Spirit Z100 Service Manual Download | Manualshive

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SERVICE MANUAL

Z 100
Z 500
Z 900

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Summary of Contents for Z100

Page 1: ...SERVICE MANUAL Z 100 Z 500 Z 900 ...

Page 2: ...torque boost 6 Procedure 7 Replacing controller 6 Procedure 8 Replacing wire harness 6 Procedure 9 Replacing drive motor 6 Procedure 10 Replacing incline motor 7 Procedure 11 Controller diagram 7 Procedure 12 Wiring diagram 8 Procedure 13 Engineering mode 9 Z Series Warranty Contacting Technical Service 10 Treadmill Warranty 10 Warranty Policy 11 Parts Order Form 12 Warranty Labor Credit Form 13 Z...

Page 3: ... harness for continuity procedure 2 3 Look at LED labeled PWM procedure 11 If it lights up when the START button is pressed replace the controller If it does not light when the START button is pressed replace the console 1 Run the calibration procedure procedure 1 2 Check wire harness for continuity procedure 2 3 If there is an ERR message in the incline window make sure that all the wires from th...

Page 4: ... Check belt to see if it needs to be tracked 2 Take off motor hood to make sure noise is from belt 3 Check belt and deck for damage 4 Clean deck and re lube 1 Check wires around motor for rubbing 2 Remove clean and re insert the motor brushes 3 Replace motor procedure 9 1 Tighten deck bolts 2 Clean and re lube deck 4 ...

Page 5: ... wire harness for continuity 2 1 Set your multimeter to read ohms 2 2 Place the test leads at opposite ends of the wire make sure both leads are on the same wire and are in contact with metal 2 3 If the reading is close to 0 ohms the wire has continuity unbroken 2 4 If the reading is very high or there is no reading at all there is no continuity 2 5 If there is no continuity the harness needs to b...

Page 6: ... the controller 7 5 Insert new controller secure with Phillips screws 7 6 Reconnect wires to controller See Procedure 12 PROCEDURE 8 Replacing wire harness 8 1 Turn power switch off 8 2 Unplug harness from console and controller 8 3 Tie the end of the new harness to the old harness with a zip tie or spare wire 8 4 As you pull the old harness out of the upright you will pull the new harness in 8 5 ...

Page 7: ...CEDURE 11 Controller diagram JK 6 DOWN COM UP AC 1 AC 2 FUSE UP Down JK 7 JK 5 JK 3 TORQUE SPEED SENSOR JK 2 JK 3 M POWER SHUT DOWN JK 3 MOT DRV JK 1 PWM LIMIT M 1 2 3 4 5 6 7 8 9 10 1 AC1 White wire from power switch 2 AC2 Black wire from power switch 3 Incline Motor Connection Down Black wire to inc mtr Com White wire to inc mtr Up Red wire to inc mtr 4 Transformer Connections JK5 Black Black JK...

Page 8: ...n JK 7 RED FUSE AC 1 AC 2 RED BLACK SHUT DOWN JK 6 JK 3 MOT DRV POWER JK 1 LIMIT JK 5 TORQUE PWM SPEED JK 2 SENSOR M M JK 3 JK 3 Speed Sensor Z 100 700 4 21 05 BLACK RED JK 6 BLUE BLUE JK 2 Transformer JK 2 JK 5 JK 10 JK 3 JK 9 JK 5 To Tether Cord JK 1 To Inc Switch JK 3 JK 2 JK 4 To Fan Assy Motor Heart Rate Rec Amp Board JK 5 8 ...

Page 9: ...he speed Incline Calibration In this mode you can test the incline Factory Settings This mode will allow you to view the Wheel size Max inc Max and Min speed Use the UP and DOWN buttons to scroll through They cannot be changed here Security Child Lock On Off Press ENTER to turn on or off To unlock display press START and ENTER Functions Sleep Mode On Off Press ENTER to turn on or off Units English...

Page 10: ...ervisor ext 630 Jerry Savage Customer Support ext 632 Travis Lawrence Customer Support ext 633 Kevin Thomas Customer Support ext 628 If the technician you choose is unavailable leave a detailed message Leave only one message Do not call another extension Do not leave multiple messages This results in a duplication of effort and keeps our technicians from assisting you and other customers in a prom...

