Spirit XE526SE User manual

Service Manual
Elliptical XE526SE

Elliptical XE526SE Service Manual
Plastic Parts
Round Disk Right Handle Bar Cover (Front/Rear)
Round Disk Cover Console Pedal (R)
Side Case (R)
Left Handle Bar Cover (Front/Rear) Console Mast Cover
Pedal Arm Cover (L) Rear Stabilizer Cover (A)
Connecting Arm Cover B (R) Slide Wheel Cover Rear Stabilizer Cover (B)
Connecting Arm Cover A (L) Pedal (L)
Front Stabilizer Cover Side Case (L)

Skeleton
Cross Bar
Bushing Housing Connecting Arm (R)
Console Mast
Swing Arm (R)
Main Frame Rear Rail Assembly
Flywheel
Pedal Arm (L) Pedal Arm (R)
Drive Pulley
Connecting Arm (L) Slide Wheel

Table of Contents：
I. Replacing Parts
1. The Console
2. Swing Arms and Connecting Arms
3. Pedal Arms
4. Side Cases
5. The Cross Bar
6. The Belt
7. The Idler Wheel Assembly
8. The Flywheel
9. The Drive Pulley
10. The Bushing Housing
11. Slide Wheels
II. Troubleshooting
1. The Console
2. Side Cases and Round Disk
3. The Flywheel
4. The Drive Belt
5. Swing Arms
6. The Bushing Housing
7. Pedal Arms, Connecting Arms and Slide Wheels
III. Q＆
＆＆
＆A
1. Noises
2. Slippage
3. Plays
4. Smoothness
5. Other Problems

Model XE526SE Work Replacing Parts
The Part 1. The Console Rev.
Procedures：
1. Use Phillips head screw driver to release
four M5 x 10 mm Phillips head screws
which secure the console, then disconnect
the computer cable, handle wire (red and
white) and hand pulse cable in order to
take the console apart, as shown in
figures 1 & 2.
2. To resume, connect the computer cable,
handle wire (red and white) and hand
pulse cable with the console and tighten
four M5 x 10 mm Phillips head screws,
beware not to twist cables.
3. If taking apart the console bottom cover
is necessary, release 3.5x12 self tapping
screws, as shown in figure 3.
1
2
3

Model XE526SE Work Replacing Parts
The Part 2. Swing Arms and Connecting Arms Rev.
Procedures：
1. Use Phillips head screw driver to release
3.5x12 self tapping screws, which secure
handle bar covers and M5x15mm,
3.5x12 self tapping screws which secure
connecting arm covers, as shown in
figures 1 & 2.
2. Then use 12mm and 13mm wrenches to
release 5/16" x1-1/4" hex head screw,
5/16" x 20 x 1.5T flat washer and
5/16" x 7T nut, which secure the rod end
bearing, as shown in figure 3.
3. Use 12mm wrench to release
5/16" x 15m/m hex head screw and
5/16" x 23 x1.5T flat washer, which
secure the swing arm, to take it apart, as
shown in figure 4.
1
2
3
4

Model XE526SE Work Replacing Parts
The Part 2. Swing Arms and Connecting Arms Rev.
Procedures：
4. Use 12mm wrench to release
5/16" x 15m/m hex head screw and
5/16" x 20 x1.5T flat washer, which
secure the connecting arm, then release
the carriage bolt under the pedal to take
the connecting arm apart, as shown in
figure 5.
5. Release four M5x10mm Phillips head
screws, which secure the pedal, to take
the pedal from the connecting arm, as
shown in figure 6.
6. Reverse above procedures to resume
parts by returning the carriage bolt and
tightening 5/16" x 15m/m hex head
screw and 5/16" x 23 x 1.5T flat washer,
as shown in figure 7.
5
6
7

Model XE526SE Work Replacing Parts
The Part 3. Pedal Arms Rev.
Procedures：
1. Follow procedure 2 to take apart the
connecting arm.
2. Use M8 wrench and 14mm wrench to
release 3/8” x 2-1/4” Socket Head Cap
Bolt, two 3/8"×19×1.5T flat washers
and 3/8” x 11T nut, which secure the
pedal arm and bushing housing, and
take the pedal apart, as shown in figures
2 & 3.
3. Use 12mm wrench to release
5/16" x 15m/m hex head screw and
5/16" x 35 x1.5T flat washer and take
the bushing housing apart, as shown in
figure 4.
4. Reverse above steps to resume parts.
1
2
3
4

