Horizon Fitness E51 Service Manual
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Horizon Fitness E51 Service Manual

Horizon Fitness E51 Service Manual

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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

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Summary of Contents for Horizon Fitness E51

  • 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: Table Of Contents

    TABLE OF CONTENTS Warranty Safety Instructions Basic Troubleshooting Tips Required Tools Preventive Maintenance Console Troubleshooting Resistance Troubleshooting Drive Train Troubleshooting Voltage Checkpoints Elliptical Part Replacement...
  • Page 3 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.
  • Page 4 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.

  • Page 5: Warranty

    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.

  • Page 6: Safety Instructions

    • 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.

  • Page 7: Basic Troubleshooting Tips

    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.

  • Page 8: Required Tools

    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.

  • Page 9: Preventive Maintenance

    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 •...

  • Page 10: Console Troubleshooting

    CONSOLE TROUBLESHOOTING CONTENTS No display on console Partial LCD display on console No RPM, speed or watts readout Console resets intermittently Erratic or no heart rate readout Switching from mph to km...

  • Page 11: No Display On Console

    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.
  • Page 12 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).

  • Page 13: Partial Lcd Display On Console

    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.

  • Page 14: No Rpm, Speed Or Watts Readout

    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.

  • Page 15: Console Resets Intermittently

    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.

  • Page 16: Erratic Or No Heart Rate Readout

    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.

  • Page 17: Switching From Mph To Km

    Switching the Console from MPH to KM 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.

  • Page 18: Resistance Troubleshooting

    RESISTANCE TROUBLESHOOTING CONTENTS No resistance change Inconsistent resistance change Resistance is too hard or too weak...
  • Page 19 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.
  • Page 20 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.
  • Page 21 is binding or is crimped slightly, it will not move smoothly. Remove any binding or crimping by repositioning the tension wire (Manual Resistance). 4. If problem persists, replace the tension cable (Manual Resistance). 5. Remove the side covers. Locate the servomotor and IC board. Below the servomotor, there should be a black sensor wire (zero switch), which also connects to the IC board.
  • Page 22 Resistance is Too Hard or Too Weak Possible causes: 1. Tension cable is not connected properly to the tension knob (Manual Resistance). 2. Tension cable is not connected properly to the brake (all models). 3. Tension cable is binding or is crimped (Manual Resistance). 4.

  • Page 23: Drive Train Troubleshooting

    DRIVETRAIN PROBLEM TROUBLESHOOTING CONTENTS Noise while pedaling Internal noise while pedaling at high resistance levels only Rough feel while pedaling Alignment issues with the pedal arms Crank arms loosen during use...

  • Page 24: Noise While Pedaling

    Noise Internally While Pedaling Possible causes: 1. Crank disks rubbing against side cover. 2. Loose crank arms. 3. Improper alignment of the drive belt. 4. Crank pulley wheel is rubbing against the side of the brake assembly. 5. The drive belt may be over-tightened. 6.
  • Page 25 4. Remove the side covers and manually spin the flywheel. Confirm that there is approximately a 3mm gap between the crank pulley 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.

  • Page 26: Internal Noise While Pedaling At High Resistance Levels Only

    Noise Internally While Pedaling at Higher Resistance Levels Only Possible causes: 1. Crank pulley wheel is rubbing against the side of the brake assembly. 2. Brake assembly is rubbing against the flywheel. Fix: 1. Remove the side covers and manually spin the flywheel. Confirm that there is approximately a 3mm gap between the crank pulley wheel and the side of the brake assembly.

  • Page 27: Rough Feel While Pedaling

    There should not be any side-to-side play in the crank arms if tightened properly. 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.
  • Page 28 4. Remove the side covers and inspect the drive belt alignment. If the drive belt is not centered on the one-way pulley, there may be excessive noise created. Reposition the drive belt by carefully walking the drive belt towards the appropriate direction with one hand, while spinning the flywheel with the other.

  • Page 29: Alignment Issues With The Pedal Arms

    Alignment Issues with Pedal Arms Possible causes: 1. Dual action handlebars welding improperly, causing pedal arms to track improperly on guide rails. 2. Crank arm 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.
  • Page 30 Important Note: Refer 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...
  • Page 31 For further instruction, please contact the Horizon Fitness Customer Service Department. 2. The issue may be caused by a crooked weld on the crank arm pin (AJ1). If the problem has not been resolved by removing the lower connecting arm.

  • Page 32: Crank Arms Loosen During Use

    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.

