ProII

Service Manual

SALES: 800-278-3933

CUSTOMER SERVICE: 800-745-1373

Revision: August 1999

Table of Contents

Section

I. Overview

II. Troubleshooting Tables

Page

2

3

III. Maintenance Procedures

Procedure 1 – Removal and Reinstallation of the Power Supply Board 7

Procedure 2 – Checking Voltage at the

Power Supply Board

Procedure 3 – Checking and Adjusting the

Speed Sensor

Procedure 4 – Removal and Replacement of the Brake Assembly

Procedure 5 –Tightening the Poly-V Belt

Procedure 6 – Checking and Adjusting the

Slack in the Chains

8

9

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

7

8

13

Figure 4 – ProII Wiring Diagram

V. ProII Parts List

14

15

1

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 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

Problem

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

Possible Reasons

Faulty power supply board (Item 92).

Faulty fuse.

Loose cable connection.

Power supply board

(Item 92) 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 92) is faulty.

Ribbon cable (Item 6) connections are loose.

Faulty power supply board (Item 92).

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 92).

Solutions

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.

1.10 Can’t select program or enter information and no beep when buttons are pressed.

Ribbon cable connection is loose (Item 6).

Power cord is loose.

Display board is faulty.

Ribbon cable (Item 6) connection is loose.

Display board (Item 2) is faulty.

Display board (Item 2) is faulty.

Overlay/switch panel

(Item 1) is faulty.

Check cable connection at power supply and display boards (Items 92 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.

4

Table 2 – Mechanical Troubleshooting

Problem

2.1 Poly-V belt (Item 74) 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 and pedals are turned.

Possible Reasons

Belt tension is not adjusted properly.

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.

Solutions

See Procedure 5.

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

2.4 Crank bars (Items 8 and

53) stick and/or slide roughly into the crank hub assy. (Item 55).

2.5 Freewheels (Item 69) make grinding noise, operate roughly, and/or stick.

Crank bars have dents and/or burrs.

Freewheel 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 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 chain and rotate each sprocket in the freewheel direction.

Replace if source of noise and/or rough operation.

5

2.6 Handles and pedals lock up while operating.

Power supply board

(Item 92) is faulty.

Brake (Item 73) is faulty.

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 73) are disconnected.

Power supply board

(Item 92) is faulty.

Speed sensor (Item 79) improperly adjusted.

Bad speed sensor connection with power supply board (Item 92).

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.

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.

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 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 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. 4. Use a voltmeter to measure the DC voltage across the speed sensor pins on the power supply board.

7

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, proceed 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 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

8

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 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

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 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 Slack 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 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 ½-20 nut still on the shaft, use a hammer to knock the entire shaft assembly a few millimeters in the prescribed direction.

4. Tighten the 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 – 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 – Pro II Wiring Diagram

14

V. Pro II Parts List

Item Description

1 overlay/switch panel

Part No. Qty.

65112 1

2 Display board

3 standoffs, 1", 6-32

4 Console

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

6 cable, ribbon, assy

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

8 bar, hand crank

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

10 handle, handcrank

65110

P1051

65202

65120

66311

P1173

67356

11 washer, 5/8, plastic

12 ring, snap, retainer, 5/8

13 shaft, crank, hand 67306

4

2

2

14 washer, cover, plastic, black

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

16 decal, body, Pro II

17 cover, gray, right, dull, new

12

16

65025 2

65201RG2 1

1

4

2

4

2

1

10

1

4

18 decal, serial number

19 nut, 5/16-18, blk.

20 lockwasher, 5/16, blk.

21 wheel, front, pro II

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

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

24 cover, crank hub

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

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

27 lockwasher, #8, pltd.

28 pedal, Pro II, pair

29 decal, UL certification

30 base, Pro II

31 extrusion, rail, roller, seat

32 nut, pan, 5/16-18

33 lockwashers, 5/16, pltd.

