Z100/Z500/Z900 Service Manual
Contents
1. 10 Treadmill 10 Warranty POMGCY 11 Parts Order 12 Warranty Labor Credit Form 13 Troubleshooting Guide ELECTRONIC SYSTEM No power There is no power to the console LS error Belt movement for a few seconds then LS error LS error No belt movement at all then LS error Incline does not work Belt surging Belt speeds up and slows down frequently BONS v Pun 9 a Unit must be plugged into an outlet with power Power switch must be illuminated Tether cord must be in place Check treadmill circuit breaker procedure 4 Check POWER LED on controller procedure 11 Make sure wires on board are plugged in securely Check wire harness for continuity procedure 2 If LED s on controller are not lit test fuse on controller If fuse is good replace controller procedure 7 If LED s are on replace console Run the calibration procedure procedure 1 Adjust speed sensor procedure 3 Check roller for magnet Procedure 5 Check wire harness for continuity procedure 2 If roller has a magnet and sensor adjustment does not fix replace speed sensor Run the calibration procedure procedure 1 Check wire harness for continuity procedure 2 Look at LED labeled PWM procedure 11 If it lights up when the START button2. O eS 7900 Exploded View 950517PM 1645 105 A 18 104 Z900A A82 Part List SPIRIT NO DESCRIPTION 1 MAIN FRAME 2 INCLINE BRACKET 3 HANDRAIL SUPPORT 4 RIGHT HANDRAIL 5 LEFT HANDRAIL 6 CONSOLE SUPPORT 7 20x40x1 5Tx680L_DECK CROSS BRACE 8 10_ 9 DRIVE BELT 240J 610J 10 110 x 75_FRONT ROLLER W PULLEY 11 75_REAR ROLLER 12 1410 680 25 DECK 13 560 3250 x 2 ST RUNNING BELT 14 38 x 225m m x 3T_HANDGRIP FOAM 15 38 x 295 m m x 3T_CONSOLE SUPPORT FOAM 16 0 6T_SPRING 17 WIRE TIE MOUNT 18 LUBRICANT 19 765x390L_BOTTOM FRAME COVER 20 MOTOR 3 0hp YC 21 INCLINE MOTOR 22 CONTROLLER 23 1000 mm_SENSOR W CABLE 24 15A_BREAKER 25 POWER SOCKET 26 ON OFF SWITCH 27 POWER CORD 28 100mm x 764 x 764_CONNECTING CABLE BLACK 29 150mm 764 764 CABLE WHITE 30 150mm x 764 x 764_CONNECTING CABLE BLACK 31 800 mm_COMPUTER CABLE UPPER 32 800 mm_COMPUTER CABLE LOWER 33 1300 mm_COMPUTER CABLE MIDDLE 34 800 mm_SPEED CABLE UPPER 35 800 mm_INCLINE CABLE UPPER 36 TRANSFORMER 37 CONSOLE 37 1 CONSOLE COVER 37 2 BOOK RACK does not come as set 37 3 BEVERAGE HOLDER OF CONSOLE 37 4 FACE PLATE LENS 37 13 AUDIO CABLE Speaker Amp Harness 37 14 SPEAKER 37 16 2 3x6 m m_SELF TAPPING SCREW 38 290 m m_SPEED ADJUSTMENT SWITCH W CABLE 39 290 m m_INCLINE ADJUSTMENT SWITCH W CABLE 40 FRAME
3. part order is for stock We encourage all dealers to stock parts Spirit will dited shipping charges always be fair to all dealers on credit for parts Spirit reserves the right to Special Instructions 2nd Day Air subject parts returns to a 20 restocking fee if Spirit determines that the Next Day Air dealer has excessively ordered parts randomly to repair a problem Saturday Delivery Buyer Signature 12 REQUEST FOR WARRANTY LABOR CREDIT SPIRIT www spiritfitness com Labor Warranty Spirit is responsible ay Customer is responsibl 2037 JONESBORO ARKANSAS 72402 Date of Repair Model Serial Number Service Company Sve CoAcct Number Owner s Name Owner s Address Selling Dealer Selling Dir Acct Phone Number With Area Code Date Sold Number Problem Repair Done FACTORY USE ONLY INVOICE QUANTITY PART PART DESCRIPTION wry TEST RESULTS UNIT PRICE work oroen ORDER FACTORY USE ONLY FREIGHT LABOR SHIPPING TRIP WARRANTY CREDIT WILL BE ISSUED TO DEALER ACCOUNT TOTAL LABOR ALL PARTS MUST BE RETURNED TO FACTORY UNLESS INSTRUCTED OTHERWISE Authorization No CLAIMS MUST BE RETURNED TO SPIRIT CORP WITHIN 7 DAYS OF REPAIR SHADED AREAS FACTORY USE ONLY WARRANTY ADMINISTRATOR FAX TO SPIRIT 870 930 9013 13 7100 Exploded View 950913PM13
