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Horizon Fitness EX-44 Service Manual
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Horizon Fitness EX-44 Service Manual

2006
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Summary of Contents for Horizon Fitness EX-44

  • Page 2 Ws rra flty Safety Instructions Required Tools Preventative Maintenance Voltage Checks Elliptical Troubleshooting Part Replacement...
  • Page 3 EXCLUSIONS AND LiMtTATtONS FRAMEo LIFETIME Horizon Fitness warrants the frame W,@ is covered.. against defects in workmanship TheoNg/na/ owner and is not transferable. and materials for the fifefime of the, original owner. What iS covered.. o Repair or replacement eta defective rnotor, ebctron/c component, or defective...
  • Page 4 ii_ii_T_ ii_ Warning statements indicate a particularly dangerous activity, P/ease read the following warnings before us- ing, repairing or maintaining your exercise equipment: o Never drop or insert any object into any opening. o Never operate the exercise equipment if it is not working properly, if it has been damaged, or immersed in water.
  • Page 5 The following 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, o Phi/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"...
  • Page 6 WHtIT KllvDOFROUTINE M AllvTEIVAIVCE IS REQb'IRED.} Weusesealedbearingsthroughoutour ellipticals solubrication is not needed,Themost important maintenance step is to simply wipeyour perspirationoff tf,,etrainer after each use, flOWDOI CLEAlv MYELLIPTICAL.} Cleanwith soap and water cleanersonly,lveveruse solventson plastic parts, Cleanliness of your efiiptical and its operating environment will keep maintenance problems and service cads to a minimum, For this reason, Hon_=on Fitness recommends that tbe fo/lewing preventive maintenance schedule be fo/lewefl, AFTEREACHUSE (DAILY)
  • Page 7 ToolsRequired: Phillips Screwdriver o 11ram,19ramSocketand CombinationWrenches Procedure: I, Remove top cap or top side covers, 2. Checkthe tensionof the drive belt avai!able, t hedrivebe!t Should haveabout0,25'_ deflection when pressing do_;=_ firmlyonthedrivebe!t, Flywheel 3. Loosenboth nuts _), which hold the fly_,l_eel to frame. 4.

  • Page 8: Tools Required

    Tools Required: , Phillips Screwdriver 11mm ]3mm. ISmm. 17ram.19mm Socketand CombinationWrenches e 5ramA!len Wrench o CrankPuller Procedure: L Remove crank disk and side covers.,'Reference CrankDisk!SideCover/Crank ArrnReplacement -L2E & 2.2E or 3.2E & 4.2Eon PPd 2. Checkthe tensionof the drive belt. Thecorrectbelt tensiontoleranceis I20=J40 /bs.
  • Page 9 ToolsRequire_ o Phillips Screwdriver o 8mm, 13ram,17ramSocketanfi CombinationWrenches o 5ram AdenWrench o CrankPuller Procedu;e: I, 1,2E only-Mjust tension knob to highest setting, 2, Turn on unit anfi Press start, 3, Set rns/stance highest level anfi power off unit, 4, Remove s/fie covers, (Reference side cover replacement in Parts Replacement section,) 4.
  • Page 10 TootsRequired- Phillips Screwdriver o 12ram,13ram,14ram,17ramSocketanti CombinationWrenches e 5ramAllen Wrench o CrankPuffer Procedure: ]. Turnon unit and Pressstart. Z Set resistance highest level and power off unit, 3, Remove crank disk and side covers, (t_eference Crank Disk!Side Cover/Crank Arm Replacement in Parts Replacement section,) 4.
  • Page 11 All Models Except 1.2E The back 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,...
  • Page 12 Using Engineering Mode o Poweron the elliptical _,Pressand hold the resistance ,,A,,and speed"v"for 3- 5 secondsto enter the ErdineeHngModeMenu. Press and bold resistance #2 and resistance #20 for tile 2.2E o Theconsolewill beep2-3 times and HARDWARE TEST will be displayed. o Press '_Enter"to movethrough the different menusin engineeringmode.
