SERVICE MANUAL

Z 100

Z 500

Z 900

Table of Contents

Troubleshooting Guide

Electronic System……………………………………………….3

Mechanical System……………………………………………...4

Repair Procedures

Procedure 1 (Calibrating the unit)………………………………5

Procedure 2 (Checking wire harness)…………………………...5

Procedure 3 (Speed sensor adjustment)…………………………5

Procedure 4 (Checking treadmill circuit breaker)………………5

Procedure 5 (Checking roller for magnet)………………………6

Procedure 6 (Adjust 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

Z100

Exploded View...…………………………………………………14

Parts List....................................................................................15-17

Z500

Exploded View....………………………………………………...18

Parts List......................................................................................19-21

Z900

Exploded View....………………………………………………...22

Parts List......................................................................................23-25

2

Troubleshooting Guide

ELECTRONIC SYSTEM

No power

There is no power to the console.

1.

Unit must be plugged into an outlet with power

2.

Power switch must be illuminated

3.

Tether cord must be in place

4.

Check treadmill circuit breaker. (procedure 4)

5.

Check “POWER” LED on controller. (procedure 11)

6.

Make sure wires on board are plugged in securely.

7.

Check wire harness for continuity. (procedure 2)

8.

If LED’s on controller are not lit, test fuse on controller. If fuse is good, replace controller.

(procedure 7)

9.

If LED’s are on, replace console.

LS error

Belt movement for a few seconds then LS error

LS error

No belt movement at all then LS error

1.

Run the calibration procedure. (procedure 1)

2.

Adjust speed sensor. (procedure 3)

3.

Check roller for magnet (Procedure 5)

4.

Check wire harness for continuity. (procedure 2)

5.

If roller has a magnet and sensor adjustment does not fix, replace speed sensor.

1.

Run the calibration procedure. (procedure 1)

2.

Check wire 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.

Incline does not work

Belt surging

Belt speeds up and slows down frequently

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 the incline motor are connected to the controller correctly (procedure 12). If they are connected correctly, and the calibration does not fix, replace the incline motor. (procedure

10)

4.

When the UP and DOWN buttons are pressed, there should be a “beep” and a number change in the incline window. If there isn’t, replace the console.

5.

Observe the UP and DOWN diagnostic lights on the controller (procedure 11). When the

UP or DOWN buttons are pressed, you should (1) see one of the lights come on and (2) hear a relay click.

If there is no relay click and no diagnostic lights, replace console and controller

(procedure 7).

If there is a relay click and a diagnostic light and motor wires are connected correctly, replace incline motor.

1.

Adjust torque boost (procedure 6)

2.

Adjust speed sensor (procedure 3)

3.

Replace controller (procedure 7)

3

Troubleshooting Guide

MECHANICAL SYSTEM

Belt noise

1.

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.

Drive motor noise

1.

Check wires around motor for rubbing.

2.

Remove, clean, and re-insert the motor brushes

3.

Replace motor. (procedure 9)

Deck noise

Squeaking or creaking while walking

1.

Tighten deck bolts

2.

Clean and re-lube deck

4

Repair Procedures

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

PROCEDURE 1: Calibrating the unit

Remove tether cord.

Press and hold the START and FAST buttons. Replace the tether cord while maintaining the buttons. Display will show “FACTORY SETTING”. Press ENTER.

Units English / Metric. Press UP or DOWN to change. Press ENTER.

Adjust wheel diameter using UP or DOWN. Should be 2.75. Press ENTER.

Adjust minimum speed to 0.5 using UP and DOWN. Press ENTER.

Adjust maximum speed to 12 using UP and DOWN. Press ENTER.

Adjust maximum elevation to 15 using UP and DOWN.

Press START to begin calibration. DO NOT STAND ON BELT DURING CALIBRATION

.

2.1

2.2

2.3

2.4

2.5

PROCEDURE 2: Checking wire harness for continuity

Set your multimeter to read ohms.

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.

If the reading is close to 0 ohms, the wire has continuity (unbroken).