4. SERVICE MANUAL Z 100 Z 500 Z 900 Table of Contents Troubleshooting Guide Parts Exploded VIEW Parts DBIsSU22 wee oe Exploded Parts Electronic System 3 Mechanical System 4 Repair Procedures Procedure 1 Calibrating the unit 5 Procedure 2 Checking wire harness 5 Procedure 3 Speed sensor adjustment 5 Procedure 4 Checking treadmill circuit breaker 5 Procedure 5 Checking roller for magnet 6 Procedure 6 Adjust torque 6 Procedure 7 Replacing 2 2 6 Procedure 8 Replacing wire 8 6 Procedure 9 Replacing drive 6 Procedure 10 Replacing incline 7 Procedure 11 Controller 7 Procedure 12 Wiring diagram 8 Procedure 13 Engineering mode 9 Z Series Warranty Contacting Technical Service
5. 7 10x 24x 3T_NYLON WASHER 50x 13x 3T_ NYLON WASHER 30 x 3 8 FOOT PAD SENSOR RACK SAFETY KEY BELT GUIDE 14x 10x 35 WHEEL SLEEVE MAGNET FOOT RAIL 1 2 x 1 1 4 CARRIAGE BOLT 1 2 x 1 _HEX HEAD SCREW 3 8 x 4 1 2 5 HEAD CAP SCREW 3 8 x 3 3 4 BUTTON HEAD SOCKET SCREW 3 8 x 1 1 2 HEAD SCREW 3 8 x 1 _HEX HEAD SCREW 3 8 x 2 FLAT HEAD SOCKET SCREW 5 16 x 1 _BUTTON HEAD SOCKET SCREW 20 022720 022721 022719 000619 000588 000591 000592 000598 022946 022940 000581 022558 022559 022482 022967 000127 000603 000604 022024 000586 000587 000313 000314 000596 000582 000593 000594 022484 022713 022989 022945 000595 023101 010041 000583 000062 000061 022885 000125 NN f NNNNNNF e NANDE WKN NR RRR FN KN DNDN DR RR RNR KN BR 88 89 90 92 93 94 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 112 113 114 115 116 117 118 119 120 121 122 124 125 126 127 128 130 131 132 133 134 135 136 137 138 5 16 x 2 3 4 _BUTTON HEAD SOCKET SCREW 8 x 60m m_HEX HEAD SCREW 8 x 80m m_SOCKET HEAD CAP SCREW M8 x 35m m_FLAT HEAD COUNTERSINK SCREW M3 x 10m m_PHILLIPS HEAD SCREW 5 x 15m m_PHILLIPS HEAD SCREW 5 16 x 42 m m _PHILLIPS HEAD SCREW 5 NYLON NUT 1 2 x 8T_ NYLON NUT 3 8 x 7T_ NYLON NUT 5 16 x 6T_ NYLON NUT 8 8 NYLON 3 8
6. x 6 5T_ NUT for Foot Pad M3_ NUT 35 5 16 x 1 5T_ FLAT WASHER 25x 10x 1 5T_ FLAT WASHER 19x 10x 1 5T_ FLAT WASHER 5 7 10x 1 0 _ FLAT WASHER 5 16 x 18 x 1 5T_ FLAT WASHER 5 7 12x 1 0 _ FLAT WASHER 5 7 15x 1 0T_ FLAT WASHER 7 6 23 7 13x5 5T x 3T_NYLON DISHED WASHER 6 5 x 25 x 50 x 1 5 2 5 CONCAVE WASHER 10 SPRING WASHER M3_SPRING WASHER M5_RAISED WASHER 4x12m m_SELF TAPPING SCREW 5x16m m_TAPPING SCREW Black 5x19m m_TAPPING SCREW 3 5 x 6 m m_SELF TAPPING SCREW 5 x 16m m_TAPPING SCREW Black 3 x10m m_SELF TAPPING SCREW 3 5 x 12 m m_SELF TAPPING SCREW 3x10 m m_TAPPING SCREW 4x38m m_SELF TAPPING SCREW 3 5 x 16 m m_TAPPING SCREW 3 x 10 m m_SELF TAPPING SCREW 5 IRON PLATE NUT 5 16 x 1 2 BUTTON HEAD SOCKET SCREW 022314 023082 000913 023102 000080 030039 010125 000126 000077 000070 010110 010125 010110 023082 010113 010115 000325 022979 023082 010109 000085 COMBINATION 5 ALLEN WRENCH amp PHILLIPS HEAD SCREW DRIVER M6 ALLEN WRENCH 3 10 m m _SELF TAPPING SCREW 3x 8m m_SELF TAPPING SCREW PLASTIC WASHER FRONT MOTOR COVER TOP MOTOR COVER PLATE 0 8T_SPRING FOR CONSOLE HARDWARE KIT FAN ASSEMBLY DECAL SIDE DECAL CONSOLE 21 022973 023082 000590 000589 022680 000616 000623 000624 L L ANY WHE Q PER WV 9 oo S S O N N 00008
7. 58 10 7100 XZ200 A82 2 00 15 95 WN 2 9 L2 K v gt SA Q X gt DURUN AIA AWN 39 2 39 3 39 4 39 5 40 41 42 43 DESCRIPTION MAIN FRAME FRAME BASE INCLINE BRACKET RIGHT HANDRAIL LEFT HANDRAIL CONSOLE SUPPORT INNER SLIDE OUTER SLIDE 5x 8 25L_CLEVIS PIN 5x 8x 9L_ FASTENING BUSHING 8 x30L SHAFT 8 7 12 7 x 12L_ SHAFT BUSHING 2T_ FASTENING BRACKET 2T_LINK 1 0 DUAL ROTA SPRING CLENCHING HANDLE ASSY Handle Only 000506 CHENCHING ROTA SPRING CYLINDER 900N DRIVE BELT 2401 6107 FRONT ROLLER W PULLEY REAR ROLLER RUNNING DECK RUNNING BELT FOAM A FOAM B STEEL ROPE ROTA SPRING WIRE CLAMP WIRE TIE MOUNT LUBRICANT STEEL ROPE TOP FRAME COVER BOTTOM FRAME COVER MOTOR 3HP YC INCLINE MOTOR CONTROLLER 800 m m _ SPEED CABLE 800 m m CABLE HANDPULSE ASSY 650 m m_HANDPULSE CABLE HANDPULSE ASSEMBLY TOP HANDPULSE ASSEMBLY BOTTOM HANDLE BAR E
