintoposition on bothsidesof theflywheel
toadjust thetensionof the drivebelt. 5'mportantNote_- Makesurethat both bolts aretightenedequallyso
that flywheelsits straight in frameand both thefly wheelandcrankpulleyareproperlyaligned.
5.Oncethebelttensionis set properly,tighten thenuts _) on bothsidesof tbeflywheel.
Flywheel
B
ToolsRequired:
, Phillips Screwdriver
11mm ]3mm. ISmm. 17ram.19mmSocketand CombinationWrenches
e 5ramA!len Wrench
o CrankPuller
Procedure:
L Removecrankdisk andside covers.,'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 onthedrivebelt.
3. Loosenbothnuts (A),whichholdthe flywheelto frame.
!i:ii{:!ii_
37 02
4. Tightenorloosenthenuts (B)holding thetensioningbolts flTtopositionon bothsidesof theflywheel
to adjust thetensionof thedrivebelt.
Makesurethat bothbolts aretightenedequallysothat fi}w@ee!sits straight in frame and
both the fi_/wheel and CrankpulleyareproperlyalL,ned.
5. Oncethebelt tensionis setproperly,tighten the nuts (.4)onbothsides of theflywheel
R09
12
R20
R08
Rt2
ToolsRequire_
o Phillips Screwdriver
o 8mm, 13ram,17ramSocketanfi CombinationWrenches
o 5ramAdenWrench
o CrankPuller
Procedu;e:
I, 1,2Eonly-Mjust tension knob to highest setting,
2, Turn on unit anfi Press start,
3, Set rns/stance highest level anfi power off unit,
4, Removes/fie covers, (Reference side coverreplacement 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
o 12ram,13ram,14ram,17ramSocketanti CombinationWrenches
e 5ramAllen Wrench
o CrankPuffer
Procedure:
]. Turnonunit andPressstart.
Z Set resistance 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
!iiiii:!ii_
5./t maybenecessarytoalsoadjust the top ha/f of the magneticbrake.Todothis, loosenthe two
5ramboltsthat attach themagneticbraketo theframe.Adjust tbe positionof themagnetic"brakecloseror
furtherfromthe h_v_;_,,eeL
Flywheel
....¸¸¸¸¸¸6
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 _ R EP
Using Engineering Mode
oPowerontheelliptical
_,Pressandholdtheresistance,,A,,andspeed"v"for 3- 5secondsto entertheErdineeHngModeMenu.
Pressand boldresistance #2 and resistance#20 for tile 2.2E
/
i!!i!
o Theconsolewill beep2-3 timesandHARDWARETESTwill be displayed.
oPress'_Enter"to movethroughthe differentmenusin engineeringmode.
oPress"Start" toenter desiredmenu.
o.Pressandhold "Start/Stop" toexit a//specific engineeringmenu.
oPressandhold "Start!Stop" again tocompletelyexitengineeringmodeandreturntostandard operating
mode,
Hardware Test
o indicates _;_,,etherconsole is set for Miles or tfM,
o/ndioates w;_ether console is set for an e/liptioal or astationary bike
o Displays RPM'sand heart rate similar to standard operating mode.
e Displays resistance as the number of turns the resistance motor has made,
LCDTest
o Displaysaft LCD'sat onceorindividually bypressingmd/v/dualbuttons.
Indicates software version,
Information
o Displaysthenumberof hoursand milethe machinehas logged.
Z2E doesnot dave tflis menu.
If tile consoleis ever cflangedtflis reformation willreset 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:
o Gripping the heart rate handlebars too tight. Tryto maintain moderate orcssurc while holding onto the
heart rate handlebars.
o Constant movement and vibration due to constantly holding the heart rate grips while exercising.
o Whenyou arc brcathing heavily during a workout.
o Whenyour hands arc constricted by wearing a ring.
o Whenyour hands arc dry or cold. Trymoistening your palms or rubbing them together to warm.
o Anyone with heavy arrhythmia.
o Anyone with arteriosclerosis orperipheral circulation disorder
o Anyone 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'.
