Spirit XT175 Manuel utilisateur

SERVICE MANUAL

XT175

XT275

XT375

XT475

XT675

Table of Contents

TroubleshootingGuide

ElectronicSystem………………………………………………...3

Mechanical System…………………………………………….....4

Repair Procedures

Procedure 1 (Calibrating the unit)………………………………...5

Procedure 2 (Checking wire harness)………………………….....6

Procedure 3 (Speed sensor adjustment)…………………………..6

Procedure 4 (Checking treadmill circuit breaker)………………...6

Procedure 5 (Checking roller for magnet)………………………..6

Procedure 6 (Adjust torque boost)………………………………..6

Procedure 7 (Replacing controller)…………………………….....7

Procedure 8 (Replacing wire harness)…………………………....7

Procedure 9 (Replacing drive motor)……………………………..7

Procedure 10 (Replacing incline motor)………………………….7

Procedure 11 (Controller diagram)……………………………….8

Procedure 12 (Wiring diagram)…………………………………..9

Procedure 13 (Engineering mode)……………………………......10

XT Series Warranty

ContactingTechnical Service…………………………………......11

TreadmillWarranty…………………………………………….....12

WarrantyPolicy…………………………………………………..13

Parts Order Form………………………………………………....14

Warranty Labor Credit Form……………………………………...15

XT175

Exploded view……………………………………………............16

Parts list........................................................................................17 - 19

XT275

Exploded view…………………………………………………....20

Parts list........................................................................................21 - 23

XT375

Exploded view…………………………………………………....24

Parts list........................................................................................25 - 28

XT475

Exploded view...............................................................................29

Parts list.........................................................................................30 - 33

XT675

Exploded view...............................................................................34

Parts list.........................................................................................35 - 37

Troubleshooting Guide

ELECTRONIC SYSTEM

No power

There is no power to the console.

LS error

Belt movement for a few seconds then LS error 1. Run the calibration procedure. (procedure 1)

2. Adjust speed sensor. (procedure 3)

3. Check roller for magnet (Procedure 5)

4. Check wire harness for continuity. (procedure 2)

5. If roller has a magnet and sensor adjustment does not fix, replace speed

sensor.

LS error

No belt movement at all then LS error

Incline does not work

Belt surging

Belt speeds up and slows down frequently

1. Unit must be plugged into an outlet with power

2. Power switch must be illuminated

3. Tether cord must be in place

4. Check treadmill circuit breaker. (procedure 4)

5. Check “POWER” LED on controller. (procedure 11)

6. Make sure wires on board are plugged in securely.

7. Check wire harness for continuity. (procedure 2)

8. If LED’s on controller are not lit, test fuse on controller. If fuse is good,

replace controller. (procedure 7)

9. If LED’s are on, replace console.

1. Run the calibration procedure. (procedure 1)

2. Check wire harness for continuity. (procedure 2)

3. Look at LED labeled “PWM”. (procedure 11)

-If it lights up when the START button is pressed, replace the controller.

- If it does not light when the START button is pressed, replace the

console.

1. Run the calibration procedure. (procedure 1)

2. Check wire harness for continuity. (procedure 2)

3. 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)

4. 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.

5. Observe the UPand DOWN diagnostic lights on the controller (procedure

11). When the UPor 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,

lower and middle wire harness (procedure 8), and controller

(procedure 7).

- If there is a relay click and a diagnostic light and motor wires

are connected correctly, replaced incline motor

1. Adjust torque boost (procedure 6)

2. Adjust speed sensor (procedure 3)

3. Replace controller (procedure 7)

Troubleshooting Guide

MECHANICAL SYSTEM

Belt noise

Drive motor noise

Deck noise

Squeaking or creaking while walking

1. Check belt to see if it needs to be tracked.

2. Take off motor hood to make sure noise is from belt.

3. Check belt and deck for damage.

4. Clean deck and re-lube.

1. Check wires around motor for rubbing.

2. Remove, clean, and re-insert the motor brushes

3. Replace motor. (procedure 9)

1. Tighten deck bolts

2. Clean and re-lube deck

PROCEDURE 1: Calibrating the unit

XT175

1.1 Remove tether cord.

1.2 Press and hold the START and FAST buttons. Replace the tether cord while maintaining the buttons.

Displaywill go into test mode. “SET” will blink in the middle of the screen.