8. 9 023082 010109 000085 000089 022973 023082 000590 000589 022680 000546 000624 NNEFNEEAADNKEKE HANAN HAN DANK GRR CRRANHEENRPANHE WE WARE HHH ONY 7500 Exploded View 950913PM1328 13 105 Ae 113 105 U Z500 XZ600 A82 39 2 39 3 39 4 39 5 40 41 42 43 44 DESCRIPTION MAIN FRAME FRAME BASE INCLINE BRACKET RIGHT HANDRAIL LEFT HANDRAIL CONSOLE SUPPORT INNER SLIDE OUTER SLIDE 3x 8 25L_CLEVIS PIN 75 8x 9L_ FASTENING BUSHING 8 301 SHAFT 78 12 7 x 12L_ SHAFT BUSHING 2T_ FASTENING BRACKET 2T_LINK 10 DUAL ROTA SPRING CLENCHING HANDLE ASSY CHENCHING ROTA SPRING CYLINDER 1000N DRIVE BELT 240J 610J FRONT ROLLER W PULLEY REAR ROLLER RUNNING DECK RUNNING BELT FOAM A FOAM B STEEL ROPE ROTA SPRING WIRE CLAMP WIRE TIE MOUNT LUBRICANT STEEL ROPE TOP FRAME COVER BOTTOM FRAME COVER MOTOR 3 0hp YC INCLINE MOTOR CONTROLLER 800 m m _ SPEED CABLE 800 m m _INCLINE CABLE HANDPULSE ASSY 650 m m_HANDPULSE CABLE HANDPULSE ASSEMBLY TOP Handle ONLY 000506 HANDPULSE ASSEMBLY BOTTOM HAND
9. BASE CAP R 23 PART 000562 000634 000632 000631 000633 000611 000507 022553 000499 000500 000492 000495 000606 000605 010083 022271 000866 000602 022696 022882 022561 022448 022658 022476 022812 022720 000503 022719 022754 022755 022791 000621 000588 000591 000592 000598 000565 022946 023105 022558 022559 000608 lt n SU S po a S NO 41 42 42 1 42 2 42 3 42 4 42 5 42 6 43 44 45 47 48 49 50 50 2 50 3 50 4 50 5 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 78 79 80 81 FRAME BASE L 000607 FAN ASSEMBLY 000616 BOTTOM FAN COVER TOP FAN COVER FAN SWITCH DEFLECTOR FAN GRILL FAN GRILL ANCHOR FAN M8 x 30x 35 58243 Softer 30060 81 35 023016 MOTOR COVER 000557 1400m m_FOOT RAIL 000532 BEVERAGE HOLDER 000635 38 BUTTON HEAD END CAP 022024 HANDPULSE ASSY 022672 650 m m_HANDPULSE CABLE 022756 HANDPULSE ASSEMBLY TOP 022757 HANDPULSE ASSEMBLY BOTTOM 022758 HANDLE BAR END CAP 022759 FRAME FRONT COVER 000599 BOTTOM CONSOLE COVER 000596 HANDGRIP SIDE CAP R Comes as SET 000610 HANDGRIP SIDE CAP L Comes as SET REAR ADJUSTMENT BASE L 000612 REAR ADJUSTMENT BASE R 000613 MOTOR COVER ANCHOR 000922 24x 10x 3T_NYLO
10. D COUNTERSINK SCREW M3 x 10m m_PHILLIPS HEAD SCREW 5 x 15m m_PHILLIPS HEAD SCREW 5 16 42 _PHILLIPS HEAD SCREW 5 NYLON NUT 1 2 x 8T_NYLON NUT 3 8 x 7T_ NYLON NUT 5 16 x 6T_ NYLON NUT 8 8 NYLON NUT 3 8 x 6 5T_ NUT for Foot Pad M3_ NUT 35 5 16 x 1 5T_ FLAT WASHER 7 25x 10x 1 5T_ FLAT WASHER 7 19x 10x 1 5T_ FLAT WASHER 5 7 10x 1 0T_ FLAT WASHER 5 16 x 18 x 1 5T_ FLAT WASHER 5 7 12x 1 0T_ FLAT WASHER 5 7 15x 1 0T_ FLAT WASHER 23 7 13x5 5T x DISHED WASHER 6 5 x 25 x 50 x 1 5 2 5 _ WASHER 10 SPRING WASHER M3_SPRING WASHER 5 15 WASHER 4x12m m_SELF TAPPING SCREW 5x16m m_TAPPING SCREW Black 5x19m m_TAPPING SCREW 3 5 x 6 m m_SELF TAPPING SCREW 5 x 16m m_TAPPING SCREW 3 x10m m_SELF TAPPING SCREW 3 5 x 12 m m_SELF TAPPING SCREW 3x10 m m_TAPPING SCREW 4x38m m_SELF TAPPING SCREW 3 5 x 16 m m_TAPPING SCREW 3 x 10 m m_SELF TAPPING SCREW 5 IRON PLATE NUT 5 16 x 1 2 HEAD SOCKET SCREW COMBINATION M5 ALLEN WRENCH amp PHILLIPS HEAD SCREW DRIVER M6 ALLEN WRENCH 3 x 10 m m _SELF TAPPING SCREW 3x 8m m_SELF TAPPING SCREW PLASTIC WASHER FRONT MOTOR COVER TOP MOTOR COVER PLATE 0 8T_SPRING FOR CONSOLE Hardware Kit Decal Side Decal Console 17 023082 000913 023102 000080 030039 010125 000126 000077 000070 010110 010125 010110 023082 010113 010115 000325 02297
