Spirit XE520s Service Manual
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Spirit XE520s Service Manual

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Service Manual
Elliptical XE520s

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Summary of Contents for Spirit XE520s

  • Page 1 Service Manual Elliptical XE520s...

  • Page 2: Console

    Plastic Parts Hand Pulse Handle Right Handle Bar Covers (Front & Rear) Left Handle Bar Covers (Front & Rear) Left Pedal Arm Cover Console Left Chain Cover Left Pedal Console Mast Cover (Left & Right) Rear Shroud (B) Slide Wheel Cover Connecting Arm Cover Right Pedal Arm Cover Rear Shroud (A)
  • Page 3 Skeleton: Console Mast Left Handle Bar Left Pedal Arm Right Handle Bar Left Connecting Arm Bushing Housing Left Adjustable Pedal Gear Motor Drive Pulley Rail Assembly Right Pedal Arm Main Frame Right Adjustable Pedal Locking Pin Assembly Sliding Wheel Flywheel（Brake） Cross Bar Right Connecting Arm...

  • Page 4: Table Of Contents

    Contents： I. Replacing Parts 1. Console 2. Handle Bar Assembly 3. Connecting Arm Assembly 4. Pedal Arm Assembly 5. Console Mast 6. Chain Covers 7. Cross Bar Assembly 8. Idler Wheel Assembly 9. Flywheel (Brake) and the Belt II. Troubleshooting Console Chain Covers and Round Disk iii.
  • Page 5 Model XE520s Service Replacing Parts Part 1. Console Rev. Procedures： 1. Use Phillips head screw driver to release four M5x10mm Phillips head screws which secure the console on top of the mast, as shown in figure 1. 2. Disconnect computer cable and...

  • Page 6: Handle Bar Assembly

    Model XE520s Service Replacing Parts Part 2. Handle Bar Assembly Rev. Procedures： 1. Use Phillips Head Screw Driver to release three 3.5x12mm Sheet Metal Screws which secure Handle Bar Covers, as shown in figure 1. 2. Release further two M5x15mm...
  • Page 7 Model XE520s Service Replacing Parts Part 2. Handle Bar Assembly Rev. Procedures： 5. Reverse above procedures to resume Handle Bar Assembly together with 17 washer, if there is on the shaft Ø when you took it apart, as shown in...
  • Page 8 Model XE520s Service Replacing Parts Part 3. Connecting Arm Rev. Procedures： 1. Follow procedures 2 to disassemble Handle Bar (only the lower part and fish-eye bearing), as shown in figure 2. Use 12mm wrench to release 5/16" × 15m/m_Hex Head Bolt and 5/16 "...
  • Page 9 Model XE520s Service Replacing parts Part 3. Connecting Arm Rev. Procedures： 4. Use Phillips screw driver to release four M5x10 mm screws to take apart Locking Pin Assembly, as shown in figure 6. 5. Use Phillips screw driver to release...

  • Page 10: Pedal Arm Assembly

    Model XE520s Service Replacing parts Part 4. Pedal Arm Assembly Rev. Procedures： 1. Follow procedure 3 to take apart Connecting Arm and use Phillips head screw driver to unscrew Pedal Arm Cover, as shown in figure 1. 2. Use 8mm and 14 mm wrenches to release 3/8"...

  • Page 11: Console Mast

    Model XE520s Service Replacing parts Part 5. Console Mast Rev. Procedures： 1. Follow procedures 1 and 3 to take apart the Console and Connecting Arm. 2. Use Phillips head screw driver to release 6pcs 3.5x12mm Sheet Metal Screws and take apart left and right Mast Covers, as shown in figure 1.