  • Page 13 Problem: There is 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. Check your exercise environment for sources of interfercnce such as high oower fines, large motors, etc. Youmay experience an erratic"...
  • Page 14 Handlebars directly pulse Place the palm of your hands on the grip handlebars, 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,...
  • Page 15 0 P2 Ground-From Motor 0 P3 Zero Switch Sensor --_0 P1 Ground-From RPM Sensor 0 P4 Optic Count-From Motor __JO Power To Resistance Up ___0 Power To Resistance Down :-._!0 RPM Sensor _"jO Power To Console-From Power Suppl! (VDD _------'_0 P9: Ground-From Power Socket NJfO PIO: Power To Console [VCC) CORRECT VOLTAGE FOR WIRE HARNESS PI: Purple n/a ground...
  • Page 16 With the powersupplypluggefi in to the waft,place the positive leafl of your multi-meter into the powersupply jack and the negative leafl on the outside of the powersupplyjack, Thevoltageof the powersupp/yshouifl be as follows: Unloaded vo!fagesmaybe higher !iiiii:!ii_...
  • Page 17 I) ForModelsEX-22- EX-44/OSE 3.5 & 4.5/EGS/2.2E Only- Removeplastic housingto accessIC boardpins, Conso/eCab/e ServoMotor 2) Placethe positive lead ofyour multi-meter on the top solderedpin on the backsideof the IC board, 3) Placenegative lead on the secondsolderedpin on the backsideof tbe /C board,...
  • Page 18 Red 0 PI: Power to DC Motor IC Board (VCC) Black0 P2: Ground-From Motor Brown 0 P3: Optic Count-From Motor P4: Zero Switch Sensor Green 0 P5: Power To Resistance Up White 0 P6: Power To Resistance Down CORRECT VOLTAGE FOR WIRE HARNESS PI: Red +5.0 VDC P4: Orange If zero switch engaged +5.0 VDC Any other resistance 0.0 VDC Short P2: Black n/a Ground...
  • Page 19 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 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...
  • Page 20 Nodisplay on console. _aiied batteries. (l.2E only) Replacebatteries. Improper wiring. - Verifythe connections between Connectwires correctly or the power supply and the power replace parts as needed. ack. - Verifythe connections between consolecable and console. - Verifypowersupply is not _inchedor damaged. rai/efi or improper p owersupply - PeAbrm voltage check on Replacepower supply...

  • Page 21: Console Resets Intermittently

    Console Resets Intermittently. Poor connection between console Verifyproper connections be- and sensor wire. (L2E only) tweensensor wire and console byremoving consoleand snap- 9ing console wire and sensor wires firmly together (1.2E) Weak batteriesin console. (L2E Replacebatteries. only) Poor cmmection betweenpower Verifytha t the power supp/} is supp/y and pcwetjack.
  • Page 22 Erratic or no heart rate. 7ser Error 'Reference ProperHeartRate Usagesection.) (Handgrips on or separate frem console) :ailedheartrategrips. 'Reference PreperHeartRate tf thereis absolutely noheart Usagesection.) response, replaceheartrate grips. -ailed console. 'Reference ProperHeartRate ff preper heart rate insflucfiens Usagesection.) are Mlewed and heart rate continues to be erratin, replace console.
  • Page 23 Tensioncable,is not connected Removetension knob from the Reattach cable. (Reference No resistance change or erratic or continuous resis- to tension knob. (L2E Oflly) console mast. Verifytha t the TensionCable Replacement in tance change. copper cable from the tension Parts Replacement section.) knob is seated properly in the keyhole/ecated on the tension knob.
  • Page 24 Reattaeh cable.(Reference 7es/stance is Too Hard or Too Tenskmeabte is not connected Removetension knob from the Tension CableReplacement i n Weak to tension knob. (L2E Only) consob mast. Verifythat the PartsReplacement s ection.) copper cabb from the tension knob is seated properly in the keyholelocated on the tension knob.