IJii
I i'i'i"I
i i....
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
_'_'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, orpositioned irnpreper/_Kyou may receive an erratic or inconsistent
heart rate readout, W4RNING!Theheart rate function is not amedical device, Variousfactors may affect the
accuracy ofyour heart rate reading, Theheart rate reading is intended only as an exercise aid,
!iiiii:!ii_
0 P2 Ground-From Motor
0 P3 Zero Switch Sensor
--_0 P1 Ground-From RPM 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: Power To Console [VCC)
CORRECTVOLTAGE FOR WIRE 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,withfunctionbg consoleand resistancemotor,
Note2: All groundssamepoint oncepluggedinto consolewith or withoutpoweron.
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,
!iiiii:!ii_
Withthe powersupplypluggefiin to the waft,place thepositive leafl ofyourmulti-meter into thepowersupply
jack and thenegativeleafl ontheoutsideof thepowersupplyjack, Thevoltageofthe powersupp/yshouiflbe
as follows:
Unloaded vo!fagesmaybe higher
I) ForModelsEX-22- EX-44/OSE3.5 &4.5/EGS/2.2EOnly- Removeplastic housingtoaccessIC boardpins,
Conso/eCab/e
ServoMotor
2) Placethepositiveleadofyour multi-meter on the top solderedpin onthe backsideof theIC board,
3) Placenegativeleadonthesecondsolderedpin onthebacksideof tbe/Cboard,
\
CORRECTVOLTAGEFOR WIRE 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
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
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 withfunctioning conso/eandresistancemotor,
Note2:All groundssamepoint oncep/uggedintoconsolewith or withoutpoweron,
Note3: If measuredWhite(÷) to Green(_)l#len resistanceincreasing= -7,7vdc if decreasing= ÷7,7 vdc,
!1:ii::!ii_
_e newstyleservomotor vo/ta_emeasurementsare: (Ex22-Ex44/CSE3,5& 4,5/EG5)
Orange=3,0 vdcif resistanceat/owest,O,2vdcif resistanceat anypositionotherthan/owest,
i iiiiiiii!i
Brown÷3,0 vdcif optic sensoropen,0,2 vdcas wheelpassesthroughoptic sensor,
gionalservemotor.(Z2E, 3.2E.4.2E)
/
/
(
\
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 onthe
outside of the sensor wire jack,
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 onpage 16) _
Turncrank to produced an rpm in order to get continuity through the sensor wire.
Nodisplay on console. _aiiedbatteries. (l.2E only)
Replacebatteries.
Improperwiring.
rai/efiorimproperpowersupply
railedconsole,cable.
- Verifythe connectionsbetween
the powersupply and the power
ack.
- Verifythe connectionsbetween
consolecable and console.
- Verifypowersupply is not
_inchedor damaged.
- PeAbrm voltagecheck on
powersuppl}<(Reference
Power Supply VoltageCheck in
Voltage Checkssection.)
- Verifythe powersupply and
makesure theadapter is the
correct vottage.(Reference
Power Supply VoltageCheck in
Voltage Checkssection.)
- l/erifyconsolecableis not
Anchedordamaged.
- Performvoltagecheckoncon-
solecable.(ReferenceConsole
cableVoltageCheckin Voltage
Checkssection.)
Connectwirescorrectly or
replace parts asneeded.
Replacepower supply
,Replaceconsole cable. (Refer-
once Console Cable Replace-
meat in Parts Replacement
section.)
railedconsole.
Partial LCDDisplay on Replacebatteries.
Console.
railedbatteries.(t.2Eonly)
_ensm'ewassubjectedtocm'd
!emperatums.
l/erifyproper connectionsbe-
tweensensor wire andconsole
byremoving consoleand snap-
ping consolewireand sensor
wiresfirmly together ( l.2E only)
_ailedconsole.
Replaceconsm'e.
Allow machineto warmto room
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.
