Matrix E5x-02 Service Manual Download

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9.2 faStEnErS & aSSEMbly toolS

QUantity

part #

SkEtcH

dEScription

packagE color

Z11

PHILLIPS SCREWDRIVER

Z12

13 MM OPEN WRENCH

Z13

4 MM ALLEN WRENCH

6 MM ALLEN WRENCH

8 MM ALLEN WRENCH

Z31

SOCKET HEAD CAP SCREW (M8 X 20L)

PINK

Z32

WASHER (8.4 X 15.5 X 1.6T)

PINK

Z13

SAME AS Z31

SOCKET HEAD CAP SCREW (M10 X 15L)

RED

Z03

SOCKET HEAD CAP SCREW (M5 X 10L)

RED AND YELLOW

Z14

SAME AS Z31

SOCKET HEAD CAP SCREW (M8 X 20L)

RED

Z01

SAME AS Z31

SOCKET HEAD CAP SCREW (M8 X 15L)

BLUE AND ORANGE

Z12

SAME AS Z31

SOCKET HEAD CAP SCREW (M8 X 25L)

BLUE

Z02

WAVE WASHER (20.5 x 29 x 1.5T)

ORANGE

Z08

SAME AS Z02

WAVE WASHER (20.7 x 29.1 x 1.5T)

ORANGE

Z09

SAME AS Z03

SOCKET HEAD CAP SCREW (M5 X 12L)

ORANGE

E42

CONNECT PLATE

ORANGE

Z05

SOCKET HEAD CAP SCREW (M8 X 55L)

YELLOW

Z06

SAME AS Z32

WASHER (8.2 X 16 X 1.0T)

YELLOW

Z07

NYLON NUT (M8 X 1.25P)

YELLOW

Z30

AXLE

YELLOW

Z04

SOCKET HEAD CAP SCREW (M8 X 65L)

GREEN

Z41

SAME AS Z31

SOCKET HEAD CAP SCREW (M5 X 8L)

cHaptEr 9: Elliptical trainEr SpEcificationS and aSSEMbly gUidE

Summary of Contents for E5x-02

Page 1: ...E 5 x 0 2 e l l i p t i c a l T r a i n e r S E R V IC E M AN U A l...

Page 2: ......

Page 3: ...art Rate 10 4 7 Workout Setup Steps Constant Watts 10 CHAPTER 5 Manager MODE 5 1 Manager Mode Overview 11 5 2 Manager Mode Information 12 CHAPTER 6 engineering Service mode 6 1 Engineering Service Mod...

Page 4: ...ent 40 8 14 Dual Action Handlebar Replacement 41 8 15 Console Mast Replacement 42 8 16 Foot Pedals Replacement 43 8 17 Pedal Arm Replacement 44 8 18 Crank Arm Replacement 46 8 19 Roller Replacement 49...

Page 5: ...1 1 1 SERIAL NUMBER LOCATION Chapter 1 serial number location...

Page 6: ...2 console serial number location 1 1 SERIAL NUMBER LOCATION CONTINUED chapter 1 serial number location...

Page 7: ...supply cord or use the cord as a handle Close supervision is necessary when the Elliptical Trainer is used by or near children or disable persons Do not use outdoors Do not operate where aerosol spra...

Page 8: ...Trainer must be grounded If it should malfunction or break down grounding provides a path of least resistance for electric current to reduce the risk of electric shock The Elliptical Trainer is equip...

Page 9: ...quipment free from dust and dirt DO NOT use any equipment that is damaged or has worn or broken parts Use only replacement parts supplied by Matrix Fitness Systems maintain labels and nameplates Do no...

Page 10: ...ems that require specific attention the latest version will always be available on the Matrix web site www matrixfitness com DAILY MAINTENANCE ITEMS 1 Look and listen for loose fasteners unusual noise...

Page 11: ...ent STOP Ends workout and shows workout summary data NUMBER KEYPAD Workout data input for workout setup Level adjustment during workout COOL DOWN Puts the Elliptical Trainer into Cool Down Mode FAN Al...