11. IP RUBBER L NON SLIP RUBBER R BOTTOM CONSOLE COVER HANDGRIP SIDE CAP R COMES AS SET HANDGRIP SIDE CAP L REAR ADJUSTMENT BASE L REAR ADJUSTMENT BASE R MOTOR COVER ANCHOR D 710 7 24x 3T_NYLON WASHER 50 13 x 3T_NYLON WASHER 30 x 3 8 FOOT PAD SENSOR RACK SAFETY KEY BELT GUIDE 7 14x 10x 35_ WHEEL SLEEVE MAGNET FOOT RAIL 1 2 x 1 1 4 CARRIAGE BOLT 1 2 x 1 HEAD SCREW 3 8 x 4 1 2 SOCKET HEAD CAP SCREW 3 8 x 3 3 4 _BUTTON HEAD SOCKET SCREW 3 8 x 1 1 2 HEAD SCREW 3 8 x 1 _HEX HEAD SCREW 3 8 x 2 FLAT HEAD SOCKET SCREW 5 16 x 1 _BUTTON HEAD SOCKET SCREW 5 16 x 2 3 4 _BUTTON HEAD SOCKET SCREW 16 022812 022720 022721 022719 000617 000588 000591 000592 000597 022946 022940 000581 022558 022559 022482 022967 000127 000603 000604 022024 000586 000587 000313 000314 000596 000582 000593 000594 022484 022713 022989 022945 000595 023101 010041 000629 000062 000061 022885 000125 022314 NINNA me e NNNNNNR KN ABN 52 N ND RR 1 12 NNO BR N RR 89 90 92 93 94 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 124 125 126 127 128 130 131 132 133 134 135 136 137 138 M8 60 HEAD SCREW M8 80m m_SOCKET HEAD SCREW M8 x 35m m_FLAT HEA
12. LE BAR END CAP SENSOR W CABLE BREAKER 15 Amp POWER SOCKET ON OFF SWITCH POWER CORD 19 000561 000628 000627 022928 030101 000564 000865 023095 022553 000497 000498 000491 000601 022972 023068 010026 010083 022271 000574 000572 000602 022696 022670 022754 022755 022672 22756 022757 022758 02 2759 022561 022448 022658 022476 022812 45 46 47 48 49 50 51 52 52 1 52 2 52 3 52 4 52 14 52 16 53 54 55 56 57 58 59 60 61 62 63 64L 64R 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 100m m 764 x 764_CONNECTING CABLE BLACK 300m m x 764 764 CABLE WHITE 300m m 764 764_CONNECTING CABLE BLACK 800 m m_COMPUTER CABLE UPPER 1150 m m_COMPUTER CABLE LOWER 1300 m m_COMPUTER CABLE MIDDLE 1000m m_GROUND WIRE CONSOLE TOP CONSOLE COVER BOOK RACK does not come as Set BEVERAGE HOLDER FACE PLATE LENS SPEAKER SOUND BOARD W CABLE SPEAKER AMP TOP MOTOR COVER SPEED ADJUSTMENT SWITCH W CABLE INCLINE ADJUSTMENT SWITCH W CABLE M8 30 x 35_CUSHION softer 030060 75_WHEEL A 62_WHEEL B FOOT RAIL CAP L FOOT RAIL CAP R 38_ BUTTON HEAD END CAP FRAME BASE CAP L FRAME BASE CAP R NON SLIP RUBBER L NON SLIP RUBBER R BOTTOM CONSOLE COVER HANDGRIP SIDE CAP R Comes as SET HANDGRIP SIDE CAP L REAR ADJUSTMENT BASE L REAR ADJUSTMENT BASE R MOTOR COVER ANCHOR D
13. N WASHER A 50x 13x 3T_NYLON WASHER B 38 x 3 8 _FOOT PAD 22713 25 x 50 END CAP 000630 1 2 x 4 13m m _BOLT 000636 SAFETY KEY 022945 BELT GUIDE 000595 1 2 x 57m m_HEX HEAD SCREW 3 8 x 4 1 2 _SOCKET HEAD CAP SCREW 000580 3 8 x 4 SOCKET HEAD CAP SCREW 3 8 x 1 3 4 HEAD SCREW 020349 8 60m m_HEX HEAD SCREW M8 x 80m m_SOCKET HEAD CAP SCREW 8 x 50m m_FLAT HEAD COUNTERSINK SCREW 8 30m m_FLAT HEAD COUNTERSINK SCREW 3 8 x 3 4 _BUTTON HEAD SOCKET SCREW 022999 3 8 x 1 HEAD SCREW 000061 1 2 x IST_NYLON NUT 3 8 x 7T_NYLON NUT 000080 M8 amp _NYLON NUT 719 7 10x 1 5T_FLAT WASHER 25 7 10x 1 5T_FLAT WASHER 5x 15x 1 0T_FLAT WASHER 7 6 5 x 25 x 1 5T x 2 5H_CONCAVE WASHER 24 02248 AARON D ENN ENE 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 5 RAISED WASHER 6 5 x 25 x 1 5T x 5 8H_ CONCAVE WASHER 5 IRON PLATE NUT 10 x1 5T_SPRING WASHER 5 x19 m m_TAPPING SCREW 5 x16 m m_TAPPING SCREW Black 4x12 m m_SELF TAPPING SCREW 3 5x12 m m_SELF TAPPING SCREW 3 5x43 m m_SELF TAPPING SCREW 3x10 m m_SELF TAPPING SCREW 5x16 m m_ TAPPING SCREW Black 3x10 m m_ TAPPING SCREW 4x38 m m_SELF TAPPING SCREW 3x10 m m_SELF TAPPING SCREW 3 5 xl16m m_TAPPI
14. ND CAP SENSOR W CABLE BREAKER 15 AMP POWER SOCKET ON OFF SWITCH 15 PART 000561 000628 000627 022928 030101 000563 000865 022554 022553 000497 000498 000488 000600 022972 023068 010026 010083 022271 000571 000572 000602 022696 022670 022754 022755 022672 022756 022757 022758 022759 022561 022448 022658 022476 DO Nee CN ND 13 DN 44 45 46 47 48 49 50 51 52 52 1 52 2 52 3 52 4 52 14 52 16 53 54 55 56 57 58 59 60 61 62 63 64L 64R 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 POWER CORD 100m m x 764 x 764 CABLE BLACK 300m m x 764 x 764_CONNECTING CABLE WHITE 300m m x 764 x 764_CONNECTING CABLE BLACK 800 m m_COMPUTER CABLE UPPER 1150 m m_COMPUTER CABLE LOWER 1300 m m_COMPUTER CABLE MIDDLE 1000m m_GROUND WIRE CONSOLE TOP CONSOLE COVER BOOK RACK order as separate pcs 2 racks per console BEVERAGE HOLDER FACE PLaTE LENS SPEAKER SOUND BOARD W CABLE SPEAKER AMP TOP MOTOR COVER SPEED ADJUSTMENT SWITCH W CABLE INCLINE ADJUSTMENT SWITCH W CABLE M8 x 30 x 35_CUSHION softer 030060 75_WHEEL A 62_WHEEL B FOOT RAIL CAP L FOOT RAIL CAP R 38 BUTTON HEAD END CAP FRAME BASE CAP L FRAME BASE CAP R NON SL
