Spirit XE860 User manual

XE860 Service Manual

Plastic Parts

Front Mast Cover Console Rear Handlebar Cover (R)

Rear Mast Cover Console Mast Cover Round Disk Cover, Crank

Rear Handlebar cover (L) Chain Cover (R)

Round Disk Cover

front Stabilizer Cover Rear Stabilizer Cover Right Pedal

Connecting Arm CoverA(L, R) Left Pedal Left Rail Cover(Metal)

Pedal Arm Cover Right Rail Cover(Metal)

Connecting Arm Cover B(L, R) Chain Cover (L) Rail Suppoert Assembly(Metal)

Slide Wheel Cover (Inside metal Rail Cover)

Skeleton

Bushing Housing Left Handlebar

Left Pedal Console mast

Left Pedal Arm Right handlebar

Rail Assembly Inductive Flywheel

Right Pedal Arm Cross Bar

Right Connecting arm Idler Wheel Assembly Main Frame

Drive Pulley

CONTENTS：

I. Disassembling and assembling pf parts

1. Console

2. Connecting Arm Assembly

3. Pedal Arm Assembly

4. Left and right Chain Covers

5. Cross Bar Assembly

6. The Belt

7. Idler Wheel assembly

8. Inductive Flywheel

9. Drive Pulley

10. Bushing Housing

11. Slide Wheel

II. Troubleshooting

1. Console

2. Left/Right Chain covers and Round Disk Cover,

Crank

3. Inductive Flywheel

4. The Belt

5. Left and right Handlebars

6. Bushing Housing

7. Pedal Arms, Connecting Arms and Slide Wheels

III. Q＆A

1. Noises

2. Slippage

3. Wobble

4. Smoothness

5. Other Problems

Model XE860 Work Assembling/Disassembling

Part 1 Console Rev

Procedures

1. Use Phillips head screwdriver to

release

3pcs of M5x12mm screws,

2pcs of self tapping screws and

4pcs of M5 x 10 mm screws.

Disconnect computer cables and

handpulse cables and take apart

the Console, as shown in figure 1

and 2.

2. To resume, Connect the cables

back on and tighten 4pcs of M5 x

10 mm to secure the Console.

Return and secure Fron Mast

Covers.

1

2

Model XE860 Work Assembling/Disassembling

Part 2 Connecting Arms Rev

Procedures

1. Use Phillips head screwdriver to

unscrew Connecting arm Covers

A and B, as shown in figure 1.

2. Use 12 mm and 13 mm wrenches

to release hex head bolt, which

secures the Fish-eye bearing,

together with 5/16" x 18 x 1.5T

flat washer and 5/16" x 7T

nut, as

shown in figure 2.

3. Use 12 mm wrench to

release5/16" x 15m/m hex head

bolt and 5/16" x 23 x 1.5T flat

washer, which secure the

Connecting Arm. Then release

the carriage bolt and take apart

the Connecting Arm, as shown in

figures 3 and 4.

1

2

3

4

Model XE860 Work Assembling/Disassembling

Part 2 Connecting Arms Rev

Procedures

4. Use Phillips head screwdriver to

release 4pcs ofM5x10mm and

take apart the plastic Pedal, as

shown in figure 5.

5. To resume, return and tighten the

Pedal back on the Connecting

Arm and joint it with Pedal Arm

by inserting the carriage bolt and

tighten with 5/16" x 15m/m hex

head bolt and 5/16" x 23 x 1.5T

flat washer, as shown in figure 6.

6. Secure Fish-eye bearing with

5/16" x1-1/4" hex head bolt,

5/16"x 18 x 1.5T flat washer and

5/16" x 7T nut.

7. Return Connecting Arm Covers

A and B.

5

6

Model XE860 Work Assembling/Disassembling

Part 3 Pedal Arms Rev

Procedures

1. Follow procedure 2 to take apart

Connecting Arm.

2. Use Phillips head screwdriver to

release Pedal Arm Cover, then

release 6pcs of M5x12m/m

screws to and take left and right

Front Covers, as shown in figures

1 and 2.

3. Use M6 and 13 mm wrenches to

release M8 x 50 socket head cap

screw, which secures Pedal Arm

and Bushing Housing, together

with 2pcs of 5/16"×20×1.5T flat

washer and M8 x 7T nut. Pull

Pedal arm backward to take it

apart, as shown in figures 3 and

4.

4. To resume, join Pedal Arm with

Bushing Housi

ng and secure with

M8 x 50socket head cap screw,

2pcs of 5/16"×20×1.5T flat

washer and M8 x7T nut and

return Pedal Arm Cover and

Front Covers.

5. Follow procedure 2-5 to return

Connecting Arm.

1

2

3

4

Model XE860 Work Assembling/Disassembling

Part 4 Chain Covers Rev

Procedures

1. Follow procedures 2 and 3 to

take apart Connecting Arm and

Pedal Arm.

2. Press Console Mast Cover

slightly to release it from left and

right Chain Covers, as shown in

figure 1.

