Spirit XE520s, Service Manual

Page 1: ...Service Manual Elliptical XE520s ...

Page 2: ... Front Rear Left Handle Bar Covers Front Rear Left Pedal Arm Cover Console Left Chain Cover Left Pedal Console Mast Cover Left Right Rear Shroud B Slide Wheel Cover Connecting Arm Cover Right Pedal Arm Cover Rear Shroud A Round Disk Cover Right Pedal Round Disk ...

Page 3: ...dal Arm Right Handle Bar Left Connecting Arm Bushing Housing Left Adjustable Pedal Gear Motor Drive Pulley Rail Assembly Right Pedal Arm Main Frame Right Adjustable Pedal Locking Pin Assembly Sliding Wheel Flywheel Brake Cross Bar Right Connecting Arm ...

Page 4: ...st 6 Chain Covers 7 Cross Bar Assembly 8 Idler Wheel Assembly 9 Flywheel Brake and the Belt II Troubleshooting i Console ii Chain Covers and Round Disk iii Flywheel Brake iv The Belt v Handle Bar Assembly vi Connecting Arm Assembly vii Gear Motor Q A 1 Noises 2 Slippage 3 Resistance and Ramp 4 Smoothness 5 Other Problems ...

Page 5: ...10mm Phillips head screws which secure the console on top of the mast as shown in figure 1 2 Disconnect computer cable and hand pulse cable from the console to take the console apart as shown in figure 2 3 To resume connect the cables with the console put it on top of the mast and secure with four M5x10mm Phillips head screws ...

Page 6: ...elease further two M5x15mm Phillips Head Screws which secure Connecting Arm Covers as shown in figure 2 3 Use 12m m_Wrench and 13m m_Wrench to release 5 16 1 1 4 _Hex Head Bolt 5 16 x20x1 5 T flat washer and 5 16 x7T nut which secure Connecting Arm and fish eye bearing as shown in figure 3 4 Use 12m m_Wrench to release 5 16 15m m_Hex Head Bolt and 5 16 x23x1 5T washer which secure the Handle Bar a...

Page 7: ...ervice Replacing Parts Part 2 Handle Bar Assembly Rev 5 Procedures 5 Reverse above procedures to resume Handle Bar Assembly together with Ø 17 washer if there is on the shaft when you took it apart as shown in figure 5 ...

Page 8: ...hown in figure 1 2 Use 12mm wrench to release 5 16 15m m_Hex Head Bolt and 5 16 x23 flat washer and then pull out the Carriage Bolt to take Connecting Arm apart as shown in figures 2 3 3 Pull out Pedal Latch Spring on the Locking Pin holding plate and release the Latch Spring with C ring Pliers The pedal and Locking Pin Assembly can thus be taken apart as shown in figures 4 5 ...

Page 9: ...Procedures 4 Use Phillips screw driver to release four M5x10 mm screws to take apart Locking Pin Assembly as shown in figure 6 5 Use Phillips screw driver to release four M5x10 mm screws and take apart the Pedal as shown in figure 7 Reverse above procedures to resume parts ...

Page 10: ...hes to release 3 8 2 1 4 _Socket Head Cap Bolt with 3 8 x19x1 5T flat washer and 3 8 x11T nut which secure Pedal Arm and Bushing Housing as shown in figure 2 3 Use 12 mm wrench to release 5 16 x 15mm Hex Head Bolt together with 5 16 x23x1 5T flat washer and take Bushing Housing apart as shown in figure 3 4 Use C ring pliers to release Ø 17 C ring in order to take apart Slide Wheels as shown in fig...

Page 11: ...cs 3 5x12mm Sheet Metal Screws and take apart left and right Mast Covers as shown in figure 1 3 Use 14 mm wrench to release 3 8 3 4 _Hex Head Bolt 3 8 23 2T_Curved Washer 3 8 2 1 4 _Hex Head Bolt and 3 8 2T_Split Washer which secure the Console Mast as shown in figures 2 3 4 Pull the Mast out of the Mainframe and split the control cable 5 Reverse above steps to resume Mast Console and Connecting A...

Page 12: ... respectively 2 Use Phillips head screw driver to release eight 3 5x16mm Sheet Metal Screws and three 5 6m m_Tapping Screws which secure right Chain Cover as shown in figures 1 2 3 Use again Phillips head screw driver to release 3 5x12 Sheet Metal Screw 1 4 x19 flat washer and three 5 16m m_Tapping Screws which secure right Chain Cover as shown in figures 4 5 ...

Page 13: ... mainframe and take apart left Chain Cover as shown in figure 5 5 If replacing DC cable is required then release the nut which secures the cable on left Chain Cover 6 Reverse above steps to resume parts Make sure to return 5 16x23x1 5 flat washer on left Chain Cover and DC cable is free from pinched by the Chain Cover or touching Round Disk as shown in figure 6 ...

Page 14: ...and use 12 mm and 6 mm wrenches to release 5 16 x15mm Hex Head Bolt and 5 16 x35x1 5T flat washer together with M8 30m m_Socket Head Cap Bolt to take apart the Cross Bar as shown in figures 1 2 3 3 Use Phillips head screw driver to release eight 5x16mm Tapping Screws which secure Round Disk on the Cross Bar and separate two parts apart as shown in figure 4 ...