15. NG SCREW 3 8 5 16 x 3 4 HEAD SOCKET SCREW 5 16 1 2 BUTTON HEAD SOCKET SCREW 3 8 x 2 HEAD SOCKET SCREW 3 8 x 2T_ SPRING WASHER M3 x 18 m m_TAPPING SCREW COMBINATION 5 ALLEN WRENCH amp SCREWDRIVER M6 ALLEN WRENCH 3 x 10 m m_SELF TAPPING SCREW 3x 8m m_SELF TAPPING SCREW PLASTIC WASHER NON SLIP RUBBER L NON SLIP RUBBER R SENSOR RACK MOTOR FAN for CONTROLLER M4x35 m m_TAPPING SCREW NYLON NUT 4x 10x 1 0T_FLAT WASHER 250m m_ BLACK CONNECTING CABLE OF MOTOR FAN 250m m_ WHITE CONNECTING CABLE OF MOTOR FAN HARDWARE KIT DECAL SIDE DECAL CONSOLE 25 010109 030057 010110 000070 010113 023082 010110 010115 000325 023082 022979 000100 000085 023090 000053 022248 000089 022973 023082 000313 000314 022989 000876 000637 000538 000614 000615 000624 ENE DANKE EP
16. ack on PROCEDURE 9 Replacing drive motor 9 1 Turn power switch off 9 2 Disconnect red and black motor wires from controller 9 3 Loosen tension bolt and remove four motor bolts 9 4 Take off drive belt 9 5 Insert new motor into place 9 6 Put drive belt on 9 7 Putin four motor bolts Do not tighten them all the way down 9 8 Tighten the tension bolt until you only have about an inch of play in the drive belt 9 9 Tighten down the four motor bolts 9 10 Plug the motor wires into the controller PROCEDURE 10 Replacing incline motor 10 1 Turn power switch off 10 2 If possible fold up unit 10 3 Turn treadmill onto its side 10 4 Disconnect motor wires from controller 10 5 Remove bolt from incline tube 10 6 Remove bolt from top of incline motor and take out motor 10 7 Insert new motor and put in bolt on the top 10 8 Reconnect motor wires to controller 10 9 Turn on unit The new motor should turn until it is at zero 10 10 Insert bolt into incline tube PROCEDURE 11 Controller diagram 1 1 3515 AC 2 SHUT DOWN 5 DOWN POWER LIMIT UP SPEED PWM SENSOR JK3 e Down U 1 JK2 1 1 White wire from power switch 2 AC2 Black wire from power switch 3 Incline Motor Connection Down Black wire to inc mtr Com White wire to inc mtr Up Red wire to inc mtr 4 Transformer Connections JK5 Black Black JK6 Blue B
17. ase labor fee to the dealer 6 Units that are dealer stock or floor models 7 Trips for diagnostic visit 8 Residential units in a commercial setting Credit will not be issued for repairs in which 1 Parts required for return are not returned to Spirit within 30 days 2 All paperwork is not completed or returned 3 Spirit confirms that work was not completed Warranty Labor Reimbursement Policy Spirit has established a set of guidelines that are fair to both independent service companies and to Spirit Our policy on labor warranty reimbursement is simple we pay a one time flat completion fee of 80 per service occurrence Once all work required to complete the repair has been finished and all parts required for return have been returned to Spirit either credit or payment in the amount of 80 will be issued to your company The one time flat completion fee of 80 will be paid only when the repair is complete and the unit has been returned to proper working condition If your company needs consideration for labor or trip fees that are higher than Spirit s standard fees they will be evaluated on a case by case basis e g travel to perform service work in Manhattan Any change in the fee schedule must be approved in writing by Spirit before any work is performed For Dealers That Wish To Use Third Party Service It is Spirit s policy that all dealers service products that they sell to end users If your company chooses to use an ind
