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Fuel Fitness XE322 Service Manual

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Service Manual
Elliptical XE322

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Summary of Contents for Fuel Fitness XE322

  • Page 1 Service Manual Elliptical XE322...
  • Page 2 Plastic Parts Pedal (L) Front Handle Bar Cover (L) Console Assembly Rear Handle Bar Cover (L) Drink Bottle Holder Console Mast Cover Side Case (L) Rear Handle Bar Cover (R) Slide Wheel Cover Front Handle Bar Cover (R) Rear Stabilizer Cover (B)) Pedal (R) Rear Stabilizer Cover (B)) Round Disk Cover Rear Stabilizer Cover (A) Connecting Arm Cover (L)
  • Page 3 Skeleton Lower Handle Bar (L) Swing Arm (R) Cross Bar Connecting Arm (L) Lower Handle Bar (R) Swing Arm (L) Console Mast Bushing Housing Rear Rail Assembly Pedal Arm (L) Main Frame Pedal Arm (R) Idler Wheel Assembly Drive Pulley Connecting Arm (R) Flywheel...
  • Page 4 Table of Contents I. Replacing Parts 1 The Console 2 Side Cases 3 Idler Wheel Assembly 4 The Flywheel 5 The Steel Cable 6 The Cross Bar 7 The Belt 8 The Drive Pulley 9 Connecting Arms 10 Pedal Arms and the Bushing Housing 11 Slide Wheels II.
  • Page 5 Model XE322 Work Replacing Parts The Part 1. The Console Rev. Procedures： 1. Use Phillips head screw driver to release four M5x10mm Phillips head screws, disconnect the computer cable and hand-pulse cable to take the console apart, as shown in figure 1.
  • Page 6 Model XE322 Work Replacing Parts The Part 2. Side Cases – the right side Rev. Procedures： Take the pedal arm apart as shown in figure 5. Slap the console mast cover backward to separate it from side covers, as shown in figure 6.

  • Page 7: The Console

    Model XE322 Work Replacing Parts The Part 2. Side Cases – the left side Rev. Procedures： 1. Follow the procedures to take the right side case apart. 2. Use Phillips head screw driver to release 4x16mm self tapping screw and 1/4”x19 flat washer on the console mast, as shown in figure 1.

  • Page 8: Side Cases

    Model XE322 Work Replacing Parts The Part 3 Idler Wheel Assembly Rev. Procedures： 1. Follow the procedures to take apart the right side case and use 13mm wrench to loosen M8x7T nut on the J-bolt and use 13mm wrench to release M8x20mm carriage bolt, 5/16”x23x1.5...

  • Page 9: Idler Wheel Assembly

    Model XE322 Work Replacing Parts The Part 4 The Flywheel Rev. Procedures： 1. Follow the procedure 2 to take apart side cases and procedure 3 to take apart idler wheel assembly. 2. Plug in and turn on the power. Adjust...

  • Page 10: The Flywheel

    Model XE322 Work Replacing Parts The Part 4 The Flywheel Rev. Procedures： 6. To resume the flywheel, return the belt onto the flywheel notches and install the flywheel on the mainframe. 7. Tighten the flywheel the both 3/8" -UNF26 x 9T nuts.

  • Page 11: The Steel Cable

    Model XE322 Work Replacing Parts The Part 5 The Steel cable Rev. Procedures： 1. Follow procedure 4 to take apart flywheel. 2. Use 10mm wrench release the nut on the steel cable and take it apart, as shown in figures 1 & 2.

  • Page 12: The Cross Bar

    Model XE322 Work Replacing Parts The Part 6 The Cross Bar Rev. Procedures： 1. Follow procedure 2 to take apart side cases. 2. Tip the round disk cover to take it apart, as shown in figure 1. 3. Use 12mm wrench to release 5/16”...

  • Page 13: The Belt

    Model XE322 Work Replacing Parts The Part 7 The Belt Rev. Procedures： 1. Follow the procedures 2, 4 and 6 to take apart side cases, flywheel and the cross bar respectively, as shown in figure 1. 2. Reverse above procedures to resume...

  • Page 14: The Drive Pulley

    Model XE322 Work Replacing Parts The Parts 8 The Drive Pulley Rev. Procedures： 1. Follow procedures 2, 4, 6 and 7 to take apart side cases, the flywheel, the cross bar and the belt in order, respectively. 2. Take apart the Woodruff Key and use C-ring pliers to release Ø...

  • Page 15: Connecting Arms

    Model XE322 Work Replacing Parts The Parts 9 Connecting Arms Rev. Procedures： 1. Take apart the connecting arm covers as shown in figure 1. 2. Use 12mm and 13mm wrenches to release 5/16” x 1-1/4” hex head screw, 5/16” x20x1.5T flat washer and 5/16”...

