SCIFIT PRO2 Service manual
Contents
1. 4 85 p e m recep for daisychain 65177 1 86 module power entry RF EFI 65178 1 87 screw 3 16 32x3 8 p h 1 88 cover supply power A1043 1 89 starwasher 6 8 90 screw 6 32x3 8 p h 8 91 standoffs 3 6 32 4 92 power supply lower serial 65150S 1 93 cotter pin 9mm 66372 4 94 mount hub sleeve sprocket thin 66355 2 1 95 ring chain sprocket 65340 2 96 clip u type 12 97 axle short bottom 66370S 1 bearing axle 66370B 2 nut M2x1 5 2 shell bearing crank hub Sin0407 1 ring snap retainer 1 2 98 mount hub sleeve thin 66354 2 1 99 idler chain sprocket w hub 65396 1 100 shaft idler chain 69394 1 101 hub brake drive pulley nohub 68316 1 1 shaft brake drive pulley 68312 2 1 bearing hub brake drive 68012 2 ring snap retainer 1 2 1 102 washer 1 2 pltd 3 103 lockwasher 1 2 pltd 3 104 nut 1 2 20 pltd 3 105 mount hub sleeve sprocket wide 66355 1 1 106 board heartrate PCB 65160 1 107 nut 5 16 18 pltd 6 108 axle long top 66370L 1 bearing axle 66370B 2 nut M2x1 5 2 shell bearing crank hub Sin0407 1 ring snap retainer 1 2 109 mount hub sleeve wide 66354 1 1 18 110 lockwasher 5 16 pltd 6 111 bolt 5 16 18x2 5 pltd 62. noise With the chains removed rotate each sprocket in the freewheel direction Replace if source of noise and or rough operation 2 4 Crank bars Items 8 and 53 stick and or slide roughly into the crank hub assy Item 55 Crank bars have dents and or burrs Inspect mating surfaces of crank bars and hubs for burrs and sharp edges Burnish as required with a fine file or emery cloth 2 5 Freewheels Item 69 make grinding noise operate roughly and or stick Freewheel is faulty Remove chain and rotate each sprocket in the freewheel direction Replace if source of noise and or rough operation 6 2 6 Handles and pedals lock up while operating Power supply board Item 92 is faulty Brake Item 73 is faulty Unplug power cord If handles now move freely replace power supply board If handles and pedals do not move with power cord unplugged replace brake See Procedure 4 2 7 No resistance on handles and pedals when in a program No speed signal Wires going to brake Item 73 are discon nected Power supply board Item 92 is faulty Check and adjust the speed sensor Item 79 as needed See Procedure 3 Check that brake wires are properly connected Check and replace power supply board as needed See Procedure 2 2 8 Very little resistance at any level Speed sensor Item 79 improperly adjusted Bad speed sensor connection with power supply board Item 92 Check and adjust the speed s
3. D s on upper board Item 2 blinking off on then go dead Ribbon cable Item 6 connections are loose Faulty power supply board Item 92 Display board Item 2 is faulty Check and replace accordingly Unplug and re plug machine to reset Check and replace power supply board as needed See Procedure 2 Replace display board 1 5 Heart rate displays zero 0 in window Chest strap and trans mitter improperly worn Loose sensor lead connection at display board Item 2 Faulty receiver Verify that they are being properly worn Check and adjust as needed If there is no audible signal replace receiver 1 6 Unit keeps blowing fuses Too many units are daisy chained together Faulty power supply board Item 92 Do not daisy chain more than 3 units together Check and replace power supply board as needed See Procedure 2 4 1 7 The upper display Item 2 resets after starting a program Ribbon cable connection is loose Item 6 Power cord is loose Display board is faulty Check cable connection at power supply and display boards Items 92 and 2 respectively Check and adjust as needed Replace display board 1 8 Program stops lines of dots shoot across screen Ribbon cable Item 6 connection is loose Display board Item 2 is faulty Check and adjust cable connection as needed Replace display board 1 9 Machine shuts down in programs but works in manual Display board I
4. Revision August 1999 ProII Service Manual SALES 800 278 3933 CUSTOMER SERVICE 800 745 1373 1 Table of Contents Section Page I Overview 2 II Troubleshooting Tables 3 III Maintenance Procedures Procedure 1 Removal and Reinstallation of the Power Supply Board 7 Procedure 2 Checking Voltage at the Power Supply Board 7 Procedure 3 Checking and Adjusting the Speed Sensor 8 Procedure 4 Removal and Replacement of the Brake Assembly 8 Procedure 5 Tightening the Poly V Belt 9 Procedure 6 Checking and Adjusting the Slack in the Chains 9 IV Figures Figure 1 ProII Total Assembly Items 1 59 11 Figure 2 ProII Main Frame Items 60 111 12 Figure 3 Power Entry Module with Fuse Holder 13 Figure 4 ProII Wiring Diagram 14 V ProII Parts List 15 2 I Overview Purpose This manual is designed to assist in service of SCIFIT ProII exercise machines The manual is divided into sections to diagnose and isolate problems Troubleshooting tables and procedures along with drawings are provided to aid technicians in servicing equipment The Item Numbers given in the parts list in Section V can be used to determine the location of various parts in Figures 1 and 2 When troubleshooting the actions taken to resolve problems should be performed in the order stated Deviating from this sequence may cause damage to the equipment and lead to unnecessary repairs Technical Support For further