18. e motor brushes 3 Replace motor procedure 9 Deck noise 1 Tighten deck bolts Squeaking or creaking while walking 2 Clean and re lube deck Repair Procedures PROCEDURE 1 Calibrating the unit 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 Remove tether cord Press and hold the START and FAST buttons Replace the tether cord while maintaining the buttons Display will show FACTORY SETTING Press ENTER Units English Metric Press UP or DOWN to change Press ENTER Adjust wheel diameter using UP or DOWN Should be 2 75 Press ENTER Adjust minimum speed to 0 5 using UP and DOWN Press ENTER Adjust maximum speed to 12 using UP and DOWN Press ENTER Adjust maximum elevation to 15 using UP and DOWN Press START to begin calibration DO NOT STAND ON BELT DURING CALIBRATION PROCEDURE 2 Checking wire harness for continuity 2 1 2 2 2 3 2 4 2 5 Set your multimeter to read ohms Place the test leads at opposite ends of the wire make sure both leads are on the same wire and are in contact with metal If the reading is close to 0 ohms the wire has continuity unbroken If the reading is very high or there is no reading at all there is no continuity If there is no continuity the harness needs to be replaced PROCEDURE 3 Speed sensor adjustment 3 1 3 2 3 3 Take off the motor hood The speed sensor is located on the frame near where the drive belt goes around the front roller The sensor should be adjusted
19. ependent company for service you are responsible for all service work Our labor reimbursement policies apply in every case and any charges in excess of Spirit s one time flat completion fee will be billed back to the selling dealer In certain circumstances we will work directly with an independent service company but we will not pay for any service that deviates from our policy for dealers wishing to have this arrangement Dealers will be responsible to the service company for all charges disallowed by Spirit Any deviation from Spirit policy must be approved in advance in writing 11 Fax to 870 930 9013 SPIRIT 5 www spiritfitness com Attenti on PARTS PURCHASE ORDER Fill in completely for processing All orders are shipped F O B Spirit Mfg Jonesboro Arkansas Dealer Name Account No Ship to Street amp No Street amp No City State i City State Phone Number Fax Number Phone Number Fax Number Purchase Order Dealer Buyer s Name All parts ordered are considered stock orders unless a serial number is listed below each Date of Order parts description box A serial number listed will qualify it for warranty evaluation Description _ Order Completion Orders must be signed Shipping Instructions All orders will be shipped via ground delivery part is not accompanied by a serial number it will be assumed that the unless otherwise indicated Buyer will be responsible for all expe
20. ff To unlock display press START and ENTER Functions Sleep Mode On Off Press ENTER to turn on or off Units English Metric Press ENTER to change Maintenance Lube Message Reset Press ENTER to reset Odometer Reset Press ENTER to reset Pause Mode On Off Press ENTER to turn on or off Display Test Test all LED s Key Test Test all buttons on console CONTACTING CUSTOMER SERVICE It is the responsibility of the Dealer to assemble and setup any Spirit product they have sold as well as diagnose problems and perform service regardless of the product s location Recognizing the importance of insuring the consumer s satisfaction Spirit technical support will always be available to assist the Dealer in diagnosing a problem All warranties are valid from the