Vision Fitness S60 Service Manual
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Vision Fitness S60 Service Manual

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Vision Fitness S60 (EP615)

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Summary of Contents for Vision Fitness S60

  • Page 1 Service Manual Vision Fitness S60 (EP615)

  • Page 2: Table Of Contents

    TABLE OF CONTENTS CHAPTER 1: MAINTENANCE PROCEDURE Preventive Maintenance Schedule…………………………………………………………..4 Cleaning the Grooves………………………………………..........5 CHAPTER 2: WIRING DIAGRAM INSTRUCTION Electrical Installation……………………………………………………………………..….…..6 Electrical Diagram………………………….….………………………………………….…..7 Wiring Diagram………………………………………………………………………………..8 Lower Control Board Wiring Diagram…….………….…………………………………..……...8 Console Wiring Diagram…………………………………………………………………..……...9 CHAPTER 3: ENGINEERING MODE Using Engineering Mode.....................10 CHAPTER 4: TROUBLESHOOTING 4.1 Console Error Codes………………………………………………………………………………12 4.2 Troubleshooting –...
  • Page 3 CHAPTER 5: PART REPLACEMENT GUIDE 5.14 Foot Pedals Replacement……....................34 5.15 Pedal Arm Replacement ......................35 5.16 Link Arm Replacement......................36 5.17 Incline Arm Cover Replacement…...................37 5.18 Swing Arm Replacement…………....................38 5.19 Vertical Stabilizer Arm Replacement..................39 5.20 Incline Arm Replacement……....................41 5.21 Heart Rate Grips Replacement……..................43 5.22 Testing the Elliptical........................47 CHAPTER 6: SOFTWARE UPGRADE PROCEDURE 6.1 Software Upgrade Instructions…....................48...

  • Page 4: Chapter 1: Maintenance Procedure

    CHAPTER 1: MAINTENANCE PROCEDURE 1.1 Preventative Maintenance Schedule PREVENTIVE MAINTENANCE SCHEDULE Item Daily Weekly Monthly Quarterly Biannual Annual Console Mounting Inspect Bolts Frame Inspect Display Console Clean Inspect Handlebar Clean Inspect Handrail & Clean Inspect Handlebar Belt Grooves Inspect V Belt Clean Inspect...

  • Page 5: Cleaning The Grooves

    CHAPTER 1: MAINTENANCE PROCEDURE 1.2 Cleaning the Grooves If there is any dust in the grooves of the Poly-V belts and pulleys, noises will be generated during operation. Frequency: Every 3 to 4 months. [Procedure]: 1. Remove the Poly-V belts (490-J8) and check the grooves of the belt for dirt or dust and clean if any is present. 2.

  • Page 6: Chapter 2: Wiring Diagram Instruction

    CHAPTER 2: WIRING DIAGRAM INSTRUCTION 2.1 Electrical Installation...

  • Page 7: Electrical Diagram

    CHAPTER 2: WIRING DIAGRAM INSTRUCTION 2.2 Electrical Diagram...

  • Page 8: Wiring Diagram

    CHAPTER 2: WIRING DIAGRAM INSTRUCTION 2.3 Wiring Diagram P01- CONSOLE WIRE 2.4 Lower Control Board Wiring Diagram 7 pin terminal to the console 3 pin terminal to the generator 2 pin terminal to the power resistor...

  • Page 9: Console Wiring Diagram

    Select switch JQK – Quick key for S70 JQK1 – Quick key for R70 JHD – Console digital wire for S70 JAI – Console wire for S60, U/R 70 JHG1, JHG2 – Hang grip Port Function Quick key cable for S70...

  • Page 10: Chapter 3: Engineering Mode

    CHAPTER 3: ENGINEERING MODE 3.1 Using Engineering Mode 1. Press & Hold both UP and DOWN RESISTANCE keys at the same time for 3-5 second to enter Engineering Mode as shown in Figure A. The display will show “P1 MAX TIME” as shown in Figure B. 2.
  • Page 11 CHAPTER 3: ENGINEERING MODE 3.1 Using Engineering Mode – Continued CUSTOMSETTING DEFAULT MINIMUM MAXIMUM DESCRIPTION Sets the total run time of any program. MAX TIME 99 min 20 min 99 min Max Time Workout time when GO is pressed or when no USER TIME 30 min 10 min...