ConsoleResetsIntermittently.Poorconnectionbetweenconsole
andsensorwire.(L2Eonly)
Verifyproperconnections be-
tweensensor wire andconsole
byremoving consoleand snap-
9ing consolewireand sensor
wiresfirmly together (1.2E)
OnlytimeWorksonConsote
(Nowoddoad,distance,etc.)
Weakbatteriesin console.(L2E
only)
Poorcmmectionbetweenpower
supp/yand pcwetjack.
Failedpowersupp/_
Failed consotecame.
Failed console.
Poorconnectionbetweenconsote
and sensor wire. (1.2Eonly)
Verifythat thepowersupp/} is
securelyinserted fittothe power
Jack.
-Perform voltagecheckon
9owersupply (Reference
Power Supply Voltage Check fit
Voltage Checks section.)
,- Verifyconsole,cableisnot
9inchedordamaged.
-Performw_ltagecheckoncon-
Jsm'ecable.(ReferenceConsole
¢aflleVoltageCheckfit Voltage
Checkssection.)
iVerifyproperconnections be-
!weensensor wire andconsm'e
byremovfitg consoleand snap-
9ing consolewireand sensor
w/?esfirmly together (I.2E only,
Replacebatteries.
Replacepowersupply.
Replaceconso/'ecable.(Refer-
onceConsoleCableReplace-
mentin PartsReplacement
section.)
Replaceconsole.
Failedsensor wire.
Missing tom magnet oncrank
assemblyor misatigned RPM
Seflso,_
Failed console.
PerformRPMcontinuitycheck.
(ReferenceRPMSensorConti-
nuityCheckin VoltageChecks
section.)
j_ieuallyvefifypresence or
_agnet andatignment of RPM
_efiSOL
Replacesensorwire.(Refer-
onceRPMSensorReplacement
inPartsReplacementsection.)
Replacemagnet and/ormposi-
tion RPMsenso,:(Reference
RPMSensor Replacement
fit Parts Replacement section.)
Replaceconsole.
Erraticornoheart rate.
(Handgrips onorseparate
frem console)
7serError
:ailedheartrategrips.
'ReferenceProperHeartRate
Usagesection.)
'ReferencePreperHeartRate
Usagesection.)
tf thereisabsolutelynoheart
response,replaceheartrate
grips.
Heartrate erratic or noheart
rate function. (Telemetric
chest strap)
-ailed console.
[Jsef eYFor
[tectremagnetic interference.
_ai/efitelemetriccheststrapor
_e/arreceiver
'ReferenceProperHeartRate
Usagesection.)
'ReferenceProperHeartRate
Usagesection.)
CheckRnmediatearea for
causesof intertemnce (Fle-
rescent lighting, ebctHc dog
fences,large electric"motors,
etc.)
'ReferenceProperHeartRate
Usagesection.)
ffpreper heart rate insflucfiens
areMlewed and heart rate
continues tobe erratin, replace
console.
Replacecheststrapand/orpo-
larreceiver(ReferencePreper
HeartRateUsagesectien.)
No resistancechange or
erratic orcontinuousresis-
tancechange.
Tensioncable,is not connected Removetensionknob from the
to tensionknob. (L2E Oflly) consolemast. Verifythat the
coppercable from the tension
knobis seatedproperlyin the
keyhole/ecated on the tension
knob.
Reattach cable.(Reference
TensionCable Replacement in
Parts Replacement section.)
Tensioncameis not connected
to thebrake or has failed.
Failed or improperpowersuppl_
Failedconsm'ecable.
Failedservomotor
Verifythat the tensioncable is
connectedto the break or has
not failed.
-Perform volta@ checkon
ipowersuppl_ (Reference
Power Supply VoltageCheck it,
Voltage Checkssection.)
- Verifythe powersupply and
makesure theadapter is the
correct voltage. (Reference
Power Supply VoltageCheck i_
]Voltage Checks section.)
- Verifyconsolecable is not
pinched or damaged
-Perferm volta@checkon con-
sole cable. (Reference Console
cable Voltage Check ifl VeRag_
iChecks section.)
