Spirit Z100 Manuel utilisateur

SERVICE MANUAL

Z 100

Z 500

Z 900

Table of Contents

TroubleshootingGuide

ElectronicSystem……………………………………………….3

MechanicalSystem……………………………………………...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 boost)………………………………6

Procedure 7 (Replacing controller)……………………………...6

Procedure 8 (Replacing wire harness)…………………………...6

Procedure 9 (Replacing drive motor)……………………………6

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

Procedure 11 (Controller diagram)………………………………7

Procedure 12 (Wiring diagram)………………………………….8

Procedure 13 (Engineering mode)…………………………….....9

Z-SeriesWarranty

ContactingTechnical Service…………………………………....10

TreadmillWarranty……………………………………………...10

WarrantyPolicy………………………………………………….11

Parts Order Form………………………………………………...12

Warranty Labor Credit Form…………………………………….13

Z100 ExplodedView...…………………………………………………14

Parts List....................................................................................15-17

Z500 ExplodedView....………………………………………………...18

Parts List......................................................................................19-21

Z900 ExplodedView....………………………………………………...22

Parts List......................................................................................23-25

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

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 notlit, 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. 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.

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 STARTbutton 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 (procedure12). 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

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.

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

Repair Procedures

PROCEDURE 1: Calibrating the unit

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 “FACTORY SETTING”. Press ENTER.

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

1.4 Adjust wheel diameter using UP or DOWN. Should be 2.75. Press ENTER.

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

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

1.7 Adjust maximum elevation to 15 using UP and DOWN.

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

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”.

10.10 Insert bolt into incline tube.

PROCEDURE 11: Controller diagram

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 12: Wiring diagram

To Spd. Switch

Incline

To Pulse Grip

Motor

To Upright Harness

BLACK

WHITE

BLACK

RED

DOWN

COM

Down

JK 7

RED

FUSE

AC 1

AC 2

RED

BLACK

SHUT DOWN

JK 6

JK 3

MOT

DRV

POWER

JK 1

LIMIT

JK 5

TORQUE

PWM

SPEED

JK 2

SENSOR

M-

M+

JK 3

Speed Sensor

Z 100-700

4-21-05

BLACK

RED

JK 6

BLUE

JK 2

Transformer

JK 2

JK 5

JK 10

JK 3

JK 9

JK 5

To Tether Cord

JK 1

To Inc. Switch

JK 3

JK 2

JK 4

To Fan Assy.

Motor

Heart Rate Rec.

Amp. Board

JK 5

PROCEDURE 13: Engineering mode

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.

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 machine.

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.

CallingfromCustomerLocation

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.

TREADMILLWARRANTY

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

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