If the reading is very high or there is no reading at all, there is no continuity.

If there is no continuity, the harness needs to be replaced.

PROCEDURE 3: Speed sensor adjustment

3.1

3.2

3.3

Take off the motor hood.

The speed sensor is located on the frame, near where the drive belt goes around the front roller.

The sensor should be adjusted to about 1/16 th

of an inch from the front roller.

PROCEDURE 4: Checking treadmill circuit breaker

4:1 The circuit breaker is a small, red button between the power cord and the power switch.

4.2

Press the button in to reset.

5

PROCEDURE 5: Check roller for magnet

5.1

5.2

5.3

The front roller should have a round magnet and a round counter weight.

Take a screw or something metallic and test each one.

Only one should be magnetic.

PROCEDURE 6: Adjust Torque Boost

6.1

Using a small screw driver, turn the dial counter clockwise until it stops.

6.2

Press the START button on the console.

6.3

With someone standing on the walking belt, turn clockwise until the belt begins to move.

6.4

Increase the speed and check for smooth belt movement.

(See PROCEDURE 11 for location of Torque Boost)

PROCEDURE 7: Replacing controller

7.1

Disconnect power cord from unit.

7.2

Remove motor hood.

7.3

Remove two Phillips screws holding in the controller.

7.4

Disconnect all wires connected to 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

Connect to board and console, & turn power back on.

PROCEDURE 9: Replacing drive motor

9.1

Turn power switch off.

9.2

Disconnect red and black motor wires from controller.

9.3

Loosen tension bolt and remove four motor bolts.

9.4

Take off drive belt.

9.5

Insert new motor into place.

9.6

Put drive belt on.

9.7

Put in four motor bolts. Do not tighten them all the way down.

9.8

Tighten the tension bolt until you only have about an inch of play in the drive belt.

9.9

Tighten down the four motor bolts.

9.10 Plug the motor wires into the controller.

6

PROCEDURE 10: Replacing incline motor

10.1

Turn power switch off.

10.2

If possible, fold up unit.

10.3

Turn treadmill onto its side.

10.4

Disconnect motor wires from controller.

10.5

Remove bolt from incline tube.

10.6

Remove bolt from top of incline motor and take out motor.

10.7

Insert new motor and put in bolt on the top.

10.8

Reconnect motor wires to controller.

10.9

Turn on unit. The new motor should turn until it is at “zero”.

10.10 Insert bolt into incline tube.

PROCEDURE 11: Controller diagram

1

2

3

AC 1

AC 2

DOWN

COM

UP

JK 5

JK 7

JK 6

MOT

DRV

Down UP

JK 3

4

5

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.

6

4) Transformer Connections : JK5- Black,Black

JK6- Blue, Blue

JK7- Red, Red

5) Incline Potentiometer (VR)

6) Lower Wiring Harness Connection

7) Speed Sensor Connection

8) Torque Boost Adjustment - Adjust at lower speeds to eliminate motor surging

9) Motor Connection M- : Black motor wire

10) Motor Connection M+ : Red motor wire

M+

JK 3

M-

JK 3

10

9

8

SHUT DOWN

POWER LIMIT

JK 1

PWM

SPEED

SENSOR

JK 2

7

7

PROCEDURE 12: Wiring diagram

To Upright Harness

To Fan Assy.

Amp. Board

JK 5

To Pulse Grip

To Spd. Switch

JK 3

JK 5

JK 10 JK 9

JK 1

JK 2

To Tether Cord

JK 5

JK 2

JK 2

JK 4

JK 3

JK 6

To Inc. Switch

Heart Rate Rec.