  • Page 33: Voltage Checkpoints

    VOLTAGE READINGS CONTENTS Console cable chart Power supply voltage check IC Board voltage check RPM sensor continuity check...
  • Page 34 Console Cable Voltage Check (Programmable Resistance) - Imput from RPM Sensor - Motor Ground - Power to Photo-Optic Reset - Power to Photo-Optic Count - Power to Magnet Motor - Power to Magnet Motor - Input from RPM Sensor - Power to Console - Ground Wire - Power to Console CORRECT VOLTAGE FOR WIRE HARNESS:...
  • Page 35 Power Supply Voltage Check (Programmable Resistance) 16.5 With the power supply plugged in 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–...
  • Page 36 IC Board Voltage Check (Programmable Resistance) To check for voltage 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.
  • Page 37 RPM Sensor Continuity Check Manual Resistance - To check for continuity on the sensor wire, turn your multimeter setting to Ohms. Place the positive lead of your multimeter on the tip of the sensor wire jack and the negative lead on the outside of the sensor wire jack.

  • Page 38: Elliptical Part Replacement

    ELLIPTICAL PART REPLACEMENT CONTENTS Replacing the sensor wire Proper sensor wire position Replacing the console cable Replacing the servomotor/IC Board Replacing the tension cable Replacing the crank assembly Replacing the flywheel/drive belt Adjusting the drive belt tension Adjusting the magnetic brake Replacing the side case Replacing the pedal arm...
  • Page 39 Replacing the Elliptical RPM Sensor (Manual Resistance) Tools: Phillips screwdriver, 13mm socket, 14mm socket, 17mm wrench, 5mm Allen wrench, crank puller 1. Remove the 13mm nut and associated bolt that attach the lower handlebar to the lower link arm. 2. Remove the 5mm bolt that attaches the left lower handlebar to the left pedal arm.
  • Page 40 19. Slide console mast boot back into place. 20. Attach the crank disk and crank arm to the crank axle. Place black cap onto the center of the crank disk. 21. Attach pedal arm onto crank arm. Replace nut attaching pedal arm to crank arm (using 17mm wrench).
  • Page 41 Replacing the Elliptical RPM Sensor (Programmable Resistance) Tools: Phillips screwdriver, 13mm socket, 14mm socket, 17mm wrench, 5mm Allen wrench, crank puller 1. Unplug power supply from elliptical. 2. Remove the 13mm nut and associated bolt that attach the lower handlebar to the lower link arm. 3.
  • Page 42 21. Attach the crank disk and crank arm to the crank axle. Place black cap onto the center of the crank disk. 22. Attach pedal arm onto crank arm. Replace nut attaching pedal arm to crank arm (using 17mm wrench). 23.
  • Page 43 Proper sensor wire alignment guide Crank pulley Magnet Sensor Sensor bracket Magnet should pass evenly over the edge of the sensor wire. The sensor wire should not cover the whole magnet!
  • Page 44 Replacing the Elliptical Console Cable (Programmable Resistance) Tools: Phillips screwdriver, 13mm socket, 14mm socket, 17mm wrench, 5mm Allen wrench, crank puller 1. Unplug power supply from elliptical. 2. Remove the 13mm nut and associated bolt that attach the lower handlebar to the lower link arm. 3.
  • Page 45 19. Attach the left side cover and secure with screws. 20. Attach the accent piece, placing the bottom tab into position first and then placing the top tab into position. 21. Slide console mast boot back into place. 22. Attach the crank disk and crank arm to the crank axle. Place black cap onto the center of the crank disk.
  • Page 46 Replacing the Elliptical Servomotor/IC Board (Programmable Resistance) Tools: Phillips screwdriver, 13mm socket, 14mm socket, 17mm wrench, 2.5mm wrench, 5mm Allen wrench, crank puller. Note: Refer to diagram on following page. 1. Unplug power supply from elliptical. 2. Remove the 13mm nut and associated bolt that attach the lower handlebar to the lower link arm.
  • Page 47 21. Attach the accent piece, placing the bottom tab into position first and then placing the top tab into position. 22. Slide console mast boot back into place. 23. Attach the crank disk and crank arm to the crank axle. Place black cap onto the center of the crank disk.
  • Page 48 Replacing the Elliptical Tension Cable (Manual Resistance) Tools: Phillips screwdriver, 10mm wrench, 13mm socket, 14mm socket, 17mm wrench, 5mm Allen wrench, crank puller, needle-nose pliers 1. Remove the screw that attaches the tension knob to the console mast, using a Phillips screwdriver. 2.