Page 11: ... issued for repairs in which 1 Parts required for return are not returned to Spirit within 30 days 2 All paperwork is not completed or returned 3 Spirit confirms that work was not completed Warranty Labor Reimbursement Policy Spirit has established a set of guidelines that are fair to both independent service companies and to Spirit Our policy on labor warranty reimbursement is simple we pay a one...

Page 12: ... be assumed that the part order is for stock We encourage all dealers to stock parts Spirit will always be fair to all dealers on credit for parts Spirit reserves the right to subject parts returns to a 20 restocking fee if Spirit determines that the dealer has excessively ordered parts randomly to repair a problem Buyer Signature_____________________________ Date____________ Shipping Instructions...

Page 13: ...Serial Number Owner s Name Owner s Address Selling Dealer Selling Dlr Acct Number Problem Repair Done Phone Number With Area Code Date Sold FACTORY USE ONLY QUANTITY PART NUMBER PART DESCRIPTION WTY TEST RESULTS UNIT PRICE WORK ORDER INVOICE TOTAL LABOR _________________________________________ WARRANTY ADMINISTRATOR TRIP LABOR Authorization No ___________________________ FAX TO SPIRIT 870 930 901...

Page 14: ...130 118 117 50 117 115 115 106 117 43 44 20 34 42 127 117 29 41 29 56 102 99 84 56 81 29 126 117 36 70 35 117 82 115 71 56 117 111 56 117 75 66 54 125 25 61 21 78 101 89 53 120 120 120 120 92 45 78 47 46 92 56 111 117 29 117 111 92 92 116 76 116 92 112 120 137 60 117 112 119 59 117 92 79 64L 64R 24 92 92 131 132 117 79 23 112 30 112 81 1 56 117 111 117 90 73 73 69 22 94 17 100 108 97 109 96 18 90 ...

Page 15: ... 1 21 FRONT ROLLER W PULLEY 000497 1 22 REAR ROLLER 000498 1 23 RUNNING DECK 000488 1 24 RUNNING BELT 000600 1 25 FOAM A 022972 2 26 FOAM B 023068 2 27 STEEL ROPE ROTA SPRING 010026 1 28 WIRE CLAMP 1 29 WIRE TIE MOUNT 010083 6 30 LUBRICANT 022271 1 31 STEEL ROPE 1 32 TOP FRAME COVER 000571 1 33 BOTTOM FRAME COVER 000572 1 34 MOTOR 3HP YC 000602 1 35 INCLINE MOTOR 022696 1 36 CONTROLLER 022670 1 37...

Page 16: ...1 60 FOOT RAIL CAP R 000604 1 61 38_BUTTON HEAD END CAP 022024 2 62 FRAME BASE CAP L 000586 1 63 FRAME BASE CAP R 000587 1 64L NON SLIP RUBBER L 000313 1 64R NON SLIP RUBBER R 000314 1 65 BOTTOM CONSOLE COVER 000596 1 66 HANDGRIP SIDE CAP R COMES AS SET 000582 2 67 HANDGRIP SIDE CAP L 2 68 REAR ADJUSTMENT BASE L 000593 1 69 REAR ADJUSTMENT BASE R 000594 1 70 MOTOR COVER ANCHOR D 022484 2 71 10 x 2...

Page 17: ...H_CONCAVE WASHER 4 113 10 _SPRING WASHER 4 114 M3_SPRING WASHER 1 115 M5_RAISED WASHER 4 116 4x12m m_SELF TAPPING SCREW 000070 4 117 5x16m m_TAPPING SCREW Black 010110 59 118 5x19m m_TAPPING SCREW 010125 1 119 3 5 x 6 m m_SELF TAPPING SCREW 2 120 5 x 16m m_TAPPING SCREW 010110 13 121 3 x10m m_SELF TAPPING SCREW 023082 2 122 3 5 x 12 m m_SELF TAPPING SCREW 010113 16 124 3x10 m m_TAPPING SCREW 01011...

Page 18: ... 97 18 92 92 92 92 92 92 92 92 23 24 82 35 123 125 132 132 125 125 125 78 5 78 5 78 6 66 25 26 89 101 21 14 14 6 39 5 39 5 117 117 65 117 117 55 26 54 67 68 69 950913PM1328 133 134 30 118 36 130 122 122 135 135 39 4 39 3 39 3 39 4 126 76 116 116 117 56 115 42 106 99 41 43 128 44 29 84 56 81 29 102 56 61 120 120 120 120 120 34 70 117 117 40 74 127 127 115 81 56 71 56 29 127 127 111 117 73 73 90 117...