Incline

Motor

Transformer

RED

RED

BLACK

BLUE

BLUE

BLACK

BLACK

WHITE

RED

AC 1

AC 2

DOWN

COM

UP

M+

JK 3

M-

JK 3

Down

JK 5

JK 7

JK 6

MOT

DRV

UP

JK 3

SHUT DOWN

POWER LIMIT

JK 1

PWM

SPEED

SENSOR

JK 2

RED

BLACK

Motor

Speed Sensor

Z 100-700

4-21-05

8

PROCEDURE 13: Engineering mode

1. Remove the tether cord.

2. Press and hold the START, ENTER, and STOP buttons and replaced the tether cord.

3. The display will say ENGINEERING MODE. Press ENTER.

4. Press the UP and DOWN buttons to scroll through the following sub menus:

-Calibration

-Factory Settings

-Security

-Functions

-Display Test

-Key Test

5. Press ENTER to access the desired program.

-Calibration

Speed Calibration – In this mode, you can test the 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/Metric. Press ENTER to change.

Maintenance

Lube Message Reset. Press ENTER to reset.

Odometer Reset. Press ENTER to reset.

Pause Mode On/Off. Press ENTER to turn on or off.

-Display Test

Test all LED’s

-Key Test

Test all buttons on console.

9

CONTACTING CUSTOMER SERVICE

I t is the responsibility of the Dealer to assemble and setup any Spirit product they have sold, as well as diagnose problems and perform service, regardless of the product’s location. Recognizing the importance of insuring the consumer’s satisfaction, Spirit technical support will always be available to assist the Dealer in diagnosing a problem. All warranties are valid from the original date of purchase by the original purchaser.

PARTS ORDERS Fax 870-930-9013

Fax your order using a completed parts purchase order to (870) 930-9013. Please do not call to place your parts orders, fax only. Service technicians are available to assist in the repair of treadmills. If taking parts orders by telephone, technical service calls will go unanswered. Standard shipping is UPS ground. If you

need an order shipped by another method, you must pay for shipping.

CUSTOMER SERVICE Call 800-258-4555

Calling from Store Location

Dial 1 to reach the first available technician, or select the extension number for one technician. You must have

the serial number of the machine.

Eddie Greene, Customer Service Supervisor 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 prompt manner.

Calling from Customer Location

Dial 0 for an operator. Relay to the operator you are a dealer and in a customer’s home. You will be assisted by the first available technician.

TREADMILL WARRANTY

Spirit Manufacturing Inc. warrants all its treadmills’ parts for a period of 5 years from the date of retail sale, as determined by sale receipt, or eighteen (18) months from the original factory shipping date, whichever comes first. Spirit’s responsibilities include providing new or remanufactured parts, at Spirit’s option, and technical support to our independent dealers and servicing organizations. In the absence of a dealer or service organization, these warranties will be administered by Spirit directly to a consumer. An extended warranty period applies to the following components:

Drive Motor 30 Years

Deck Wear 5 Years

Electronics / Belt / Rollers 5 Years

Frame Weldments Lifetime

All other Components 5 Years

10

WARRANTY POLICY

Parts Returns

It is very important that you have not only the model number but also the serial number on hand when placing a parts order. If a serial number is provided at the time a warranty parts order is placed the required parts will be sent to you at no charge. If the unit is no longer covered under warranty the parts will be billed to you on 30 day payment terms.

If a warranty replacement part is required to be returned to Spirit it will be noted on the packing list included in your shipment. Also noted on the packing list will be the amount you will be invoiced if the parts are not returned within

30 days.

Parts Required to be Returned for Credit

Upper and Lower Electronics - All STS / SC / SL / Inspire / Z / XT Series

Paperwork Requirement:

A copy of your invoice or packing list and diagnostic form (if included with replacement part) must be returned with the defective part to receive warranty consideration.

Warranty Labor Reimbursement Procedure

Complete Request for Warranty Labor Credit Form.

Fax completed form to Terry Jordan at (870) 930-9013.

Once Spirit has received your returned parts, your request will be processed and returned by fax to you.

What is Not Covered

1) Failures created due to improper installation or maintenance.

2) Repairs requiring only simple adjustments, fuses, or calibrations.

3) Damages sustained from shipping - Freight claim must be filed with your carrier.

4) Repairs that are made beyond the warranty period.

5) Repairs where the customer is paying the base labor fee to the dealer.