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

35 seat, roller, base, weldment

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

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

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

70400

66304

65550

70396

A1030

P1059

C1168

P1038

1

18

18

18

1

2

12

12

12

24

27

1

1

2

2

2

2

2

2

4

16

15

39 spring, gas

40 adaptor, gas shock, seat, sq.

41 extension, seatbase, Pro II, weldment

42 frame, seat

43 lockwasher, 1/4, black

44 seat pad (back)

45 seat pad (bottom)

46 lockwasher, 1/4, pltd.

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

48 pin, popper, turn to release

49 plunger

50 track, adjustment, stainless

51 sticker, seat adjustment

52 decal, manufacturing date

53 bar, foot crank 9/16x20, right bar, foot crank 9/16x20, left

54 endcap, 3"dia

55 hub, crank, assy.

56 manual, operator's

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

58 roll pin, 3/16x1/2

59 cover, left, gray, dull

60 frame, main, Pro II

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

62 shaft, brake, drive, pulley

63 bolt, M5x.8x19, socket cap

64 lockwasher, #10, pltd.

65 bearing, brake drive hub

66 hub, brake drive pulley, hubed

67 ring, snap, retainer, 1/2

68 pulley, brake drive

69 freewheel, Pro II, shimano

70 0.020" and 0.035" shims

71 tape, pickup, speed

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

73 brake, assy.

74 belt, brake, poly-v

75 channel, transformer

76 screws, 4-40 x 1/2, p.h., pltd.

77 washer, #4, split, pltd.

78 washer, #4, flat, pltd.

65141

68000

68014

A1359

P1177

A1166

C1169

71385

71101

71100

P1056

P1223

71200

71395

66302-1

66302-2

70330

A1364

P1104

65169

3

65200LG2 1

69321 1

3

2

4

1

1

68312-2

68012

68316-2

68313

68013

1

1

1

4

1

3

3

2

1

1

1

1

NA

1

1

1

1

1

1

1

1

4

1

1

1

4

1

1

4

1

1

1

2

16

79 sensor, speed, assy.

80 bracket, speed sensor

81 transformer, 24V, 5.4 A

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

83 washer, M4, pltd.

84 nut, M4x.7, pltd.

85 p.e.m., recep for daisychain

86 module, power entry, RF/EFI

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

88 cover, supply, power

89 starwasher, #6

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

91 standoffs, 3", 6-32

92 power supply, (lower), serial

93 cotter pin, 9mm

94 mount, hub, sleeve, sprocket, thin

95 ring, chain (sprocket)

96 clip, u-type

97 axle, short, bottom bearing, axle nut, M2x1.5 shell, bearing, crank hub ring, snap, retainer, 1

98 mount, hub, sleeve, thin

99 idler, chain, sprocket w/ hub

100 shaft, idler, chain

101 hub, brake drive pulley, nohub shaft, brake, drive, pulley bearing, hub, brake drive ring, snap, retainer, 1/2

102 washer, 1/2, pltd.

103 lockwasher, 1/2, pltd.

104 nut, 1/2-20, pltd.

105 mount, hub, sleeve, sprocket, wide

106 board, heartrate, PCB

107 nut, 5/16-18, pltd.

108 axle, long, top bearing, axle nut, M2x1.5 shell, bearing, crank hub ring, snap, retainer, 1

109 mount, hub, sleeve, wide

17

3

3

1

1

1

1

2

1

3

6

1

2

2

1

2

1

4

1

4

1

1

1

8

8

2

12

1

2

2

1

2

1

1

1

4

4

1

1

1

1

1

4

68316-1

68312-2

68012

66355-1

65160

66370L

66370B

Sin0407

66354-1

65140

69403

65180

65177

65178

A1043

65150S

66372

66355-2

65340

66370S

66370B

Sin0407

66354-2

65396

69394

110 lockwasher, 5/16, pltd.

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

6

6

18