Horizon Fitness EX79-02 & Endurance 5-02 Service and Troubleshooting Guide

1.1 EX79-02 Serial Number Location

The serial number for the EX79-02 model is located on a label on the elliptical frame. The label displays:

• Model Number: EP566-1US
• MODEL: EX79-02
• S/N: EP5661210C00120
• Product Identifier: 1537632
• Origin: DESIGNED IN U.S. MADE IN CHINA

1.2 Endurance 5-02 Serial Number Location

The serial number for the Endurance 5-02 model is located on a label on the elliptical frame. The label displays:

• Model Number: EP566B-2K
• MODEL: Endurance 5-02
• S/N: EP566B1210C00120
• Product Identifier: 1538903
• Origin: DESIGNED IN U.S. MADE IN CHINA

2.1 Engineering Mode

To enter Engineering Mode:

1. Press and hold the LEVEL UP and DOWN keys simultaneously for 3-5 seconds until the Engineer Menu appears on the display.
2. Use the LEVEL or INCLINE UP and DOWN keys to scroll through the list of parameters.
3. Press ENTER to select a parameter setting.
4. Use the LEVEL or INCLINE UP and DOWN keys to change the parameter, and the ENTER key to save the change.
5. Press and hold the STOP key to exit Engineering Mode and return to normal operation.

Console Display Overview:

The Horizon EX-79 console display shows various metrics and controls. Key elements include: Incline level (0-100%), Speed, Time, Distance, Calories, Heart Rate, and an Energy Saver indicator. Workout program categories are listed as Interval Workouts (speed, endurance, peak), Weight Loss Workouts (cardio, burn, toner), and Muscle Strength (peak builder, descent, custom climb, nature trail). Control buttons include: Incline UP/DOWN, Fan, Change Display, Start/Pause, Stop/Hold to Reset, Goal Center, and Level UP/DOWN.

2.2 Engineering Mode Overview

3.1 EX79-02 Electronic Diagram

A complex wiring diagram illustrating the electronic components and connections for the Horizon Fitness EX79-02 elliptical trainer. It shows the console, keypads, ECB motor, power supply, and other internal circuitry, depicting signal and power flow between these parts.

3.2 Endurance 5-02 Electronic Diagram

A complex wiring diagram illustrating the electronic components and connections for the Horizon Fitness Endurance 5-02 elliptical trainer. It shows the console, keypads, ECB motor, power supply, and other internal circuitry, depicting signal and power flow between these parts.

4.1 Troubleshooting – No RPM Displayed

Symptom: No RPM shown on the console.

Reason:

1. Bad connection between the console cable and the console, or a damaged console cable.
2. The speed sensor wire is damaged or not working.
3. The magnet is not present on the drive pulley.
4. The console is defective.

Solution:

1. Check the console cable connection at the console; ensure there are no kinks or pinches. Replace the cable if damaged.
2. Check the speed sensor wire connection at the ECB motor. Verify the gap between the speed sensor and the magnet on the pulley (Figure 2). The gap should be within 5mm; adjust if too large.
3. Install a new magnet (Figure 1).
4. Replace the console set.

Figure 1 shows a magnet attached to a pulley. Figure 2 shows a speed sensor positioned near a magnet on a pulley, illustrating the required gap for operation.

4.2 Troubleshooting – No Resistance or Incorrect Resistance

Symptom:

1. The resistance is not adjustable during an exercise.
2. The resistance is reverse or much too heavy.

Reason:

1. The speed sensor wire is defective.
2. The console cable or ECB motor is defective.
3. The steel rope of the magnet system is not routed correctly.
4. The inside magnet is defective.

Solution:

1. Check if the console shows RPM value. If not, refer to Section 4.1 (Troubleshooting – No RPM Displayed).
2. Remove front shrouds. Turn on the console and check the ECB motor. At resistance level 1, the head of the steel rope should point towards the top right side (around 45 degrees). If it points downwards or left, resistance is reversed; adjust the steel rope position.
3. Press the LEVEL UP key to adjust resistance.
1. If the ECB motor does not move, resistance won't change. The ECB motor or console cable is defective. Check the console cable connection at the ECB motor. Use a multi-meter to measure voltage through the console cable; it should be 12VDC.
2. If no voltage is present, the console cable is defective; replace it.
3. If voltage is 12VDC, the ECB motor is defective; replace it.
4. If the ECB motor moves but resistance remains too heavy, check the gap between the orange block and the bottom of the ECB track. It should be within 1-2 mm. Adjust the cable for the correct gap range.
4. If all conditions are okay and resistance is still too heavy, the magnet inside the ECB is defective. Replace the ECB.

Images show the ECB motor with a steel rope routed around a pulley for resistance adjustment. An arrow indicates the steel rope's position. Another image shows ECB motor connections with an 'OK' label. A wiring diagram details pin assignments for a connector: +12V, SDA, SF, SDB, GND.

4.3 Troubleshooting – No Power to the Console

Symptom: Console does not light up.

Reason:

1. The power adaptor is not correct or is defective.
2. The console cable has a bad connection or is defective.
3. The console is defective.

Solution:

1. The adaptor for this model is 12V - 1A. Ensure the correct power adaptor is used. Test the adaptor on a known good outlet and replace if defective.
2. Check the console cable connection at the console. Unplug the cable and use a multi-meter to check voltage; it should normally be 12VDC. If no voltage is present, the console cable is defective and should be replaced.
3. If the voltage through the console cable is 12VDC, the console is defective and should be replaced.

A wiring diagram shows connector pin assignments for power and data, including +12V, SDA, SF, SDB, and GND.

4.4 Troubleshooting – No or High Heart Rate

Symptom: No heart rate reading or the heart rate is consistently too high.

Reason:

1. The heart rate grips are not connected properly or are defective.
2. The heart rate grip wiring is damaged or not connected correctly.
3. The HR board or console is damaged.

Solution:

1. Using a multi-meter set for DC voltage, place one terminal on each HR grip plate. The HR grip should yield a voltage reading between 0.5 and 2.0VDC.
1. If the voltage is outside this range, remove the 3 screws holding the HR grip together and check the HR grip wiring connection.
2. Check the continuity of the HR grip wiring.
1. Set a multi-meter for resistance. Place one terminal on the HR grip wiring at the grip, and the other terminal on the HR grip wiring at the console. An ohm reading around 1 is expected; if higher than 1, replace the HR grip wiring.
3. If the HR grips and wiring do not resolve the issue, replace the console.

4.5 Troubleshooting – Knocking or Creaking Noises

Symptom: Knocking or creaking noises during workout.

Reason:

1. Hardware is not tight or is missing.
2. The noise is related to the incline mechanism.
3. Belt tension is not high enough, or the belts are dirty.

Solution:

1. Inspect the unit for any loose hardware, paying special attention to areas where arms connect. Tighten hardware as needed.
2. If noise occurs only during incline, ensure Teflon washers are installed at the incline motor connection point (Figure A).
1. Lubricate the gear shaft of the incline motor with grease (Vision recommends Super Lube brand Lithium Grease if available).
3. Remove covers and check belt tension. Tighten the drive belt tension by moving the spring tension clip to another hole if necessary.
4. Clean the belts. If worn or cannot be cleaned, replace the belts.

Figure A shows the incline motor connection point, indicating the location for Teflon washers and lubrication of the gear shaft.