  • Page 25 Noise internally while Verifythe correct position of _eposifion the magnetic Magnetic b rake isrubbing pedaling at higher,_sis- against the flywheel. magnetic brake. (Reference brake.(Reference Adjust- tance levels only. _djustiflg the Magnetic rag the Magnetic Brake in Brake in Maintenance sec- f#aintenaflce section.) tion.) Noise internally/externally Machine may not be on level...
  • Page 26 Verifyassemblysteps us- Tightenall bolts used for Noise externally while improper assembly or ing owner'sguide, assembly. pedafing, rough feel loose assembly bolts, while pedaling, or Loose crank arms, lighten crank arms, _eda/ arm will jump off (Reference Pedal he/ of guide rail, Set Replacementin Parts Replacement section.) -Ifthe noise ceases or...
  • Page 27 Tools Required': o Phifiips Screwdriver o ]3ram, ]Tram Socket and Combination Wrenches o 4ram, 5ram Allen Wrenches Procedure: J) ForMoflelsEX-44/CSE 4.5 Only- Removelowerlink arm elbowcovers,(FigureJS) INSIBE ELBOW COVER LOWER O ANDLEBAR OUTSIIE ELBOW COVER SCREW(L) 2) Remove bolt CA)and nut (B) holding link arm to lower handlebar, (Figure Below) BBLT (A) LOWER L INK ARM TEFLON W ASIEBS ( F)
  • Page 28 TCP SIDECOVERS IEX-22) ACEESSflff¥ TEAY T@ SIDE E_VERS ..... SIDEE_VER 3) Removeaccessory trays and top side covers.(FigureAbove) _flRemove ACAdaptorreceptaclefrom side coverif appiicabie. (FiguresBeiow) 5) Remove side covers, _ iiiI iii iiii...
  • Page 29 ToolsRequired: o Philfips Screwdriver o Right AngleScrewdriver o 13mm,17nrlmSocketand CombinationWrenches o 4ram, 5mmARenWrenches Procedure: I) Remove side covers(Reference SideCover Replaoemeflt for fflis seotiofl.) 2) Remove the sensorwirebracket, Sensor Bracket 3) Remove the old sensorwire from the sensorwire bracket, 4) Disconnect sensor mire from console cab/e, Sensor Wire...
  • Page 30 5)Attach the newsensorw/re to the sensorwire bracket 6) Attach bracket to the frame and position correctly, Frame / 7) Turn crank by hand to make sure that there is a RPM reading on the consoie, ii:ii::i_i...
  • Page 31 Tools Required: o Phifiips Screwdriver o 13ram, 17ram Socket and Combination Wrenches o 4ram, 5ram Allen Wrenches Procedure: I) Unplug power supply from elliptical, 2) Remove side covers (Reference Side Cover Replacement in Parts Replacement 3) Disconnect console cable from the speed sensor and servomotor, _"...
  • Page 32 d! Remove the console 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 You may need to unscrew the water bottle bracket screws in order to fish the console ,'3ableeasilj.
  • Page 33 ToolsRequired: o Phifi/ps Screwdiriver o 13ram, 17ram Socket and Combination Wrenches o 4ram, 5ram Allen Wrenches Procedure: I) Turnpoweronand pressstart on console, 2) Setresistancelevel to highest position and turn off console, 3) Unplugpowersupply from efi/pticaL 4) Remove sidlecovers(Reference SideCover Replacement for this sectionJ 5) Disconnectconsolecable from servomotor, Fi_ pe 32 S_rwM_,or...
  • Page 34 Tools Required- o Phillips Screwdriver ]3ram ]4mm. 17mmSocketand CombinationWrenches e 4ram 5ram Allen Wrenches e Snap-nngPliers RubberManet _,ThreadLoc_ Procedure: ]) Removesidecovers.(Reference SideCover Replacement for this section) 2 Removethe left and right crankarm bolts, Thecrank arms arepressedin dace. so it may be necessaryto hit the endsof the crank arms with a rubber manet.
