Evolve 3 & 5 Service Manualproductload.johnsonfit.com/inc/uploaded_media/594eaf6c...5) Fill in your profile information to finish the xID account set up process. You will be asked

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Evolve 3 & 5 Service Manual

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Contents

CHAPTER 1: SERIAL NUMBER LOCATION ..................................................................................................... 5

CHAPTER 2: CONSOLE INSTRUCTIONS

2.1 Console Overview ........................................................................................................................................ 6

2.1.1 Evolve 3 Console Overview ...................................................................................................................... 6

2.1.2 Evolve 5 Console Overview ...................................................................................................................... 7

2.2 Display Window Indication ........................................................................................................................... 8

2.3 Getting Started & Selecting a Workout ....................................................................................................... 9

2.4 Program Information .................................................................................................................................. 11

CHAPTER 3: ENGINEERING MODE

3.1 Engineering Mode ...................................................................................................................................... 13

3.2 Engineering Mode Overview ..................................................................................................................... 14

CHAPTER 4: TROUBLESHOOTING

4.1 Electrical Diagram ................................................................................................................................... 16

4.2 Troubleshooting –No Power to The Console ......................................................................................... 18

4.3 ECB Controller Instructions ..................................................................................................................... 19

4.4 Troubleshooting – No RPM display ........................................................................................................ 20

4.5 Troubleshooting – No Resistance .......................................................................................................... 21

4.6 Troubleshooting –Heart Rate Function Issues ...................................................................................... 22

CHAPTER 5: PART REPLACEMENT GUIDE

5.1 Console Replacement ............................................................................................................................. 23

5.2 Console Mast Replacement .................................................................................................................... 24

5.3 Arm Set Replacement ............................................................................................................................. 25

5.4 Link Arm Replacement ............................................................................................................................ 26

5.5 Crank Set Replacement .......................................................................................................................... 27

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5.6 Side Cover Replacement ........................................................................................................................ 28

5.7 ECB Motor Replacement ........................................................................................................................ 29

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CHAPTER 1: Serial Number Location

1.1 SERIAL NUMBER LOCATION

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CHAPTER 2: Console Instructions

2.1 CONSOLE OVERVIEW

2.1.1 EVOLVE 3 Console Overview

Note: There is a thin protective sheet of clear plastic on the overlay of the console that should be removed before use.

A) LCD DISPLAY WINDOW: time, distance, speed, calories, RPM, Watts, level, and heart rate.

B) START/PAUSE KEY: press to start workout and pause workout.

C) ENTER KEY: press to confirm selection during programming setup.

D) CHANGE DISPLAY: press to change display feedback during workout.

E) RESISTANCE KEYS: press to adjust resistance level.

F) QUICK KEYS: used to reach desired resistance level quickly.

G) SPEAKERS: plays music through speakers when connected to your media player.

H) READING RACK: holds reading material.

I) WI-FI CONNECT & SYNC: press to reset and connect your wireless internet connection. See Page 8 for more info.

J) PASSPORT CONNECTS & SYNC: press to reset and connect your Passport box for Virtual Active programming.

K) VOLUME: used to adjust volume up or down.

L) AUDIO IN JACK: plug your media player into the console using the included audio adaptor cable.

M) ENERGY SAVER LIGHT: indicates if machine is in Energy Saver mode.

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2.1.2 EVOLVE 5 Console Overview

Note: There is a thin protective sheet of clear plastic on the overlay of the console that should be removed before use.

A) LCD DISPLAY WINDOW: time, distance, speed, calories, RPM, Watts, level, and heart rate.

B) START/PAUSE KEY: press to start workout and pause workout.

C) ENTER KEY: press to confirm selection during programming setup.

D) CHANGE DISPLAY: press to change display feedback during workout.

E) RESISTANCE KEYS: press to adjust resistance level.

F) QUICK KEYS: used to reach desired resistance level quickly.

G) SPEAKERS: plays music through speakers when connected to your media player.

H) READING RACK: holds reading material.