Model XE526SE Work Replacing Parts
The Part 4. Side Cases Rev.
Procedures：
1. Follow procedures 2 & 3 to take apart
the connecting arm and pedal arm,
respectively.
2. Slap backward the console mast cover
so that it separate from side covers, as
shown in figure 1.
3. Use Phillips head screw driver to
release seven 4x19 self tapping screws
and three 5x16 tapping screws, which
secure right side case to take it apart,
as shown in figures 2 & 3.
4. To take left side case apart, release
4x15 self tapping screws, 1/4"x19 flat
washers and three 5x16 tapping screws
on the main frame, then disconnect DC
cables, as shown in figures 4, 5 & 6.
1
2
3
4

Model XE526SE Work Replacing Parts
The Part 4. Side Cases Rev.
Procedures：
5. To resume, first connect DC cables.
6. Install left side case on the main frame,
with 5/16" x 23 x 1.5T flat washer
between the side case and the main
frame, then tighten three 5x16 tapping
screws, with the side case and round
disk at the center, and 4x15 self tapping
screws, as shown in figure 7 & 8.
7. Match right side case with left side case
and tighten with seven 4x19 self tapping
screws and three 5x16 tapping screws.
8. Follow procedures 3~4 and 2~5 to
resume the pedal arm and the
connecting arm.
5
6
7
8

Model XE526SE Work Replacing Parts
The Part 5. The Cross Bar Rev.
Procedures：
1. Follow procedures 2, 3 & 4 to take apart
the connecting arm, pedal arm and side
cases.
2. Tip off the round disk cover, as shown in
figure 1.
3. Use 12mm wrench to release
5/16" x 15m/m hex head screw and
5/16" x 35 x 1.5T flat washer then use
M6 wrench and 13mm wrench to release
M8x40 Socket Head Cap Bolt and two
M8x6.3T nuts in order to take the cross
bar and the drive pulley apart, as shown
in figures 2 & 3.
4. To separate the cross bar from the drive
pulley, take apart the bushing housing
first, then use Phillips head screw driver
to release eight 5x16 tapping screws and
1/4"x19 flat washers, as shown in
figure 4.
1
2
3
4

Model XE526SE Work Replacing Parts
The Part 5. The Cross Bar Rev.
Procedures：
5. To resume, first install the drive pulley
onto the cross bar and return it on the
crank axle, insert 7x7x25L Woodruff
Key and tighten M8x40 Socket Head
Cap Bolt with M8x6.3T nuts until 500
kg-
f of torque then tighten 5/16" x 15m/m
hex head screw with 5/16" x 35 x 1.5T
flat washer, as shown in figures 5 & 6.
6. Follow procedures 4, 3 and 2 to return
the connecting arm, pedal arm and side
covers with round disk cover.
5
6

Model XE526SE Work Replacing Parts
The Part 6. The Belt Rev.
Procedures：
1. Follow procedures 2, 3, 4 & 5 to take
apart the connecting arm, pedal arm,
side cases and cross bar, respectively.
.
2. Use 13mm wrench to loosen M8 x 9T
nut on M8x170mm J-bolt and M8 x 7T
nut on idler wheel assembly in order to
take the belt apart, as shown in figures
1, 2 & 3.
3. To resume, first return the belt on the
drive pulley and the flywheel and tighten
M8 x 9T nut. Make sure the belt is as
tight as the sound wave gauge reads 170
+/- 10 Hz before tightening up M8 x 7T
nut, as shown in figure 4.
4. Follow procedures 5, 4, 3 and 2 to return
all parts.
1
2
3
4

Model XE526SE Work Replacing Parts
The Part 7.The Idler Wheel Assembly Rev.
Procedures：
1. Follow procedures 2, 3, 4, 5 & 6 to take
apart the connecting arm, pedal arm, side
cases, the cross bar and the belt.
2. Use 13mm wrench to loosen M8 x 9T
nut with 5/16" x 23 x 1.5T flat washer
on M8x170mm J-bolt and take the J-bolt
apart. Then use again 13mm wrench to
release M8 x 20 carriage bolt, 5/16" x 20
x 1.5T flat washer and M8 x 7T nut,
which secure the idler wheel assembly,
to take it apart, as shown in figures 1 & 2.
3. To take apart the bearing of the idler
wheel, Use C-clip pliers to release ψ17
C-ring on the axle, and 6203 bearing
can thus be taken apart.
4. Reverse above steps to resume all parts.
1
2

