SX1000 Service Manual
Contents
1. o L gt ON GREEN GREEN POWER SUPPLY BOARD TRANSFORMER BLACK 2 AMP WHITE WHITE WHITE mm PAV ds 67 BLACE BLACK 2 i 1 SPEED 2 110V SENSOR 23 RED BRAKE N y N RED BRAKE N 4 oO 14 Figure 5 SX1000 Spindle Bearing Lubricant Application V SX1000 Parts List Item Description Console Display board overlay switch panel heart rate pickup cable assy standoffs 1 6 32 screw 6 32x 5 b h pltd screws 6 32x 250 f h pltd mount display weldment bolts 1 4 20 x 5 8 pltd bolt 5 16 18 x 1 2 pltd lockwashers 1 4 plate side drivetrain right plate side drivetrain left bolts 5 16 18 x 5 8 pltd nuts 5 16 18 pltd lockwashers 5 16 grommet hole 1 dia bracket wheel left bracket wheel right plate power entry module power entry module outlet power screw 10 32x 5 black b h socket cap wheel front cable ribbon assy grip 1 1 4 dia x 14 grip 1 1 4 dia x 10 cover electronics lower plate mounting electronics lower bracket PCB lower lockwasher 8 screws 8 32 x 1 2 pan head pltd nuts 10 32 pltd lockwasher 10 frame base weldment endcap 3 dia roller rail urethane bearing roller rail urethane washer 10 flat washer 10 star kit bolt roller rail Part No 65202 65110 65112 A10662. SX1000 Service Manual SALES 800 278 3933 CUSTOMER SERVICE 800 745 1373 Revision August 1999 Table of Contents Section Overview Troubleshooting Tables Maintenance Procedures Procedure 1 Removing the Power Supply Board Procedure 2 Checking Voltage at the Power Supply Board Procedure 3 Checking and Adjusting the Speed Sensor Procedure 4 Removal and Replacement of the Brake Assembly Procedure 5 Checking the Rail Alignment Procedure 6 Adjusting the Rail Alignment Figures Figure 1 SX1000 Main Frame Figure 2 SX1000 Total Assembly Figure 3 Power Entry Module with Fuse Holder Figure 4 SX1000 Wiring Diagram Figure 5 SX1000 Spindle Bearing Lubricant Application SX1000 Parts List 10 11 12 14 15 16 l Overview Purpose This manual is designed to assist in service of SCIFIT SX1000 elliptical exercise machines The manual is divided into sections to diagnose and isolate problems Troubleshooting tables and procedures along with drawings are provided to aid technicians in servicing equipment The Item Numbers given in the parts list in Section V can be used to determine the location of various parts in Figures 1 and 2 When troubleshooting the actions taken to resolve problems should be performed in the order stated Deviating from this seguence may cause damage to the eguipment and lead to unnecessary repairs Technical Support For further
3. and J5 pin 2 on the power supply board Refer to Fig 4 The voltmeter should read 4 5 VDC If there is no voltage replace the power supply board If 4 5 volts are present replace the speed sensor Procedure 4 Removal and Replacement of the Brake Assembly 1 Remove each rail from its crank arm spindle First remove the snap ring at the spindle outer edge then slide the rail outward and upward off the machine Remove the two screws holding the bottle cage below the handlebars Remove the single screw located just above the power entry module Remove the five screws from side of the left cover Position the left crank arm pointing backward and parallel to the base frame Pull the front edge of the cover and slide it inward and backward to clear crank arm Repeat step 3 on right side Disconnect the two red wires on the right side of brake Remove the 7 nuts and lockwashers from both brake studs Remove the 10 32 allen head screw on the right side of brake Remove the tensioning screws at the top center of the brake on each side of the sheet metal frame Remove the V belt from the plastic pulley by wedging a screwdriver blade between the belt and pulley while rotating the brake slowly downward to work the belt off the pulley Take care not to damage pulley 10 Lift the brake upward to clear frame and pull the speed sensor bracket off the left brake stud Remove the brake from the mac
