Pro1000

Service Manual

SALES: 800-278-3933

CUSTOMER SERVICE: 800-745-1373

Revision: August 1999

Table of Contents

Section Page

Procedure 1 – Removing the Power Supply

7

Procedure 2 – Checking Voltage at the

Power Supply Board

Procedure 3 – Checking and Adjusting the

7

Procedure 4 – Removal and Replacement of

the Brake Assembly

Procedure 5 – Tightening the Poly-V Belt

Procedure 6 – Checking and Adjusting

the Tension in the Chains

IV. Figures

Figure 1 – Pro1000 Total Assembly (1-53)

Figure 2 – Pro1000 Main Frame (54-99)

Figure 3 – Pro1000 Optional Parts (100-112)

8

9

9

11

12

13

Figure 4 – Power Entry Module with

Figure 5 – Pro1000 Wiring Diagram 15

Pro1000 16

1

I. Overview

Purpose.

This manual is designed to assist in service of SCIFIT Pro1000 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 1-4.

Figures 1-2 show the standard Pro1000. Figure 3 shows an optional hand crank bar that is adjustable while Figure 4 shows an optional seat assembly that is vertically adjustable. Be sure to consult the correct figures when servicing equipment.

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 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.

2

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 87).

Faulty fuse.

Loose cable connection.

Power supply board

(Item 87) 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 87) is faulty.

Ribbon cable (Item 6) connections are loose.

Faulty power supply board (Item 87).

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 87).

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. 4)

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 6).

Power cord is loose.

Display board is faulty.

Ribbon cable connection is loose (Item 6).

Display board (Item 2) is faulty.

Display board (Item 2) is faulty.

Check cable connection at power supply and display boards (Items 87 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 Poly-V belt (Item 69) is slipping.

2.2 Excessive free play exists when the cranks are turned.

2.3 Machine makes noise and feels rough when the hand cranks are turned.

2.4 Crank bars (Item 101) stick and/or slide roughly into the crank hub assy. (Item 105).

2.5 Freewheels (Item 64) make grinding noise, operate roughly, and/or stick.

2.6 Handles lock up while operating.

Belt tension is not adjusted properly.

See Procedure 5.

The chain(s) is too loose. See Procedure 6.

Bearings (Item 8) in handle (Item9) are faulty.

Chains are too tight.

Bearings on the hand crank axles are faulty

(Item 94).

Bearings in Items 62 and/or 90 are faulty.

Bearings in the brake assy. (Item 68) are faulty.

Freewheel is faulty.

Crank bars have dents and/or burrs.

Freewheel is faulty.

Power supply board

(Item 87) is faulty.

Brake (Item 68) is faulty.

Rotate hand cranks about the hand crank shaft (Item 12). Replace bearings if source of noise.

See Procedure 6.

Remove the chains and rotate each axle separately. Replace bearings if source of noise.

With chains and poly-v belt (Item

69) removed, rotate each item separately. Replace bearings if source of noise.

With chains and poly-v belt removed, rotate the brake assy.

Replace bearings if source of noise.

With the chains removed, rotate each sprocket in the freewheel direction. Replace if source of noise and/or rough operation.

Inspect mating surfaces of crank bars and hubs for burrs and sharp edges. Burnish as required with a fine file or emery cloth.

Remove the chains and rotate each sprocket in the freewheel direction.

Replace if source of noise and/or rough operation.

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

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

Procedure 4.

5

2.7 No resistance on handles and pedals when in a program.

2.8 Very little resistance at any level.

No speed signal

Wires going to brake

(Item 68) are disconnected.

Power supply board

(Item 87) is faulty.

Speed sensor (Item 74) improperly adjusted.

Bad speed sensor connection with power supply board (Item 87).

Check and adjust the speed sensor

(Item 74) 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.

6

III. Maintenance Procedures

Procedure 1 - Removal and

Reinstallation of the Power Supply

Board

1. Unplug the unit from the power source.

2. Remove the crank bars and crank hub assemblies (Items 7 or

105) from the unit.