-Perforrnvolta@checkonser-
vometm:(ReferenceServomo-
tor VoltageCheckin Voltage
Checkssection.)
Reattachcable.(Reference
TensionCableReplacementfor
t.2EandServomotorReplace-
mentin PartsReplacement
sectionfor allet,#ermodels.)
Replacepower supp/_
Replaceconsole cable. (Refer-
ence Console Cable Replace-
ment in Parts Replacement
section.)
Replaceservomoto,_(Reference
ServomotorReplacementin
PartsReplacementsection.)
Failed consm'e.
Replaceconsole.
7es/stanceis TooHard or Too Tenskmeabteis not connected
Weak to tensionknob. (L2E Only)
Removetensionknob from the
consob mast. Verifythat the
coppercabb from the tension
knobis seatedproperlyin the
keyholelocated on thetension
knob.
Reattaehcable.(Reference
TensionCableReplacementin
PartsReplacementsection.)
Tensioncable is not connected
to the brake or has failed.
Magneticbrakeispositioned
improperly
l/erifythatthetensmncameis
connectedtothebreakorhas
notfailed.
l/erifythecorrectpositionof
magnetiebrake.(Reference
Adjustingthe MagneticBrake
in Maintenancesection.)
Reattachcane.(Reference
TensionCableReplacement
for #.2Eor ServomotorRe-
_facementin PartsReplace-
mentsectionfor allother
models.)
Repositionthemagnetiebrake.
(ReferenceMjusting theMag-
neticBrakein Maintenance
section.)
Noiseinternally while
pedaling at higher,_sis-
tancelevels only.
Magneticbrakeisrubbing
against theflywheel.
Verifythe correctposition of
magnetic brake.(Reference
_djustiflg the Magnetic
Brake in Maintenance sec-
_eposifionthe magnetic
brake.(Reference Adjust-
ragthe Magnetic Brake in
f#aintenaflcesection.)
tion.)
Noiseinternally/externally Machinemay notbe onlevel Verifysurface is level 4djust levelerson machine.
whilepedafing or rough surface.
feel whMepedaling.
Improperassemblyor loose Verifyassemblysteps using Tightenaft bolts used for
assemblybolts, owner'sguide, assembly.
__s w_ pe a
arms due to improperassem-
bly or improper welds.
Accessbuild uponor defec-
tive tonerw;heels.
Loose crank ah'flS.
fmpmpera/?gnmentof the
drive belt orimpropertension
of the drivebelt.
ReferenceAlignment Issues
with PedalArms Trouble-
ishoofing.
i-_;pe off tonerwheelsand
iguide rails wit,_dampcloth.
- Checkmiter wheelsfor
anyabnormal wear.Rofler
wheelsshouldhave smooth
texture.
- ff therough feel seems
ire be ononesideom_ try
iswitchiMsuspectroller
wheel to oppositepedalarm.
f_ep/acerollerwheels.
Tightencrankarms. (Ref-
erencePedal Axel Set
Replacementin Parts
f_eplacemefltsection.)
4h_ndrivebelt andadjust to
oropertension.(Reference
Tensioningthe Drive Belt in
f_aintenaflcesection.)
Defectiveflywheelor pedal
axleset.
_Teplaceflywheeland/or
_edalaxleset. (Reference
Flywheelor Pedal Axel
SetReplacement in Parts
Replacementsection.)
Noise externally while
pedafing, rough feel
while pedaling, or
_eda/arm will jump off
of guide rail,
improper assembly or
loose assembly bolts,
Loosecrank arms,
Verifyassemblysteps us-
ing owner'sguide,
Tightenall boltsusedfor
assembly.
lighten crankarms,
(ReferencePedalhe/
SetReplacementin Parts
Replacementsection.)
