Matrix E5X-04 Service Manual Download

Page: 2 / 85

cHaptER 1: SERial nuMbER location

........................................................... 1

cHaptER 2: iMpoRtant SafEty inStRuctionS

2.1

Read and Save These Instructions ............................................................................. 3

2.2

Electrical Requirements ............................................................................................. 4

cHaptER 3: pREVEntatiVE MaintEnancE

3.1

Recommended Cleaning Tips .................................................................................... 5

3.2

Check for Damaged Parts ......................................................................................... 5

3.3

Care and Maintenance Instructions ........................................................................... 6

cHaptER 4: conSolE oVERlay and woRkout dEScRiption

4.1

Console Description ................................................................................................... 7

4.2

Workout Setup Steps - Manual ................................................................................... 8

4.3

Workout Setup Steps - Fat Burn ................................................................................. 8

4.4

Workout Setup Steps - Training Workout.................................................................... 8

4.5

Workout Setup Steps - Cooper Fitness Test ............................................................... 9

4.6

Workout Setup Steps - Target Heart Rate .................................................................. 10

4.7

Workout Setup Steps - Constant Watts ...................................................................... 10

cHaptER 5: ManagER ModE

5.1

Manager Mode Overview ............................................................................................ 11

5.2

Manager Mode Information ......................................................................................... 12

cHaptER 6: EnginEERing ModE

6.1

Engineering Mode Overview ....................................................................................... 13

cHaptER 7: SERVicE ModE

7.1

Service Mode Overview .............................................................................................. 14

cHaptER 8: tRoublESHooting

8.1

Electrical Diagram ...................................................................................................... 15

8.2

Error Codes on the Console ....................................................................................... 19

8.3

LCB LED Indicators .................................................................................................... 20

8.4 LCB1 Wiring Connection ............................................................................................. 21

8.5

Troubleshooting - Error 04A0 ...................................................................................... 22

8.6

Troubleshooting - Error 04B0 ...................................................................................... 23

8.7

Troubleshooting - Error 0248 ...................................................................................... 24

8.8

Troubleshooting - Error 02B4 ...................................................................................... 25

8.9

Troubleshooting - Error 02AB ..................................................................................... 26

8.10

Troubleshooting - Error 01AC ..................................................................................... 27

8.11

Troubleshooting - No Resistance ................................................................................ 28

8.12

Troubleshooting - Heart Rate Issues .......................................................................... 29

8.13

Troubleshooting - No Power to the Console ............................................................... 30

8.14

Troubleshooting - Keypad Issues................................................................................ 31

cHaptER 9: paRt REplacEMEnt guidE

9.1

Front Disk Replacement ............................................................................................ 32

9.2

Front Shroud Replacement ......................................................................................... 33

9.3

Lower Control Board (LCB) Replacement .................................................................. 36

9.4

Generator Replacement .............................................................................................. 38

9.5

Generator Belt Replacement ...................................................................................... 39

9.6

Drive Belt Replacement .............................................................................................. 40

9.7

Pulley Axle Set Replacement ...................................................................................... 41

tablE of contEntS

Summary of Contents for E5X-04

Page 1: ...E 5 x 0 3 S u s p e n s i o n e l l i p t i c a l S E R V IC E M ANUA l E 5 X 0 4 S U S P E N S ION E LLIPTICAL S E R V IC E M ANUA l...

Page 2: ...gineering mode 6 1 Engineering Mode Overview 13 CHAPTER 7 SERVICE MODE 7 1 Service Mode Overview 14 CHAPTER 8 TROUBLESHOOTING 8 1 Electrical Diagram 15 8 2 Error Codes on the Console 19 8 3 LCB LED In...

Page 3: ...rtical Stabilizer Arm Replacement 56 9 19 Incline Arm Cover Replacement 57 9 20 Handlebar Service 58 9 21 Testing the Suspension Elliptical 59 CHAPTER 10 Suspension Elliptical SPECIFICATIONS AND ASSEM...

Page 4: ...1 1 1 SERIAL NUMBER LOCATION SERIAL Number LOCATION CHAPTER 1 Serial Number Location...

Page 5: ...2 console serial number location 1 1 SERIAL NUMBER LOCATION CONTINUED Chapter 1 Serial Number Location SN PLACEMENT...