  • Page 12: Chapter 4: Troubleshooting

    CHAPTER 4: TROUBLESHOOTING 4.1 Console Error Codes Error Messages on the Console Code Class Description Solution When UCB implements a command, LCB has not 0x0441 Check the console cable connection, replace the LCB. received this command. Power resistor is short circuited (over 4A), or the current 0x01AC Check the connection of power resistor or replace power resistor is over 3.7A for 1 second.

  • Page 13: Troubleshooting - No Display On The Console Or The Display Is Dim

    CHAPTER 4: TROUBLESHOOTING 4.2 Troubleshooting – No Display on the Console or the Display is Dim NO DISPLAY ON THE CONSOLE OR THE DISPLAY IS DIM POSSIBLE CAUSES: 1. The console is damaged or the console cable is not connected properly. 2.

  • Page 14: Troubleshooting - No Rpm Is Displayed During The Exercise

    CHAPTER 4: TROUBLESHOOTING 4.3 Troubleshooting – No RPM is Displayed During the Exercise NO RPM IS DISPLAYED DURING THE EXERCISE POSSIBLE CAUSES: 1. The console is damaged or the console cable is not connected properly. 2. Poor connection to all the terminals on the lower control board. 3.

  • Page 15: Troubleshooting - All Or Some Of The Function Key Do Not Respond

    CHAPTER 4: TROUBLESHOOTING 4.4 Troubleshooting – All or Some of the Function Keys Do Not Respond ALL OR SOME OF THE FUNCTION KEYS DO NOT RESPOND POSSIBLE CAUSES: 1) The keypad connection ribbon cable has not been plugged in correctly. 2) The keypad is damaged.

  • Page 16: Troubleshooting - High Or No Resistance

    CHAPTER 4: TROUBLESHOOTING 4.5 Troubleshooting – High or No Resistance HIGH OR NO RESISTANCE POSSIBLE CAUSES: 1) The console is damaged or the console cable is not connected properly. 2) The console cable is damaged. 3) The power resistor is damaged. 4) The LCB is damaged.

  • Page 17: Troubleshooting - Pedals Slipping

    CHAPTER 4: TROUBLESHOOTING 4.6 Troubleshooting – Pedals Slipping PEDALS SLIPPING POSSIBLE CAUSES: 1) The belt tension is not high enough. 2) The one way bearing is damaged. SOLUTION: 1) Remove the shrouds and check the belt tension. a. Tighten the drive belt tension if needed by moving the spring tension clip to another hole. b.

  • Page 18: Troubleshooting - Heart Rate Function Does Not Work Or Is Reading Incorrectly

    CHAPTER 4: TROUBLESHOOTING 4.8 Troubleshooting – Heart Rate Function Does Not Work or is Reading Incorrectly HEART RATE FUNCTION DOES NOT WORK OR IS READING INCORRECTLY POSSIBLE CAUSES: 1) The heart rate grips are not connected properly or are defective. 2) The heart rate grip wiring is damaged or not connected correctly.

  • Page 19: Chapter 5: Part Replacement Guide

    CHAPTER 5: PART REPLACEMENT GUIDE 5.1 Shroud Replacement 1) Remove the link arm plastic caps (Figures A). 2) Detach the link arm (Figure B). FIGURE A FIGURE B 3) Remove the 6 screws at both sides that hold the back cover to the shrouds and remove the back cover (Figures C & D). FIGURE C FIGURE D...
  • Page 20 CHAPTER 5: PART REPLACEMENT GUIDE 5.1 Shroud Replacement - Continued 4) Remove the 5 screws on right side holding the side covers in place (Figures E). 5) Remove the 5 screws on left side holding the side covers in place (Figures F). FIGURE E FIGURE F 6) Remove the shroud for frame access (Figure G).

  • Page 21: Lower Control Board Replacement

    CHAPTER 5: PART REPLACEMENT GUIDE 5.2 Lower Control Board Replacement 1) Remove the shrouds as outlined in Section 5.1. 2) Disconnect all wires from the LCB (Figure A). FIGURE A 3) Remove the 2 screws holding the LCB to the frame (Figure B) and remove the LCB. FIGURE B 4) Reverse Steps 1- 3 to install a new LCB.