5. assistance in service of SCIFIT products please call 800 745 1373 extension 21 The technical support department is staffed from 8 AM to 5 PM C S T Monday through Friday A voicemail service is available 24 hours daily for recording messages to request technical support and to order replacement parts Please have the following information prior to calling technical support Model number of equipment Serial number of equipment Point of contact name and phone number Detailed description of symptoms encountered 3 II Troubleshooting Tables Table 1 Electrical Troubleshooting Problem Possible Reasons Solutions 1 1 The machine appears to be off when plugged in and switched on Faulty power supply board Item 92 Faulty fuse Loose cable connection If buttons on the control display beep when pressed replace power supply board See Procedure 1 Otherwise check power supply board See Procedure 2 Check and replace fuse if needed See Fig 3 Check wire connections at power supply and display boards 1 2 Upper control panel Item 2 lights are dim Power supply board Item 92 is faulty Replace power supply board See Procedure 1 1 3 Upper board Item 2 accepts commands but rotational resistance does not change Dip switch setting is incorrect Power supply board Item 92 is faulty Set dip switch to 01 Check and replace power supply board as needed See Procedure 2 1 4 LE
6. e 65202 1 5 screws 6 32x 5 b h blk 4 6 cable ribbon assy 65120 1 7 screw M6x1 0x25 s h 4 8 bar hand crank 66311 2 9 bearing flanged 5 8 dia igus P1173 4 10 handle handcrank 67356 2 11 washer 5 8 plastic 4 12 ring snap retainer 5 8 2 13 shaft crank hand 67306 2 14 washer cover plastic black 12 15 screw 1 4 20x1 25 black b h socket cap 16 16 decal body Pro II 65025 2 17 cover gray right dull new 65201RG2 1 18 decal serial number 2 19 nut 5 16 18 blk 2 20 lockwasher 5 16 blk 2 21 wheel front pro II 70400 2 22 bolt 5 16 18 x 1 75 blk 2 23 bolt 3 4 18x6 blk 2 24 cover crank hub 66304 4 25 screw M5x1 0x25 s h blk 16 26 screw M5x 8x12 b h blk 24 27 lockwasher 8 pltd 27 28 pedal Pro II pair 65550 1 29 decal UL certification 1 30 base Pro II 70396 1 31 extrusion rail roller seat A1030 2 32 nut pan 5 16 18 12 33 lockwashers 5 16 pltd P1059 12 34 bolt 5 16 18 x 3 pltd 12 35 seat roller base weldment C1168 1 36 screw 5 16 18 p h black 18 37 roller urethane 1 1 4 dia X 3 8 P1038 18 38 nuts lock 5 16 18 pltd 18 16 39 spring gas P1177 1 40 adaptor gas shock seat sq A1166 1 41 extension seatbase Pro II weldment C1169 1 42 frame seat 71385 2 43 lockwasher 1 4 black 4 44 seat pad back 71101 1 45 s
7. eat pad bottom 71100 1 46 lockwasher 1 4 pltd P1056 4 47 bolt 1 4 20x1 25 pltd 4 48 pin popper turn to release P1223 1 49 plunger 71200 1 50 track adjustment stainless 71395 1 51 sticker seat adjustment 1 52 decal manufacturing date 1 53 bar foot crank 9 16x20 right 66302 1 1 bar foot crank 9 16x20 left 66302 2 1 54 endcap 3 dia 70330 2 55 hub crank assy A1364 4 56 manual operator s P1104 1 57 cord power 110V 9 10 65169 1 58 roll pin 3 16x1 2 3 59 cover left gray dull 65200LG2 1 60 frame main Pro II 69321 1 61 screw 10 32x 75 s h blk 3 62 shaft brake drive pulley 68312 2 1 63 bolt M5x 8x19 socket cap 3 64 lockwasher 10 pltd 3 65 bearing brake drive hub 68012 2 66 hub brake drive pulley hubed 68316 2 1 67 ring snap retainer 1 2 1 68 pulley brake drive 68313 1 69 freewheel Pro II shimano 68013 4 70 0 020 and 0 035 shims NA 71 tape pickup speed 65141 1 72 bolt 8 36x1 188 blk 1 73 brake assy 68000 1 74 belt brake poly v 68014 1 75 channel transformer A1359 1 76 screws 4 40 x 1 2 p h pltd 1 77 washer 4 split pltd 1 78 washer 4 flat pltd 1 17 79 sensor speed assy 65140 1 80 bracket speed sensor 69403 1 81 transformer 24V 5 4 A 65180 1 82 screw M4x 7x10 s h blk 4 83 washer M4 pltd 4 84 nut M4x 7 pltd
