TC1000

Service Manual

SALES: 800-278-3933

CUSTOMER SERVICE: 800-745-1373

Table of Contents

Section

I. Overview

Procedure 1 – Removal and Reinstallation of the Power Supply Board

Procedure 2 – Checking Voltage at the

Power Supply Board

Procedure 3 – Checking and Adjusting the

Procedure 4 – Removal and Replacement of

IV. Figures

Figure 1 – TC1000 Total Assembly (Items 1-20)

Figure 2 – TC1000 Main Frame (Items 21-43)

Figure 3 – Power Entry Module with

Figure 4 – TC1000 Wiring Diagram

Page

2

6

6

9

10

12

TC1000 13

1

I. Overview

Purpose.

This manual is designed to assist in service of SCIFIT TC1000 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 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 CST 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.

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II. Troubleshooting Tables

Table 1 – Electrical Troubleshooting

1.1 The machine appears to be off when plugged in and switched “on”.

Faulty power supply board (Item 23).

Faulty fuse.

Loose cable connection.

Power supply board

(Item 23) is faulty.

1.2 Upper control panel

(Item 2) lights are dim.

1.3 Upper board (Item 2) accepts commands but rotational resistance does not change.

1.4 LED’s on upper board

(Item 2) blinking off/on, then go dead.

1.5 Heart rate displays zero

(0) in window

Dip switch setting is incorrect.

Power supply board

(Item 23) is faulty.

Ribbon cable (Item 5) connections are loose.

Faulty power supply board (Item 23).

Display board (Item 2) is faulty.

Chest strap and transmitter improperly worn.

Loose sensor lead connection at display board (Item 2).

Faulty receiver.

1.6 Unit keeps blowing fuses.

Too many units are daisy-chained together.

Faulty power supply board (Item 23).

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.

Replace power supply board. See

Procedure 1.

Set dip switch to 01.

Check and replace power supply board as needed. See Procedure 2.

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.

Verify that they are being properly worn.

Check and adjust as needed.

If there is no audible signal, replace receiver.

Do not daisy chain more than 3 units together.

Check and replace power supply board as needed. See Procedure 2.

3

1.7 The upper display (Item

2) resets after starting a program.

1.8 Program stops, lines of dots shoot across screen.

1.9 Machine shuts down in programs but works in manual.

Ribbon cable connection is loose (Item 5).

Power cord is loose.

Display board is faulty.

Ribbon cable (Item 5) connection is loose.

Display board (Item 2) is faulty.

Display board (Item 2) is faulty.

Check cable connection at power supply and display boards (Items 23 and 2, respectively).

Check and adjust as needed.

Replace display board.

Check and adjust cable connection as needed.

Replace display board.

Replace display board.

Replace overlay/switch panel. or enter information and no beep when buttons are pressed.

(Item 1) is faulty.

4

Table 2 – Mechanical Troubleshooting

2.1 Pedals lock up while operating.

Power supply board

(Item 23) is faulty.

Brake (Item 30) is faulty.

2.2 No resistance on pedals when in a program.

2.3 Very little resistance at any level.

No speed signal

Wires going to brake

(Item 30) are disconnected.

Power supply board

(Item 23) is faulty.

Speed sensor (Item 37) improperly adjusted.

Bad speed sensor connection with power supply board (Item 23).

Unplug power cord. If pedals now move freely, replace power supply board.

If pedals do not move with power cord unplugged, replace brake. See

Procedure 4.

Check and adjust the speed sensor

(Item 37) as needed. See

Procedure 3.

Check that brake wires are properly connected.

Check and replace power supply board as needed. See Procedure 2.

Check and adjust the speed sensor as needed. See Procedure 3.

Check voltage at power supply board. See Procedure 2.

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III. Maintenance Procedures

Procedure 1 - Removal and

Reinstallation of the Power Supply

Board

1. Unplug the unit from the power source.

2. Remove the screws (Item 17) that fasten the covers (Items 10 and 16) to the main frame. The covers can be removed now.

3. Locate the power supply cover

(Item 22) on unit. Remove the four (4) screws and the power supply cover. Be careful when removing the power supply cover because of the plastic ties and brake wires.

4. Cut all the plastic ties.

5. Before disconnecting any of the wires, make note of the wiring sequence. Refer to the wiring diagram, Fig. 4.

6. 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

23) 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 turn 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. Press SCAN/HOLD so that the CLIMB RATE indicator light stays lit. e. Move the pedals as if exercising. f. Verify that the values are increasing in the CLIMB

RATE window. g. Press the down arrow key to slow the pedal speed. It should be slow and smooth. If not, consult the troubleshooting table. h. Press the up arrow key to increase pedal speed. The stepping motion should be fast and smooth. If not, refer to the troubleshooting table.

Procedure 2 - Checking voltage at the Power Supply Board

1. Follow steps 1-3 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.

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.