Alignment issues with
_eda/arms due to im-
proper welds,
Dhconnectappropri-
atelink arm from lower
handlebarassemblyand
oedalunit,
-Ifthe noise ceases or
pedal does not jump off
guide rail replace lower
link arm
- if there is no change
replace lower handle bar,
pedal arm, and crank,
ToolsRequired':
o Phifiips Screwdriver
o ]3ram, ]Tram Socket and Combination Wrenches
o 4ram, 5ram Allen Wrenches
Procedure:
J) ForMoflelsEX-44/CSE4.5 Only- Removelowerlink arm elbowcovers,(FigureJS)
INSIBE
ELBOWCOVER LOWEROANDLEBAR
_\ I OUTSIIE
/ ELBOWCOVER
SCREW(L)
2) Removebolt CA)and nut (B) holding link arm to lower handlebar, (Figure Below)
BBLT (A)
\
LOWERLINKARM TEFLONWASIEBS(F)
TCPSIDECOVERS
IEX-22)
J
ACEESSflff¥TEAY
T@ SIDE E_VERS
............. SIDEE_VER
3)Removeaccessorytraysand top sidecovers.(FigureAbove)
_flRemoveACAdaptorreceptaclefrom sidecoverif appiicabie. (FiguresBeiow)
5) Removesidecovers,
_ iiiI iii
iiii
%
ToolsRequired:
o Philfips Screwdriver
o RightAngleScrewdriver
o 13mm,17nrlmSocketand CombinationWrenches
o 4ram,5mmARenWrenches
Procedure:
I) Removesidecovers(ReferenceSideCoverReplaoemefltfor fflis seotiofl.)
2) Removethesensorwirebracket,
j Sensor
/
/
Z
Bracket
3) Removetheoldsensorwire from thesensorwirebracket,
4) Disconnect sensor mire from console cab/e,
SensorWire
5)Attach thenewsensorw/retothesensorwirebracket
6) Attach bracket to the frame and position correctly,
Frame/
RPM
\
\
ii:ii::i_i
/
/
/
7) Turncrank by hand to make sure that there is a RPMreading on the consoie,
ToolsRequired:
o Phifiips Screwdriver
o 13ram, 17ram Socket and Combination Wrenches
o 4ram, 5ram Allen Wrenches
Procedure:
I) Unplug power supply from elliptical,
2) Removeside covers (Reference Side Cover Replacement in Parts Replacement
3) Disconnect console cable from the speed sensor and servomotor,
_" ServoMotor
ConsoleCaMe
@ \\
Consolecable
ConnectionFor
RPMSensor
SensorWire
\
\
\
\
ConnectionFor
ServoMotor
d! Remove theconsole 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 masL
Youmay need to unscrew the water bottle bracket screws in order to fish the console
,'3ableeasilj.
CONSOLE
EX-22
6) Reconnect console cable k speed sensor and servomotor,
ToolsRequired:
o Phifi/ps Screwdiriver
o 13ram, 17ram Socket and Combination Wrenches
o 4ram, 5ram Allen Wrenches
Procedure:
I) Turnpoweronand pressstart onconsole,
2) Setresistanceleveltohighestpositionand turn off console,
3) Unplugpowersupplyfromefi/pticaL
4) Removesidlecovers(ReferenceSideCoverReplacementfor this sectionJ
5)Disconnectconsolecablefromservomotor,
Fi_ pe 32 S_rwM_,or
@
\
\
\
\
\
\
\
6) Removethe tension cable from the servomotor,
7)RemoveServomotor,
ToolsRequired-
oPhillips Screwdriver
]3ram ]4mm. 17mmSocketand CombinationWrenches
e 4ram 5ramAllen Wrenches
e Snap-nngPliers
RubberManet
_,ThreadLoc_
Procedure:
]) Removesidecovers.(ReferenceSideCoverReplacementfor this section)
2 Removetheleft and right crankarm bolts,
Thecrankarmsarepressedin dace. soit maybenecessaryto hit theendsof the
crankarms with a rubbermanet.
3) Remove the c-dip on the right-hand side of tbe pedal axle set
4) Taptbe pedal axle set from tbe frame, pounding on tbe right-hand side towards tbe left.