3. Remove the screws (Item 14) that fasten the covers (Item 16) to the main frame. The covers can be removed now.

4. Locate the power supply cover

(Item 83) on side of unit. Remove the four (4) screws and remove the power supply cover. Be careful when removing the power supply cover 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. 5.

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. 5. 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. 5. e. The one (1) ribbon cable.

8. The power supply board (Item

87) 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. 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. 5. 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

7

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 7 or 101) 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, proceed to the next step to adjust the speed sensor.

4. Remove the crank arms and cover (Item 7 or 105 and Item 16) from the right side of the machine.

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

- 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. 5. The voltmeter should read 4-5 VDC.

9. If there is no voltage, replace the power supply board (Item 87); see Procedure 1. 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 ½-

20 nut attached to item 62.

Loosen the set screw (Item 72). If the pulley brake drive shaft does not move on its 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 to SCIFIT (request a UPS call tag by phone).

8

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 in 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 ½-20 nut that fastens the brake drive pulley shaft (Item

57) 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

68).

3. After knocking the brake drive pulley shaft a few millimeters away from the brake assembly, tighten the set screw (Item 67) so that it butts up to the brake drive pulley shaft.

4. Tighten the ½-20 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 complete. If noise persists, return to step 1.

9

Procedure 6 – Checking and

Adjusting the Tension in the

Chains

1. Check the deflection in the two chains along their longest spans.

The two chains should never have less than ¼” 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 ½-

20 nut that fastens the shaft assembly (Item 90) to the main frame.

3. To tighten the chain, the shaft assembly needs to be moved in the direction of the seat. To loosen the chain, the shaft assembly needs to be moved towards the brake drive pulley.

With the nut still on the shaft, use a hammer to knock the entire shaft assembly a few millimeters in the prescribed direction.

4. Tighten the ½-20 nut and check the deflection as in step 1.

5. Repeat steps 1-4 until the desired stiffness is reached.

10

IV. Figures

Figure 1 – Pro1000 Total Assembly (Items 1-53)

11

Figure 2 – Pro1000 Main Frame (Items 54-99)

12

Figure 3 – Pro1000 Optional Parts (Items 100-112)

13

Figure 4 – Power Entry Module with Fuse Holder

14

Figure 5 – Pro1000 Wiring Diagram

15

V. Pro II Parts List

Item Description

1 overlay/switch panel

2 Display board

3 standoffs, 1", 6-32

4 Console

5 screw, 6-32x.5, b.h., blk.

6 cable, ribbon, assy

7 hub, crank, fixed, long, machine

8 bearing, flanged, 5/8 dia., igus

9 handle, handcrank

10 washer, 5/8, plastic

11 ring, snap, retainer, 5/8

12 shaft, crank, hand

13 washer, cover, plastic, black

14 screw, 1/4-20x1.25, black, b.h., socket cap

15 decal, body, Pro 1000

16 cover, right, gray, dull

cover, left, gray, dull

17 decal, serial number

18 nut, 5/16-18, blk.

19 lockwasher, 5/16, blk.

20 wheel, front, pro II

21 bolt, 5/16-18 x 1.75, blk.

22 bolt, 3/4-18x6, blk.

23 decal, UL certification

24 base, Pro II

25 extrusion, rail, roller, seat

26 nut, pan, 5/16-18

27 lockwashers, 5/16, pltd.

28 bolt, 5/16-18 x 3, pltd.

30 screw, 5/16-18, p.h., black

31 roller, urethane, 1 1/4 dia. X 3/8

32 nuts, lock, 5/16 -18 pltd.

33 screw, 10-32x.5, black, b.h., socket cap

34 rod, lock, pos., seat, PRO1000

35 pin, clevis, 1/4x1"

36 brkt., pos., adj., lever

37 pin, carter, 3/32 x 3/4

Part No. Qty.