Page 12: ...Interval Training program is a level based program that automatically adjusts the resistance of the machine from low to high intensity settings at regular intervals 1 Start pedaling and press the INTE...

Page 13: ...als Once the test ends a recovery period cool down will begin and the user s results are calculated and displayed Results are based on the number of stages completed Incline will not be adjustable dur...

Page 14: ...press the HEART RATE key 2 Select Age by using the UP or DOWN LEVEL keys and press SELECT 3 Select Target HR Percentage by using the UP or DOWN LEVEL keys and press SELECT 4 Select Time by using the U...

Page 15: ...in Manager Mode use the UP and DOWN LEVEL keys Each of the custom settings will show on the display 3 To select a custom setting press the ENTER key when the desired setting is shown 4 To change the v...

Page 16: ...m calorie expenditure calculations Accumulated Distance N A 0 65 000 Miles Total distance for all programs Accumulated Time N A 0 65 000 hours Total time for all programs displayed in hours Software V...

Page 17: ...INEERING MODE DISABLE ERRORS Displays the class A and B error codes SPEED UNIT Sets the distance to show in miles or kilometers MACHINE TYPE Should be set for Elliptical Trainer at all times POWER SAV...

Page 18: ...14 7 1 Electrical Diagram chapter 7 troubleshooting...

Page 19: ...15 7 1 electrical diagram Chapter 7 Troubleshooting...

Page 20: ...16 7 1 electrical diagram chapter 7 troubleshooting...

Page 21: ...8V or over 15V Check the wire connections at the battery Replace the battery 0x0441 b When the UCB implements a command the LCB is not receiving this command Check the machine type in Engineering Mod...

Page 22: ...ration LED 7 Status 2 Resistance value in middle 1 2 VCC LED 8 Status 3 Digital Communication LED 9 12V Console Power WITHOUT AC PLUG Normal LED 2 LED 9 On LED 1 Off No AC plug detected LED 5 On Gener...

Page 23: ...enerator has no RPM output Normal for a powered unit If unpowered and issue is still present replace the generator If LED 8 is OFF Bad communication between UCB and LCB Reconnect the console cable at...

Page 24: ...LED1 is OFF No AC power cord plugged in Normal for an unpowered unit If LED 8 is OFF Bad communication between UCB and LCB Reconnect the console cable at the LCB and UCB and check for kinks Solution i...

Page 25: ...c Test the affected keypad If the keypad works in the keypad test it may not be a functioning key in the program used for testing it 2 Check the connections of the keypad at the UCB a Remove the conso...

Page 26: ...ng variable power a Insert the probes from a multi meter into the black and red wires on the generator wire harness connector Figure A b When pedaling the output voltage from the generator should vary...

Page 27: ...r creaking noise Possible causes 1 The pedal is on the pedal arm too loosely 2 The drive axle is worn out 3 The belt tension is not enough or the belts are too dirty SOLUTION 1 Retighten the pedal ont...

Page 28: ...grips are damaged 5 The HR board is damaged 6 The UCB is damaged SOLUTION 1 Recenter the chest strap below the user s pectoral muscle Figure A and check again 2 Replace the battery in the chest strap...

Page 29: ...the crank arm plastic cap at the front disk Figure A 2 Detach the crank from the crank arm Figures B C 3 Locate the center cap in the center of the front disk Figure D figure a figure b figure c figu...

Page 30: ...d washer by turning them counter clockwise Figure F 7 Thread the Matrix disk removal tool into the center hub Figure G 8 Turn the center bolt of the removal tool clockwise until the main disk can be r...

Page 31: ...that hold the front shrouds in place and to each other on each side Figure A NOTE You will need to lift the console mast boot to remove some of the screws 3 Remove the front shrouds for frame access...

Page 32: ...de front shroud as outlined in Section 8 2 4 Disconnect all wires from the LCB Figure A 5 Remove the 2 screws holding the LCB to the frame and remove the LCB Figure B 6 Reverse Steps 1 5 to install a...