!1:iii:!ii_
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 pedal axle set and bearings.
MaM sure thereis t,_reaf!!ock appliefi tobot,_theinfier andouter diameters_f tM beatings
beforeinstafling, lt isrecommenfiedto aflowthe thread lockto adherefor 24 hoursbefore
using ttle machine.
ToolsRequired:
Phillips Screwdriver
o Iimm, _3mm, _7mm, 19ram Socket and Combination Wrenches
4ram, 5ram Allen Wrenches
Procedure:
I) Turnpoweronand pressstart onconsole,
2) Setresistanceleveltohighestpositionand turn oHconsole,
3) UnplugpowersupplyfromefiipficaL
4) Removesidecovers,(ReferenceSideCoverReplacementfor this section.)
5)Removetensioncablefromf/ywf_ee/assemb_<
g
Flywheel
TensionBolt
6) Remove both nuts _). which hold the flywheel to frame,
7) Remove the nuts (B) holding the tensioning bolts into _oslhon on both sides of the flywheel anti
remove the belt-tensioning bolts,
8 Remove drive belt from crank pufiey,
9) Place new flywheel into position and attach drive belt onto crank pulley,
I0) Slide belt-tensioning bolts onto the fly_;_leelaxle,
11) Looselythread bolts (A) onto the flywheel axle,
B
TensionBolt
12) tighten the nuts (B) to adjust the tension of the drive belt.
I3) Check the tension of the drive belt
!i:ii::!ii_
14) Oncethe belt tension is set properly, tighten the nuts (A) on both sides of the flywheel
Makesurethat bothbolts are tightened equallyso that flywheelsitsstraight inframe and
both fi_,wheeland crankpulley areproperly aligned.
Thecorrectbelt tension toleranceis i20-I40 Ibs, If a belt tensiongauge is notavariable,
the drive belt should haveabout &25" deflection whenpressingdownfirmly onthe drive
belt.
ToolsRequired:
o Philfips Screwdriver
o 14ram,15mm, 17ramSocketandCombinationWrenches
o 4ram,5mmAllen Wrenches
o CrankPuffer
I)1.2E Only- Removehandlebarcovers.
2) 1.2EOnly- Removeset screwsholdinglowerhandlebar.
3) L2E Only- Removebolt [A)holdingrinkarmto pedalarm bracket.
dJ2,2E Only - Removebolt (A) and nut (B) holding rink arm to lower handlebar.
BANBLEBAR
NUT(B)
BBLT(A)
5) Remove pedal arm cover.
!!)'!;i!':_!LI
6) Remove nut (C)holding pedal arm to crank arm and remove pedal arm.
7) Remove the crank cap from the center of the crank disk.
axle,
8)Removethe crank arm nut.
9) Threadthe crank aufler onto the crank axle and remove the crank arm and crank disk from the crank
CrankPu//er
10)Lift consolemastboot,
CONSOLEMASTBOOT
ACCENTPLATE
ll) Removethe accentpiecebygentlylifting upat the bottomof the accentpieceandlifting towards
thefrontof themachine,
12)Removeside covers,
Nut
ACAda_er
Recepficle
<i
!i<:7i
!!:"!_:!':_!LI
%171;I{¸
13) Removecrank arm from crank disk.
ACAdapterReceptac/e
SideCover
ToolsRequired':
o Phillips Screwdriver
o 74ram,75mm, 17ramSocketandCombinationWrenches
o 4ram,5mmAllen Wrenches
o CrankPuller
7)Removeinsideand outsideelbowcovers,
2) Removebolt LA)and nut (B)holdinglink armto lowerhandlebar,
3) Removepedal arm cover,
7L_ZI_I.¸¸¸¸%¸
4) Removenut (C)holding pedal arm to crank arm and remove pedal arm,
5)Removethe crankcap fromthecenterof the crankdisk,
--_____/
\
CrankPn/ler
_' X2
!iiiii:!ii_
6) Remove the crank arm nut,
7) T,_readthe crank puller onto the crank axle and remove the crank arm and crank disk from the crank
axle,
©
8)Removeto_cadortopsidecovers,
9)Removesidecovers,
10) Remove bolts (_) and remove crank arm from crank disk
l
!