  • Page 49 17. Connect the tension knob cable to the flywheel/brake assembly. 18. Slide the tension cable through the bracket on the main frame. Secure by tightening the two 10mm nuts. 19. The proper resistance setting is set when the magnetic brake is 2-3 mm from the flywheel at the highest resistance setting.
  • Page 50 Replacing the Elliptical Crank Assembly Tools: Phillips screwdriver, 13mm socket, 14mm socket, 17mm wrench, 5mm Allen wrench, crank puller, snap ring pliers, rubber mallet, bearing Loctite. 1. Remove the 13mm nut and associated bolt that attach the lower handlebar to the lower link arm. 2.
  • Page 51 12. Locate the c-clip (R34) on the left-hand side of the crank assembly axle, and remove the c-clip with a snap ring pliers. 13. Tap the crank assembly (R01) from the frame, pounding on the left- hand side towards the right. 14.
  • Page 53 Replacing the Elliptical Flywheel/Drive Belt Tools: Phillips screwdriver, 11mm wrench, 13mm socket, 14mm socket, 17mm wrench, 5mm Allen wrench, crank puller. Note: Diagram on following page. 1. Remove the 13mm nut and associated bolt that attach the lower handlebar to the lower link arm. 2.
  • Page 54 19. Tighten the horizontal bolts with metal guards on both sides with the 11mm lock nuts. It is important to tighten both sides evenly. 20. Check belt tightness. Adjust tightness by loosening or tightening lock nut on horizontal bolt. To measure the belt tension, a timing belt tension gauge is required.
  • Page 55 Adjusting the Elliptical Drive Belt Tension Tools: Phillips screwdriver, 11mm wrench, 13mm socket, 14mm socket, 17mm wrench, 5mm Allen wrench, crank puller. Note: Refer to diagram on following page. 1. Remove the 13mm nut and associated bolt that attach the lower handlebar to the lower link arm.
  • Page 56 19. Attach the crank arms and crank disks. Secure with 14mm nut. 20. Attach the black disk cap over the 14mm nut. 21. Attach pedal arms onto crank arms. Secure with 17mm nut and washers. 22. Attach the crank arm covers to the pedal arms, secure with screws. 23.
  • Page 57 Adjusting the flywheel/brake assembly (CSE2, CSE3, 4.1E only) Tools: Phillips screwdriver, 5mm Allen wrench, 12 mm wrench, 17mm wrench, 13mm socket, 14mm socket, crank puller. 1. Turn tension adjustment to the highest tension level. 2. Remove the 13mm nut and associated bolt that attach the lower handlebar to the lower link arm.
  • Page 58 19. Attach the crank arms and crank disks. Secure with 14mm nut. 20. Attach the black disk cap. 21. Attach pedal arms onto crank arms. Secure with 17mm nut and washers. 22. Attach the crank arm covers to the pedal arms, secure with screws. 23.
  • Page 59 Adjusting the flywheel/brake assembly (E51, E52, E53, E54, E6050, 3.1E only) Tools: Phillips screwdriver, 5mm Allen wrench, 12 mm wrench, 17mm wrench, 13mm socket, 14mm socket, crank puller. 1. Turn tension adjustment to the highest tension level. 2. Remove the 13mm nut and associated bolt that attach the lower handlebar to the lower link arm.
  • Page 60 20. Attach pedal arms onto crank arms. Secure with 17mm nut and washers. 21. Attach the crank 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.
  • Page 61 Replacing the Elliptical Side Case Tools: Phillips screwdriver, 5mm Allen wrench, 13mm socket, 14mm socket, 17mm wrench, crank puller. 1. Remove the 13mm nut and associated bolt that attach the lower handlebar to the lower link arm. 2. Remove the lower handlebar link from the pedal arm by removing the 5mm Allen bolt.
  • Page 63 Replacing the Elliptical Pedal Arm Tools: Phillips screwdriver, 5mm Allen wrench, 17mm wrench. 1. Remove the handlebar connecting arm (AH1) from the lower handlebar by removing the connecting bolt (H16). 2. Remove the handlebar connecting arm (AH1) from the pedal arm by removing the three attachment bolts (H11) and bracket (H10) with a 5mm Allen wrench.
  • Page 64 Pedal Arm (Non-Pivoting) Tools: Phillips screwdriver, 5mm Allen wrench, 17mm wrench. 1. Remove the handlebar connecting arm (AH1) from the pedal arm by removing the three attachment bolts (H16). 2. Remove plastic cover (Q21) to expose the nut underneath. Remove the nut (E21) attaching pedal arm to the pivot tube using 17mm wrench.
  • Page 65 Notes...

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