  • Page 16: Lower Handle Bars

    Model XE322 Work Replacing Parts The Parts 9 Connecting Arms Rev. Procedures： 5. To resume the connecting arm, align the screw holes on the connecting arm and the pedal arm and insert the pedal axle then tighten the hex head screw, as shown in figure 5 &...

  • Page 17: Pedal Arms And The Bushing Housing

    Model XE322 Work Replacing Parts The part 10 Pedal Arm and Bushing Housing Rev. Procedures： 1. Follow procedures 9 to take apart the connecting arm. 2. Use M6 wrench and 13mm wrench to release M8 x 50 Socket Head Cap Bolt, 5/16”...

  • Page 18: Slide Wheels

    Model XE322 Work Replacing Parts The Part 11 Slide Wheels Rev. Procedures： 1. Use Phillips head screw driver to release two M5x15mm Phillips head screws and take the slide wheel cover apart, as shown in figure 1. 2. Use 12,, wrench to release 5/16”...
  • Page 19 Model XE322 Work Troubleshooting The Part 1 The Console Rec. Procedures： 1. If the console does not come on, check with following procedure. 2. Check and make sure that power adaptor is plug in and the other end is insert to the unit.
  • Page 20 Model XE322 Work Troubleshooting The Part 2 The Gear Motor Rev. Procedures： 1. If there is no resistance, Adjust the resistance with the console to the maximum level and verify if there are click sounds which is the sign of motor running.

  • Page 21: Noises

    Model XE322 Work Troubleshooting The Part 3 Side Cases and the Round Disk Rev. Procedures： 1. Rubbing noises are the most case which occurs at this portion. It is caused either by the round disk off center or the swing of the round disk, as shown in figure 1.
  • Page 22 Model XE322 Work Troubleshooting The Part 4 The Belt Rev. Procedures： 1. If the belt falls off, take apart the right side case and loosen the idler wheel and resume the belt. Turn the drive pulley slowly and check the displacement and the alignment of the belt, drive pulley and the flywheel.
  • Page 23 Model XE322 Work Troubleshooting The Part 5 The Flywheel Rev. Procedures： 1. The problem with the flywheel is rare. Most of the case is the noise cause by improper adjustment of the steel cable or improper installation. Follow the replacing flywheel and the belt for adjustment, as shown in figure 1.
  • Page 24 Model XE322 Work Troubleshooting The Parts 6 Lower Handle Bars Rev. Procedures： 1. There are 0.05mm~0.07 mm tolerances with the parts for the concern of easy assembly by the user and it is normal with slight play. Noises might be caused due to these tolerances after certain time of usage.
  • Page 25 Model XE322 Work Troubleshooting The part 7 Bushing Housing Rev. Procedures： The problem with this portion is rare. 1. 1. 1. 1. Occasionally, there is noise after very long duration of usage. When this occurs, apply some heavy viscosity lubricant on the clank axle, as shown in figure 1.

  • Page 26: Slippage

    Model XE322 Work Troubleshooting The Part 8 Pedal Arms, Connecting Arms and Slide Rev. Wheels Procedures： 1. Since elliptical machine is full of moving parts with joints, parts are related to each other and proper lubrication is important. Lubricating with heavy viscosity lubricant while maintaining or replacing parts can eliminate potential problems.
  • Page 27 Model XE322 Work Troubleshooting The Part 8 Pedal Arms, Connecting Arms and Slide Rev. Wheels Procedures： 3. For maintenance, start from slide wheels by replacing them or applying some lubricant on the curvature on the slide wheels. Keep parallel parts...
  • Page 28 Q＆A Model XE322 Work Problem 1 Noises Rev. Procedures： 1. Noises are general problem for elliptical and difficult to troubleshoot, from rubbing between side cases and round disk, bushing housing and the cross bar, the belt and the drive pulley, idler wheel, handle bar and...
  • Page 29 Q＆A Model XE322 Work Problem 2 Slippage Rev. Procedures： 1. There are four situations which cause slippage. 2. M12 x P1.75 rod end (fish-eye) bearing: M12 nut on top must be tighten enough to the connecting arm and perpendicular to the rod end bearing, as shown in figure 1.
  • Page 30 Q＆A Model XE322 Work Problem 3 Play Rev. Procedures： 1. Major cause of the play is loose screw and hence tightening all screws is the first step to fix the problem of play. Wearing at the joint and improper installation lead to loose screws. Play of the pedal may caused by improper installation of the carriage bolt.
  • Page 31 Q＆A Model XE322 Work Problem 4 Smoothness and other problems Rev. Procedures： Although this manual can not cover all of elliptical problems, it describes most of it. Whatever the problem occurs, fixing the problem is back up by Dyaco technical service.

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