original date of purchase by the original purchaser PARTS ORDERS Fax 870 930 9013 Fax your order using a completed parts purchase order to 870 930 9013 Please do not call to place your parts orders fax only Service technicians are available to assist in the repair of treadmills If taking parts orders by telephone technical service calls will go unanswered Standard shipping is UPS ground If you need an order shipped by another method you must pay for shipping CUSTOMER SERVICE Call 800 258 4555 Calling from Store Location Dial 1 to reach the first available technician or select the extension number for one technician You must have the serial number of the mach
21. ine Eddie Greene Customer Service Supervisor ext 630 Jerry Savage Customer Support ext 632 Travis Lawrence Customer Support ext 633 Kevin Thomas Customer Support ext 628 If the technician you choose is unavailable leave a detailed message Leave only one message Do not call another extension Do not leave multiple messages This results in a duplication of effort and keeps our technicians from assisting you and other customers in a prompt manner Calling from Customer Location Dial 0 for an operator Relay to the operator you are a dealer and in a customer s home You will be assisted by the first available technician TREADMILL WARRANTY Spirit Manufacturing Inc warrants all its treadmills parts for a period of 5 years from the date of retail sale as determined by sale receipt or eighteen 18 months from the original factory shipping date whichever comes first Spirit s responsibilities include providing new or remanufactured parts at Spirit s option and technical support to our independent dealers and servicing organizations In the absence of a dealer or service organization these warranties will be administered by Spirit directly to a consumer An extended warranty period applies to the following components Drive Motor 30 Years Deck Wear 5 Years Electronics Belt Rollers 5 Years Frame Weldments Lifetime All other Components 5 Years 10 WARRANTY POLICY Parts Returns It is very important that you have
22. is pressed replace the controller If it does not light when the START button is pressed replace the console Run the calibration procedure procedure 1 Check wire harness for continuity procedure 2 If there is an ERR message in the incline window make sure that all the wires from the incline motor are connected to the controller correctly procedure 12 If they are connected correctly and the calibration does not fix replace the incline motor procedure 10 When the UP and DOWN buttons are pressed there should be a beep and a number change in the incline window If there isn t replace the console Observe the UP and DOWN diagnostic lights on the controller procedure 11 When the UP or DOWN buttons are pressed you should 1 see one of the lights come on and 2 hear a relay click If there is no relay click and no diagnostic lights replace console and controller procedure 7 If there is a relay click and a diagnostic light and motor wires are connected correctly replace incline motor Adjust torque boost procedure 6 Adjust speed sensor procedure 3 Replace controller procedure 7 Troubleshooting Guide MECHANICAL SYSTEM Belt noise Check belt to see if it needs to be tracked Take off motor hood to make sure noise is from belt Check belt and deck for damage Clean deck and re lube Drive motor noise 1 Check wires around motor for rubbing Remove clean and re insert th