3. Use Phillips head screwdriver to

release 7 4x19 self tapping

screws and 3pcs of 5x16 tapping

screws and take apart right Chain

Cover, as shown in figures 2 and

3.

4. To release left Chain cover,

release 4x15 self tapping screw

and 1/4"x19 flat washer, which

are on the main frame, as well as

3pcs of 5x16 tapping screws.

Disconnect red and black power

cables with grounding cable to

release left Chain cover, as

shown in figures 4, 5 and 6.

1

2

3

4

Model XE860 Work Assembling/Disassembling

Part 4 Chain Covers Rev

Procedures

5. To resume, Connect AC cables

together with grounding wire.

6. Return left Chain cover onto the

main frame (be sure to place a

5/16" x 23 x 1.5T flat washer

between Chain Cover and

mainframe) and use Phillips head

screwdriver to return 4x15 self

tapping screw and 1/4"x19 flat

washer on the main frame (not

too tight for now), then tighten

with 3pcs of 5x16 self tapping

screws (with Chain Cover and

Crank Round Disk Cover match

well). Tighten 4x15 self tapping

screw, as shown in figures 7 and

8.

7. Match right Chain Cover with

left and secure with 7pcs of

4x19self tapping screws and 3pcs

of tappinf screws.

8. Follow procedures 3-4 and 2-5 to

resume Pedal Arm and

Connecting Arm.

5

6

7

8

Model XE860 Work Assembling/Disassembling

Part 5 Cross Bar Rev

Procedures

1. Follow procedures 2, 3and 4 to

take apart Connecting Arm, Pedal

Arm and both Chain covers.

2. Use a sharp tip stick to take off

Round Disk Cover, as shown in

figure 1.

3. Use 12 mm wrench to release

5/16" x 15m/m hex head bolt

with 5/16" x 35 x 1.5T flat

washer. Then use M6 wrench to

release M8x30 socket head cap

screw and take apart Cross Bar

with Round Disk, Crank, as

shown in figures 2 and 3.

4. Use Phillips head screwdriver to

release 8pcs of 5x16 tapping

screws with 1/4"x19 flat washers

and take apart Round Disk

Cover, Crank from Cross Bar, as

shown in figure 4.

1

2

3

4

Model XE860 Work Assembling/Disassembling

Part 5 Cross Bar Rev

Procedures

5. To resume, return Crank Round

Disk on the Cross Bar and put

them back on the Crank Axle,

match with the square hole for

7x7x25L Woodruff Key to return

it in the hole. Return M8x30

socket head cap screw and

tighten until it reads 600 Kgf-cm.

Then tighten with 5/16" x 15m/m

hex head bolt and 5/16" x 35 x

1.5T flat washer, as shown in

figures 5 and 6.

6. Follow procedures 4, 3 and 2 to

return Connecting Arm, Pedal

Arm, Chain covers and Round

Disk Cover.

5

6

Model XE860 Work Assembling/Disassembling

Part 6 The Belt Rev

Procedures

1. Follow procedures 2, 3, 4 and 5

to take Connecting Arm, Pedal

Arm, both Chain Covers and

Cross Bar.

2. Use 13 mm wrench to loosen

M8 x 7T nut on M8x170mm

J-bolt Then use Phillips head

screwdriver to loosen 3pcs of

M6x15 screws on the Idler

Wheel Assembly and take off the

Belt, as shown in figures 1, 2 and

3.

3. To resume, return the Belt onto

the Drive Pulley and Induction

Flywheel then adjust M8 x 7T

nut so tight the acoustic tension

gauge reads 170 Hz +/- 10 Hz, as

shown in figure 4.

4. Follow procedures 5, 4, 3, and 2

to resume other parts.

1

2

3

4

Model XE860 Work Assembling/Disassembling

Part 7 Idler Wheel Assembly Rev

Procedures

1. Follow procedures 2, 3, 4, 5 and

6 to take apart Connecting Arm,

Pedal Arm, both Chain Covers,

Cross Bar and the Belt.

2. Use 13 mm wrench to loosen M8

x 7T nut and 5/16" x 23 x 1.5T

flat washer on M8x170mm J-bolt

to release it. Then use Phillips

head screwdriver to release 3pcs

of M6x15 screws with 1/4"

spring washers and 1/4"x13x1T

flat washers and take apart the

Idler Wheel Assembly, as shown

in figures 1 and 2.

3. To resume, use 3pcs of M6x15

screws with 1/4" spring washers

and 1/4"x13x1T flat washers to

return Idler Wheel Assembly (not

too tight until the Belt has been

returned). Then return the J-bolt

and follow procedures 6, 5, 4, 3

and 2 to return other parts.

1

2

Model XE860 Work Assembling/Disassembling

Part 8 Inductive Flywheel Rev

Procedures

1. Follow procedures 2, 3, 4, 5, 6

and 7 to take off Connecting

Arm, Pedal Arm, both Chain

Covers, Cross Bar, the Belt and

Idler Wheel Assembly.