ToolsRequired,
* PbifiipsScrewdriver
RightAngleScrewdriver
14ram.15mm,17ramS_cketandCombinationWrenches
e4ram 5ramAden Wrenches
,, CrankPuller
Procedure;
1tRemovecrank diskand sidecovers.(RefereflceCrank Disk/SideCovet/CrankArm Replacemeflf
-1.2E& 2 2Eor &2£ & 4.2E.)
2) Remove sensor wtre bracket,
©
3)Removetheold sensorwirefrom the sensorwire bracket.
4) For Models 2.2E - 4.2E Only - Disconnect sensor wire from console cable.
Sensor Wire
5) 1.2EOnty - Disconnect console from console mast.
6) 1.2EOnly - Unplug sensor from console.
7) 1.2EOnty - Attach the new sensor wire to the old sensor wire, in order to fish the sensor through the
console mast.
PIE-IHIIIEI
ICREW£I
F y " I'+
, 9 5,J
_J
8 Attach the new sensor wire t_ the sensor wire bracket,
g) Attach bracket tc the frame and oos/t!on correctly,
\
_me J_
RPM
!1:iii:!ii_
Magnet
RPMSensor
]0) Turncrank byhand' to make sure that there is a RPMreading on the console,
W _YI S, , 6+¢
1.2£> /
I
ToolsRequired':
o Phillips Screwdriver
o 1#mm,17ramSocketandCombinationWrenches
o 5ramAdenWrench
o CrankPuffer
Procedure:
I) Unplugpowersupplyfromelliptical,
2) Removecrankdisk and sidecovers,(ReferenceCrank Disk/SideCover/CrankArmRe#lacemenf
-f.2E& 2.2Eor 3.2E& 4.2E.)
3) Disconnect console cable from the speed sensor and servomotor,
New Cot sole Cable
\
\
\
\
\
\
\
\
\
#) Removethe console from the console mast,
5)Unplu£theconsolecable from the consoleandattach thenewconsolecableto the oldconsole
cable,in orderto fish thecablethroughtheconsolemast,
/
\
\
\
\
\
\
\,
Old Console Oab]e
/Q L
1;_I_I=I I =
]
Youmayneedtounscrewthewater bott!ebracketScrewsin ordertofish theconsole
ToolsRequired:
oPhillips Screwdriver
]4mm 15ram.17ramSocketand CombinationWrenches
e 5ramAllen Wrench
CrankPuller
Procedure:
1) Turn 9oweron and _ress start on console,
2 Setresistancelevelto highestpositionand turnoff console,
3 Unplugpowersupplyfrom elhDtlcaL
dJRemovecrankdiskandsidecovers,(ReferenceCrankBisk/$ide Cover/CrankArm Replacement
-1.2E& Z2E or 3.2E& 4.2E.)
5) Disconnect console cable from servomotor,
!iIii:!I_
6)Removethebrakecabiefromtheservomotor,
7JRemoveServomotoL
ToolsRequired-
oPhifiips Screwdriver
13ram Mmm, 17rnmSocket and CombinationWrenches
e 5mmAllen Wrench
NeedleNosePliers
o CrankPuller
Procedure:
], Turnthe tension knobto thehighestresistancelevel,
2, Removethe bolt that attaches thetensionknobto theconsolemast,
3, Removethe tensionknobfrom the tensioncable bypulling uponthetensionknob,
!iiiii:!ii_
PRE°UNSTALLEH .........HEHUHTANCE
BOLT&WASHER KNOB
i
TENSIONWIRE
TOPKEYHBLE
BBTTOMKEYHOLE
y
TENSION
CABLE
RESISTANCE
KNOBBRACKET
4, Removecrank diskand sidecovers,;ReferenceCrankDisk/SideCover/CrankArmReplacement
-f.2E& ZZE.)