Page 33: ...sen the large nut on the tension eye bolt on both sides of the frame Figure C 7 Remove the tension eye bot nut from the ECB bracket on both sides of the frame Figure D 8 Once the tension eye bolts hav...

Page 34: ...the frame Figure B 6 Remove the tension eye bot nut from the ECB bracket on both sides of the frame Figure C 7 Once the tension eye bolts have been removed slide the ECB towards the back of the unit...

Page 35: ...enough slack in the belt to remove it Figures A B 4 Walk the new drive belt into position on the drive assembly 5 Once the drive belt is in place reapply tension by rotating the tension pulley clockwi...

Page 36: ...8 6 6 Remove the 75 mm nut holding the pulley axle in place using the large socket available from Matrix Figure A 7 Use a hammer or mallet to remove the pulley axle from the left side Figure B and cl...

Page 37: ...g the drive axle set to the frame Figure A 7 Remove the 75 mm nut holding the drive axle set to the frame using the large socket available from Matrix Figure B 8 Remove the drive axle set from the rig...

Page 38: ...ve the console Figure B 3 Reconnect 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 cons...

Page 39: ...and remove the faulty overlay Figure B 4 Clean the console area with alcohol to remove any left over adhesive Figure C 5 Remove the protective film over the display window of the overlay Figure D 8 1...

Page 40: ...rom the back of the overlay Figure E 7 Push the overlay ribbon cable through the hole in the console and plug it in Figure F 8 Match the overlay to the cutout on the console Figure G 8 10 CONSOLE KEYP...

Page 41: ...otective film Figure H I 10 Once the overlay is in the correct position press down on the overlay with a cloth to adhere it to the console plastic Figure J 11 Use the same procedure to replace any add...

Page 42: ...connectors on the ends come free and disconnect 4 To install a new handlebar assembly connect the new handlebar and carefully push the heart rate wires into the console mast 5 Attach the new handleba...

Page 43: ...e metal plate Figure B 3 Remove the 3 screws holding the HR grip together Figure C NOTE You may need to remove the console to give access to the HR grip screws 4 Disconnect the level button and remove...

Page 44: ...crews holding the cup holder onto the console mast Figure A 2 Remove the cup holder Figure B 3 Reverse Steps 1 2 to install a new cup holder 8 13 CUP HOLDER REPLACEMENT figure a figure b chapter 8 par...

Page 45: ...re B 3 Remove the two bolts holding the dual action handlebar to the console mast pivot Figure C 4 Remove the pivot cap and handlebar Figure D 5 Reverse steps 1 4 to install a new dual action handleba...

Page 46: ...st onto the frame Figure D 5 Remove the console mast being careful to pull the console wires out of the bottom of the mast without damaging them 6 Reverse Steps 1 5 to install a new console mast NOTE...

Page 47: ...A 2 Remove the 4 Phillips screws that hold the plastic foot pedal to the foot plate Figure B 3 Remove the plastic foot pedal Figure C 4 Reverse Steps 1 3 to install a new foot pedal 5 Test the Ellipti...

Page 48: ...n handlebar meets the pedal arm Figure A 2 Remove the bolt and bushings where the dual action handlebar and the pedal arm meet Figure B NOTE Be sure to move the bushings from the old pedal arm to the...

Page 49: ...rank arm pedal arm joint Figure D Note the plastic washer that mounts at the end of the shaft Figure E 5 Slide the pedal arm shaft out of the crank arm housing Figure F noting the order of the washers...

Page 50: ...from the crank assembly Figure B 3 Remove the 3 bolts that hold on the mounting plate at the crank arm pedal arm joint Figure C Note the plastic washer that mounts at the end of the shaft Figure D 8 1...

Page 51: ...ure E noting the order of the washers on the pedal arm shaft Figure F 5 Remove the 2 screws on each side holding on the rear end cap and remove it Figure G H figure e figure f figure g figure h 8 18 C...

Page 52: ...wards the rear of the unit Figure I 7 Remove the 3 screws holding the top roller track in place Figure J 8 Once the top track is removed the crank arm can be removed from the unit 9 Reverse Steps 1 8...