2. Disconnect all electric cables for

Inductive Flywheel and cut the

tie for the Cables, as shown in

figures 1, 2 and 3.

3. Use 11 mm wrench to release

4pcs of 1/4" x 3/4" hex head bolt

with 1/4" spring washers and

1/4"x13x1T

flat washers and take

the Inductive Flywheel apart, as

shown in figure 4.

4. To resume, Return the Inductive

Flywheel back on the Main

Frame and secure with 4pcs of

1/4" x 3/4" hex head screws with

3pcs of 1/4" spring washer and

3pcs of flat washers then connect

all electric cables back on.

5. Follow procedures 7, 6, 5, 4, 3

and 2 to resume all other parts.

1

2

3

4

Model XE860 Work Assembling/Disassembling

Part 9 Drive Pulley Rev

Procedures：

1. Follow procedures 2, 3, 4, 5 and

6 to take apart Connecting Arm,

Pedal Arm, both Chain Covers,

Cross Bar and the Belt.

2. Use C-ring pliers to release 2pcs

of ψ25 C-rings on Crank Axle

to release Crank Axle together

with Drive Pulley, as shown in

figures 1 and 2. Use a hammer if

necessary.

3. To separate Drive Pulley from

the Crank Axle, use C-ring pliers

to release ψ25 C-ring and use

two 11 mm wrenches to release

4pcs of 1/4" x 3/4" hex head bolt

and 1/4" nuts, as shown in figure

3.

4. To resume Drive Pulley, return

one C-ring back on the Crank

Axle and put it back on the Main

Frame then secure with

remaining C-rings.

5. Follow procedures 6, 5, 4, 3 and

2 to return other parts.

1

2

3

Model XE860 Work Assembling/Disassembling

Part 10 Bushing Housing Rev

Procedures：

1. Follow procedures 2 and 3 to

release Connecting Arm and

Pedal Arm.

2. Use 12 mm wrench to release

5/16" x 15m/m hex head bolt

with 5/16" x 35 x 1.5T flat

washer and take Bushing

Housing apart, as shown in figure

1.

3. To resume, return ψ25 wave

washer on the shaft and place

Bushing Housing back on the

shaft, which is applied with

lubricant. Secure Bushing

Housing with 5/16" x15m/mhex

head bolt and 5/16" x 35 x 1.5T

flat washer, as shown in figures 2

and 3.

4. Follow procedures 3-4 and 2-5 to

resume Pedal Arm and

Connecting Arm

1

2

3

Model XE860 Work Assembling/Disassembling

Part 11 Slide Wheels Rev

Procedures：

1. Follow procedures 2 and 3 to

release Connecting arm and

Pedal Arm.

2. Use Phillips head screwdriver to

unscrew Slide Wheel Cover, as

shown in figure 1.

3. Use C-ring pliers to release ψ17

C-ring and take apart the Slide

Wheel, as shown in figure 2.

4. To resume, return ψ17 wave

washer, Slide Wheel, ψ17 wave

washer in sequence onto the

wheel shaft and secure with

C-ring, as shown in figure 3.

Return the Slide Wheel Cover

5. Follow procedures 3-4 and 2-5 to

return Pedal Arm and Connecting

Arm.

1

2

3

Model XE860 Work Troubleshooting

Part 1 Console Rev

Procedures

1. Display: Follow the procedures

below if the display is blank.

2. Make sure that power is plug in

properly and AC breaker is not

activated, as shown in figure 1.

3. Make sure that all connectors,

including computer cables vs.

Console, are connected properly.

Disassemble the Console to check

computer cables inside the Console

if necessary.

4. If cables are all connected properly,

then check for cable damage or

Console/lower Controller failure, as

shown in figure 2.

1

2

Model XE860 Work Troubleshooting

Part 2 Chain covers and Round Disk, CrankRev

Procedures

1. Major problem is noises cause by

rubbing between two parts. Identify

if the noise is caused by shifting or

swing of the Round Disk, Crank, as

shown in figures 1 and 2.

2. If it is the shifting of the Round

Disk, Crank which is causing the

noise, release both left and right

Chain Covers and re-assemble them

again. (Follow procedure 4)

3. If it the swing of the Round Disk,

Crank which is causing the noise,

then release both Chain Covers and

Round Disk, Crank then use Phillips

head screwdriver to release 16pcs of

5x16m/m tapping screws with

1/4"x19m/m flat washers on Round

Disk, Crank. Put Cross Bar with

Round Disk, Crank on a level

surface and check for any sign of

warp. Correct the warp with force to

within 3 mm tolerance.

1

2

Model XE860 Work Troubleshooting

Part 3 Inductive Flywheel Rev

Procedures

1. The problem with Inductive

Flywheel is rare. If there is no

resistance, take off both Chain

Covers and check for disconnection

or breakage for electric cables, as

shown in figure 1.

2. If there is no power generated, check

AC power switch for fuse blown.

Replace with a new AC switch if

necessary. (follow procedure 8) as

shown in figure 2 and 3.

1

2

3

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