Page 6: ...o not carry this unit by it s supply cord or use the cord as a handle Close supervision is necessary when the Suspension Elliptical is used by or near children or disable persons Do not use outdoors D...

Page 7: ...ension Ellipticals into should not have anything else running on that same circuit besides other Suspension Ellipticals up to 3 per 15 amp circuit and 4 per 20 amp circuit The easiest way to verify th...

Page 8: ...y 100 lint free cloth and water soap mixture wipe down the entire console area including the hand grips and hand rails MONTHLY 1 Vacuum under and around the Elliptical Trainer If you need to move it u...

Page 9: ...t Team identifies items that require specific attention the latest version will always be available on the Matrix website www matrixfitness com DAILY MAINTENANCE ITEMS 1 Attempt to wobble the unit bac...

Page 10: ...workout and shows workout summary data NUMBER KEYPAD Workout data input for workout setup Level adjustment during workout COOL DOWN Puts the Suspension Elliptical into Cool Down Mode FAN Allows for fa...

Page 11: ...display will read 3 2 1 Begin and then the program will start 4 3 workout setup steps fat burn ROLLING HILLS The Rolling Hills program is a level based program that automatically adjusts the resistan...

Page 12: ...the next level The test could take upwards of 30 minutes for very fit individuals Once the test ends a recovery period cool down will begin and the user s results are calculated and displayed Results...

Page 13: ...ng You can grab these sensors in any program to view your current heart rate 1 Start pedaling and press the HEART RATE key Then press ENTER 2 Select Age by using the UP or DOWN LEVEL keys and press SE...

Page 14: ...s in Manager Mode use the UP and DOWN LEVEL keys Each of the custom settings will show on the display 3 To select a custom setting press the ENTER key when the desired setting is shown 4 To change the...

Page 15: ...t used for program calorie expenditure calculations Accumulated Distance N A 0 99 999 Miles Total distance for all programs Accumulated Time N A 0 999 999 hours Total time for all programs displayed i...

Page 16: ...year 11 12 MM is the month e g 08 09 10 nnnnn is the actual serial number Use the UP DOWN LEVEL keys to navigate the layers and the number keys to input the serial number The product name is dependent...

Page 17: ...ally sets the Accumulated Distance and Time Service 4 CSafe RF Test Press the ENTER key to test CSAFE Press the ENTER key again to test the RF Service 5 Error Log Shows the last 10 errors Press and LE...

Page 18: ...15 8 1 Electrical DiagramS CHAPTER 8 Troubleshooting HURES5x C Electrical block diagram...

Page 19: ...16 8 1 electrical diagramS CONTINUED Pulse Sensor Wire Chapter 8 Troubleshooting...

Page 20: ...17 8 1 electrical diagramS Continued CHAPTER 8 Troubleshooting Digital Communication Wire Digital Communication Wire E5x F Electrical block diagram...

Page 21: ...18 POWER RESISTANCE WIRE ECB Wire 8 1 electrical diagramS Continued CHAPTER 8 Troubleshooting...

Page 22: ...or over 15V Check the wire connections at the battery Replace the battery 0x0441 b When the UCB implements a command the LCB is not receiving this command Check the machine type in Engineering Mode Ch...

Page 23: ...ulate Status bright Normal LED8 UCB LCB Communication Status blinking OK Hardware definition LED1 AC plug in Status bright AC LED2 DC 5V Status bright OK LED3 AC plug in Status bright AC LED4 DC 12V S...

Page 24: ...21 8 4 LCB1_ErP wiring connection CHAPTER 8 Troubleshooting...

Page 25: ...ommunication disconnected 2 SOLUTION 1 Check the connection of the console cable at the UCB and LCB Also check the console cable for damage replace as needed 2 If the console cable connections are goo...

Page 26: ...ommunication disconnected 2 SOLUTION 1 Check the connection of the console cable at the UCB and LCB Also check the console cable for damage replace as needed 2 If the console cable connections are goo...

Page 27: ...tery disconnection or fail When the power is on LCB battery voltage is less than 6 VAC 2 SOLUTION 1 Check the battery wire connection between the battery and LCB Figure A 2 Check the battery voltage F...