6) Units that are dealer stock or floor models.

7) Trips for diagnostic visit.

8) Residential units in a commercial setting.

Credit will not be 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 time flat completion fee of $80 per service occurrence.

Once all work required to complete the repair has been finished and all parts required for return have been returned to

Spirit either credit or payment in the amount of $80 will be issued to your company. The one-time flat completion fee of $80 will be paid only when the repair is complete and the unit has been returned to proper working condition.

If your company needs consideration for labor or trip fees that are higher than Spirit’s standard fees, they will be evaluated on a case-by-case basis. (e.g. - travel to perform service work in Manhattan). Any change in the fee schedule must be approved in writing by Spirit before any work is performed.

For Dealers That Wish To Use Third Party Service

It is Spirit’s policy that all dealers service products that they sell to end users. If your company chooses to use an independent company for service, you are responsible for all service work. Our labor reimbursement policies apply in every case and any charges in excess of Spirit’s one time flat completion fee will be billed back to the selling dealer.

In certain circumstances, we will work directly with an independent service company, but we will not pay for any service that deviates from our policy for dealers wishing to have this arrangement. Dealers will be responsible to the service company for all charges disallowed by Spirit. Any deviation from Spirit policy must be approved in advance in writing.

11

Fax to: 870-930-9013

Attention:

PARTS PURCHASE ORDER

Fill in completely for processing.

All orders are shipped F.O.B. Spirit Mfg., Jonesboro, Arkansas.

Dealer Name Account No. Ship to

Street & No. Street & No.

City State Zip

Phone Number Fax Number

City State Zip

Phone Number Fax Number

Purchase Order No. Dealer Buyer’s Name All parts ordered are considered stock orders unless a serial number is listed below each Date of Order

parts’ description box. A serial number listed will qualify it for warranty evaluation.

Qty. Part No. Description Unit Price Amount

Order Completion - Orders must be signed!

If a part is not accompanied by a serial number, it will 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____________

12

Shipping Instructions: (All orders will be shipped via ground delivery unless otherwise indicated.) Buyer will be responsible for all expe-

dited shipping charges.

Special Instructions: 2nd Day Air________________

Next Day Air_______________

Saturday Delivery___________

Initial Your Special Shipping Instructions Here______________________

(Orders for expedited shipping without initials will be shipped via ground delivery.)

REQUEST FOR WARRANTY LABOR CREDIT

Labor Warranty : Spirit is responsible

Customer is responsible

Date of Repair Model# Serial Number

Owner’s Name

Service Company Svc CoAcct Number

P.O. BOX 2037 JONESBORO, ARKANSAS 72402

Owner’s Address

Selling Dealer Selling Dlr Acct

Number

Problem

Phone Number With Area Code Date Sold

Repair Done

QUANTITY PART NUMBER PART DESCRIPTION

FACTORY USE ONLY

WTY TEST RESULTS UNIT PRICE WORK ORDER INVOICE

FACTORY USE ONLY

LABOR

TRIP

TOTAL LABOR

Authorization No.___________________________

_________________________________________

WARRANTY ADMINISTRATOR

FAX TO SPIRIT (870) 930-9013

13

FREIGHT:

SHIPPING:

WARRANTY CREDIT WILL BE ISSUED TO

DEALER ACCOUNT.

____________

ALL PARTS MUST BE RETURNED TO FACTORY

UNLESS INSTRUCTED OTHERWISE.

____________

CLAIMS MUST BE RETURNED TO SPIRIT

CORP. WITHIN 7 DAYS OF REPAIR.

____________

SHADED AREAS FACTORY USE ONLY

_

Z100 Exploded View

14

U-Z100 (XZ200-A82)

NO.

