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Horizon Fitness EX-22 Service Manual
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Horizon Fitness EX-22 Service Manual

Horizon Fitness EX-22 Service Manual

2006 range
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See also: User Manual
Ho r iz o n Fit ness
Models
EX-22, EX-33, EX-44,
CSE 3.5, CSE 4.5, EG5,
1.2E, 2.1E, 3.1E, 4.1E
2 0 0 6
E ll i p ti c a l S e r v i ce M a n u a l

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Summary of Contents for Horizon Fitness EX-22

  • Page 1 Ho r iz o n Fit ness Models EX-22, EX-33, EX-44, CSE 3.5, CSE 4.5, EG5, 1.2E, 2.1E, 3.1E, 4.1E 2 0 0 6 E ll i p ti c a l S e r v i ce M a n u a l...

  • Page 2: Table Of Contents

    TABL E OF C ONTENTS Warranty Safety Instructions Required Tools Preventative Maintenance Voltage Checks Elliptical Troubleshooting Part Replacement...

  • Page 3: Warranty

    AT YOUR OWN device remains in the possession of RISK and Horizon Fitness shall have no liability for any injury to the person or prop- erty arising from such repairs.

  • Page 4: Safety Instructions

    Safety Instruction Warning statements indicate a particularly dangerous activity. Please read the following warnings before us- ing, repairing or maintaining your exercise equipment: • Never drop or insert any object into any opening. • Never operate the exercise equipment if it is not working properly, if it has been damaged, or immersed in water.

  • Page 5: Required Tools

    R e qui red To oles and Equip men t The following list is a summary of the tools and equipment required by the procedures in this manual. Tools are not supplied by Horizon Fitness. • Phillips screwdrivers • Flat-head screwdrivers •...

  • Page 6: Preventative Maintenance

    Clean with soap and water cleaners only. Never use solvents on plastic parts. Cleanliness of your elliptical 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.
  • Page 7 Tension ing the Drive Be lt (EX -22, EX - 33, EX-44, C SE 3 .5, 4 .5 , E G5 ) Tools Required: • Phillips Screwdriver • 11mm, 19mm Socket and Combination Wrenches Procedure: 1. Remove top cap or top side covers. Fi gur e 1 2.
  • Page 8 Te nsion ing the Dr i ve Be lt (1 .2 -4. 2E) Tools Required: • Phillips Screwdriver • 11mm, 13mm, 15mm, 17mm, 19mm Socket and Combination Wrenches • 5mm Allen Wrench • Crank Puller Procedure: 1. Remove crank disk and side covers. (Reference Crank Disk/Side Cover/Crank Arm Replacement -1.2E &...
  • Page 9 A dj us tin g t he Mag netic Br ake ( E X - 2 2 , E X -33 , EX -44 , CS E 3 . 5, 4 . 5 , E G5 , 1 . 2 E , 3 . 2 E , 4 . 2 E ) Tools Required: •...
  • Page 10 Adj u sting the Magnetic Bra k e (2 .2 E) Tools Required: • Phillips Screwdriver • 12mm, 13mm, 14mm, 17mm Socket and Combination Wrenches • 5mm Allen Wrench • Crank Puller Procedure: 1. Turn on unit and Press start. 2.
  • Page 11 S wi tchi ng the Console f r om MPH t o KM All Models Except 1.2E The back of the console features a switch to convert the speed readout from mph to km. To convert from mph to km, simply flip the switch. Please note that the console needs to be reset before the change will be detected. To verify speed setting, upon powering up console, look for Miles or KM to flash briefly on display.
  • Page 12 Eng i ne ering Mode Using Engineering Mode • Power on the elliptical. • Press and hold the resistance “^” and resistance “v”for 3- 5 seconds to enter the Engineering Mode Menu. Press and hold resistance #2 and resistance #20 for the 2.2E •...
  • Page 13 H e art Rat e Trou bleshooting Problem: There is no heart rate reading. Solution: Remove the console and verify that the heart rate cables are attached properly, making sure that the cables are securely inserted into the console. Check your exercise environment for sources of interference such as high power lines, large motors, etc. You may experience an erratic Heart Rate readout under the following conditions: •...
  • Page 14 Hea rt Rate Tr oub lesho ot in g Fi g u r e 1 1 Fi gure 12 WIRELESS CHEST TRANSMITTER (CSE4.5, EX44, 4.2E SOLD SEPARATELY) Prior to wearing the wireless chest transmitter on your chest, moisten the two rubber electrodes with water. Center the chest strap just below the breast or pectoral muscles, directly over your sternum, with the logo facing out.