1.3 Use STOP button to change from Km (metric) to M (English) in the Speed window.

1.4 Wheel size will be displayed in the Speed window. Use the FAST or SLOW buttons to change. It

should be set to 2.50. Press START.

1.5 Minimum speed will be displayed in the Speed window. Use the FAST or SLOW buttons to change.

It should be set to 0.5. Press START.

1.6 Max speed will be displayed in the Speed window. Use the FAST or SLOW buttons to change. It

should be set to 10.0. Max elevation will be displayed in the Incline window. Use UPor DOWN

buttons to change. It should be set to 15.

1.7 Press START. Unit will now auto-calibrate the speed and incline. Do not stand on belt during

calibration. Unit will reset when it completes the calibration.

XT275

1.1 Remove the tether cord.

1.2 Replace the tether cord while maintaining the buttons. Display will go into test mode. Press ENTER.

1.3 Adjust wheel size. Use UP or DOWN buttons to change. Should be set to 2.30. Press ENTER.

1.4 Adjust minimum speed. Use UP or DOWN buttons to change. Should be set to 0.5. Press ENTER.

1.5 Adjust maximum speed. Use UP or DOWN buttons to change. Should be set to 10.0. Press

ENTER.

1.6 Adjust maximum elevation. Use UP or DOWN buttons to change. Should be set to 15. Press

ENTER.

1.7 Grade return On/Off. Use UP or DOWN buttons to change. Should be ON. Press START.

1.8 Unit will now auto-calibrate the speed and then incline and will reset when complete. Do not stand

on belt during calibration.

XT375 XT475 XT675

1.1 Remove tether cord.

1.2 Press and hold the START and FAST buttons. Replace the tether cord while maintaining the buttons.

Display will show “FACTORYSETTING”. Press ENTER.

1.3 Power On/Off. Press UP or DOWN to change. Press ENTER.

1.4 Units English / Metric. Press UP or DOWN to change. Press ENTER.

1.5 Adjust wheel diameter using UP or DOWN. Should be 2.810 for XT200 & XT600

3.060 for XT800. Press ENTER.

1.6 Adjust minimum speed to 0.5 using UP and DOWN. Press ENTER.

1.7 Adjust maximum speed to 12 using UP and DOWN. Press ENTER.

1.8 Adjust maximum elevation to 15 using UP and DOWN.

1.9 Press START to begin calibration. DO NOT STAND ON BELT DURING CALIBRATION.

Repair Procedures

PROCEDURE 2: Checking wire harness for continuity

2.1 Set your multimeter to read ohms.

2.2 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.

2.3 If the reading is close to 0 ohms, the wire has continuity (unbroken).

2.4 If the reading is very high or there is no reading at all, there is no continuity.

2.5 If there is no continuity, the harness needs to be replaced.

PROCEDURE 3: Speed sensor adjustment

3.1 Take off the motor hood.

3.2 The speed sensor is located on the frame, near where the drive belt goes around the front roller.

3.3 The sensor should be adjusted to about 1/16th of an inch from the front roller.

PROCEDURE 4: Checking treadmill circuit breaker

4:1 The circuit breaker is a small, red button between the power cord and the power switch.

4.2 Press the button in to reset.

PROCEDURE 5: Check roller for magnet

5.1 The front roller should have a 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.

7.5 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, & turn power back 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 Put in 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”.

10.10Insert bolt into incline tube.

JK 6

DOWN

COM

AC 1

AC 2

FUSE

Down

JK 7

JK 5

JK 3

TORQUE

SPEED

SENSOR

JK 2

JK 3

M-

POWER

SHUT DOWN

JK 3

MOT

DRV

JK 1

PWM

LIMIT

M+

456

1) AC1 : 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, Blue

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 11: Controller diagram

PROCEDURE 12: Wiring diagram

PROCEDURE 13: Engineering mode (XT375-XT475-XT675 only)

1. Remove the tether cord.

2. Press and hold the START, ENTER, and STOP buttons and replaced the tether

cord.

3. 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

-DisplayTest

-Key Test

5. Press ENTER to access the desired program.

-Calibration

Speed Calibration – In this mode, you can test the speed.

Incline Calibration – In this mode, you can test the incline.

-FactorySettings

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 off. 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. 10

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