Vision Fitness U70-02 User manual

Vision Fitness U70-02 (CB68C) Service Manual

2
TABLE OF CONTENTS
CHAPTER 1: MAINTENANCE PROCEDURE
1.1 Preventive Maintenance Schedule…………………………………………………………..4
1.2 Cleaning the Grooves………………………………………...............................................5
CHAPTER 2: WIRING DIAGRAM INSTRUCTION
2.1 Electrical Installation…………………………………………………………………….…....6
2.2 Electrical Diagram…………………………….………………………………………….…...7
2.3 Wiring Diagram……………………………………………………………………………......8
2.4 Lower Control Board Wiring Diagram………………….………………………….………...8
2.5 Console Wiring Diagram……………………………………………………………………...9
CHAPTER 3: ENGINEERING MODE
3.1 Using Engineering Mode...............................................................................................11
CHAPTER 4: TROUBLESHOOTING
4.1 Console Error Codes………………………………………………………………………….12
4.2 Troubleshooting – No Display on the Console or the Display is Dim..………………….13
4.3 Troubleshooting – No RPM is Displayed During the Exercise………………..…….…....14
4.4 Troubleshooting – All or Some of the Function Keys Do Not Respond………….......….15
4.5 Troubleshooting – High or No Resistance…………………………………………..…...…16
4.6 Troubleshooting – Pedals Slipping…………………………………….…………..……..….17
4.7 Troubleshooting – Knocking or Creaking Noise………….……………………………...…17
4.8 Troubleshooting – Heart Rate Function Does Not Work or is Reading Incorrectly……..18
CHAPTER 5: PART REPLACEMENT GUIDE
5.1 Console Replacement.....................................................................................................19
5.2 Heart Rate Handlebar Replacement ..............................................................................20
5.3 Heart Rate Grip Replacement ........................................................................................21
5.4 Cup Holder Replacement................................................................................................22
5.5 Seat Pad Replacement...................................................................................................23
5.6 Back Pad Replacement..................................................................................................24
5.7 Seat Post Replacement..................................................................................................25
5.8 Seat Post Insert Replacement........................................................................................26
5.9 Pedal Replacement........................................................................................................27
5.10 Crank Removal…...........................................................................................................28
5.11 Shrouds Removal...........................................................................................................28
5.12 Lower Control Board Replacement ...............................................................................29
5.13 Drive Belt Replacement..................................................................................................31

3
CHAPTER 5: PART REPLACEMENT GUIDE
5.14 Idler Set Replacement....................................................................................................32
5.15 Generator Belt Replacement..........................................................................................33
5.16 Generator Replacement.................................................................................................35
5.17 Transmission Axle Set Replacement .............................................................................37
5.18 Pulley Axle Set Replacement.........................................................................................39
5.19 Rear Stabilizer Replacement......................................................................................…42
5.20 Testing the Bike......................................................................................................... …43
CHAPTER 6: SOFTWARE UPGRADE PROCEDURE
6.1 Software Upgrade Instructions…....................................................................................44

4
CHAPTER 1: MAINTENANCE PROCEDURE
1.1 Preventive Maintenance Schedule
PREVENTIVE MAINTENANCE SCHEDULE
Item Daily Weekly Monthly Quarterly Biannual Annual
Console Mounting
Bolts
Inspect
Frame Inspect
Display Console Clean Inspect
Seat Guide Rods Clean Lubricate
Pedals Clean Inspect
Handlebar Clean Inspect
Handrail &
Handlebar Clean
Inspect
Belt Grooves Inspect
V Belt Clean Inspect

5
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 (450-JFG) and check the grooves of the belt for dirt or dust and clean if any is present.
2. Check the grooves in the pulley for dirt or dust and clean if any is present.
3. Check the grooves in the roller pulley for dirt or dust and clean if any is present.

6
CHAPTER 2: WIRING DIAGRAM INSTRUCTION\
2.1 Electrical Installation

7
CHAPTER 2: WIRING DIAGRAM INSTRUCTION\
2.2 Electrical Diagram

8
CHAPTER 2: WIRING DIAGRAM INSTRUCTION\
2.3 Wiring Diagram
P01- CONSOLE WIRE
2.4 Lower Control Board Diagram
J2 7 pin terminal to the console
J3 3 pin terminal to the generator
J4 2 pin terminal to the power resistor
J3
J4
J2