  • Page 22: Power Resistor Replacement

    CHAPTER 5: PART REPLACEMENT GUIDE 5.3 Power Resistor Replacement 1) Remove the shrouds as outlined in Section 5.1. 2) Remove the 2 screws holding the power resistor to the frame (Figure A). FIGURE A 3) Unplug the power resistor wire from the LCB and remove the resistor. 4) Reverse Steps 1-3 to install a new power resistor.

  • Page 23: Generator Replacement

    CHAPTER 5: PART REPLACEMENT GUIDE 5.4 Generator Replacement 1) Remove the shrouds as outlined in Section 5.1. 2) Remove the cable ties on the wire connector of the generator (Figure A). 3) Unplug the power cable connector of the generator (Figure B). FIGURE A FIGURE B 4) Remove the screw and washer on the right side of the frame that keeps the generator from spinning freely (Figure C).
  • Page 24 CHAPTER 5: PART REPLACEMENT GUIDE 5.4 Generator Replacement – Continued 6) Loosen the nuts putting tension on the generator belt (Figure E). Then remove the eye bolt with plate (Figure F). FIGURE E FIGURE F 7) Once the tension has been removed, the generator belt can be walked off of the secondary pulley (Figure G). 8) Pull the generator out of the frame towards the back of the unit and remove the generator belt (Figure H).

  • Page 25: Generator Belt Replacement

    CHAPTER 5: PART REPLACEMENT GUIDE 5.5 Generator Belt Replacement 1) Remove the shrouds as outlined in Section 5.1. 2) Remove the cable ties on the wire connector of the generator (Figure A). 3) Unplug the power cable connector of the generator (Figure B). FIGURE A FIGURE B 4) Remove the screw and washer on the right side of the frame that keeps the generator from spinning freely (Figure C).
  • Page 26 CHAPTER 5: PART REPLACEMENT GUIDE 5.5 Generator Belt Replacement – Continued 6) Loosen the nuts putting tension on the generator belt (Figure E). Then remove the eye bolt with plate (Figure F). FIGURE E FIGURE F 7) Once the tension has been removed, the generator belt can be walked off of the secondary pulley (Figure G). 8) Pull the generator out of the frame towards the back of the unit and remove the generator belt (Figure H).

  • Page 27: Drive Belt Replacement

    CHAPTER 5: PART REPLACEMENT GUIDE 5.6 Drive Belt Replacement 1) Remove the shrouds as outlined in Section 5.1. 2) Loosen the belt tension bolt on the right side of the tension pulley and rotate the pulley counter-clockwise until there is enough slack in the belt to remove it (Figures A &...

  • Page 28: Pulley Axle Set Replacement

    CHAPTER 5: PART REPLACEMENT GUIDE 5.7 Pulley Axle Set Replacement 1) Remove the shrouds as outlined in Section 5.1. 2) Loosen the belt tension bolt on the right side until there is enough slack to remove the drive belt (Figure A). 3) On the right side of the frame, remove the retaining clip that holds the pulley axle bearing into the frame (Figure B).

  • Page 29: Drive Axle Set Replacement

    CHAPTER 5: PART REPLACEMENT GUIDE 5.8 Drive Axle Set Replacement NOTE: A Vision Fitness special tool is needed to correctly replace a drive axle. Order part # 0000094817 from Vision Fitness CTS. 1) Remove the shrouds as outlined in Section 5.1.
  • Page 30 CHAPTER 5: PART REPLACEMENT GUIDE 5.8 Drive Axle Set Replacement – Continued 9) The drive axle should come with an iron plate installed (Figure G). 10) Assemble the Vision Fitness special tool as shown in Figure H. Kits number: 0000094817 FIGURE G FIGURE H 11) Slide the drive axle into the hole in the frame.
  • Page 31 CHAPTER 5: PART REPLACEMENT GUIDE 5.8 Drive Axle Set Replacement – Continued 15) Turn the nut until the iron plate is close to the frame on the right side (Figure M). 16) Remove the tools. Then insert the bearing into the hole in the frame on the left side (Figure N). FIGURE M FIGURE N 17) Again use the screw, washer and nut to attach tool #1 to the drive axle (Figure O).
  • Page 32 CHAPTER 5: PART REPLACEMENT GUIDE 5.8 Drive Axle Set Replacement – Continued 21) Use a screwdriver to take off the iron plate (Figures S & T). FIGURE S FIGURE T 22) Reinstall the belts as outlined in Sections 5.5 and 5.6. 23) Test the Elliptical for function as outlined in Section 5.22.