8. ensor as needed See Procedure 3 Check voltage at power supply board See Procedure 2 7 III Maintenance Procedures Procedure 1 Removal and Reinstallation of the Power Supply Board 1 Unplug the unit from the power source 2 Remove all the crank bars Items 8 and 53 and crank hub assemblies Item 55 from the unit 3 Remove the screws Item 15 that fasten the covers Items 17 and 59 to the main frame The covers can be removed now 4 Locate the power supply cover Item 88 on side of unit Remove the four 4 screws and remove the power supply cover Be careful when removing the power supply board because of the plastic ties and brake wires 5 Cut all the plastic ties 6 Before disconnecting any of the wires make note of the wiring sequence Refer to the wiring diagram Fig 4 7 Disconnect the following a The two 2 white 110 V and two 2 black 24 V transformer wires These are all the wires from J4 on Fig 4 b The black and white wires from the power entry module total of two 2 These are the wires at terminals ACIN1 and ACIN2 on the LCB c The two 2 red brake wires d The one 1 speed sensor plug J5 on Fig 4 e The one 1 ribbon cable 8 The power supply board Item 92 can now be removed Reinstallation is the reverse of removal 9 After reinstalling the power supply board perform the following procedure to test correct reinstallation a Plug into power source and tu
9. lete If noise persists return to step 1 10 Procedure 6 Checking and Adjusting the Slack in the Chains 1 Check the deflection in the two chains along their longest spans The two chains should never have less than nor more than 1 deflection at their longest spans Since some parts of the chain are stiffer than others the deflection should be checked across the entire length of the chain This can be done by rotating the crank handles in 45 increments and checking the deflection of the chain between increments 2 If the chain needs adjusting loosen but do not remove the 20 nut that fastens the idler shaft Item 100 to the main frame 3 To tighten the chain the idler shaft needs to be moved upwards To loosen the chain the shaft needs to be moved downwards With the 20 nut still on the shaft use a hammer to knock the entire shaft assembly a few millimeters in the prescribed direction 4 Tighten the 20 nut and check the deflection as in step 1 5 Repeat steps 1 4 until the desired stiffness is reached 11 IV Figures Figure 1 ProII Total Assembly Items 1 59 12 Figure 2 ProII Main Frame Items 60 111 13 Figure 3 Power Entry Module with Fuse Holder 14 Figure 4 Pro II Wiring Diagram 15 V Pro II Parts List Item Description Part No Qty 1 overlay switch panel 65112 1 2 Display board 65110 1 3 standoffs 1 6 32 P1051 10 4 Consol
10. n and turn on machine but don t press any buttons The display will be scrolling the message SCIFIT Slowly rotate the crank arm assembly and the message will change to a programming prompt The following values will be displayed 20 00 in TIME 0 in RPM and 4 in LEVEL If the display doesn t default to these values perform Procedure 3 13 Press the START STOP button once and press the SCAN HOLD button to hold the RPM function Press and hold the DOWN ADJUST arrow until 0 0 is displayed in the LEVEL window 14 Rotate the crank arms at one revolution per second and ensure display accurately reads about 60 RPM 15 Press and hold the UP ADJUST arrow button to the maximum level 22 Rotate the crank arms as rapidly as possible Brake resistance should become increasingly difficult momentarily Procedure 5 Tightening the Poly V Belt 1 Loosen the 20 nut that fastens the brake drive pulley shaft Item 62 to the main frame 2 With the nut still on the shaft use a hammer to knock the entire brake drive pulley assembly away from the brake assembly Item 73 3 After knocking the brake drive pulley shaft a few millimeters away from the brake assembly tighten the set screw Item 72 so that it butts up to the brake drive pulley shaft 4 Tighten the 20 nut that holds the pulley shaft 5 Check that job is complete by rotating crank handles If there is no noise due to belt slippage the job is comp
11. oceed to the next step to adjust the speed sensor 4 Remove the crank hub assemblies Item 55 on the right side of the machine along with the right side cover Item 17 5 The air gap between the brake flywheel and speed sensor should be 1 8 3 16 6 The speed sensor must be pointed directly at the flywheel so the eyes of the sensor will intersect the center of the axis of the brake Adjust as needed 7 Rotate the crank arm again at 1 rev per second If the RPM window displays a number greater than zero 0 but not within 60 10 rpm repeat steps 1 6 If a reading of zero 0 is displayed proceed to step 8 8 Use a voltmeter to measure the DC voltage across J5 pin 1 and J5 pin 2 on the power supply board Refer to Fig 4 The voltmeter should read 4 5 VDC 9 If there is no voltage replace the power supply board Item 92 If 4 5 volts are present replace the speed sensor Procedure 4 Removal and Replacement of the Brake Assembly 1 Remove all the crank bars Items 8 and 53 and crank hub assemblies Item 55 from the unit 2 Remove the screws Item 15 that fasten the covers Items 17 and 59 to the main frame The covers can be removed now 3 Disconnect the two red wires on the right side of brake Item 73 4 Relieve the tension in the poly v belt Item 74 by loosening the 20 nut attached to item 62 Loosen the set screw Item 72 If the pulley brake drive shaft does not move on it
