Spirit XE520s User manual

Service Manual
Elliptical XE520s

1
I. 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) Round Disk Cover
Right Pedal Round Disk

2
II. 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

3
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
i. Console
ii. Chain Covers and Round Disk
iii. Flywheel (Brake)
iv. The Belt
v. Handle Bar Assembly
vi. Connecting Arm Assembly
vii. Gear Motor
Q＆A
1. Noises
2. Slippage
3. Resistance and Ramp
4. Smoothness
5. Other Problems

4
Model XE520s Service Replacing Parts
Part 1. Console Rev.
1
2
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
hand pulse cable from the
console to take the console
apart, as shown in figure 2.
3. To resume, connect the cables
with the console, put it on top of
the mast and secure with four
M5x10mm Phillips head screws.

5
Model XE520s Service Replacing Parts
Part 2. Handle Bar Assembly Rev.
1
2
3
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
Phillips Head Screws which
secure Connecting Arm Covers,
as shown in figure 2.
3. Use 12m/m_Wrench and
13m/m_Wrench to release 5/16"
× 1-1/4"_Hex Head Bolt,
5/16 " x20x1.5 T flat washer and
5/16 " x7T nut which secure
Connecting Arm and fish-eye
bearing, as shown in figure 3.
4. Use 12m/m_Wrench to release
5/16" × 15m/m_Hex Head Bolt
and 5/16 " x23x1.5T washer which
secure the Handle Bar, as shown
in figure 4.
4

6
Model XE520s Service Replacing Parts
Part 2. Handle Bar Assembly Rev.
5
Procedures：
5. Reverse above procedures to resume
Handle Bar Assembly together with
Ø 17 washer, if there is on the shaft
when you took it apart, as shown in
figure 5.

7
Model XE520s Service Replacing Parts
Part 3. Connecting Arm Rev.
1
2
3
4
Procedures：
1. Follow procedures 2 to disassemble
Handle Bar (only the lower part and
fish-eye bearing), as shown in figure
1.
2.
Use 12mm wrench to release 5/16" ×
15m/m_Hex Head Bolt and 5/16 "
x23
flat washer and then pull out the
Carriage Bolt to take Connecting
Arm apart, as shown in figures 2 &
3.
3. Pull out Pedal Latch Spring (on the
Locking Pin holding plate) and release
the Latch Spring with C-ring Pliers. The
pedal and Locking Pin Assembly can
thus be taken apart, as shown in figures 4
& 5.

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Model XE520s Service Replacing parts
Part 3. Connecting Arm Rev.
5
6
7
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
four M5x10 mm screws and take
apart the Pedal, as shown in figure 7,
Reverse above procedures to resume
parts.

9
Model XE520s Service Replacing parts
Part 4. Pedal Arm Assembly Rev.
1
2
3
4
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" × 2-1/4"_Socket Head
Cap Bolt with 3/8 " x19x1.5T flat
washer and 3/8 " x11T nut which
secure Pedal Arm and Bushing
Housing, as shown in figure 2.
3. Use 12 mm wrench to release 5/16 " x
15mm Hex Head Bolt together with
5/16 " x23x1.5T flat washer and take
Bushing Housing apart, as shown in
figure 3.
4. Use C-ring pliers to release Ø 17
C-ring in order to take apart Slide
Wheels, as shown in figure 4.
5. Reverse above steps to resume Pedal
Arm.

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Model XE520s Service Replacing parts
Part 5. Console Mast Rev.
1
2
3
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.
3. Use 14 mm wrench to release 3/8" ×
3/4"_Hex Head Bolt, 3/8" × 23 ×
2T_Curved Washer, 3/8" ×
2-1/4"_Hex Head Bolt and 3/8" ×
2T_Split Washer which secure the
Console Mast, as shown in figures 2
&3.
4. Pull the Mast out of the Mainframe
and split the control cable.
5.
Reverse above steps to resume Mast,
Console and Connecting Arm.

11
Model XE520s Service Replacing part
Part 6. Chain Covers Rev.
1
2
3
4
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 × 6m/m_Tapping
Screws which secure right Chain
Cover, as shown in figures 1&2.
3. Use again Phillips head screw driver
to release 3.5x12 Sheet Metal Screw,
1/4 " x19 flat washer, and three 5 ×
16m/m_Tapping Screws which secure
right Chain Cover, as shown in figures 4
&5.

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Model XE520s Service Replacing parts
Part 6. Chain Covers Rev.
5
6
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.
6. Reverse above steps to resume parts.
Make sure to return 5/16x23x1.5 flat
washer on left Chain Cover and DC
cable is free from pinched by the
Chain Cover or touching Round
Disk, as shown in figure 6.

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Model XE520s Service Replacing parts
Part 7. Cross Bar Rev.
1
2
3
4
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
and 5/16 " x35x1.5T flat washer
together with M8 × 30m/m_Socket
Head Cap Bolt to take apart the
Cross Bar, as shown in figures 1, 2
&3.
3. Use Phillips head screw driver to
release eight 5x16mm Tapping
Screws, which secure Round Disk
on the Cross Bar, and separate two
parts apart, as shown in figure 4.

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Model XE520s Service Replacing parts
Part 7. Cross Bar Rev.
5
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.

15
Model XE520s Service Replacing parts
Part 8. Idler Wheel Rev.
1
2
3
4
Procedures：
1. F
ollow 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
wrench to release M8x20 Carriage
Bolt, M8x7T nut and 5/16 " x20x1.5T
flat washer, which secure the Idler
Wheel, to take apart the Idler Wheel,
as shown in figures 1 &2.
3. Reverse above steps to resume and
adjust the belt tension by turning the
nut on J Bolt for proper tension,
170HZ(±10 sound wave frequency,
as shown in figures 3 & 4.

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Model XE520s Service Replacing parts
Part 9. Flywheel and the Belt Rev.
1
2
3
4
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.
3. Use 15 mm wrench to loosen
3/8 " -UNF26x9T nut which secure
the Flywheel on the Mainframe and
the Flywheel and Belt can be taken
apart, as shown in figures 2 &3.
4. Reverse above steps to resume. Be
sure that the Belt is put in the
middle, as shown in figure 4, before
returning all parts.

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Model XE520s Service Troubleshooting
Part 1. Console Rev.
1
2
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
connectors are all connected well and
make sure wire are free from damage, as
shown in figure 2.

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Model XE520s Service Troubleshooting
Part 2. Chain Covers and Round Disk Rev.
1
2
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.
2. If Round Disk is not in center and
causes noise, refer the procedure to
replacing Chain Covers and
reassemble.
3. If Round Disk swings too much,
then take apart Chain Covers
together with Round Disk and use
Phillips head screw driver to release
5x16mm Tapping Screws together
with 1/4"x19mm flat washers and
put the Cross Bar with Round Disk
on a flat surface and check for warp.
Correct the warp with force until
Round Disk swings between +/- 3
mm.

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Model XE520s Service Troubleshooting
Part 3. Flywheel Rev.
1
2
3
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
& 3.
2. If the Flywheel generates noise,
check if there is foreign material
inside the Flywheel. Replace if noise
persists.