  • Page 15: Voltage Checks

    C o nso le C a bl e Voltage Check (All Mo dels Ex cept 1. 2E) Fi gure 13 Note 1: All voltages measured loaded, with functioning console and resistance motor. Note 2: All grounds same point once plugged into console with or without power on. Note 3: If measured White (+) to Green (-) when resistance increasing = -7.7vdc, if decreasing = +7.7 vdc.
  • Page 16 Power Sup ply V ol ta ge C he ck (A ll Model s Except 1.2 E ) F igure 14 14.5 With the power supply plugged in to the wall, place the positive lead of your multi-meter into the power supply jack and the negative lead on the outside of the power supply jack.
  • Page 17 S ervo mot o r Voltage Che ck ( A l l M odel s Excep t 1.2 E) 1) For Models EX-22 - EX-44/CSE 3.5 & 4.5/EG5/2.2E Only – Remove plastic housing to access IC board pins. EX-22 - EX-44/CSE 3.5 & 4.5/EG5/2.2E F ig u r e 1 5 2) Place the positive lead of your multi-meter on the top soldered pin on the backside of the IC board.
  • Page 18 Ser v omotor Vo lta ge C he ck (Al l Mo dels Exc ep t 1.2 E) Fi gu r e 1 2.2E, 3.2E, 4.2E Note 1: All voltages measured loaded, with functioning console and resistance motor. Note 2: All grounds same point once plugged into console with or without power on. Note 3: If measured White (+) to Green (-) when resistance increasing = -7.7vdc, if decreasing = +7.7 vdc.
  • Page 19 R P M S ens or Continuity Check F i g u r e 1 OHMS 1.2E 1) Turn your 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 lead on the outside of the sensor wire jack.
  • Page 20 Con so le Trou bleshooti n g P o s s ib le C a u se Te s t P r o ce d u r e R ep a i r S y mp to m No display on console. Failed batteries.
  • Page 21 C o nso le Troubl esh ooting P o s s i bl e C a u s e Te st Pr o c e d u r e Re p a i r S ym pt o m Console Resets Intermittently. Poor connection between console Verify proper connections be- and sensor wire.
  • Page 22 Hea rt Rate Tr oub lesho ot in g P o s s ib le C a u se Te s t P r o ce d u r e R ep a i r S y mp to m Erratic or no heart rate.
  • Page 23 R e sista nce Troubleshoo ting P o s s i bl e C a u s e Te st Pr o c e d u r e Re p a i r S ym pt o m No resistance change or Tension cable is not connected Remove tension knob from the Reattach cable.
  • Page 24 Resistance Troub le sho ot in g Co nt in ue d P o s s ib le C a u se Te s t P r o ce d u r e R ep a i r S y mp to m Resistance is Too Hard or Too Tension cable is not connected Remove tension knob from the...
  • Page 25 N o i se and Drive Train Tr oubl es ho ot in g P o s s i bl e C a u s e Te st Pr o c e d u r e Re p a i r S ym pt o m Noise internally while Magnetic brake is rubbing...
  • Page 26 A lign ment Issues w ith Pe da l Ar ms Tro ub l es ho oti n g P o s s ib le C a u se Te s t P r o ce d u r e R ep a i r S y mp to m Noise externally while...