12. rn on b The message SCIFIT FOR SCIENTIFIC SOLUTIONS should be scrolling across upper display board If not see troubleshooting table c Press the start button d Turn the crankshaft in a forward motion e Verify that values are being displayed in the rpm Watt window f Press the up arrow key to increase the resistance It should become more difficult to turn the crankshaft If not consult the troubleshooting table g Press the up arrow and hold until level 22 After 3 5 seconds of turning the resistance should be at its maximum level If not refer to the troubleshooting table If brake loaded up to maximum setting then the job is complete Procedure 2 Checking voltage at the Power Supply Board 1 Follow steps 1 4 in Procedure 1 2 Disconnect the speed sensor from the lower supply board at the J5 terminal See Fig 4 Use a voltmeter to measure the DC voltage across the speed sensor pins on the power supply board 8 Measure the voltage across the pin with the red wire and either one of the center pins The voltmeter should measure 4 5 volts DC 3 If there is no voltage replace the power supply board See Procedure 1 Procedure 3 Checking and Adjusting the Speed Sensor 1 Turn machine on and press start 2 Turn crank arms Item 8 at 1 revolution per second The RPM window should display around 60 10 rpm 3 If the RPM window is displaying a reading outside of the specified range pr
13. s own use a hammer to knock the shaft back a few millimeters 5 Remove the poly v belt from the plastic pulley by wedging a screwdriver blade between the belt and pulley while rotating the brake slowly downward to work the belt off the pulley Take care not to damage the pulley 6 Remove the three 3 socket head screws Item 61 that hold the brake assembly to the main frame 7 Pull brake away from main frame Be careful not to damage the speed sensor when removing the brake 8 Remove the brake from the machine and set aside to return 9 to SCIFIT request a UPS call tag by phone 9 Reinstallation is the reverse of removal Before tightening the tension in the poly v belt make sure that it is centered correctly If misaligned wedge a screwdriver blade between the face of the brake and the belt while turning assembly to align belt to center of idler pulley 10 After brake assembly has been aligned and tension set attach speed sensor tape Item 71 to the left edge of the brake armature First peel off tape backing on the end with the wide silver band and stick on the brake surface hanging down The tape should be on center with the speed sensor Slowly rotate the brake upward and wrap tape around the circumference of the brake 11 Temporarily install the crank hub bar assembly Perform the following steps 12 through 16 and perform the alignment Procedure 3 if indicated results are not attainable 12 Plug i
14. tem 2 is faulty Replace display board 1 10 Can t select program or enter information and no beep when buttons are pressed Overlay switch panel Item 1 is faulty Replace overlay switch panel 5 Table 2 Mechanical Troubleshooting Problem Possible Reasons Solutions 2 1 Poly V belt Item 74 is slipping Belt tension is not adjusted properly See Procedure 5 2 2 Excessive free play exists when the cranks are turned The chain s is too loose See Procedure 6 2 3 Machine makes noise and feels rough when the hand cranks and pedals are turned Bearings Item 9 in handle Item10 are faulty Chains are too tight Bearings on the upper and lower axles are faulty Items 108 and 97 respectively Idler wheel Item 99 is excessively worn Bearings in Items 66 and or 101are faulty Bearings in the brake assy Item 73 are faulty Freewheel Item 69 is faulty Rotate hand cranks about the hand crank shaft Item 13 Replace bearings if source of noise See Procedure 6 Remove the chains and rotate each axle separately Replace bearings if source of noise With chain removed rotate idler wheel to check for noise and play Visually inspect for excessive wear Replace bearings if necessary With chain and poly v belt Item 74 removed rotate each item separately Replace bearings if source of noise With chain and poly v belt removed rotate the brake assy Replace bearings if source of
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