_,Disconnectthe tensioncablefrom theflywheel/brakeassembly,
6, Disconnect the nut tbat attaches the tension cab/e to the main frame,
7, Fish the new tension cable through tbe console mast,
8,Makesurethat thetensionknobis sfi// set tothehighestresistanceleve/and attach thetension
knobto thetensioncableand secureto the consolemast with screw,
9, Connect tension cab/e to the flywheel/brake assemb/y and adjust so that magnetic brake is posi-
tion properl;_ (Reference Adjusting tile Magnetic Brake in Maintenance in section.)
]0. Adjust the tension knob from the lowest to highest resistance settings to ensure proper movement
and position of the flywhee//brake assemb_4
!iii:::iiii!
Too/sRequired':
* Philfips Screwdriver
o 13ram,14ram,]Tmmm Socketand&rob/nation Wrenches
e 4ram,5ramAdenWrenches
e CrankPuffer
o SnapRingPriers
o RubberMafiet
e ThreadLock
Procedofe:
I) Removecrankdiskand sidecovers,(Refereflce CrankDisM$ide Cover/CraflkArm Replacement
-L2E& Z2E or 3.2E&4.2E.)
2)Removethec-c/ip on the/eft-hand sideof thepeda/ax/eset,
3) Tapthepedalaxlesetfrom the frame, poundingonthe/eft-hand sidetowardsthe right,
!1:iii:!ii_
!!:">:_!LI
j: g _,<:_y'
PNEAGGEMBLEBPEDALA)
C-CLIP BEANING
AXLE
BEANING
C-CL/P
BEAR/#D
4) Oncethe peda/ axfe set and the bearings are removed from the frame, make sure to remove aft dirt
or grease from the frame beating housing,
5) insertnew pedai axie set and beatings,
b _gYJF_Q_ _
PREA$$EMBLEDPEDALAXPLESET
AXLE
BEADING
_keSu_ihe__t_a_/ocka_Piie_tobOi__em_e_an_ouie;_ameie_Of_e¸
beatingsbeforefl_stalling.!t isrecommendedtoaflowthethreadlockto adherefor
24hoursbeforeusing tfie macfiine.
Tools17equirefl_
oPhifiips Screwdriver
]3mm ]4mm. 17ramSocketandCombinationWrenches
e 5ramAllen Wrench
CrankPuller
Procedure:
I) Turnpoweronandpressstart onconsole.
2 Setresistancelevelto highestpositionand turnoff console.
3)Unplugpowersupplyfrom efiipticaL
4JRemovecrankdiskandsidecovers.(ReferenceCrankDisk/Side Cover/CrankArm geplacemenf
t.2E & Z2E or £2E & 4,2E,)
5)For t.2E,3.2E_and 4_2Eonly _Removetensioncable from flywheelassembl_
!iiiii:!ii_
Y
\
:' o' ; 'If:<";'
16 17 02
R1 12
R15 lR14 16
NO9
6)Removebothnuts _), M,,ichholdtbeflyv#,,eelto frame.
7)Removethe nuts (B)holding tbe tensioningboltsintoposition onbothsides of theh'ywheelandremovethe
belt-tensioningbolts.
8)Removedrive belt from crankpulley.
9)Placenewflywheelinto positionand attach drivebelt ontocrankpufiey.
70)Slide belt-tensioningbolts ontotheflywheelaxle.
771Looselythreadbolts (A)ontotheflywheelaxle.
72) Tightenthenuts (B)to adjust thetensionof thedavebelt.
frameand both fly whee!andcrank pufleyareproperlyaligned,
iii _ _i
g;7:_
lfyouhaveanyquestionsor comments,youmaycontactoneofour
trained customertechnicians viaphone,emafl or our website.
Customer TechSupport Hotline: 1=800° 244-4192
Email: comments@horizonfitness.com
Website: www.horizonfitness.com
CustomerTechSupporthours:Monday- Friday,8 am - 5 prn CST(excluflingho/iflays)
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