9
CHAPTER 2: WIRING DIAGRAM INSTRUCTION\
2.5 Console Wiring Diagram
Port Function
JQK Quick key cable for S70
JQK1 Quick key cable for R70
JHD Console wire for S70
JAI Console wire for S60, U70, R70
JHG1/JHG2 Hand grip cable for all models
Select switch Select current model by hand
Select switch
JQK
–
Quick ke
y
for S70
JQK1
–
Quick ke
y
for R70
JHD
–
Console di
g
ital wire for S70
JAI
–
Console wire for S60, U/R 70
JHG1, JHG2
–
Han
g
g
ri
p

10
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. To scroll through the list of options in Engineering Mode, use the UP and DOWN RESISTANCE keys.
3. Press the ENTER key to see the value of the function.
4. To change the value of the setting, use the UP and DOWN RESISTANCE keys.
5. To confirm and save the value of the setting, press the ENTER key.
6. Press and hold the START key for 3-5 seconds to return to normal operation.
FIGUREA
FIGURE B
KEY NAME FUNCTION
UP Select function or adjust value
DOWN Select function or adjust value
ENTER Enter the function item
START Save value or quit mode
Hold “ START” key 3’s System reset
Hold “ UP&DOWN” key 3’s Enter engineering mode

11
CHAPTER 3: ENGINEERING MODE
3.1 Using Engineering Mode – Continued
CUSTOMSETTING DEFAULT MINIMUM MAXIMUM DESCRIPTION
MAX TIME 99 min 5 min 99 min Set a maximum workout time
USER TIME 60 min 5 min 99 min Set a default workout time
DF AGE 40 10 100 Set a default age for all programs
DF LEVEL 1 1 20 Set a default resistance level for all programs
DF GENDER MALE FEMALE MALE Set a default gender for all programs
UNIT MILE KM MILE Set the unit to miles or kilometers
MACHINE BIKE BIKE ELLIPTICAL Set machine to bike or elliptical mode
ACCUMULATED
TIME _ _ _ Total time the product has been used in hours.
ACCUMULATED
DISTANCE _ _ _ Total distance the product has been used.
DISPLAY TEST －－－Used by service technicians to test LED
displays
MACHINE TEST _ _ _ Provides a way to test heart rate and
resistance without entering a program.
KEYPAD TEST _ _ _ Provides a way to test the keypads fo
r
function.
VERSION －－－Display Current software version
LANGUAGE
The native language prompts in the instruction
center

12
CHAPTER 4: TROUBLESHOOTING
4.1 Console Error Codes
Error Messages on the Console
Code Class Description Solution
0x0441 B
When UCB implements a command, LCB has not
received this command. Check the console cable connection, replace the LCB.
0x01AC C
Power resistor is short circuited (over 4A), or the current
is over 3.7A for 1 second. Check the connection of power resistor or replace power resistor
0x02AB C Machine Type Error Set the Machine Type to the correct type of LCB
0x02B3 C Resistance Type Error Set the Machine Type to the correct type of LCB
0x04A0 C
The LCB has no message returned to the UCB for ove
r
3 seconds. Check the console cable connections, replace the LCB / UCB as needed.
0x0201 A LCB Battery Low Voltage Check battery recharge function or replace new battery
0x0248 B Battery disconnection or fail. Check the connection of battery or replace new battery

13
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. Poor connection to all the terminals on the control board.
3. The lower control board is damaged.
4. The generator is damaged.
SOLUTION:
1. Check the connection of the console cable at the UCB.
2. Remove the console cable from the J5 socket on the console. Pedal the machine and set your multi-meter to DC voltage and place both
terminals on pins 1 & 4 of the console cable. There should be a reading of more than 5.5VDC (Figure A).
- If voltage is more than 5.5VDC, replace the console.
- If voltage is less than 5.5VDC, or the new console does not resolve the issue, replace the console cable.
3. Open the rear shrouds then check if all the wire harnesses are connected properly to the terminals of the LCB.
4. Unplug the generator cable from the control board, pedal the machine and set your multi-meter to AC voltage and place both terminals on pins 1 &
2, pins 2 & 3, and pins 3 & 1 of the console cable to check if the voltage is variable (Figure B).
- If the voltage reading shown is variable (varies based on RPM), replace the LCB.
- If the voltage reading shown is not variable, replace the generator.
FIGUREA FIGUREB

