Spirit SE500 User manual

SERVICE MANUAL

SE500

1

Troubleshooting for Motor Error

When “Err” signal is shown up in the message window, it means that either gear motor has lost its

original reset point or the console cannot detect the feedback signal sent by the gear motor.

Causes of Motor Error and dispositions

a. Failure of the Gear Motor:

The gear motor should be free from abnormal noises during operation. When there is chip out

with the motor gear, it creates noises while operating. Replace YJ-9902 gear motor to remedy noise

issue.

b. Defective Cable：

The cable could be stuck, not properly installed or too much tension of the spring on magnets

which should cause gear motor to be overloaded and stop functioning. Rearranging the cable properly

or replacing it is the usual way to remedy cable issues.

c. Console Malfunction:

d. The circuit failure and unable to drive the gear motor. Replacing the console is the only way to

remedy the problem.

e. Insufficient Power (Only in case of batteries are used)：

When batteries are without sufficient power and are unable to drive the gear motor, the error

message comes on. Replace the batteries to resume normal operation

EEPROM ERR

When there is a problem with EEPROM in the console, the message window will show the error

message. “Er1” and the console will stop functioning at all.

EEPROM ERR(Er1) Remedy

Remove the power and wait for 1 minute then resume the power to start the console. If the console

does the same, then it fails and must be replaced.

2

Troubleshooting guide

MECHANICAL SYSTEM

1. Noises

1. Check if there are interactions between chain cover and

the flywheel.

2. Check if there is any crack on the roller.

3. Check if the magnet system interacts with the flywheel.

2. No resistance

1. Check if there is any damage with gear motor.

2. Check if the magnet is installed properly.

3. Check if steel cable breaks.

3. Starting resistance is too

high

1. Check if safety brake is released.

2. Check if steel cable is stuck.

4. Sliding wheels not stay on

the rail

1. Check if the wave washer is on the wheel shaft.

2. Check if there is any damage with the roller.

3. Check if crank axle crooks.

5. The flywheel does not

revolve while pedaling

1. Check if the belt breaks.

3

1. Noises

1. Check if there are interactions between chain cover and the flywheel.

Turn the flywheel and check if there is gap between chain cover and the flywheel or if the flywheel

swings or any other interactions. (If there are interactions, please refer to step 1.)

Figure 1-1-1

2. Check if there is any crack on the roller.

Pull up the connecting arm, turn the rollers and see if there is crack or breakage on them. If there is,

replace the roller. (Refer to step 4-1 for replacement)

Figure 1-2-1

3. Check if the magnet system interacts with the flywheel.

Release the bolt under the right handlebar assembly, as shown in figure 1-3-1, and then the bolt

which secure the crank axle, as shown in figure 1-3-2, and remove the pedal arm assembly, as

shown in figure 1-3-3. Remove the crank axle cover, as shown in figure 1-3-4 and release the bolt

on the crank axle, as shown in figure 1-3-5. Release two screws which at the rear of left chain

cover, as shown in figure 1-3-6, then screws for right chain cover, as shown in figure 1-3-7. Unplug

DC power cable and the right chain cover can be taken apart, as shown in figure 1-3-8. Turn the

flywheel to see if it interacts with external magnet system, as shown in figure 1-3-9.

(Please refer to step 2 if there is interaction)

(Figure 1-3-1) (Figure 1-3-2) (Figure 1-3-3) (Figure 1-3-4)

4

(Figure 1-3-5) (Figure 1-3-6) (Figure 1-3-7) (Figure 1-3-8)

(Figure 1-3-9)

2. No resistance

1. Check if gear motor runs normally. If there is any damage, replace the gear motor.

(Refer to step 3 for replacing procedures.)

Figure 2-1-1

2. Check if the magnet is installed properly.

Please refer to checking procedure 1-3. (Refer to step 2 for the proper position of the magnet.)

3. Check if steel cable breaks.

Refer to checking procedure 1-3. (Please refer to step 3 to replace steel cable.)

5

3. Starting resistance is too high

1. Check if safety brake is released.

Release the safety brake if it is not released.

Figure 3-2-1

2. Check if steel cable is stuck. Replace the cable if it is stuck.

Refer to step 1-3 to replace the cable.

4. Sliding Wheel does not stay on the rail

1. Check if the wave washer is on the wheel shaft.

Remove the wheel cover, as shown in figure 4-1-1 and release the C-ring, as shown in figure 4-1-2.

Check if the wavy washer is broken or missing, as shown in figure 4-1-3. Resume the parts if wavy

washer is OK. (Replace if it is broken or missing.)