Page 15: ...4 Model XE520s Service Replacing parts Part 7 Cross Bar Rev 5 Procedure 4 Return the Cross Bar back to the Crank Axle and resume Woodruff Key as shown in figure 5 Reverse above steps to return all parts ...

Page 16: ...is on J Bolt and take off the Belt Use again 13 mm wrench to release M8x20 Carriage Bolt M8x7T nut and 5 16 x20x1 5T flat washer which secure the Idler Wheel to take apart the Idler Wheel as shown in figures 1 2 3 Reverse above steps to resume and adjust the belt tension by turning the nut on J Bolt for proper tension 170HZ 10 sound wave frequency as shown in figures 3 4 ...

Page 17: ...tance up to 20 with the Console and take apart the Steel Cable as shown in figure 1 3 Use 15 mm wrench to loosen 3 8 UNF26x9T nut which secure the Flywheel on the Mainframe and the Flywheel and Belt can be taken apart as shown in figures 2 3 4 Reverse above steps to resume Be sure that the Belt is put in the middle as shown in figure 4 before returning all parts ...

Page 18: ...s 1 When the display is all black Check the DC power 2 Check and make sure the cable is connected well to the Console as shown in figure 1 3 Dismantle the Console and check if all connectors are all connected well and make sure wire are free from damage as shown in figure 2 ...

Page 19: ...ound Disk is not in center and causes noise refer the procedure to replacing Chain Covers and reassemble 3 If Round Disk swings too much then take apart Chain Covers together with Round Disk and use Phillips head screw driver to release 5x16mm Tapping Screws together with 1 4 x19mm flat washers and put the Cross Bar with Round Disk on a flat surface and check for warp Correct the warp with force u...

Page 20: ...heel is rare In most case the Steel Cable is improperly adjusted and the noise is caused Please refer to replacing Flywheel and properly adjust the steel cable as shown in figures 1 2 3 2 If the Flywheel generates noise check if there is foreign material inside the Flywheel Replace if noise persists ...

Page 21: ...ct if Drive Pulley the Belt and Flywheel is not in line which causes the swing Then turn at the speed between 100 and 120 RPM and stop instantly to make sure everything is normal 2 Make sure that Drive Pulley the Belt and the Flywheel is in line as the way which is always done by the factory as shown in figure 2 3 If the Belt slips adjust the nut which is on the J Bolt with 13 mm wrench as shown i...

Page 22: ...e between 0 05mm and 0 07 mm in dimensions for the axle for the purpose of easy assembly so that a little bit of play is normal When there is noise due to long time of usage applying some lubricant at Ø 17x284L mast shaft will eliminate this noise If the bearing is generating noises replace 6003 bearing ...

Page 23: ...to lubricate each moving parts and joints as shown in figures 1 and 2 There are many factors which affect the feeling of smoothness The most important key point is to make sure that sliding wheels move parallel and smoothly on the rails In brief Pedal Arm should keep parallel with Connecting Arm and both Pedal Arm and mainframe keep perpendicular to the bushings Model XE520s Service Troubleshootin...

Page 24: ...ing Arm and Sliding wheels should have real circle without slippage If noises are caused by bad Rod End bearing or fish eye bearing replace the bearing by using 19 m m wrench as shown in figure 3 4 During maintenance start from sliding wheels by applying lubricant on wheels or replace if necessary as shown in figure 4 ...

Page 25: ...roubleshooting Part 7 Gear Motor Rev 1 2 3 Procedures 1 If there is no resistance Check the Console and Gear Motor Cable Release the cable and 5x19 Tapping screws which secure the Gear Motor to replace as shown in figures 1 2 3 ...

Page 26: ...m Chain Cover rubbing Crank Round Disk Cover Bushing Housing and Cross Bar Belt and Drive Pulley Idler Wheel Assembly Handlebar and Mast shaft Flywheel and Cable to Sliding Wheels and Rail Assembly even Pedals etc Insufficient lubrication smoothness or loose screws are major causes as shown in figures 1 and 2 ...

Page 27: ...3 8 x2 1 4 socket head cap screw must be firmly tightened with 3 8 x11T nut The tightness should be within 500 600 Lbs as shown in figure 2 4 Cross Bar M8x30m msocket head cap screw on the Cross Bar must be firmly tight The tightness should be within 550 600 Lbs as shown in figure 3 5 The Belt Belt slipping is quite usual because the belt gets less tensioned as time lasts Time duration and user we...

Page 28: ...o tighten all screws and check for installation faults or worn out of parts when time lasts Like a wobble pedal is usually caused by carriage bolt not installed properly If the unit wobbles adjust the screws for footpad beneath Front Stabilizer as shown in figures 1 and 2 Be sure to apply some lubricant after replacing the parts ...

Page 29: ...ness Rev 1 Procedures 1 Check tightness of screws and bolts if the unit clicks 2 Otherwise there might be foreign materials on either the rail or Slide Wheel Use rubbing alcohol to wipe and apply some lubricant both parts as shown in figure 1 ...

Page 30: ...29 Model XE520s Service Q A Part 5 Other Problems Rev 1 Procedures 1 Contact DYACO for problems not covered in this service manual Any problem solving on the unit is backed up by DYACO technical team ...