  • Page 35 ToolsRequired: Phillips Screwdriver o Iimm, _3mm, _7mm, 19ram Socket and Combination Wrenches 4ram, 5ram Allen Wrenches Procedure: I) Turnpoweronand pressstart on console, 2) Setresistancelevel to highest position and turn oH console, 3) Unplugpowersupply from efiipficaL 4) Remove side covers,(Reference Side Cover Replacementfor this section.) 5) Remove tensioncable fromf/ywf_ee/ assemb_<...
  • Page 36 Flywheel Tension Bolt Tension Bolt 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) Loosely thread bolts (A) onto the flywheel axle,...
  • Page 37 ToolsRequired: o Philfips Screwdriver o 14ram,15mm, 17ramSocketand CombinationWrenches o 4ram, 5mmAllen Wrenches o CrankPuffer I)1.2E Only- Remove handle bar covers. 2) 1.2EOnly- Removeset screwsholding lower handle bar. 3) L2E Only- Removebolt [A) holding rink arm to pedal arm bracket.
  • Page 38 dJ 2,2E Only - Remove bolt (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.
  • Page 39 Remove the crank arm nut. 9) Thread the crank aufler onto the crank axle and remove the crank arm and crank disk from the crank axle, CrankPu//er 10) Lift consolemast boot, CONSOLE M ASTBOOT ACCENT P LATE ll) Removethe accentpiece bygently lifting up at the bottomof the accent piece and lifting towards the front of the machine, 12) Remove side covers,...
  • Page 40 ACAda_er Recepficle <i ACAdapter Receptac/e !i<:7i SideCover !!:"!_:!': _!LI %171;I{¸ 13) Remove crank arm from crank disk.
  • Page 41 ToolsRequired': o Phillips Screwdriver o 74ram,75mm, 17ramSocketand CombinationWrenches o 4ram, 5mmAllen Wrenches o CrankPuller 7) Remove inside and outsideelbowcovers, 2) Remove bolt LA)and nut (B) holding link arm to lower handlebar, 3) Remove pedal arm cover,...
  • Page 42 4) Remove nut (C) holding pedal arm to crank arm and remove pedal arm, 5) Removethe crankcap from the center of the crank disk, 7L_ZI_I .¸¸¸¸%¸ --_____/ CrankPn/ler © !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,...
  • Page 43 8)Remove to_cadortopsidecovers, 9)Remove sidecovers, 10) Remove bolts (_) and remove crank arm from crank disk...
  • Page 44 Tools Required, * Pbifiips Screwdriver Right AngleScrewdriver 14ram.15mm, 17ramS_cketand CombinationWrenches e 4ram 5ramAden Wrenches ,, CrankPuller Procedure; 1 t Remove crank disk and side covers.(Refereflce Crank Disk/SideCovet/Crank Arm Replacemeflf - 1.2E& 2 2Eor &2£ & 4.2E.) 2) Remove sensor wtre bracket, ©...
  • Page 45 5) 1.2E Onty - Disconnect console from console mast. PIE-IHIIIEI ICREW£I 6) 1.2E Only - Unplug sensor from console. 7) 1.2E Onty - Attach the new sensor wire to the old sensor wire, in order to fish the sensor through the console mast.
  • Page 46 8 Attach the new sensor wire t_ the sensor wire bracket, g) Attach bracket tc the frame and oos/t!on correctly, _me J_ Magnet !1:iii:!ii_ RPMSensor ]0) Turncrank by hand' to make sure that there is a RPM reading on the console,...