23. lue JK7 Red Red 5 Incline Potentiometer VR 6 Lower Wiring Harness Connection 7 Speed Sensor Connection 8 Torque Boost Adjustment Adjust at lower speeds to eliminate motor surging 9 Motor Connection M Black motor wire 10 Motor Connection M Red motor wire PROCEDURE 12 Wiring diagram To Upright Harness Amp Board To Fan Assy To Pulse Grip Heart Rate Rec Inc Switch Transformer Motor w _ 18 8 MOT SHUTDOWN 58 S 8 2 1 RED uP Incline 2 Motor 12 Speed Sensor Z 100 700 4 21 05 PROCEDURE 13 Engineering mode 1 Remove the tether cord 2 Press and hold the START ENTER and STOP buttons and replaced the tether cord The display will say ENGINEERING MODE Press ENTER 4 Press the UP and DOWN buttons to scroll through the following sub menus Calibration Factory Settings Security Functions Display Test Key Test 5 Press ENTER to access the desired program Go Calibration Speed Calibration In this mode you can test the speed Incline Calibration In this mode you can test the incline Factory Settings This mode will allow you to view the Wheel size Max inc Max and Min speed Use the UP and DOWN buttons to scroll through They cannot be changed here Security Child Lock On Off Press ENTER to turn on or o
24. not only the model number but also the serial number on hand when placing a parts order If a serial number is provided at the time a warranty parts order is placed the required parts will be sent to you at no charge If the unit is no longer covered under warranty the parts will be billed to you on 30 day payment terms If a warranty replacement part is required to be returned to Spirit it will be noted on the packing list included in your shipment Also noted on the packing list will be the amount you will be invoiced if the parts are not returned within 30 days Parts Required to be Returned for Credit Upper and Lower Electronics STS SC SL Inspire Z XT Series Paperwork Requirement A copy of your invoice or packing list and diagnostic form if included with replacement part must be returned with the defective part to receive warranty consideration Warranty Labor Reimbursement Procedure Complete Request for Warranty Labor Credit Form Fax completed form to Terry Jordan at 870 930 9013 Once Spirit has received your returned parts your request will be processed and returned by fax to you What is Not Covered 1 Failures created due to improper installation or maintenance 2 Repairs requiring only simple adjustments fuses or calibrations 3 Damages sustained from shipping Freight claim must be filed with your carrier 4 Repairs that are made beyond the warranty period 5 Repairs where the customer is paying the b
25. to about 1 16 of an inch from the front roller PROCEDURE 4 Checking treadmill circuit breaker 4 1 4 2 The circuit breaker is a small red button between the power cord and the power switch Press the button in to reset PROCEDURE 5 Check roller for magnet 5 1 The front roller should have round magnet and a round counter weight 5 2 Take a screw or something metallic and test each one 5 3 Only one should be magnetic PROCEDURE 6 Adjust Torque Boost 6 1 Using a small screw driver turn the dial counter clockwise until it stops 6 2 Press the START button on the console 6 3 With someone standing on the walking belt turn clockwise until the belt begins to move 6 4 Increase the speed and check for smooth belt movement See PROCEDURE 11 for location of Torque Boost PROCEDURE 7 Replacing controller 7 1 Disconnect power cord from unit 7 2 Remove motor hood 7 3 Remove two Phillips screws holding in the controller 7 4 Disconnect all wires connected to the controller 7 55 Insert new controller secure with Phillips screws 7 6 Reconnect wires to controller See Procedure 12 PROCEDURE 8 Replacing wire harness 8 1 Turn power switch off 8 2 Unplug harness from console and controller 8 3 Tie the end of the new harness to the old harness with a zip tie or spare wire 8 4 As you pull the old harness out of the upright you will pull the new harness in 8 5 Connect to board and console amp turn power b
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