I) WI-FI CONNECT & SYNC: press to reset and connect your wireless internet connection. See Page 8 for more info.

J) PASSPORT CONNECTS & SYNC: press to reset and connect your Passport box for Virtual Active programming.

K) VOLUME: used to adjust volume up or down.

L) AUDIO IN JACK: plug your media player into the console using the included audio adaptor cable.

M) ENERGY SAVER LIGHT: indicates if machine is in Energy Saver mode.

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2.2 DISPLAY WINDOWS INDICATION

• TIME: Shown as minutes: seconds. View the time remaining or the time elapsed in your workout.

• SPEED: Shown as MPH. Indicates how fast the foot pads are moving.

• CALORIES: Total calories burned or remaining for your workout.

• DISTANCE: Shown as miles. Indicates distance traveled or distance remaining during your workout.

• RPM: Rotations Per Minute.

• WATTS: Displays current user power output.

• LEVEL: Shows the current level of resistance.

• HEART RATE: Shown as BPM (beats per minute). Use to monitor your heart rate (displayed when contact is made with

both pulse grips).

A) CARDIOCOMPASS™ HEART RATE WHEEL: Displays what activity zone you are in during your workout.

• WARM UP: 0-60% of maximum heart rate

• WEIGHT LOSS: 60-70% of maximum heart rate

• IMPROVE FITNESS: 70-80% of maximum heart rate

• IMPROVE PERFORMANCE: 80-90% of maximum heart rate

• MAXIMUM PERFORMANCE: 90-100% of maximum heart rate

B) PROGRAM PROFILE: Represents the profile of the program being used (resistance during resistance based programs

and incline during incline based programs).

C) PASSPORT: Indicates Passport box connection is present.

D) WI-FI: Indicates wireless connection is present and the strength (low, medium, high).


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SET UP XID ACCOUNT FOR VIAFIT™ CONNECTIVITY

Creating a xID account will allow you to save and share workout data using the ViaFit Wi-Fi. Up to four users can be saved

on a machine. This process is the first step in connecting your equipment. It must be done from a computer, tablet, or

mobile device.

1) Visit the web site: www.ViaFitness.com

2) Once at the web site, select the CONNECT YOUR EQUIPMENT option on the top menu bar.

3) The first step in connecting your equipment will to be creating your xID account. This will be your login to Via Fit.

4) Enter your phone number or another easy-to-remember 10-14 digit number. This will be your account number.

5) Fill in your profile information to finish the xID account set up process. You will be asked to provide an email address

not associated with any other xID account. Check your email after the set-up process for a link to validate your

account.

CONNECT WI-FI Once you have created your xID account, you will be able to move on to activating the Wi-Fi on your equipment. Reminder,

this requires you to use your computer, tablet, or mobile device that is connected to the internet.

1) Press and hold for 3-5 seconds until you see the message ACTIVATED on your screen.

2) On your computer or other device, go to your Wi-Fi settings. You should select the network with your model name.

Doing this enables you to connect your equipment to your wireless network.

3) A new window will pop up with the list of wireless networks your equipment can see. Select your home Wi-Fi network

and connect.

4) The remaining step is to reconnect your computer or other device back to your Wi-Fi network. Go to your settings again

and connect as you normally would.

Congratulations! You are now connected and ready to get started. 2.3 GETTING STARTED & SELECTING A WORKOUT 1) Check to make sure no objects are nearby that will hinder the movement of the elliptical.

2) Plug in the power cord.

3) Select your xID account, User, Guest, or Edit a User using and press ENTER.

4) When you log in for the first time as User 1-4, you will be prompted to enter your xID information.

a) Enter your xID account number using and press ENTER to select the numbers. Press ENTER after each input to move to the next digit. After the final input, press ENTER.

b) Enter your passcode using to select the numbers. Press ENTER after each input to move to the next digit. After the final input, press ENTER twice.

c) If you key the incorrect number at any point while entering your xID or passcode, press and hold CHANGE DISPLAY

for 3-5 seconds to clear the selection and begin again.