  • Page 12: Chain Covers

    Model XE520s Service Replacing part Part 6. Chain Covers Rev. Procedures： 1. Follow procedures 3 & 4 to take apart Connecting Arm, Pedal Arm and mast covers, respectively. 2. Use Phillips head screw driver to release eight 3.5x16mm Sheet Metal Screws and three 5 ×...
  • Page 13 Model XE520s Service Replacing parts Part 6. Chain Covers Rev. Procedures： 4. Disconnect DC cable which on left Chain Cover from the connector which is on the mainframe and take apart left Chain Cover, as shown in figure 5. 5. If replacing DC cable is required, then release the nut which secures the cable on left Chain Cover.
  • Page 14 Model XE520s Service Replacing parts Part 7. Cross Bar Rev. Procedures： 1. Follow procedure 6 to take apart Chain Covers. 2. Take off Round Disk Cover and use 12 mm and 6 mm wrenches to release 5/16 x15mm Hex Head Bolt "...
  • Page 15 Model XE520s Service Replacing parts Part 7. Cross Bar Rev. Procedure： 4. Return the Cross Bar back to the Crank Axle and resume Woodruff Key, as shown in figure 5. Reverse above steps to return all parts.
  • Page 16 Model XE520s Service Replacing parts Part 8. Idler Wheel Rev. Procedures： 1. Follow procedure to take apart Cross Bar. 2. Use 13 mm wrench to release M8x9T nut which is on J Bolt and take off the Belt. Use again 13 mm...
  • Page 17 Model XE520s Service Replacing parts Part 9. Flywheel and the Belt Rev. Procedures： 1. Follow procedure 8 to take apart the Idler Wheel. 2. Increase the resistance up to 20 with the Console and take apart the Steel Cable, as shown in figure 1.
  • Page 18 Model XE520s Service Troubleshooting Part 1. Console Rev. Procedures： 1. When the display is all black, Check the DC power. 2. Check and make sure the cable is connected well to the Console, as shown in figure 1. 3. Dismantle the Console and check if all...
  • Page 19 Model XE520s Service Troubleshooting Part 2. Chain Covers and Round Disk Rev. Procedure： 1. Most troubles are scrubbing noises. Major causes are Round Disk is not in center and swing of the Round Disk, as shown in figures 1 & 2.
  • Page 20 Model XE520s Service Troubleshooting Part 3. Flywheel Rev. Procedure： 1. The problem with Flywheel is rare. In most case, the Steel Cable is improperly adjusted and the noise is caused. Please refer to replacing Flywheel and properly adjust the steel cable, as shown in figures 1, 2 &...
  • Page 21 Model XE520s Service Troubleshooting Part 4. The Belt Rev. Procedure： 1. If the Belt falls off, take apart right Chain Cover and loosen Idler Wheel and resume the Belt. Turn slowly and check the swing of the Drive Pulley and the Belt. Correct if Drive Pulley, the Belt and Flywheel is not in line which causes the swing.
  • Page 22 Model XE520s Service Troubleshooting Part 5. Handle Bar Rev. Procedures： There is always a tolerance between 0.05mm and 0.07 mm in dimensions for the axle for the purpose of easy assembly so that a little bit of play is normal. When there is noise due to...
  • Page 23 Model Model XE520s XE520s Service Service Troubleshooting Troubleshooting Part 6. Connecting Arm Rev. Procedures： 1. Since elliptical 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 24 Part 6. Connecting Arm Rev. Procedures： 3. Both Handlebars should connect properly with their corresponding connecting Arm and Sliding wheels should have real circle without slippage. If noises are caused by bad Rod End bearing, or fish-eye bearing, replace the bearing by using 19 m/m wrench, as shown in figure 4.
  • Page 25 Model XE520s Service Troubleshooting Part 7. Gear Motor Rev. Procedures： If there is no resistance, Check the Console and Gear Motor Cable. Release the cable and 5x19 Tapping screws which secure the Gear Motor to replace, as shown in figures 1, 2,...

  • Page 26: Idler Wheel Assembly

    Q＆A Model XE520s Service part 1. Noises Rev. Procedures： 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: Slippage

    Q＆A Model XE520s Service part 2. Slippage Rev. 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 XE520s Service part 3. Wobble Rev. Procedures： 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: Smoothness

    Q＆A Model XE520s Service Part 4. Smoothness Rev. Procedures： 1. Check tightness of screws and bolts if the unit clicks. 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 XE520s Service Part 5. Other Problems Rev. Procedures： 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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