  • Page 27: Part Replacement

    S id e C ov er Rep laceme nt (EX-22, EX-3 3, EX- 44, C SE 3.5 , CS E 4 . 5 , E G5 ) Tools Required: • Phillips Screwdriver • 13mm, 17mm Socket and Combination Wrenches • 4mm, 5mm Allen Wrenches Procedure: 1) For Models EX-44/CSE 4.5 Only - Remove lower link arm elbow covers.
  • Page 28 Sid e Cover Replaceme n t C on ti nu ed (E X -22, EX-33, EX- 4 4, C S E 3 . 5 , C S E 4 . 5 , E G 5 ) F i g u r e 2 1 3) Remove accessory trays and top side covers.
  • Page 29 S enso r Wi r e Repla cement (EX -22, EX - 33, EX-44, C SE 3 .5, CS E 4 . 5 , E G5 ) Tools Required: • Phillips Screwdriver • Right Angle Screwdriver • 13mm, 17mm Socket and Combination Wrenches •...
  • Page 30 Sen s or Wir e Rep lacemen t Co nt in ue d (E X -22, EX-33, EX- 4 4, C S E 3 . 5 , C S E 4 . 5 , E G 5 ) 5) Attach the new sensor wire to the sensor wire bracket 6) Attach bracket to the frame and position correctly.
  • Page 31 C o nso le C a bl e Rep lacement (EX -22, EX - 33, EX-44, C SE 3 .5, CS E 4 . 5 , E G5 ) Tools Required: • Phillips Screwdriver • 13mm, 17mm Socket and Combination Wrenches •...
  • Page 32 Con so le Ca ble Re place men t Co nt in ue d (E X -22, EX-33, EX- 4 4, C S E 3 . 5 , C S E 4 . 5 , E G 5 ) 4) 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 mast.
  • Page 33 S ervo mot o r Replace ment (EX -22, EX - 33, EX-44, C SE 3 .5, CS E 4 . 5 , E G5 ) Tools Required: • Phillips Screwdriver • 13mm, 17mm Socket and Combination Wrenches • 4mm, 5mm Allen Wrenches Procedure: 1) Turn power on and press start on console.
  • Page 34 Ped al Axle Set Re plac eme nt (E X -22, EX-33, EX- 4 4, C S E 3 . 5 , C S E 4 . 5 , E G 5 ) Tools Required: • Phillips Screwdriver • 13mm, 14mm, 17mm Socket and Combination Wrenches •...
  • Page 35 F lyw hee l/D rive Belt Rep lac eme nt (EX -22, EX - 33, EX-44, C SE 3 .5, CS E 4 . 5 , E G 5 ) Tools Required: • Phillips Screwdriver • 11mm, 13mm, 17mm, 19mm Socket and Combination Wrenches •...
  • Page 36 Fly wheel/Drive Belt Re pl ac e men t Co nt in ue d (E X- 22, EX- 33, EX- 44 , CS E 3 .5 , CS E 4 . 5 , E G5 ) Fi gure 36 Flywheel Tension Bolt Tension Bolt 6) Remove both nuts (A), which hold the flywheel to frame.
  • Page 37 Cran k Di sk/Side Cover/Cr an k Ar m R ep l ac eme n t (1 . 2E & 2 .2E) Tools Required: • Phillips Screwdriver • 14mm, 15mm, 17mm Socket and Combination Wrenches • 4mm, 5mm Allen Wrenches •...
  • Page 38 Cra nk Disk /Si de Co ve r/ Cra n k Ar m R ep la c eme nt Con tinued (1.2E & 2. 2E ) 4) 2.2E Only - Remove bolt (A) and nut (B) holding link arm to lower handlebar. F i g u r e 3 LOWER HANDLEBAR NUT (B)
  • Page 39 C rank Dis k/Sid e Cover/Cr ank Ar m R ep la ce me nt C o nti nue d (1.2E & 2.2E ) 8) Remove the crank arm nut. 9) Thread the crank puller onto the crank axle and remove the crank arm and crank disk from the crank axle.
  • Page 40 C ran k Disk/Side Cover /C ra nk A rm Re p la ce me n t ( 1.2 E & 2.2E) Co ntin ued F ig u re 4 3 F i g u r e 4 4 13) Remove crank arm from crank disk.
  • Page 41 C rank Dis k/Sid e Cover/Cr ank Ar m R ep la ce me nt ( 3 . 2E & 4. 2E) Tools Required: • Phillips Screwdriver • 14mm, 15mm, 17mm Socket and Combination Wrenches • 4mm, 5mm Allen Wrenches •...
  • Page 42 Cra nk Disk /Si de Co ve r/ Cra n k Ar m R ep la c eme nt (3. 2 E & 4.2E ) Continue d 4) Remove nut (C) holding pedal arm to crank arm and remove pedal arm. 5) Remove the crank cap from the center of the crank disk.
  • Page 43 C rank Dis k/Sid e Cover/Cr ank Ar m R ep la ce me nt ( 3 . 2E & 4. 2E) Continued 8) Remove top cap or top side covers. Figure 4  TOP SIDE COVER SIDE COVER CRANK ARM CRANK DISK CRANK ARM NUT CRANK CAP...