4. After 3 5 seconds of turning the resistance should be at its maximum level If not refer to the troubleshooting table If brake loaded up to maximum setting then the job is complete oo Procedure 2 Checking voltage at the Power Supply Board 1 2 Follow steps 1 4 in Procedure 1 Use a voltmeter to measure the DC voltage across the speed sensor pins on the power supply board Measure the voltage across the pin with the red wire and either one of the center pins The voltmeter should measure 4 5 volts DC If there is no voltage replace the power supply board Procedure 3 Checking and Adjusting the Speed Sensor 1 2 Turn machine on and press start Turn crank arms at 1 revolution per second The RPM window should display around 60 10 rpm If the RPM window is displaying a reading outside of the specified range proceed to the next step to adjust the speed sensor Remove the hood The air gap between the brake flywheel and speed sensor should be 1 8 3 16 The speed sensor must be pointed directly at the flywheel so the eyes of the sensor will intersect the center of the axis of the brake Adjust as needed Rotate the crank arm again at 1 rev per second If the RPM window displays a number greater than zero 0 but not within 60 10 rom repeat steps 1 6 If a reading of zero 0 is displayed proceed to step 7 Use a voltmeter to measure the DC voltage across J5 pin 1
5. P1051 P1052 P1053 B1020 P1054 P1057 P1056 C1013 C1014 P1058 P1059 P1060 A1015 A1016 A1018 P1061 65177 P1062 P1063 A1067 P1068 P1069 A1017 A1019 A1047 P1073 P1074 C1011 70330 P1075 P1128 P1077 Qty D PB PB PB DMA BR RAR RAAB D ND 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 PCB supply power transformer supply power bolts 5 16 18 x 2 1 2 hex pltd lockwasher 5 16 black 1 4 20x1 Socket Cap Crank Machined 205mm assy Bracket mounting pickup heart rate Bearing flanged 3 4 dia 1 2 long igus L280 Bearing thrust 3 4 dia igus L280 ring snap 3 4 dia pedal finished Shaft spacer rail weldment guide roller extruded bolt 5 16 18 x 3 1 2P button head black cap 2 1 4 x 2 1 4 plastic black brake cover pedal right cover pedal left Bracket sensor speed brake large sensor speed cable assy belt poly V idler washer cover plastic black screws 8 32 x 3 8 f h pltd screws 4 40 x 1 2 p h pltd flangette bearing bearing pulley poly V 6 dia key square 1 4 x 1 4 x 1 shaft jack assy chain 1 2 pitch per foot Spindle Crank Assy nut jam 5 16 18 pltd cover right cover left Tape pickup speed brake large decal Scifit decal SX1000 cover rail rear weldment decal warning hi vol
6. Reasons 2 1 Rails lock up while operating 2 2Sgueaking noise external to machine drive assembly 2 3No resistance on pedals when ina program Power supply board is faulty Brake is bad Rails are not aligned properly Spindle bearings are faulty No speed signal Wires going to brake are disconnected Power supply board is faulty Unplug power cord If rails move replace power supply board If rails do not move with power cord unplugged replace brake See Procedure 4 Check and adjust rail alignment accordingly See Procedure 5 Spray a Teflon or silicone based penetrating lubricant such as WD40 on spindle bearings See Fig 5 If noise goes away but returns soon after replace spindle bearings Check and adjust the speed sensor as needed See Procedure 3 Check that brake wires are properly connected Check and replace power supply board as needed See Procedure 2 2 4 Very little resistance Speed sensor improperly Check and adjust the at any level adjusted speed sensor as needed See Procedure 3 Bad speed sensor Check voltage at power connection with power supply board See supply board Procedure 2 2 5 Belt is slipping Not enough tension on Tighten the belt to 14 the brake drive belt deflection at 10 Ib of force lll Maintenance Procedures Procedure 1 Removing the Power Supply Board 1 Unplug the unit from the power source 2 Lay it on its
7. side 3 Locate the power supply board access plate under front of unit Refer to item 31 in Fig 2 4 Remove the four 4 screws Be careful when pulling down the power supply board because of the plastic ties and brake wires 5 Cut all the plastic ties 6 Before disconnecting any of the wires make note of the wiring sequence Refer to the wiring diagram Fig 4 7 Disconnect the following a The two 2 white 110 V and o 2 black 24 V transformer wires These are all the wires from J4 on Fig 4 b The black and white wires from the power entry module total of two 2 These are the wires at terminals ACIN1 and ACIN2 on the LCB C The two 2 red brake wires d The one 1 speed sensor plug J5 on Fig 4 e The one 1 ribbon cable 8 Reinstallation is the reverse of removal 9 After reinstalling the power supply board perform the following procedure to test correct reinstallation a Plug into power source and turn on b The message SCIFIT FOR SCIENTIFIC SOLUTIONS should be scrolling across upper display board If not see troubleshooting table Press the start button Turn the crankshaft in a forward motion e Verify that values are being displayed in the rpm Watt window f Press the up arrow key to increase the resistance It should become more difficult to turn the crankshaft In not consult the troubleshooting table g Press the up arrow and hold until level 22