  • Page 33: Crank Set Replacement

    CHAPTER 5: PART REPLACEMENT GUIDE 5.9 Crank Replacement 1) Remove the shrouds as outlined in Section 5.1. 2) Detach the pedal arm from the crank bearing assembly (Figure A). 3) Remove the screw from the crank (Figure B). FIGURE A FIGURE B 4) Insert an M10 screw (should be at least 40mm long) into the crank hole.

  • Page 34: Console Replacement

    CHAPTER 5: PART REPLACEMENT GUIDE 5.10 Console Replacement 1) Remove the 4 screws holding the console to the frame (Figure A). FIGURE A 2) Disconnect the console cable and HR connections from the defective console and remove the console (Figure B). FIGURE B 3) Reinstall the wire connections to the new console.

  • Page 35: Heart Rate Handlebar Replacement

    CHAPTER 5: PART REPLACEMENT GUIDE 5.11 Heart Rate Replacement 1) Remove the console as outlined in Section 5.10. 2) Remove the 4 screws holding the heart rate handlebar to the console mast being careful to support the handlebar (Figure A). FIGURE A 3) Pull the heart rate handlebar away from the console mast to expose the HR grip wiring (Figure B).

  • Page 36: Dual Action Handlebar Replacement

    CHAPTER 5: PART REPLACEMENT GUIDE 5.12 Dual Action Handlebar Replacement 1) Remove the plastic cover where the dual action handlebar meets the link arm (Figure A). 2) Remove the bolt where the dual action handlebar and the link arm meet (Figure B). FIGURE A FIGURE B 3) Remove the cap by hand (Figure C).

  • Page 37: Console Mast Replacement

    CHAPTER 5: PART REPLACEMENT GUIDE 5.13 Console Mast Replacement 1) Remove the console as outlined in Section 5.10. 2) Remove the HR handlebars as outlined in Section 5.11. 3) Remove the dual action handlebar as outlined in Section 5.12. 4) Lift up the rubber boot at the bottom of the console mast (Figure A) and remove the 4 screws holding the console mast to the frame (Figure B). FIGURE A FIGURE B 5) Pull the wires out the bottom of the console mast and remove the mast.

  • Page 38: Foot Pedals Replacement

    CHAPTER 5: PART REPLACEMENT GUIDE 5.14 Foot Pedals Replacement 1) Pull up and remove the rubber portion of the pedal (Figures A & B). FIGURE A FIGURE B 2) Remove the 4 screws that hold the plastic pedal to the foot plate (Figure C). 3) Remove the plastic foot pedal (Figure D).

  • Page 39: Pedal Arm Replacement

    CHAPTER 5: PART REPLACEMENT GUIDE 5.15 Pedal Arm Replacement 1) Remove the foot pedal as outlined in Section 5.14. 2) Remove the 6 screws at both sides that hold the back cover to the shrouds and remove the back cover (Figures A & B). FIGURE A FIGURE B 3) Detach the pedal arm from the crank bearing assembly (Figure C).
  • Page 40 CHAPTER 5: PART REPLACEMENT GUIDE 5.15 Pedal Arm Replacement – Continued 7) Remove the three bolts that holding the link arm to the pedal arm (Figures H & I). FIGURE G FIGURE H 8) Remove the pedal arm (Figure J). FIGURE I FIGURE J 9) Reverse Steps 1-8 to install a new pedal arm.

  • Page 41: Link Arm Replacement

    CHAPTER 5: PART REPLACEMENT GUIDE 5.16 Link Arm Replacement 1) Remove the foot pedal as outlined in Section 5.14. 2) Remove the plastic cover where the dual action handlebar meets the link arm (Figure A). 3) Remove the bolt and bushings where the dual action handlebar meets the link arm (Figure B). FIGURE A FIGURE B 4) Remove the 3 bolts that hold the link arm to the pedal arm (Figures C &...

  • Page 42: Incline Arm Cover Replacement

    CHAPTER 5: PART REPLACEMENT GUIDE 5.17 Incline Arm Cover Replacement 1) Remove the 4 screws that hold the incline arm cover to the vertical stabilizer arm (Figure A). FIGURE A 2) Remove the incline arm cover (Figure B). FIGURE B 3) Reverse Steps 1-2 to install a new incline arm cover.