Figure 4-1-1 Figure 4-1-2 Figure 4-1-3

2. Check if there is any damage with the roller.

Refer to checking procedure 4-1. (Replace the wheel if it is damaged.)

3. Check if crank axle crooks.

Check if the crank axle leans or the screw is loose.

6

5. The flywheel does not revolve while pedaling

1. Check if the belt breaks. (Replace the belt following step 4 if it is broken.)

Refer to 1-3 for checking procedure.

Figure 5-1-1 Left side belt Figure 5-1-2 Right side belt

Troubleshooting Procedures

Step 1：

：：

：

Refer to step 1-3 to remove left and right chain covers and check if the C-ring, at the left side of

flywheel axle, is in the notch and stay immediately next to the bearing, as shown in figure A-1. If not,

push the C-ring to the bearing to the end. Then check if the positioning post, at left side of the flywheel

axle, is tight and immediately next to the bearing, as shown in figure A-2. If not, push the positioning

post to the bearing to the end. If both C-ring and the positioning post are in correct position, check if

left and right chain covers are deformed so that the interactions are caused. Replace deformed chain

cover and resume all parts.

Figure A-1 Figure A-2

7

Step 2：

：：

：

Adjust the resistance to maximum value so that the magnet housing and the screw on the stopper

touch each other, as shown in figure B-1 then adjust the screw, as shown in figure B-2, until the

distance between the magnet and the flywheel is 2mm, as shown in figure B-3. Check with control key

to see if it runs correctly. If not, adjust the screw so that the steel cable is as tight as possible, as

shown in figure B-4, and still keeps 2mm distance. Resume all parts in order when everything is OK.

Figure B-1 Figure B-2 Figure B-3 Figure B-4

Step 3：

：：

：

If the steel cable breaks, press the magnet housing and release the screw to separate from magnet

housing, as shown in figure C-1 and replace the cable with new one. If the cable does not break,

remove the gear motor, as shown in figure C-2 and unplug the control wire. After replacing the parts,

resume all parts in reverse order. Make sure the drive pulley does not touch the gear motor, as shown

in figure C-3.

Figure C-1 Figure C-2 Figure C-3

8

Step 4：

：：

：

Refer to step 1 to remove left and right chain covers and check if the left and right sides belts

break. If anyone does, replace it. To replace, loosen both left and right idler wheels, as shown in

figure D-1. After loosening, turn the flywheel to take off left and right belts and release the C-ring

at right side crank axle, as shown in figure D-2. Use Allen wrench to take apart the positioning

post at left side of the crank axle, as shown in figure D-3, then release screws on bearing housing,

as shown in figure D-4. Lift the flywheel assembly and replace the belt, PJ type with 8 notches,

1000mm ;ong at left side and PK type with 6 notches and 1000 mm long at right side. When the

belt is positioned, as shown in figure D-5, resume the whole flywheel assembly and bearing

housing and tighten until 300 kgf. Return the C-ring to the end to the bearing and return the

positioning post and the belt to the drive wheel. Adjust the belt tension at both sides, left belt at

540 NT, right side belt to as high as 1000 NT and return all parts.

Figure D-1 Figure D-2 Figure D-3

Figure D-4 Figure D-5

9

Customer Service

EXPLODED DIAGRAM

10

Parts list

NO.

DESCRIPTION

O'TY

1

Main Frame

1

2

Console Mast

1

3

Sliding Pedal Arm (R)

1

4

Sliding Pedal Arm (L)

1

5

Conn

ecting Pedal Arm (R)

1

6

Connecting Pedal Arm (L)

1

7

Main Crank Axle

1

8

Swing Arm (R)

1

9

Swing Arm (L)

1

10

Crank Arm

2

11

Flywheel

1

11

-

1

Nylon Round Disk

2

12

Ø174 Main Pulley

1

13

Ø174 Drive Pulley

1

14

Drive Axle

1

15

Pulley

1

16

Axle

for Idler Wheel (L)

1

17

Axle for Idler Wheel (R)

1

18

Bearing Housing, Crank Axle

2

19

Side Case bracket

2

20

Set Collar

1

21

Brake Magnet Mounting Arm

1

22

Tension Cable Retainers

2

23

Brake Mounting Bracket

1

24

Cup Washer For M8 Bolt

6

25

Bear

ing ( 6005 )

6

26

Bearing ( 6003 )