8. then go re plug machine to reset dead Faulty power supply Check and replace power board supply board as needed See Procedure 2 Display board is faulty Replace display board 1 5 Heart rate displays zero 0 in window 1 6 Unit keeps blowing fuses 1 7The upper display resets after starting a program 1 8Program stops lines of dots shoot across Screen 1 9Machine shuts down in programs but works in manual 1 10 Can t select program or enter information and no beep when buttons are pressed Chest strap and transmitter improperly worn Loose sensor lead connection at display board Faulty receiver Too many units are daisy chained together Faulty power supply board Ribbon cable connection is loose Power cord is loose Display board is faulty Ribbon cable connection is loose Display board is faulty Display board is faulty Membrane is faulty Verify that they are being properly worn Check and adjust as needed If there is no audible signal replace receiver Do not daisy chain more than 3 units together Check and replace power supply board as needed See Procedure 2 Check cable connection at power supply and display boards Check and adjust as needed Replace display board Check and adjust cable connection as needed Replace display board Replace display board Replace membrane Table 2 Mechanical Troubleshooting Possible
9. assistance in service of SCIFIT products please call 800 745 1373 extension 21 The technical support department is staffed from 8 AM to 5 PM C S T Monday through Friday A voicemail service is available 24 hours daily for recording messages to reguest technical support and to order replacement parts Please have the following information prior to calling technical support Model number of eguipment Serial number of eguipment Point of contact name and phone number Detailed description of symptoms encountered ll Troubleshooting Tables Table 1 Electrical Troubleshooting 1 1The machine Faulty power supply If buttons on the control appears to be off board display beep when when plugged in pressed replace power and switched on supply board See Procedure 1 Otherwise check power supply board See Procedure 2 Faulty fuse Check and replace fuse if needed See Fig 3 Loose cable connection Check wire connections at power supply and display boards 1 2Upper control panel Power supply board is Replace power supply lights are dim faulty board See Procedure 1 1 3 Upper board Dip switch setting is Set dip switch to 01 accepts commands incorrect but pedaling resistance does not Power supply board is Check and replace power change faulty supply board as needed See Procedure 2 1 4LED s on upper Ribbon cable Check and replace board blinking connections are loose accordingly Unplug and off on
10. breaking the studs 22 Tighten the 10 32 screw on the right side of brake 23 Rotate the brake assembly to verify the V belt is centered in the idler pulley If misaligned wedge a screwdriver blade between the face of the brake and the belt while turning Assembly to align belt to center of idler pulley 24 Attach speed sensor tape to the left edge of the brake armature First peel off tape backing on the end with the wide silver band and stick on the brake surface hanging down Slowly rotate the brake upward and wrap tape around the circumference of the brake 25 Perform the following steps 25 through 29 and perform the alignment Procedure 3 if indicated results are not attainable 26 Plug in and turn on machine but don t press any buttons The display will be scrolling the message SCIFIT Slowly rotate the crank arm assembly and the message will change to a programming prompt The following values will be displayed 20 00 in TIME 0 in RPM and 4 in LEVEL If the display doesn t default to these values perform Procedure 3 27 Press the START STOP button once and press the SCAN HOLD button to hold the RPM function Press and hold the DOWN ADJUST arrow until 0 0 is displayed in the LEVEL window 28 Rotate the crank arms at one revolution per second and ensure display accurately reads about 60 RPM 29 Press and hold the UP ADJUST arrow button to the maximum level 22 Rotate the crank arms as ra