Page 19: ... ROLLER W PULLEY 000497 1 22 REAR ROLLER 000498 1 23 RUNNING DECK 000491 1 24 RUNNING BELT 000601 1 25 FOAM A 022972 2 26 FOAM B 023068 2 27 STEEL ROPE ROTA SPRING 010026 1 28 WIRE CLAMP 1 29 WIRE TIE MOUNT 010083 6 30 LUBRICANT 022271 1 31 STEEL ROPE 1 32 TOP FRAME COVER 000574 1 33 BOTTOM FRAME COVER 000572 1 34 MOTOR 3 0hp YC 000602 1 35 INCLINE MOTOR 022696 1 36 CONTROLLER 022670 1 37 800 m m ...

Page 20: ...03 1 60 FOOT RAIL CAP R 000604 1 61 38_BUTTON HEAD END CAP 022024 2 62 FRAME BASE CAP L 000586 1 63 FRAME BASE CAP R 000587 1 64L NON SLIP RUBBER L 000313 1 64R NON SLIP RUBBER R 000314 1 65 BOTTOM CONSOLE COVER 000596 1 66 HANDGRIP SIDE CAP R Comes as SET 000582 2 67 HANDGRIP SIDE CAP L 2 68 REAR ADJUSTMENT BASE L 000593 1 69 REAR ADJUSTMENT BASE R 000594 1 70 MOTOR COVER ANCHOR D 022484 2 71 10 ...

Page 21: ...0 x 1 5Tx2 5H_CONCAVE WASHER 4 113 10 _SPRING WASHER 4 114 M3_SPRING WASHER 1 115 M5_RAISED WASHER 4 116 4x12m m_SELF TAPPING SCREW 000070 4 117 5x16m m_TAPPING SCREW Black 010110 59 118 5x19m m_TAPPING SCREW 010125 1 119 3 5 x 6 m m_SELF TAPPING SCREW 2 120 5 x 16m m_TAPPING SCREW Black 010110 13 121 3 x10m m_SELF TAPPING SCREW 023082 2 122 3 5 x 12 m m_SELF TAPPING SCREW 010113 16 124 3x10 m m_T...

Page 22: ...Z900 Exploded View 22 ...

Page 23: ...22882 1 23 1000 mm_SENSOR W CABLE 022561 1 24 15A_BREAKER 022448 1 25 POWER SOCKET 022658 1 26 ON OFF SWITCH 022476 1 27 POWER CORD 022812 1 28 100mm x 764 x 764_CONNECTING CABLE BLACK 1 29 150mm x 764 x 764_CONNECTING CABLE WHITE 1 30 150mm x 764 x 764_CONNECTING CABLE BLACK 1 31 800 mm_COMPUTER CABLE UPPER 022720 1 32 800 mm_COMPUTER CABLE LOWER 000503 1 33 1300 mm_COMPUTER CABLE MIDDLE 022719 1...

Page 24: ...TMENT BASE L 000612 1 56 REAR ADJUSTMENT BASE R 000613 1 57 MOTOR COVER ANCHOR 000922 2 58 24 x 10 x 3T_NYLON WASHER A 2 59 50 x 13 x 3T_NYLON WASHER B 4 60 38 x 3 8 _FOOT PAD 22713 2 61 25 x 50_SQUARE END CAP 000630 4 62 1 2 x 4 13m m _BOLT CAP 000636 4 63 SAFETY KEY 022945 1 64 BELT GUIDE 000595 2 65 1 2 x 57m m_HEX HEAD SCREW 2 66 3 8 x 4 1 2 _SOCKET HEAD CAP SCREW 000580 1 67 3 8 x 4 _SOCKET H...

Page 25: ...6 x 3 4 _BUTTON HEAD SOCKET SCREW 000100 4 100 5 16 x 1 2 _BUTTON HEAD SOCKET SCREW 000085 10 101 3 8 x 2 _BUTTON HEAD SOCKET SCREW 023090 2 102 3 8 x 2T_SPRING WASHER 000053 2 103 M3 x 18 m m_TAPPING SCREW 022248 3 104 COMBINATION M5 ALLEN WRENCH SCREWDRIVER 000089 1 105 M6 ALLEN WRENCH 022973 1 106 3 x 10 m m_SELF TAPPING SCREW 023082 2 107 3x 8m m_SELF TAPPING SCREW 6 108 PLASTIC WASHER 6 109 N...

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