Model XE526SE Work Replacing Parts
The Part 8. The Flywheel Rev.
Procedures：
1. Follow procedures 2, 3, 4, 5, 6 & 7
to take apart the connecting arm,
pedal arm, side cases, the cross bar
and the belt together with the idler
wheel assembly.
2. Plug in the power, adjust the
resistance to level 20 and take apart
the steel cable, as shown in figures
1 & 2.
3. Use 15mm wrench to loosen two
3/8" -UNF26 x 9T nuts and pull out
the flywheel. Take apart the belt, as
shown in figures 3 & 4.
1
2
3
4

Model XE526SE Work Replacing Parts
The Part 8. The Flywheel Rev.
Procedures：
4. To return the flywheel, locate the belt
on the flywheel notches and install
the flywheel on the mainframe.
5. Tighten both 3/8" -UNF26 x 9T nuts.
6. Return the steel cable on the flywheel
and install the idler wheel assembly,
as shown in figure 5.
7. Turn the drive pulley and adjust both
3/8"-UNF26 x 4T nuts to assure the
belt locates at the center of the drive
pulley to make sure the belt does not
fall off and tighten the screws. Adjust
the belt for proper tension, as shown
in figure 6.
8. Reverse above ateps to resume all
parts.
5
6

Model XE526SE Work Replacing Parts
The parts 9. The Drive Pulley Rev.
Procedures：
1. Follow procedures 2, 3, 4, 5 and 6 to take
apart the connecting arm, pedal arm, side
cases and cross bar together with the belt.
2. Use C-ring pliers to release twoψ25
C-rings on the crank axle to take
apart the crank axle and the drive pulley,
as shown in figures 1 & 2, use rubber
hammer to take off the crank axle if
necessary.
3. To separate the axle from the drive
pulley, use C-ring pliers to release ψ25
C-ring on the axle and then use 11mm
wrench to release four 1/4" x 3/4"hex
head screws and 1/4" nuts, as shown in
figure 3.
4. To resume, install the drive pulley and a
C-ring on the axle and return onto the
main frame and secure with two C-rings
5. Reverse above steps to resume all parts.
1
2
3

Model XE526SE Work Replacing Parts
The Parts 10. The Bushing Housing Rev.
Procedures：
1. Follow procedures 2 & 3 to take apart
the connecting arm and the pedal arm.
2. Use 12mm wrench to release 5/16" x
15m/m hex head screw and 5/16" x 35 x
1.5T flat washer and take apart the
bushing housing, as shown in figure 1.
3. To resume, return in order the plastic
wave washer and ψ25 wave washer
onto the axle then install the bushing
housing on the axle and secure with
5/16" x15m/m hex head screw and
5/16" x 35 x 1.5T flat washer, as shown
in figure 2.
4. Reverse above steps to return the pedal
arm and the connecting arm.
1
2

Model XE526SE Work Replacing Parts
The Part 11. Slide Wheels Rev.
Procedures：
1. Use Phillips head screw driver to take the
slide wheel cover apart, as shown in
figure 1.
2. Use C-ring pliers to release ψ17 C-ring
and take apart the slide wheel, as shown
in figure 2.
3. To resume, return in order ψ17 wave
washer, slide wheel and ψ17 wave
washer and secure with a C-ring.
Return the slide wheel cover, as shown
in figure 3.
4. Reverse above steps to return the pedal
arm and the connecting arm.
1
2
3

Model XE526SE Work Troubleshooting
The Part 1. The Console Rev.
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, as shown in
figure 1.
3. Make sure all harnesses are properly
connected including the console and
computer cable, computer cable and
DC cables, which can be done by
disassembling the console.
4. If harnesses are properly connected,
check for the damage of harness,
console malfunction or gear motor
malfunction, as shown in figures
2 & 3.
1
2
3