A) QUICK START

Simply press START to begin working out. Time will count up from 0:00. The resistance level will default to level 1.

B) SELECT A PROGRAM

http://www.viafitness.com/


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1) Select a PROGRAM using and press ENTER.

2) Set workout program information using and press ENTER after each selection.

3) Press START to begin workout.

NOTE: You can adjust the resistance level during your workout.

C) FINISHING YOUR WORKOUT

When your workout is complete, the console will display “workout complete” and beep. Your workout information will

stay displayed on the console for 30 seconds and then reset.

TO CLEAR CURRENT SELECTION

To clear the current program selection or screen, press and hold ENTER for 3 seconds.

MANUAL: Adjust your resistance level manually during workout. User sets time and starting resistance level.

CALORIES: Set goals for burning calories with six (Evolve 3) or nine (Evolve 5) workouts. Choose from 100, 200,

300, 400, 500, 600, and (Evolve 5 only) 700, 800, or 900 calorie burn workouts. User sets starting resistance level.

Calories burned are calculated using weight input of user profile.

DISTANCE: Push yourself and go further during your workout with 10 distance workouts. Choose from 1 mile, 2

miles, 5k, 5miles, 10k, 8 miles, 15k, 10 miles, 20k, and half marathon goals. User sets starting resistance level.

STEPS: Promotes healthy activity with 10 step-based workouts calculated using average stride length. Choose

from 1000, 2000, 3000, 4000, 5000, 6000, 7000, 8000, 9000, and 10,000 step workouts. User sets starting

resistance level. Press ENTER to see step count.

INTERVALS: An effective fat-burning workout that helps you improve your fitness level. Choose from speed

intervals and endurance intervals.

PERFORMANCE: Challenge yourself with targeted performance workouts intent on helping you improve

specific training elements. Choose from constant watts, interval watts, target heart rate zone* and % target heart

rate* workouts. (* Evolve 5 only.)

CUSTOM (EVOLVE 5 ONLY): Lets you create and reuse a perfect workout for you with specific resistance and

time combination. The ultimate in personal programming. Time-based goal. Your custom workout will be saved

automatically.


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2.4 PROGRAM INFORMATION

USING YOUR MEDIA PLAYER 1) Connect the included AUDIO ADAPTOR CABLE to the AUDIO IN JACK on the left of the console and the

headphone jack on your media player.

2) Use your media player buttons to adjust song settings.

3) Remove the AUDIO ADAPTOR CABLE when not in use.

ENERGY SAVER (STANDBY MODE) This machine has a special feature called Energy Saver mode. This mode is NOT automatically activated. When

Energy Saver mode is activated, the display will automatically enter standby mode (Energy Saver mode) after 15 minutes

of inactivity. This feature saves energy by disabling most power to the machine until a key is pressed on the console. This

feature can be turned on or off in the engineering menu.

To enter the engineering menu, press and hold the RESISTANCE key and RESISTANCE key for 3-5 seconds.

Use to navigate to SWITCH FUNCTION and press ENTER. Press ENTER to select Energy Saver mode, use

to select ENERGY SAVE ON or OFF. Press and hold ENTER for 3-5 seconds to exit SWITCH FUNCTION. Press and hold ENTER again for 3-5 seconds to exit the engineering menu.

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CHAPTER 3: Console Instruction

PASSPORT™ MEDIA PLAYER The Passport player, featuring Virtual Active™ technology, is a high definition experience that uses real destination

footage and matching ambient sounds from stunning destinations around the world. The ultimate in workout entertainment,

Passport lets you escape the confines of a regular workout routine while enjoying a dynamic experience.

A Passport player is available for purchase separately from your Horizon Fitness retailer. Additional courses are available

from your Horizon Fitness retailer.

For more information, go to: www.passportplayer.com

www.horizonfitness.com

SYNCING CONSOLE WITH PASSPORT

1) Use the arrow keys on the Passport remote to scroll to the setup icon and press select.

2) Follow the on-screen prompts to press on the equipment console.

3) The message displayed on screen will notify you if the sync was a success or failure.