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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/STOP.

2. Set the LEVEL to 0.0. Stand on the two pedals until they go down as far as they will go. The number in the DISTANCE window should increase every time the pedals are pressed down.

3. If the number in the DISTANCE window does not increase each time the pedal is depressed, proceed to the next step to adjust the speed sensor.

4. Remove the covers on the machine (Items 10 and 16).

Locate the speed sensor on the unit (Item 37).

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. Again, stand on the two pedals until they go down as far as they will go. If the number in the

DISTANCE window is greater than zero but does not increase by one, repeat steps 1-7. 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 23). If

4-5 volts are present, replace the speed sensor.

Procedure 4 – Removal and

Replacement of the Brake

Assembly

1. Remove the screws (Item 17) that fasten the covers (Items 10 and 16) to the main frame. The covers can be removed now.

2. Tip the entire unit back so that it is resting horizontally on its two rectangular shaped feet and the two pedals. This will allow better access to the brake from the underside of the unit.

3. Disconnect the two red wires on the right side of brake (Item 30).

4. Relieve the tension in the brake drive belt (Item 42) by loosening the turnbuckles (Item 29) that are attached to the brake brackets.

5. Remove the nuts and threaded bar that hold the brake drive idler

(Item 25) onto the bracket. Also, loosen the nuts at the lower end of the brake brackets. With the idler removed and the brackets loose, the brake should be loose enough to remove the belt.

6. Remove the three (3) socket head screws that hold the brake assembly to the support bracket.

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

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to SCIFIT (request a UPS call tag by phone).

9. Reinstallation is the reverse of removal. Before tightening the tension in the brake drive belt, make sure that it is centered correctly.

10. After brake assembly has been aligned and tension set, attach speed sensor tape to 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. It is extremely important that the speed sensor be centered over the tape.

11. Stand unit up in its proper position. Perform steps 12-16. If the indicated results are not attainable, see Procedure 3.

12. Plug in and turn on machine but don’t press any buttons. The display will be scrolling the message, “SCIFIT…”

13. Press the START/STOP button.

14. If the LEVEL light is not lit, press the SCAN/HOLD button until it becomes lit. Use the down arrow key to set the LEVEL to 0.0.

15. Stand on the two pedals simultaneously so that they move once through their entire range of motion. The TOTAL CLIMB window should display 1. If it does proceed to step 16; otherwise, check that the air gap between the speed sensor and brake flywheel is 1/8”-3/16” then repeat steps 14 and 15.

16. Use the UP arrow button to set the LEVEL to 4.0.

17. Stand on the pedals and begin moving them at a rate typical of a workout.

18. The resistance on the pedals should feel smooth and consistent. If it does, installation is complete; otherwise, see

Procedure 3.

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IV. Figures

Figure 1 – TC1000 Total Assembly (Items 1-20)

Figure 2 – TC1000 Main Frame (Items 21-43)

9

10

Figure 3 – Power Entry Module with Fuse Holder

11

Figure 4 – TC1000 Wiring Diagram

12

V. TC1000 Parts List

Item Description

3 Console

4 Handgrip set, TC1000

5 cable, ribbon, assy

6 Pulley, clutch, roller, assy.

8 Arm, pedal, upper

9 Cap, base, 3", adjustable

10 Cover, right, TC1000

12 Bearing, roller, 6200-2z

13 Spacer, arm, upper

14 Cap, base, rectangular

17 Screw, fastener, hood, TC1000

18 Belt, pedal, TC1000

20 Board, heartrate, PCB

22 Cover, PSB, TC1000

23 Power supply, (lower), serial

24 Transformer, 24V, 5.4A

25 Idler, brake drive, TC1000

26 Recept, PEM, Daisychain

27 Module, power entry, RF/EFI

29 Turnbuckle

31 Roller, belt, pedal, TC1000

32 Spacer, roller, TC1000

33 Bearing, roller, 608-2SR

34 Arm, pedal, lower

35 Bearing, roller, 6202-2z

36 Spacer, arm, lower

37 Sensor, speed, cable, assy.

Part No. Qty.

65112 1

65110 1

65202 1

P1368

65120

1

1

P1375

P1376

2

2

2

70330

P1362

P1389

P1390

2

1

2

8

4

P1377 2

P1378 2

P1363 1

P1369 8

P1366 2

A1124 1

65160 1

P1379 1

P1380 1

65150S

65180

P1381

1

1

1

65177

65178

1

1

P1382 2

P1383 2

68300

P1393

P1394

1

2

2

P1395

P1384

P1391

P1392

A1089

P1385 1

4

2

8

4

1

13

40 Shaft, drive, main, assy.

42 Belt, drive, brake, TC1000

43 Spring, return, pedal, TC1000

P1386 2

P1387 1

P1388 1

P1367

P1365

1

2

14