  • Page 43: Swing Arm Replacement

    CHAPTER 5: PART REPLACEMENT GUIDE 5.18 Swing Arm Replacement 1) Remove the incline arm cover as outlined in Section 5.17. 2) Remove the bolt from the upper pivot joint of the vertical stabilizer arm (Figure A). 3) Remove the plastic cap from the swing arm (Figure B). FIGURE A FIGURE B 4) Remove the bolt that holds the pedal and swing arms together (Figure C).

  • Page 44: Vertical Stabilizer Arm Replacement

    CHAPTER 5: PART REPLACEMENT GUIDE 5.19 Vertical Stabilizer Arm Replacement 1) Remove the incline arm cover as outlined in Section 5.17. 2) Remove the two bolts that hold the vertical stabilizer arm to the frame (Figures A & B). FIGURE A FIGURE B 3) Remove the two bolts that hold the incline arm to the vertical stabilizer arm (Figure C).

  • Page 45: Incline Arm Replacement

    CHAPTER 5: PART REPLACEMENT GUIDE 5.20 Incline Arm Replacement 1) Remove the two screws that hold the cover over the incline arm / console mast connection point, and remove the cover (Figure A). 2) Remove the 4 bolts that hold the incline arm to the console mast (Figure B). FIGURE A FIGURE B 3) Remove the two bolts that hold connection arm to vertical stabilizer arm (Figure C).

  • Page 46: Heart Rate Grips Replacement

    CHAPTER 5: PART REPLACEMENT GUIDE 5.21 Heart Rate Grip Replacement 1) Remove the 2 screws going upward into the top of the heart rate grip (Figure A). 2) Once the 2 screws are removed, pull apart the top and bottom portions of the heart rate grip (Figure B). FIGURE A FIGURE B 3) Disconnect the heart rate plate wiring and remove the old HR grip (Figure C).

  • Page 47: Testing The Elliptical

    CHAPTER 5: PART REPLACEMENT GUIDE 5.22 Testing the Elliptical ONCE THE UNIT OR REPLACEMENT PART IS FULLY INSTALLED AND ASSEMBLED AND PROPERLY PLACED ON THE FLOOR, USE THE FOLLOWING INSTRUCTIONS TO TEST THE MACHINE: 1) Without hitting start or entering any program modes, stand on the elliptical and hold the handlebars while pedaling to simulate exercising. While moving, listen for any odd noises or squeaks.

  • Page 48: Chapter 6: Software Upgrade Procedure

    CHAPTER 6: SOFTWARE UPGRADE PROCEDURE 6.1 Software Upgrade Instructions A. Service Tools & Accessories: 1. MSP-FET430 Gang Programmer 2. Parts number: MT00L-039 3. Software A: 14 PIN B: POWER SUPPLY SPECIFICATION: 8~15V 300MA MSP-FET430 TOOLS...
  • Page 49 CHAPTER 6: SOFTWARE UPGRADE PROCEDURE 6.1 Software Upgrade Instructions – Continued B. VISION S70 ELLIPTICAL SOFTWARE UPGRADE PROCEDURE 1. Connect the MSP-GANG430 hardware, PC, and console as shown in Figure A. FIGURE A 2. Click on the GANG430 icon located in the program group specified during installation of the software (the default group is ADT430). The MSP430 FLASH Gang Programmer GUI is displayed on the screen as shown in Figure B.
  • Page 50 CHAPTER 6: SOFTWARE UPGRADE PROCEDURE 6.1 Software Upgrade Instructions – Continued 3.3 Select the required device using the Device Type menu. 3.4 Select the console software file to be programmed into the MSP-GANG430 using the File Name menu. The format supported for the console software file is TI TXT (.txt).
  • Page 51 CHAPTER 6: SOFTWARE UPGRADE PROCEDURE 6.1 Software Upgrade Instructions – Continued 4. After the first console is installed, you can remove the RS232 cable from PC to MSP-GANG430 as shown in Figure D. Connect the other consoles being installed to MSP-GANG430 as shown in Figure E. Press the MSP430 “START” button, the “MODE” LED will to glitter about 10 sec, if the install passes, the OK green LED will light as shown in Figure F.

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