NOTE: See PASSPORT OWNER’S MANUAL for more information.

http://www.passportplayer.com/

http://www.horizonfitness.com/

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CHAPTER 3 : Engineering Mode

3.1 ENGINEERING MODE

Press and hold incline up and speed down for 3 ~5 seconds before running a program will navigate to

engineering menu.

ENG4

ENG0

ENG1

ENG2 ENG3

+ button / up arrow button





ENG8

Press and incline up + speed down for 3~5 seconds

- button / down arrow key - button / down arrow key

- button / down arrow key



Press and hold stop for 3~5 seconds


ORAutomatically after process finished




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CHAPTER 4 : Engineering Mode

3.2 ENGINEERING MODE OVERVIEW

Eng 0“Eng0” appears in the time window“DISPLAY TEST” scrolls in matrix or is static in text box

Eng 1“Eng1” appears in the time window“HARDWARE

TEST” scrolls in matrix or is static in

text box

Eng 2“Eng2” appears in the time window

“SWITCH FUNCTION” scrolls in matrix or is static

in text box

1. Standard or Metric selection.- P1 flashes in left top window- Switch MILE or KM using Start or +/- button- The display will show “0” for miles or “1” for km on the right top window OR- The display will show “STANDARD” or “METRIC” statically in the middle of text box- Press Enter to save selection and go to language selection2. Language selection- P2 flashes in left top window- Use +/- button to select language- The display will scroll newly selected language when key is pressed.- Press Enter to save selection and go to machine selection3. Machine selection- P3 flashes in left top window- Use +/- button to select a machine type from Treadmill, Elliptical, Bike and Ascent trainer.- Scroll the full name in matrix or static in the middle of text box.- Press Enter to go to model selection4. Model selection- P4 flashes in left top window- Use +/- button to select a model from the narrowed down model list.- Scrolls the mode name in matrix or static in the text box.- Press enter to save the selection and go to energy saver selection5. Energy mode selection.- P5 flashes in left top window- Use +/- button to switch between ON/OFF- Display ON/OFF in the right top window OR- Scrolls “ENERGY SAVER ON” or “ENERGY SAVER OFF” in matrix or text box.- Press enter to save the selection and go to first boot selection.6. First Boot selection- P6 flashes in left top window- Switch “First Boot” Flag using +/- button- The display will show “0” for OFF or “1” for ON statically on the right side OR - The display will show “ON” or “OFF” statically on the right side when +/- button is pressed to change- Press enter to save current setting and back to standard or metric selection

Press Enter to Select



Eng 8“Eng8” appears in the time window.“TEST” scrolls in

matrix or is static in text box

1. Program accelerator- P1 shows in the left top window- The multiple of program time defaults to 1 and display in the time window or right top window.- Press +/- to change it from 1 to 100.- Press enter to save the settings and navigate to next mode.2. Clear user’s data- P2 shows in the left top window- Clears Accumulated time and distance, and change to the default value in ENG8, in Puser, in elog, in RCT , and so on . - The Brickyard will scroll “CLEAR” or “ NO CLEAR”.- if there is no matrix, the TIME window show “0” for “CLEAR ”or “1” for “NO CLEAR”.- If the data is not cleared, hold START for 5s to clear.- Press ENTER to set to next mode P3.3. Burn-in period check- P3 shows on left top window- Burn-in period appears in time window with unit hour- Press ENTER to set next mode “P4”, 4. Quick Standby mode access- P4 shows on left top window- The Brickyard will scroll “PRESS START BUTTON TO ENTER STANDBY MODE”- Press Start button to enter standby model instantly. - Press Enter again to skip and navigate to “P5” mode.5. RPM Simulator- P5 shows on left top window- The Brickyard will scroll “RPM”- +/- adjusts an rpm signal from 0 (off) t0 140.- Resetting power will reset to 0 (off) - Press Enter again to skip and navigate to “P1” mode.

