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Spirit XE860 Service Manual

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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)

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Summary of Contents for Spirit XE860

  • Page 1 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...
  • Page 2 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...

  • Page 3: Table Of Contents

    CONTENTS： Disassembling and assembling pf parts Console Connecting Arm Assembly Pedal Arm Assembly Left and right Chain Covers Cross Bar Assembly The Belt Idler Wheel assembly Inductive Flywheel Drive Pulley 10. Bushing Housing 11. Slide Wheel II. Troubleshooting Console Left/Right Chain covers and Round Disk Cover, Crank Inductive Flywheel The Belt...
  • Page 4 Model XE860 Work Assembling/Disassembling Part 1 Console 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.
  • Page 5 Model XE860 Work Assembling/Disassembling Part 2 Connecting Arms 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"...
  • Page 6 Model XE860 Work Assembling/Disassembling Part 2 Connecting Arms 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...

  • Page 7: Connecting Arm Assembly

    Model XE860 Work Assembling/Disassembling Part 3 Pedal Arms 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.

  • Page 8: Pedal Arm Assembly

    Model XE860 Work Assembling/Disassembling Part 4 Chain Covers 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.
  • Page 9 Model XE860 Work Assembling/Disassembling Part 4 Chain Covers 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...
  • Page 10 Model XE860 Work Assembling/Disassembling Part 5 Cross Bar 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.
  • Page 11 Model XE860 Work Assembling/Disassembling Part 5 Cross Bar 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.

  • Page 12: Cross Bar Assembly

    Model XE860 Work Assembling/Disassembling Part 6 The Belt 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...

  • Page 13: Idler Wheel Assembly

    Model XE860 Work Assembling/Disassembling Part 7 Idler Wheel Assembly 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"...

  • Page 14: Inductive Flywheel

    Model XE860 Work Assembling/Disassembling Part 8 Inductive Flywheel 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...

  • Page 15: Drive Pulley

    Model XE860 Work Assembling/Disassembling Part 9 Drive Pulley 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...

  • Page 16: Bushing Housing

    Model XE860 Work Assembling/Disassembling Part 10 Bushing Housing 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...

  • Page 17: Slide Wheel

    Model XE860 Work Assembling/Disassembling Part 11 Slide Wheels 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.

  • Page 18: Console

    Model XE860 Work Troubleshooting Part 1 Console 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.
  • Page 19 Model XE860 Work Troubleshooting Part 2 Chain covers and Round Disk, Crank Rev 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.

  • Page 20: Inductive Flywheel

    Model XE860 Work Troubleshooting Part 3 Inductive Flywheel 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.

  • Page 21: The Belt

    Model XE860 Work Troubleshooting Part 4 The belt Procedures 1. If the Belt falls off, release right Chain Cover and loosen Idler Wheel Assembly and return the Belt on its place. Then turn the Belt slowly and watch for the shifting between the...

  • Page 22: Left And Right Handlebars

    Model XE860 Work Troubleshooting Part 5 Left and Right Handlebars Procedures： 1. Handlebars are not absolutely tight (with loose tolerance between 0.05 mm and 0.07 mm)for easy to assemble to the end user. It is normal for handlebars to shift a little bit.

  • Page 23: Bushing Housing

    Model XE860 Work Troubleshooting Part 6 Bushing Housing Procedures： 1. The problem with Bushing Housing is rare. However, a few units might have noise problem as time lasts. Applying some grease on ψ25 x 111.5 L shaft on Cross Bar Assembly, as shown in figure 1, may be helpful for solving this problem.

  • Page 24: Pedal Arms, Connecting Arms And Slide Wheels

    Model XE860 Work Troubleshooting 7 Pedal Arm, Connecting Arm and Slide Wheels Part Procedures： 1. Since ellipticals a lot of levers to connect and move parts, Parts interact and affect others a lot. It is very important to lubricate each moving parts and joints, as shown in figures 1 and 2.

  • Page 25: Slippage

    Model XE860 Work Troubleshooting 7 Pedal Arm, Connecting Arm and Slide Wheels Part Procedures： 3. Both Handlebars should connect properly with their corresponding connecting Arm and Sliding wheels should have real circle without slippage. 4. During maintenance, start from sliding wheels by applying lubricant on wheels or replace if necessary, as shown in figures 1 and 2.

  • Page 26: Smoothness

    Q＆A Model XE860 Work Problem 1 Noises Procedures： 1. The part making noises is hard to identify. From Chain Cover rubbing Crank Round Disk Cover, Bushing Housing and Cross Bar, Belt and Drive Pulley, Idler Wheel Assembly, Handlebar and Mast shaft, Flywheel and Cable to Sliding Wheels and Rail Assembly, even Pedals, etc.
  • Page 27 Q＆A Model XE860 Work Problem 2 Slippage Procedures： 1. There are 4 parts that may slip. 2. M12 x P1.75 Fish-eye bearing: M12 nut must be firmly tightened with Connecting Arm and fish-eye bearing perpendicular to the bolt, as shown in figure 1.
  • Page 28 Q＆A Model XE860 Work Problem 3 Wobble Procedures： 6. Wobble is usually caused by loose screw. When there is wobble, try to tighten all screws and check for installation faults or worn out of parts when time lasts. Like a wobble pedal is usually caused by carriage bolt not installed properly.
  • Page 29 Q＆A Model XE860 Work Problem 4 Smoothness Procedures： 7. Check tightness of screws and bolts if the unit clicks. 8. Otherwise, there might be foreign materials on either the rail or Slide Wheel. Use rubbing alcohol to wipe and apply some lubricant both parts,...

  • Page 30: Other Problems

    Q＆A Model XE860 Work Problem 5 Other Problems Procedures： 1. Contact DYACO for problems not covered in this service manual. Any problem solving on the unit is backed-up by DYACO technical team.

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