24

27

Rod End Bearing

2

28

Aluminum Track

4

29

C Ring 17mm dia

6

30

C Ring 25mm dia

5

31

Wave Washer 17mm dia

12

32

Nyloc Nut M6

-

6t

1

33

Nyloc Nut M8

-

7t

2

34

Nyloc Nut 5/16"

-

7t

2

35

Socket Head Cap Bo

lt M5 × 0.8

-

12mm

4

36

Socket Head Cap Bolt M5 × 0.8

-

20mm

1

37

Socket Head Cap Bolt M6 × 1.0

-

15mm

8

38

Socket Head Cap Bolt M6 × 1.0

-

50mm

1

39

Socket Head Cap Bolt M8 × 1.25

-

12mm

6

40

Socket Head Cap Bolt M8 × 1.25

-

15mm

7

41

Socket Head Cap Bolt M8 × 1.25

-

35mm

2

42

Socket Head Cap Bolt M10 × 1.5

-

20mm

4

43

Socket Head Cap Bolt M10 × 1.5

-

80 mm

1

44

Button Head Socket Bolt 5/16" × 1

-

3/4"

2

11

NO.

DESCRIPTION

O'TY

45

Phillips Head Screw M5 × 0.8

-

10mm

28

46

Phillips Head

Screw M6 × 1.0

-

10mm

8

47

Split Washer M5

4

48

Split Washer M6

8

49

Split Washer M8

1

50

Split Washer M10

4

51

Nut M5

-

4t

1

52

Set screw M5

-

5mm

2

53

Idler Adj. Bolt M10 × 1.5 × 220L

1

54

Woodruff Key ( 7 × 7 × 23L )

2

55

Shoulder Bolt M10

× 1.5 × Ø12

-

20mm

2

56

Nyloc Nut M10

-

10t

2

57

Twin Circle Key 6 × 6 × 16L

1

58

Ø5 × 10 × 1.0T_Flat Washer

4

59

Ø8 × 35 × 3.0T_Flat Washer

1

60

Tapping Screw M4 × 12mm, Black

6

61

Round Side Case Insert

2

62

Side Case (L)

1

63

Side Case (R)

1

64

Square End Cap

1

65

Crank Cover

2

66

Beverage Holder

1

67

Bearing Shaft Plug

6

68

Slide Wheel Cover, Black

2

69

Button Head Plug

4

70

Round Cap

2

71

Handgrip End Cap

6

72

Pedal (L)

1

73

Pedal (R)

1

74

Sliding Wheel

4

75

Handpulse Outer Cover

2

76

Handpulse Plate

4

77

Transportation Wheel

2

78

Console Assembly

1

78

-

1

Top Console Cover

1

78

-

2

Bottom Console Cover

1

78

-

3

Battery cover

1

78

-

4

Console Display Board

1

78

-

5

Battery Bracket

1

78

-

6

Battery

4

79

Magnet

1

80

Speed Sensor Mount

ing Bracket

1

81

Brake Return Spring

1

82

Handgrip Foam

2

83

Rubber Foot

6

84

Nut 3/8" × 7T

12

NO.

DESCRIPTION

O'TY

85

Flat Washer Ø3/8" × Ø19 × 1.5T

6

86

Flat Head Socket Bolt 3/8"×16UNC

-

2

6

87

Braking Magnet

1

88

Poly

-

V Belt, 6PK

1

89

Type PJ B

elt

1

90

Emergency Brake Lever

1

91

Emergency Brake Assembly

1

91

-

1

Emergency Brake Pad

2

92

Emergency Brake Cable

1

93

260m/m_Resistance Sensor Cable

1

94

Gear Motor

1

97

Speed Sensor W/Cable 850mm

1

98

DC Power Cord 500mm

1

99

Handpulse Wire, C

oiled 500mm

1

100

Computer Cable (Upper) 1500mm

1

101

Computer Cable (Lower) 1000mm

1

102

Flat Head Socket Screw M5 × 0.8

-

12mm

4

103

Phillips Head Screw M4 × 0.7

-

12mm

6

107

Phillips Head Screw Driver

1

108

M10_L Allen Wrench

1

109

17m/m_Wrench

1

110

M6_L Allen Wrench

1

111

13m/m_Wrench

1

112

Phillips Head Screw M5 × 0.8

-

12mm

3

114

Tension Cable Pulley

1

115

E Retaining Ring E

-

5

1

116

M8_L Allen Wrench

1

118

Ø6 × Ø16 × 1.0T_Flat Washer

8

122

C Ring

2

123

Bearing Housing

2

Spirit SE500 User manual

Spirit SE500 User manual

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