Press Enter

to Select

Eng 3“Eng3” appears in the time window“INFORMATION” scrolls in matrix or is static in text box

1. Accumulated information- Time window will show accumulated time.- Distance window will show accumulated distance.- Press enter to review software version

2. Software version- Display the UCB software version the same way as powering up.- Press enter to review MCB version

3. MCB version- Display the MCB version on screen in an appropriate way.- Press enter to navigate back to accumulated information


1. All light up as default.2. Stop turns off all lights3. Start turns on all lights4. All numerical displays increase by 1 when resistance up is pressed.5. All numerical displays decrease by 1 when resistance down is pressed6. All alpha-numerical displays change from A to Z after each incline up key press7. All alpha-numerical display change from Z to A after each incline down key press8. Matrix display lights one row up from bottom to top if a up arrow key is pressed.9. Matrix display lights one row up from top to bottom if a down arrow key is pressed.10. All the other keys or if there is keys without an associated display defined as above, display the physical key matrix as “Cxdx” in the left top window and key code in the right top window.

1. Basic function test1.1 ECB motor- Drive ECB motor up/down using resistance +/- buttons- ECB counts shows in resistance window or left top window- Drive elevation motor up/down using incline +/- buttons.- Incline ADC value shows in incline window or right top window.- Display heart rate value when heart rate detected.1.2 Induction Brake- Change from PWM1 to PWM5 using resistance +/- buttons- PWM value shows in resistance window or left top window.- Drive elevation motor up/down using incline +/- buttons.- Incline ADC value shows in incline window or right top window.- Display heart rate value when heart rate detected.- Press enter to go to USB port test

2. USB port test- “USB PORT TESTING...” scrolls in matrix or is static in text box.- “PASS” scrolls in matrix or is static in text box if passed test. OR “FAIL” scrolls in matrix or is static in text box if failed in test.- Press enter to go to Wi-Fi testing

Note:1. USB port testing is only for the consoles which have USB interface.2. First Boot flag is only used for consoles which work for different machine and/or model types.3. A text box must be implemented when multi language is available.4. Console goes to model selection after cycling the power when First Boot flag is set to ON.5. If there is confliction between process number “Px” and other display items, the process number will only display for 1 second and then display the real items. 6. Display items alternatively when a few items needs to be displayed in the same window. Light up the indictor if the indicator exists. 7. A text box or LED/LCD matrix is needed if the console work for different machine and/or model types.

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CHAPTER 4: Troubleshooting

4.1 ELECTRIC DIAGRAME

EVOLVE 3

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EVOLVE 5

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4.2 No power to the console

Symptom: Console does not light up.

Reason: 1. Adaptor incorrect or defective.

2. Console cable defective.

3. Console defective.

Solution: 1. The adaptor for this model is 12V -1A. Make sure to use an adapter with the correct

specification, and replace the adaptor if it is defective.

2. A) First, try to re-connect the wires.

B) Test pins 1 & 2 of the connecter to verify that the voltage of the console cable is 12V-1A (Fig A). If it is

not, make sure that the DC cable and ECB cable are fully connected. Replace the cables as necessary.

C) Check the wires in the console to make sure they are all fully connected.

(Fig A)

(Console cable’s connectors with PCB) If the console cable’s output is DC 12V but the console does not light up, the console PCB is defective. Replace the console set.

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4.3 ECB Controller Instructions

1. Attach the steel cable here 2. Reposition the orange block to adjust the resistance (left side is minimum and right side is

maximum)

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4.4 No RPM display

Symptom: No RPM shown on the console.

Reason: 1. Bad connection between the console cable and the console

2. Speed sensor wire defective

3. Magnet has fallen off of pulley

4. Console defective

Solution: 1. Re-connect the console wire.

2. Check the gap between the speed sensor and magnet on pulley. It is normally within 5mm (Fig. A). If

the gap is larger, adjust the sensor.

3. Re-install a new magnet (Fig. B).

4. Replace the console set

(Fig. A)

(Fig. B)


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4.5 No resistance or incorrect resistance

Symptom：1. The resistance cannot be adjusted during exercise.