  • Page 47 W _YI 1.2£> 6+¢ ToolsRequired': o Phillips Screwdriver o 1#mm,17ramSocketand CombinationWrenches o 5ram AdenWrench o CrankPuffer Procedure: I) Unplugpowersupply from elliptical, 2) Remove crank disk and side covers,(Reference Crank Disk/SideCover/CrankArm Re#lacemenf - f.2E & 2.2Eor 3.2E & 4.2E.) 3) Disconnect console cable from the speed sensor and servomotor, New Cot sole Cable 1;_I_I=I Old Console...
  • Page 48 Tools Required: o Phillips Screwdriver ]4mm 15ram. 17ramSocketand CombinationWrenches e 5ramAllen Wrench CrankPuller Procedure: 1) Turn 9ower on and _ress start on console, 2 Setresistancelevel to highest position and turn off console, 3 Unplugpowersupply from elhDtlcaL dJRemovecrank disk and side covers,(ReferenceCrank Bisk/$ide Cover/CrankArm Replacement - 1.2E&...
  • Page 49 6)Remove thebrake cabie fromtheservomotor, 7JRemove ServomotoL...
  • Page 50 Tools Required- o Phifiips Screwdriver 13ram Mmm, 17rnmSocket and CombinationWrenches e 5mmAllen Wrench NeedleNosePliers o CrankPuller Procedure: ], Turnthe tension knobto the highest resistancelevel, 2, Remove the bolt that attaches the tensionknob to the consolemast, 3, Remove the tensionknob from the tensioncable bypulling up on the tensionknob, PRE°UNSTALLEH ..
  • Page 51 4, Remove crank disk and side covers,;ReferenceCrank Disk/Side Cover/CrankArm Replacement - f.2E & ZZE.) _, Disconnectthe tensioncable from the flywheel/brakeassembly, 6, Disconnect the nut tbat attaches the tension cab/e to the main frame, 7, Fish the new tension cable through tbe console mast, 8, Makesure that the tensionknobis sfi// set to the highest resistanceleve/and attach the tension knob to the tensioncable and secureto the consolemast with screw, 9, Connect tension cab/e to the flywheel/brake assemb/y and adjust so that magnetic...
  • Page 52 Too/s Required': * Philfips Screwdriver o 13ram,14ram,]Tmmm Socketand &rob/nation Wrenches e 4ram,5ram AdenWrenches e CrankPuffer o SnapRing Priers o RubberMafiet e ThreadLock Procedofe: I) Removecrank disk and side covers,(Refereflce Crank DisM$ide Cover/CraflkArm Replacement - L2E & Z2E or 3.2E& 4.2E.) !iii:::iiii! 2) Removethe c-c/ip on the/eft-hand side of the peda/ax/e set, 3) Tapthe pedalaxle set from the frame, poundingon the/eft-hand side towardsthe right,...
  • Page 53 b _gYJF_Q _ _ C-CL/P BEAR/#D PREA$$EMBLED PEDALAXPLESET AXLE BEADING 4) Once the 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) insert new pedai axie set and beatings, _keSu_ i he_ _ t_a_/ocka_Piie_ tobOi_ _e m_e_ an_ o uie;...
  • Page 54 Tools 17equirefl_ o Phifiips Screwdriver ]3mm ]4mm. 17ramSocketand CombinationWrenches e 5ramAllen Wrench CrankPuller Procedure: I) Turnpoweron and press start on console. 2 Setresistancelevel to highest position and turn off console. 3) Unplugpowersupply from efiipticaL 4JRemovecrank disk and side covers.(Reference Crank Disk/Side Cover/CrankArm geplacemenf t.2E &...
  • Page 55 :' o' ; 'If:<";' 16 17 lR14 6) Remove both nuts _), M,,ichhold tbe flyv#,,eel to frame. 7) Remove the nuts (B) holding tbe tensioning bolts into position on both sides of the h'ywheel a nd removethe belt-tensioningbolts. 8) Remove drive belt from crank pulley. 9) Placenewflywheelinto position and attach drive belt ontocrank pufiey.
  • Page 56 lf you have any questions or comments, y ou may contact one of our trained customertechnicians via phone,emafl or our website. Customer Tech Support 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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