14
CHAPTER 4: TROUBLESHOOTING
4.3 Troubleshooting – No RPM is Displayed During the Exercise
NORPMISDISPLAYEDDURINGTHEEXERCISE
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. The lower control board is damaged.
4. The generator is damaged.
SOLUTION:
1. Check the connection of the console cable at the UCB.
2. Remove the console cable from the J5 socket on the console. Pedal the machine and set your multi-meter to resistance and place a terminal on pin
3 of the console cable at both the LCB and UCB. There should be a resistance (ohm) reading (Figures A & B).
- If a resistance reading is shown, replace the console.
- If the there is no resistance reading, or a new console does not resolve the issue, replace the console cable.
3. Open the rear shrouds and check if all the wire harnesses are connected properly to the terminals of the LCB.
4. Unplug the generator cable from the LCB and pedal the machine to check if the voltage is variable.
- If a variable voltage reading is shown (varies based on RPM), replace the LCB.
- If the voltage reading shown is not variable, replace the generator.
FIGUREA FIGUREB

15
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.
3) The UCB is damaged.
SOLUTION:
1) Check the connections of the keypad at the UCB.
a. Remove the console from the console mast.
b. Remove the 6 screws holding the back of the console to the front (Figure A).
c. Inspect the keypad ribbon cable connection at the UCB (Figure B).
d. Even if the keypad ribbon cable appears to be connected correctly, unplug and reseat the cable, then retest.
2) Replace the affected keypad.
3) Replace the UCB.
FIGUREA FIGUREB

16
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.
5) The generator is damaged.
SOLUTION:
1) Check the console cable connections at the UCB and LCB.
2) Remove the rear shrouds and check if the console cable is connected properly to the LCB.
3) Set your multi-meter to resistance (ohms) and place both terminals on the power resistor wires .Check the power resistor wires for resistance (Figure
A).
-If the power resistor wire does not have resistance, replace the power resistor.
4) Unplug the generator cable from the LCB. Pedal the machine and set your multi-meter to AC voltage and place both terminals on pins 1 & 2, pins 2 &
3, and pins 3 & 1 of the console cable to check if the voltage is variable (Figure B).
- If a variable voltage reading is shown (varies based on RPM), replace the LCB.
- If the voltage reading shown is not variable, replace the generator.
FIGUREA FIGUREB

17
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 covers and check the belt tension.
a. Tighten the drive belt tension if needed by moving the spring tension clip to another hole.
b. The generator belt should be tightened to 85 ft / lbs.
2) If the belts are tensioned correctly and the pedals are still slipping, the one way bearing is damaged, replace the drive assembly.
4.7 Troubleshooting – Knocking or Creaking Noise
KNOCKING OR CREAKING NOISE
POSSIBLE CAUSES:
1) The pedal is on the crank too loosely.
2) The crank or axle is worn out.
3) The belt tension is not high enough, or the belts are too dirty.
SOLUTION:
1) Tighten the pedal on the crank.
2) Tighten the crank on the drive axle. Replace the crank or axle as needed.
3) Remove the covers and check the belt tension.
a. Tighten the drive belt tension if needed by moving the spring tension clip to another hole (see Section 5.17).
b. The generator belt should be tightened to 85 ft / lbs.
4) Clean the belts. If they are worn or will not clean, replace the belts.

18
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.
3) The HR board is damaged.
4) The UCB is damaged.
SOLUTION:
1) With a multi-meter set for DC voltage, place one terminal on each of the HR grip plates. The HR grip should give a voltage reading of between 0.5 and
2.0VDC.
a. If the voltage is not between 0.5 and 2.0VDC, remove the 3 screws holding the HR grip together and check the connection of the HR grip wiring.
2) Check continuity of the HR grip wiring.
a. Place one terminal of a multi-meter set for resistance on the HR grip wiring at the HR grip, and the other terminal on the HR grip wiring at the
console. An ohm reading of around 1 should be expected. If the reading is higher than 1, replace the HR grip wiring.
3) Remove the console. Remove the 6 screws holding the front of the console to the rear. Check the connection of the HR board wiring to the UCB.
a. If all the wiring is intact and has good contact, replace the HR board.
4) If the HR board, HR grips, and HR grip wiring do not solve the issue, replace the UCB.

19
CHAPTER 5: PART REPLACEMENT GUIDE
5.1 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.
4) Carefully push the wires into the console and mast until they are clear of the console / mast connection and attach the console to the mast using the 4
screws.
5) Test the bike for function as outlined in Section 5.20.

20
CHAPTER 5: PART REPLACEMENT GUIDE
5.2 Heart Rate Handlebar Replacement
1) Remove the 4 screws holding the heart rate handlebar to the console mast being careful to support the handlebar (Figure A).
FIGURE A
2) Carefully pull the wires from the console mast until the connectors are showing, and then disconnect the 3 wires from the handlebar and remove the
defective handlebar (Figure B).
FIGURE B
3) Reverse Steps 1-2 to install a new handlebar.
4) Test the bike for function as outlined in Section 5.20.