65112 1

70400

70396

A1030

P1059

65110

P1051

65202

65120

66325M

P1173

67356

67306

65024

16

2

65201RG2 1

65200LG2 1

2

4

2

2

12

1

10

1

4

1

2

4

2

2

1

1

2

2

2

2

2

12

12

12

P1038

P1062

A1121

A1115

18

18

18

9

1

2

1

2

16

17

38 brkt., pivot, rod, lock

39 spring

40 frame, seat

41 lockwasher, 1/4, blk.

42 seat pad (back)

43 seat pad (bottom)

44 lockwasher, 1/4, pltd.

A1119

71385

71101

71100

P1056

45 bolt, 1/4-20x1.25, pltd.

46 bracket, spring A1120

47 sticker, track adjustment

48 track, adjustment, seat, stainless steel, Pro1000 A1114

49 decal, manufacturing date

50 endcap, 3"dia

51 screw, M5x1.0x25, s.h., blk.

52 manual, operator's

70330

53 cord, power, 110V, 9'10"

54 frame, main

55 screw, 10-32x.75, s.h., blk.

56 lockwasher, #10, pltd.

57 shaft, brake, drive, pulley

58 bolt, M5x.8x19, socket cap

59 ring, snap, retainer, 1/2

60 bearing, hub, brake drive

61 lockwasher, #8, pltd.

62 hub, brake drive pulley, hubed

63 pulley, brake drive

64 freewheel, Pro II, shimano

65 0.020" and 0.035" shims

66 tape, pickup, speed

67 bolt, 8-36x1.188, blk.

68 brake, assy.

69 belt, brake, poly-v

70 channel, transformer

71 screws, 4-40x.5 p.h. pltd.

72 washer, #4, split, pltd.

73 washer, #4, flat, pltd.

74 sensor, speed, assy.

75 transformer, 24V, 5.4 A

76 bracket, speed sensor

77 screw, M4x.7x10, s.h., blk.

78 washer, M4, pltd.

68014

A1359

65140

65180

69403

65169

69321

68312-2

68012

68316-2

68313

68013

65141

68000

11

1

1

4

NA

1

1

1

1

3

1

2

1

1

3

3

1

1

1

1

1

1

1

1

4

4

1

2

16

1

4

1

1

1

4

1

1

4

1

1

2

79 nut, M4x.7, pltd.

80 p.e.m., recep for daisychain

81 module, power entry, RF/EFI

82 screw, 3/16-32x3/8, p.h.

83 cover, supply, power

84 starwasher, #6

85 screw, 6-32x3/8, p.h.

86 standoffs, 3", 6-32

87 power supply, (lower), serial

88 clip, u-type

89 shell, bearing, crank hub

90 hub, brake drive pulley, nohub

shaft, brake, drive, pulley

bearing, hub, brake drive

ring, snap, retainer, 1/2

91 mount, hub, sleeve, sprocket, wide

92 board, heartrate, PCB

93 nut, 5/16-18, pltd.

94 axle, long, top

bearing, axle

nut, M2x1.5

shell, bearing, crank hub

ring, snap, retainer, 1

95 cotter pin, 9mm

96 mount, hub, sleeve, wide

97 lockwasher, 5/16, pltd.

98 bolt, 5/16-18x2.5, pltd.

99 bolt, 3/8-24x2.75, pltd.

100 screw, M6x1.0x25, s.h.

101 bar, hand crank

102 roll pin, 3/16x1/2

103 screw, M5x.8x12, b.h., blk.

104 cover, crank hub

105 hub, crank, assy.

106 seatbase, ProII, weldment

107 spring, gas

108 adapter, gas shock, seat, sq.

109 extension, seatbase, ProII, weldmnt.

110 pin, popper, turn to release

111 plunger, adjust, seat height

112 track, adjustment, stainless

18

1

16

2

2

6

4

2

2

2

1

6

1

6

1

2

2

1

2

1

1

1

1

1

1

1

4

1

12

1

1

1

2

1

1

1

1

8

8

4

1

1

65160

66370L

66370B

Sin0407

66372

66354-1

66311

66304

A1364

65177

65178

A1043

65150S

Sin0407

68316-1

68312-2

68012

66355-1

C1168

P1177

A1166

C1169

P1223

71200

71395