  • Page 44 RP M Sensor Repl aceme nt (1. 2 E, 2.2E , 3.2E, 4.2 E) Tools Required: • Phillips Screwdriver • Right Angle Screwdriver • 14mm, 15mm, 17mm Socket and Combination Wrenches • 4mm, 5mm Allen Wrenches • Crank Puller Procedure: 1) Remove crank disk and side covers.
  • Page 45 R P M S ens or Replacem ent ( 1 . 2E , 2.2 E , 3. 2E, 4.2E) Cont in u ed 5) 1.2E Only - Disconnect console from console mast. F i gur e 53 6) 1.2E Only - Unplug sensor from console. 7) 1.2E Only - Attach the new sensor wire to the old sensor wire, in order to fish the sensor through the console mast.
  • Page 46 RP M Sensor Repl aceme nt (1. 2 E, 2.2E , 3.2E, 4.2 E) C on ti nu ed 8) Attach the new sensor wire to the sensor wire bracket. 9) Attach bracket to the frame and position correctly. F ig u r e 5 5 F i g u r e 5 6 Magnet Frame...
  • Page 47 C o nso le C a bl e Rep lacement ( 2 . 2E , 3.2 E , 4. 2E) Tools Required: • Phillips Screwdriver • 14mm, 17mm Socket and Combination Wrenches • 5mm Allen Wrench • Crank Puller Procedure: 1) Unplug power supply from elliptical.
  • Page 48 Ser v omotor Repla ceme nt (2 . 2E , 3. 2E , 4 .2 E) Tools Required: • Phillips Screwdriver • 14mm, 15mm, 17mm Socket and Combination Wrenches • 5mm Allen Wrench • Crank Puller Procedure: 1) Turn power on and press start on console. 2) Set resistance level to highest position and turn off console.
  • Page 49 S ervo mot o r Replace ment (2 .2 E, 3 . 2E , 4. 2E ) C o nti nue d F i g u r e 6 1 6) Remove the brake cable from the servomotor. 7) Remove Servomotor.
  • Page 50 Te nsion Cabl e Rep lac eme nt (1. 2 E) Tools Required: • Phillips Screwdriver • 13mm, 14mm, 17mm Socket and Combination Wrenches • 5mm Allen Wrench • Needle Nose Pliers • Crank Puller Procedure: 1. Turn the tension knob to the highest resistance level. 2.
  • Page 51 Tension C able Repla cement ( 1 . 2E ) Con tinue d 4. Remove crank disk and side covers. (Reference Crank Disk/Side Cover/Crank Arm Replacement -1.2E & 2.2E.) 5. Disconnect the tension cable from the flywheel/brake assembly. F i gur e 63 6.
  • Page 52 Ped al Axle Set Re plac eme nt (1. 2 E, 2.2E , 3.2E, 4.2 E) Tools Required: • Phillips Screwdriver • 13mm, 14mm, 17mmm Socket and Combination Wrenches • 4mm, 5mm Allen Wrenches • Crank Puller • Snap Ring Pliers •...
  • Page 53 P e dal A xle Set Rep laceme nt ( 1 . 2E , 2.2 E , 3. 2E, 4.2E) Conti nu e d Figure 65 C-CLIP BEARING PREASSEMBLED PEDAL AXPLE SET AXLE BEARING 4) 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.
  • Page 54 Fl ywheel/Drive Be lt Re p la ce me nt (1 .2E, 2.2E, 3 .2E , 4.2 E) Tools Required: • Phillips Screwdriver • 13mm, 14mm, 17mm Socket and Combination Wrenches • 5mm Allen Wrench • Crank Puller Procedure: 1) Turn power on and press start on console. 2) Set resistance level to highest position and turn off console.
  • Page 55 F lyw hee l/D rive Belt Rep lac eme nt ( 1 . 2E , 2.2 E , 3. 2E, 4.2E) Conti nu e d Fi g u r e 6 Fi gure 6  TENSION BOLT TENSION BOLT TENSION BOLT TENSION BOLT FLYWHEEL FLYWHEEL...
  • Page 56 C US T OMER TEC H SU P PO R T If you have any questions or comments, you may contact one of our trained customer technicians via phone, email or our website. Customer Tech Support Hotline: 1 -  0 0 - 2 4 4 - 4 1  2 Email: comments@horizonfitness.com Website: www.horizonfitness.com Customer Tech Support hours: Monday - Friday, 8 am - 5 pm CST (excluding holidays)

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