35

36

37

38

39

30

31

32

33

34

25

26

27

28

29

20

21

22

23

24

39~2

39~3

39~4

39~5

40

41

42

43

15

16

17

18

19

9

10

11

12

13

6

7

4

5

8

1

2

3

DESCRIPTION PART #

MAIN FRAME

FRAME BASE

INCLINE BRACKET

RIGHT HANDRAIL

LEFT HANDRAIL

CONSOLE SUPPORT

INNER SLIDE

OUTER SLIDE

000561

000628

000627

022928

˜ 5 x˜ 8 x 25L_ CLEVIS PIN

˜ 5 x˜ 8 x 9L_ FASTENING BUSHING

˜ 8 x30L _LINK SHAFT

˜ 8 x˜ 12.7 x 12L_ SHAFT BUSHING

2T_ FASTENING BRACKET

030101

2T_LINK

˜ 1.0_ DUAL ROTA-SPRING

CLENCHING HANDLE ASSY. (Handle Only - 000506) 000563

CHENCHING ROTA-SPRING 000865

CYLINDER - 900N 022554

DRIVE BELT - 240J/610J

FRONT ROLLER W/ PULLEY

REAR ROLLER

RUNNING DECK

RUNNING BELT

FOAM (A)

FOAM (B)

STEEL ROPE ROTA-SPRING

WIRE CLAMP

WIRE TIE MOUNT

LUBRICANT

STEEL ROPE

TOP FRAME COVER

BOTTOM FRAME COVER

MOTOR - 3HP YC

INCLINE MOTOR

CONTROLLER

800 m/m _ SPEED CABLE

800 m/m _INCLINE CABLE

HANDPULSE ASSY.

O’TY

022553

000497

000498

000488

000600

022972

023068

010026

010083

022271

650 m/m_HANDPULSE CABLE

HANDPULSE ASSEMBLY TOP

HANDPULSE ASSEMBLY BOTTOM

HANDLE BAR END CAP

SENSOR W/CABLE

BREAKER - 15 AMP

POWER SOCKET

ON / OFF SWITCH

000571

000572

000602

022696

022670

022754

022755

022672

022756

022757

022758

022759

022561

022448

022658

022476

15

1

1

1

1

2

1

1

1

1

1

1

1

2

2

6

1

1

1

1

1

1

1

1

2

2

1

2

1

1

1

1

1

1

1

2

1

1

2

1

1

1

1

1

1

1

1

72

73

74

75

76

67

68

69

70

71

58

59

60

61

62

63

64L

64R

65

66

82

83

84

85

86

77

78

79

80

81

87

88

53

54

55

56

57

52~2

52~3

52~4

52~14

52~16

44

45

46

47

48

49

50

51

52

52~1

POWER CORD

100m/m x 764 x 764_CONNECTING CABLE(BLACK)

300m/m x 764 x 764_CONNECTING CABLE (WHITE)

300m/m x 764 x 764_CONNECTING CABLE(BLACK)

800 m/m_COMPUTER CABLE (UPPER)

1150 m/m_COMPUTER CABLE (LOWER)

1300 m/m_COMPUTER CABLE (MIDDLE)

1000m/m_ GROUND WIRE

CONSOLE

TOP CONSOLE COVER

BOOK RACK (order as separate pcs.-2 racks per console)

BEVERAGE HOLDER

FACE PLaTE LENS

SPEAKER

SOUND BOARD W/CABLE - SPEAKER AMP

TOP MOTOR COVER

SPEED ADJUSTMENT SWITCH W/CABLE

INCLINE ADJUSTMENT SWITCH W/CABLE

M8 x ˜ 30 x 35_CUSHION (softer = 030060)

˜ 75_WHEEL(A)

˜ 62_WHEEL(B)

FOOT RAIL CAP (L)

FOOT RAIL CAP (R)

˜ 38_BUTTON HEAD END CAP

FRAME BASE CAP (L)

FRAME BASE CAP (R)

NON-SLIP RUBBER(L)

NON-SLIP RUBBER(R)

BOTTOM CONSOLE COVER

HANDGRIP SIDE CAP (R) COMES AS SET

HANDGRIP SIDE CAP (L)

REAR ADJUSTMENT BASE (L)

REAR ADJUSTMENT BASE (R)