Page 28: ...r use on HUREA5x frame ERROR CODE 02B4 1 SYMPTOM 02B4 Resistance type error 2 SOLUTION 1 Check if the machine has the correct resistance system resistor or ECB Figures A B 2 Check if the console is ma...

Page 29: ...ine type is E5x 02 Machine type is E5x 03 ERROR CODE 02AB 1 SYMPTOM 02AB Machine type error 2 SOLUTION 1 Check if the console machine type is matched with the correct frame in Engineering Mode Remarks...

Page 30: ...AC Figure A ERROR CODE 01AC 1 SYMPTOM 01AC Resistance over current 2 SOLUTION 1 Check the resistance coming out of the resistor Figure A If the resistance value is under 8 ohms replace the power resis...

Page 31: ...TROUBLESHOOTING 1 SYMPTOM No resistance 2 SOLUTION 1 Check the power resistance wire connection between the power resistor and LCB Figure A 2 Check the resistance coming out of the resistor Figure A I...

Page 32: ...from the unit and verify continuity of the HR grip wiring With a multi meter set for ohms place one prong on the HR grip wiring coming up the console mast Figure C and the other on the appropriate pla...

Page 33: ...ess room power b If LED9 is still not lit check the incoming AC power to the LCB If the incoming power is not correct replace the power cord c Replace the LCB if all power components are OK and there...

Page 34: ...ER c Test the affected keypad If the keypad works in the keypad test it may not be a functioning key in the program used for testing it 2 Check the connections of the keypad at the UCB a Remove the co...

Page 35: ...ckwise Figures A B 2 Remove the 3 screws holding the disk to the axle Figure C 3 Remove the disk Figure D 4 Reverse Steps 1 3 to install a new disk NOTE The 3 screws removed in Step 2 should be torque...

Page 36: ...cure the handlebar so that it is out of the way Figure D 4 Remove the front disks as outlined in Section 9 1 5 Detach the pedal arm from the crank bearing assembly Figure E 6 Remove the 2 screws that...

Page 37: ...the unit Figure H 9 Remove the 2 screws to disassemble and remove the middle stabilizer sweat cover Figures I J 10 Remove the 1 screw exposed when the cup holder is removed holding the orange slot cov...

Page 38: ...other Figure M 13 Turn the crank to the slotted portion of the shroud Figure N 14 Remove the front shrouds for frame access Figures O P 15 Reverse Steps 1 14 to install new shrouds NOTE The bolt nut...

Page 39: ...disks from the machine as outlined in Section 9 1 3 Disconnect all wires from the LCB Figure A 4 Remove the 2 screws holding the LCB to the frame Figure B 5 Reverse Steps 1 4 to install a new LCB 6 Te...

Page 40: ...ront shrouds as outlined in Section 9 2 4 Cut the cable tie holding the cable to the frame Figure A 5 Unplug the power cable connector of the generator Figure B 6 Loosen the nut holding the generator...

Page 41: ...tor belt Figure F 10 Remove the generator from the frame 11 Reverse Steps 1 10 to install a new generator Re install the belts as outlined in Section 9 5 NOTE The 3 screws removed in Step 7 should be...

Page 42: ...ned in Section 9 4 5 To install a new belt first put the belt installation tool on the pulley Figure A 6 Put the new belt on the installation tool Figure B 7 Turn the pulley until the belt is installe...

Page 43: ...e pulley counter clockwise until there is enough slack in the belt to remove it Figures A B 4 Install the replacement belt and reverse necessary steps to secure the assembly until the belt is tight NO...

Page 44: ...e Figure B 5 On the left side of the frame remove the retaining ring that holds the pulley axle bearing into the frame Figure C 6 Remove the pulley axle set assembly from the frame Clean any debris fr...

Page 45: ...f the frame remove the retainer clip that holds the drive axle bearings in the frame Figure A 5 Install an M10 screw into the drive axle Figure B 6 Turn the screw until the head is close to the drive...

Page 46: ...igure I 13 Mount the other tool from Figure H behind the bearing cap portion of the tool Use the M10 x 65L screw with a washer and a nut to attach the tool to the drive axle Figure J 14 Turn the screw...

Page 47: ...asher and a nut to attach the tool to the drive axle Figure O 19 Turn the screw at least 4 full revolutions into the drive axle Then turn the nut until it is close to the cup portion of the tool Figur...