Page 53: ...m pedal arm joint Figure A Note the plastic washer that mounts at the end of the shaft Figure B 2 Slide the pedal arm shaft out of the crank arm housing Figure C noting the order of the washers on the...

Page 54: ...rews on each side holding on the rear end cap and remove it Figure E F 4 Remove the middle plastic cover from between the pedals by pulling it towards the rear of the unit Figure G 8 19 Roller replace...

Page 55: ...lace Figure H 6 Remove the screw holding the roller to the crank arm Figure I 7 Remove the roller from the crank arm using the roller puller available from Matrix Figure J 8 Reverse Steps 1 7 to insta...

Page 56: ...arm pedal arm joint Figure A Note the plastic washer that mounts at the end of the shaft Figure B 2 Slide the pedal arm shaft out of the crank arm housing Figure C noting the order of the washers on...

Page 57: ...he rear end cap and remove it Figure E F 4 Remove the middle plastic cover from between the pedals by pulling it towards the rear of the unit Figure G figure e figure f figure g 8 20 ROLLER TRACK REPL...

Page 58: ...e Figure H 6 Move the crank arm to the side off of the roller track 7 Remove the 3 screws holding the bottom roller track to the frame Figure I and remove the roller track Figure J 8 Reverse Steps 1 7...

Page 59: ...t set for EP change to EP using the UP or DOWN LEVEL key and press ENTER to save f Press and hold the STOP key for 3 5 seconds to return to normal function 1 Without hitting start or entering any exer...

Page 60: ...Compatible No Nike iPod Compatible No Personal Fan Yes Technical data Resistance Technology JID Brushless ECB Power Requirements0 Self Powered 120V 60Hz AC Power is Optional Minimum Watts 22 Minimum R...

Page 61: ...ew M8 x 20L red 04 Z01 same as z31 Socket head cap screw M8 x 15L blue and orange 02 Z12 same as z31 Socket head cap screw M8 x 25L blue 02 Z02 wave washer 20 5 x 29 x 1 5t orange 02 Z08 same as z02 W...

Page 62: ...9 3 ELLIPTICAL TRAINER ASSEMBLY STEPS after these assembly steps are complete be sure to setup and test the unit as outlined in section 8 21 chapter 9 elliptical trainer specifications and assembly gu...

Page 63: ...59 9 3 elliptical trainer assembly steps continued Chapter 9 elliptical trainer specifications and assembly guide...

Page 64: ...60 9 3 elliptical trainer assembly steps continued chapter 9 elliptical trainer specifications and assembly guide...

Page 65: ...61 9 3 elliptical trainer assembly steps continued Chapter 9 elliptical trainer specifications and assembly guide...

Page 66: ...62 9 3 elliptical trainer assembly steps continued chapter 9 elliptical trainer specifications and assembly guide...

Page 67: ...63 9 3 elliptical trainer assembly steps continued Chapter 9 elliptical trainer specifications and assembly guide...

Page 68: ...64 step 7 9 3 elliptical trainer assembly steps continued chapter 9 elliptical trainer specifications and assembly guide...

Page 69: ...65 step 8 Chapter 9 elliptical trainer specifications and assembly guide 9 3 elliptical trainer assembly steps continued...

Page 70: ...66 9 3 elliptical trainer assembly steps continued final assembly chapter 9 elliptical trainer specifications and assembly guide...

Page 71: ...cates that your elliptical trainer needs to be leveled Determine which leveler is not resting completely on the floor Loosen the nut with one hand to allow the leveler to rotate Rotate the left or rig...

Page 72: ...B drive into the Reprogram Port in the back of the console back cover Figure A 4 The upgrade procedure will run automatically When the console beeps remove the USB drive 5 Cycle power on the Elliptica...

Page 73: ...69 notes...

Page 74: ...70 MATrix Fitness systems corp 1610 Landmark Drive Cottage Grove wi 53527 USA TOLL FREE 866 693 4863 www matrixfitness com FAX 608 839 1717 REV 02 KO...

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Matrix E5x-02, Service Manual

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