MOTOR COVER ANCHOR(D)

˜ 10 x ˜ 24 x 3T_NYLON WASHER (A)

˜ 50 x ˜ 13 x 3T_ NYLON WASHER (B)

˜ 30 x 3/8" _FOOT PAD

SENSOR RACK

SAFETY KEY

BELT GUIDE

˜ 14 x˜ 10 x 35_ WHEEL SLEEVE

MAGNET

FOOT RAIL

1/2" x 1-1/4" _CARRIAGE BOLT

1/2" x 1"_HEX HEAD SCREW

3/8" x 4-1/2"_SOCKET HEAD CAP SCREW

3/8" x 3-3/4"_BUTTON HEAD SOCKET SCREW

3/8" x 1-1/2"_HEX HEAD SCREW

3/8" x 1"_HEX HEAD SCREW

3/8" x 2"_FLAT HEAD SOCKET SCREW

5/16" x 1"_BUTTON HEAD SOCKET SCREW

5/16" x 2-3/4"_BUTTON HEAD SOCKET SCREW

16

022812

022713

022989

022945

000595

023101

010041

000629

000062

000061

022885

000125

022314

1

1

4

2

2

1

2

2

1

2

1

1

1

1

2

1

2

2

1

1

1

4

1

1

2

2

2

2

2

2

2

2

1

6

1

1

2

1

2

2

1

1

1

1

1

1

1

1

1

1

1

1 022720

022721

022719

000617

000588

000591

000592

000597

022946

022940

000581

022558

022559

022482

022967

000127

000603

000604

022024

000586

000587

000313

000314

000596

000582

000593

000594

022484

124

125

126

127

128

118

119

120

121

122

113

114

115

116

117

108

109

110

111

112

130

131

132

133

134

135

136

137

138

103

104

105

106

107

98

99

100

101

102

89

90

92

93

94

96

97

M8 x 60m/m_HEX HEAD SCREW

M8 x 80m/m_SOCKET HEAD CAP SCREW

M8 x 35m/m_FLAT HEAD COUNTERSINK SCREW

M3 x 10m/m_PHILLIPS HEAD SCREW

M5 x 15m/m_PHILLIPS HEAD SCREW

5/16" x 42 m/m _PHILLIPS HEAD SCREW

M5_ NYLON NUT

1/2" x 8T_ NYLON NUT

3/8" x 7T_ NYLON NUT

5/16" x 6T_ NYLON NUT

M8x 8T_ NYLON NUT

3/8" x 6.5T_ NUT (for Foot Pad)

M3_ NUT

˜ 35 x ˜ 5/16" x 1.5T_ FLAT WASHER

˜ 25 x ˜ 10 x 1.5T_ FLAT WASHER

˜ 19 x ˜ 10 x 1.5T_ FLAT WASHER

˜ 5 x ˜ 10 x 1.0T_ FLAT WASHER

˜ 5/16" x ˜ 18 x 1.5T_ FLAT WASHER

˜ 5 x ˜ 12 x 1.0T_ FLAT WASHER

˜ 5 x ˜ 15 x 1.0T_ FLAT WASHER

˜ 6 x ˜ 23 x ˜ 13 x 5.5T x 3T_NYLON DISHED WASHER

˜ 6.5 x 25 x 50 x 1.5Tx2.5H_CONCAVE WASHER

˜ 10 _SPRING WASHER

M3_SPRING WASHER

M5_RAISED WASHER

4x12m/m_SELF TAPPING SCREW

5x16m/m_TAPPING SCREW - Black

5x19m/m_TAPPING SCREW

3.5 x 6 m/m_SELF TAPPING SCREW

5 x 16m/m_TAPPING SCREW

3 x10m/m_SELF TAPPING SCREW

3.5 x 12 m/m_SELF TAPPING SCREW

3x10 m/m_TAPPING SCREW

4x38m/m_SELF TAPPING SCREW

3.5 x 16 m/m_TAPPING SCREW

3 x 10 m/m_SELF TAPPING SCREW

M5_ IRON PLATE NUT

5/16" x 1/2"_BUTTON HEAD SOCKET SCREW

COMBINATION M5 ALLEN WRENCH & PHILLIPS HEAD SCREW DRIVER

M6 ALLEN WRENCH

3 x 10 m/m _SELF TAPPING SCREW

3x 8m/m_SELF TAPPING SCREW

PLASTIC WASHER

FRONT MOTOR COVER

TOP MOTOR COVER PLATE

0.8T_SPRING FOR CONSOLE

Hardware Kit

Decal (Side)