Page 48: ...Use a screwdriver to remove the iron plate from the drive axle Figures S T 23 Re install the belts as outlined in Sections 9 5 and 9 6 24 Test the Suspension Elliptical as outlined in Section 9 21 fig...

Page 49: ...w should be at least 40 long into the crank hole Then turn the screw until the crank can be separated from the axle Figure B 5 Install the replacement crank There should be a 4mm gap between the end o...

Page 50: ...screws that hold the mounting plate to the console Figure C 5 Attach the mounting plate to the new console 6 Connect the wire connections to the new console 7 Carefully push the wires into the consol...

Page 51: ...connect the cord from the machine 2 Remove the console as outlined in Section 9 10 3 Remove the back cover of the console Figure A 4 Unplug and remove the faulty overlay Figure B 5 Clean the console a...

Page 52: ...Figure G 10 Press down on the corners of the overlay to keep it in place then remove the protective film Figure H I 11 Once the overlay is in the correct position press down on the overlay with a clot...

Page 53: ...fully remove the wires from inside the console mast until the connectors on the ends come free and disconnect Figure C 5 To install a new handlebar assembly connect the new handlebar and carefully pus...

Page 54: ...bolts that hold on the pivot cap and remove the cap Figure C 4 Unplug and separate the heart rate connector exposed once the pivot cap is removed Then remove the 4 screws that hold the dual action ha...

Page 55: ...that hold the plastic pedal to the foot plate Figure B 3 Remove the plastic foot pedal Figure C 4 Clean the foot plate to remove any rubber or debris 5 Reverse Steps 1 4 to install a new foot pedal 6...

Page 56: ...her Figure D 5 The swing arm can now be separate from the pedal arm Figure E 6 Remove the bolt that holds the link arm to the pedal arm and remove the pedal arm Figure F 7 Reverse Steps 1 5 to install...

Page 57: ...ushings where the dual action handlebar meets the link arm Figure B 3 Remove the bolt that holds the link arm to the pedal arm and remove the link arm Figure C 4 Reverse Steps 1 3 to install a new lin...

Page 58: ...turn it into the shaft Figure D 5 Use a mallet to hit the head of the bolt until the swing arm can be separate from the pedal arm and remove the pedal arm Figures E F 6 Reverse Steps 1 5 to install a...

Page 59: ...r pivot joint of the vertical stabilizer arm Figure C 3 Remove the vertical stabilizer arm Figure D 4 Reverse Steps 1 3 to install a vertical stabilizer arm NOTE Tighten the bolt removed in Step 2 to...

Page 60: ...LACEMENT 1 Remove the screw that holds the plastic cover on the arm Figures A B 2 Remove the incline arm cover Figure C 3 Reverse Steps 1 2 to install a new incline arm figure C figure B figure a Chap...

Page 61: ...screwdriver from the underside of the bar 2 Once the screws are removed lift the part carefully then disconnect any wire connections to fully remove the part This includes the resistance buttons and h...

Page 62: ...anual for procedure 3 Without hitting start or entering any exercise modes stand on the machine and hold the handlebars while initiating movement to simulate exercising While moving listen for any odd...

Page 63: ...k TIME ELAPSED TIME REMAINING TOTAL PROGRAM TIME CLOCK DISTANCE KILOMETERS OR MILES CALORIES SPEED LEVEL RPM HEART RATE METS WATTS STATIC PROFILE DISPLAY User defined multi language display Yes Englis...

Page 64: ...0 8P x 10L Yellow 2 Screw M5 x 0 8 x 12L Black 2 bags 4 Spring Washer 8 2 x 15 4 x 2 0t black 2 bags 4 Socket head cap screw M8 x 1 25P x 20L 10 9 grade minimum Black 2 bags 1 socket head cap screw m8...

Page 65: ...62 10 3 SUSPENSION ELLIPTICAL ASSEMBLY STEPS step 1 CHAPTER 10 SUSPENSION ELLIPTICAL SPECIFICATIONS AND ASSEMBLY GUIDE...

Page 66: ...63 10 3 Suspension Elliptical assembly steps continued step 2 RED HARDWARE BAG CHAPTER 10 SUSPENSION ELLIPTICAL SPECIFICATIONS AND ASSEMBLY GUIDE...