2. The resistance is reversed or too strong.

Reason：

1. Speed sensor wire is defective.

2. Console cable or ECB motor is defective.

3. ECB motor’s steel rope is positioned incorrectly.

4. Inside magnet is defective.

Solution：

1. Turn on the console, and check the ECB motor.

In resistance level 1, the head of steel rope should point to the top right side (around 45 degrees).

If the head of steel rope points to bottom left side, the resistance will be reverse. Adjust the head of

steel rope to the correct position.

2. Press key “+” to adjust the resistance.

A) If ECB motor cannot move, the resistance will not be changed. The ECB motor or console cable is

defective. Make sure the console cable is inserted in the ECB motor. Next, try to re-connect the

console cable. If the issue remains, replace the console cable. If the issue remains after replacing the

console cable, replace the ECB motor.


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4.5 No resistance or incorrect resistance (continued)

B) If the ECB motor can move, the resistance can be adjusted. If the resistance is too strong,

check they flywheel to make sure that the gap between orange block and the bottom is within 1-2 mm.

If the gap is bigger than 1-2 mm, the resistance will be stronger than normal. Adjust the cable to the correct gap

range.

3. If steps 1 & 2 do not fix the issue, the inside magnet is defective. Replace the inside magnet.


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4.6 Heart Rate Function Issues

Symptom: Heart rate function does not work or is reading incorrectly

Solution: 1. With a multi-meter set for DC voltage, place one terminal on each of the HR grip plates. The HR grip should give a

voltage reading of between 0.5 and 2.0VDC. If the voltage is not between 0.5 and 2.0VDC, remove the 3 screws holding

the HR grip together and check the connection of the HR grip wiring.

2. Check continuity of the HR grip wiring. Place one terminal of a multi-meter set for resistance on the HR grip wiring at the

HR grip, and the other terminal on the HR grip wiring at the console. The multi-meter should register an ohm reading of

around 1. If the reading is higher than 1, replace the HR grip wiring.

3. Remove the console. Remove the 6 screws holding the front of the console to the rear. Check the connection of the

HR board wiring to the UCB. If all the wiring is intact and has good contact, replace the HR board.

4. If the HR board, HR grips, and HR grip wiring do not solve the issue, replace the UCB.

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CHAPTER 5: PART REPLACEMENT GUIDE

5.1 CONSOLE REPLACEMENT

1. Remove the 4 screws of the console mast (Figure A).

2. Take off the console and disconnect the wires.

FIGURE A

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CHAPTER 5: Part Replacement Guide

5.2 CONSOLE MAST REPLACEMENT

1. Remove the two console mast covers (Figure A).

FIGURE A

2. Loosen the 4 nuts and then take off the console mast (Figure B).

FIGURE B

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5.3 ARM SET REPLACEMENT

1. Loosen the screw and take off the washers, then move to the next step (Figure A）.

2. Loosen the screw and remove the washers to take off the whole arm set (Figure B).

3. Take off the arm set (Figure C).

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5.4 LINK ARM REPLACEMENT

1. Loosen the screws and washers to remove the link arm from the arm set.

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5.5 CRANK SET REPLACEMENT

1. Loosen the screws and remove the cover (Figure A).

FIGURE A

2. You will see the crank set. Loosen the screws to take off the crank set (Figure B).

FIGURE B

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5.6 SIDE COVER REPLACEMENT

1. Loosen the 4 screws in the side covers (Figure A).

FIGURE A FIGURE B

2. Loosen the 4 screws at the bottom of the side covers (Figure B）.

3. After removing the side cover, you will see the inside structure (Figure C).

FIGURE C

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5.7 ECB MOTOR REPLACEMENT

1. Loosen the two different screws (Figure A).

2. Loosen the screws on the other side, remove the belt, and then take off the ECB (Figure B).

FIGURE A FIGURE B

Documents

Evolve 3 & 5 Service Manualproductload.johnsonfit.com/inc/uploaded_media/594eaf6c...5) Fill in your profile information to finish the xID account set up process. You will be asked