11. hine and set aside to return to SCIFIT reguest a UPS call tag by phone Hoist the replacement brake above the frame mounting slots and wrap V belt around brake hub Position V belt hanging behind the idler pulley 12 Put the speed sensor bracket on the left brake stud Note If old brake has a smaller diameter 7 vs 9 a replacement speed sensor bracket must be used Remove the single screw holding the speed sensor to the old bracket and attach the sensor with the same orientation to the new bracket Refer to Procedure 3 if needed 13 Slide the brake studs and speed sensor bracket inside and to the bottom of the frame mounting slots 14 Connect the two red wires to the brake 15 Loosely attach the lockwashers and nuts to the brake studs 16 Rotate the stator of brake to align the screw hole on the right side of brake with sheet metal frame Loosely attach the 10 32 screw to this hole 17 Slip the V belt over the plastic pulley while slowly turning the brake downward to install and center the belt on the pulley 18 Insert the left tensioner screw and finger tighten Repeat this process on the right side 19 Tighten the left side tensioner screw with an allen wrench until the angle brackets begin to bend inward Repeat this process on the right 20 Position the speed sensor bracket vertically 21 Snugly tighten the brake stud nuts until the lock washers compress Do not over tighten to avoid
12. pidly as possible Brake resistance should become increasingly difficult momentarily 30 Replace the covers and rails in the reverse order of steps 1 through 4 Procedure 5 Checking the Rail Alignment 1 2 Remove the rear rail cover item 85 Check alignment of the guides item 58 on the rollers item 40 by moving the rail assemblies item 57 forwards and backwards and making sure that the rollers run in the flat center section of the roller guides If the guides are not tracking correctly see Procedure 6 Procedure 6 Adjusting the Rail Alignment 1 2 Remove both rail assemblies item 57 Remove the left crank arm item50 and Woodruff key item 102 Remove the left and right side covers items 81 and 80 respectively Note this may be done without removing the right crank arm Reinstall the left crank arm at the same angle as the right crank arm Do not use the Woodruff key when putting the crank arm on Secure the left crank with the pinch bolts Reinstall the rail assemblies Partially loosen the nuts and bolts holding the crank shaft bearings item 73 and flangettes item 72 Leave enough tension on the bolts to hold the bearings in place but will allow bearings to be moved Check alignment of the roller guides item 58 on the rear 10 11 12 13 rollers item 40 The flat section of the roller guides should be centered on each roller If the guides are not cen
13. tage decal serial number manual operator s 65150 65180 P1079 A1172 A1124 A1180 P1179 A1028 A1131 B1109 A1110 P1086 P1087 A1331 A1041 A1042 A1176 A1089 P1090 P1091 55 P1095 P1096 P1097 P1098 A1050 P1072 A1048 P1099 P1036 P1035 A1190 P1100 P1101 A1022 P1102 P1103 P1104 mn mn mn mn nnn BE RAD ROO 0 RO RK 89 90 91 92 93 94 95 96 97 98 99 100 101 102 104 105 106 cord power AC grommet hole 1 1 2 dia support cover decal plate scuff holder bottle water bracket tension upper bracket tension lower socket head 10 32x2 5 flat d h pltd bolt 3 8 24 x 2 1 2 hex pltd nuts 3 8 24 lockwashers 3 8 bolt 3 8 16 x 1 1 2 hex pltd nut 3 8 16 Key 806 1 4x3 4 Woodruff washer 4 flat pltd washer 4 split pltd Spacer bearing roller 65169 P1105 A1033 P1106 P1092 A1116 A1117 P1078 D po YO NM MD MD ND AH 0 A
14. tered grab the ends of the rail assemblies and move them sideways until the guides are centered on the rollers The crank shaft bearings and flangettes should move slightly when the rail assemblies are moved Retighten the crank shaft bearing bolts and nuts in their new position Check alignment of the guides on the rollers by moving the rail assemblies forwards and backwards and making sure that the rollers run in the flat center section of the roller guides If the guides are not tracking correctly repeat steps 6 8 until satisfactory alignment is achieved Note if one or both rail assemblies cannot be made to track on flat center section of the roller guide there may be a problem with the rail itself If this is the case please contact SCIFIT Service at 800 745 1373 Also check the chain tension The chain should be tight enough to eliminate backlash but not so tight as to bind and cause excessive noise Remove the rail assemblies Remove and reinstall the left crank arm at a 180 orientation from the right arm Put removable threadlocker blue LOCTITEG on the pinch bolts and tighten Reinstall the side covers Reinstall the rail assemblies IV Figures Figure 1 SX1000 Main Frame 11 Figure 2 SX1000 Total Assembly 12 Figure 3 Power Entry Module with Fuse Holder Figure 4 SX1000 Wiring Diagram POWER ENTRY MUDULE PLUG WITH FUSE RECEPTICAL
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