Page 67: ...64 10 3 SUSPENSION ELLIPTICAL ASSEMBLY STEPS CONTINUED step 3 Pink hardware bag CHAPTER 10 SUSPENSION ELLIPTICAL SPECIFICATIONS AND ASSEMBLY GUIDE...

Page 68: ...65 10 3 Suspension Elliptical assembly steps continued Torque this bolt to 80 N m step 4 Green Yellow HARDWARE BAG CHAPTER 10 SUSPENSION ELLIPTICAL SPECIFICATIONS AND ASSEMBLY GUIDE...

Page 69: ...66 10 3 SUSPENSION ELLIPTICAL ASSEMBLY STEPS CONTINUED step 5 Red hardware bag CHAPTER 10 SUSPENSION ELLIPTICAL SPECIFICATIONS AND ASSEMBLY GUIDE...

Page 70: ...67 10 3 Suspension Elliptical assembly steps continued step 6 CHAPTER 10 SUSPENSION ELLIPTICAL SPECIFICATIONS AND ASSEMBLY GUIDE...

Page 71: ...68 10 3 SUSPENSION ELLIPTICAL ASSEMBLY STEPS CONTINUED step 7 Blue Black hardware bag CHAPTER 10 SUSPENSION ELLIPTICAL SPECIFICATIONS AND ASSEMBLY GUIDE...

Page 72: ...69 10 3 Suspension Elliptical assembly steps continued step 8 White hardware Bag CHAPTER 10 SUSPENSION ELLIPTICAL SPECIFICATIONS AND ASSEMBLY GUIDE...

Page 73: ...70 10 3 SUSPENSION ELLIPTICAL ASSEMBLY STEPS CONTINUED step 9 pink hardware bag CHAPTER 10 SUSPENSION ELLIPTICAL SPECIFICATIONS AND ASSEMBLY GUIDE...

Page 74: ...71 10 3 Suspension Elliptical assembly steps continued step 10 pink hardware Bag CHAPTER 10 SUSPENSION ELLIPTICAL SPECIFICATIONS AND ASSEMBLY GUIDE...

Page 75: ...72 10 3 SUSPENSION ELLIPTICAL ASSEMBLY STEPS CONTINUED step 11 pink hardware bag CHAPTER 10 SUSPENSION ELLIPTICAL SPECIFICATIONS AND ASSEMBLY GUIDE...

Page 76: ...73 10 3 Suspension Elliptical assembly steps continued step 12 pink hardware Bag CHAPTER 10 SUSPENSION ELLIPTICAL SPECIFICATIONS AND ASSEMBLY GUIDE...

Page 77: ...l for optimum use Once you have placed your unit where you intend to use it raise or lower one or both of the adjustable levelers located on the bottom of the frame Use a 6mm Allen wrench through the...

Page 78: ...s outlined in Section 9 1 2 Remove the 6 screws holding the console front to the back and split the console Figures A B 3 Remove the 2 screws holding on the blank headphone jack plastic to the console...

Page 79: ...f installing a MYE TV the PCTV does not use the entertainment overlay 8 Remove the existing heart rate overlay from the lower portion of the console Figure I 9 Clean the console area with alcohol to r...

Page 80: ...4 pin black connector to the power wire coming up the console mast from the base of the unit 16 Plug the side of the controller wire labeled To Console into the CSafe board mounted on the console back...

Page 81: ...2 screws Figure U The small cover with the Matrix logo that makes up the top of the rear console cover is no longer used with a TV bracket 20 Mount the console back onto the unit making sure to make a...

Page 82: ...the TV bracket being sure to tuck the tabs of the plate installed during Step 20 into the console plastic Figure BB 28 Mount the TV to the TV bracket using 4 screws sent with the TV Figure CC 29 Put t...

Page 83: ...the software files into the UCB folder on the USB flash drive the access should read MATRIX FW UCB Figure B 3 Insert the USB flash drive into the USB port on the console Figure C 4 With the display is...

Page 84: ...81 notes...

Page 85: ...MATrix Fitness systems corp 1610 Landmark Drive Cottage Grove wi 53527 USA TOLL FREE 866 693 4863 www matrixfitness com FAX 608 839 1717 REV 01 KO...

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