Decal (Console)

023082

000913

023102

000080

030039

010125

000126

000077

4

1

000070

4

4

010110 59

2

4

1

1

4

4

4

1

2

2

3

1

4

4

3

1

1

8

1

1

1

2

010125 1

2

010110 13

023082 2

010113 16

010115 12

000325 2

022979

023082

010109

6

2

6

000085 12

000089 1

022973

023082

1

2

000590

000589

6

6

1

1

2

1 022680

000546

000624

2

2

17

Z500 Exploded View

18

39~2

39~3

39~4

39~5

40

41

42

43

44

U-Z500 - (XZ600-A82)

27

28

29

30

31

32

33

34

35

36

37

38

39

23

24

25

26

18

19

20

21

22

12

13

15

16

17

7

8

9

10

11

4

5

2

3

6

NO.

1

DESCRIPTION

MAIN FRAME

FRAME BASE

INCLINE BRACKET

RIGHT HANDRAIL

LEFT HANDRAIL

CONSOLE SUPPORT

PART #

000561

000628

000627

022928

INNER SLIDE

OUTER SLIDE

˜ 5 x˜ 8 x 25L_ CLEVIS PIN

˜ 5 x˜ 8 x 9L_ FASTENING BUSHING

˜ 8 x30L _LINK SHAFT

030101

˜ 8 x˜ 12.7 x 12L_ SHAFT BUSHING

2T_ FASTENING BRACKET

2T_LINK

˜ 1.0_ DUAL ROTA-SPRING

CLENCHING HANDLE ASSY. (Handle ONLY=000506) 000564

CHENCHING ROTA-SPRING

CYLINDER - 1000N

DRIVE BELT - 240J/610J

FRONT ROLLER W/ PULLEY

REAR ROLLER

RUNNING DECK

RUNNING BELT

FOAM (A)

FOAM (B)

STEEL ROPE ROTA-SPRING

WIRE CLAMP

WIRE TIE MOUNT

LUBRICANT

STEEL ROPE

TOP FRAME COVER

BOTTOM FRAME COVER

MOTOR - 3.0hp YC

INCLINE MOTOR

CONTROLLER

800 m/m _ SPEED CABLE

800 m/m _INCLINE CABLE

HANDPULSE ASSY.

000865

023095

022553

000497

000498

000491

000601

022972

023068

010026

010083

022271

000574

000572

000602

022696

022670

022754

022755

022672

650 m/m_HANDPULSE CABLE

HANDPULSE ASSEMBLY TOP

HANDPULSE ASSEMBLY BOTTOM

HANDLE BAR END CAP

SENSOR W/CABLE

BREAKER - 15 Amp

POWER SOCKET

ON / OFF SWITCH

POWER CORD

22756

022757

022758

022759

022561

022448

022658

022476

022812

19

1

1

1

1

1

1

2

2

2

1

1

1

1

1

1

1

6

1

1

1

1

2

2

2

1

1

1

1

1

1

1

1

1

2

2

1

1

1

1

1

1

O’TY

1

1

1

1

1

1

73

74

75

76

77

68

69

70

71

72

59

60

61

62

63

64L

64R

65

66

67

83

84

85

86

87

78

79

80

81

82

54

55

56

57

58

52~3

52~4

52~14

52~16

53

45

46

47

48

49

50

51

52

52~1

52~2

100m/m x 764 x 764_CONNECTING CABLE(BLACK)

300m/m x 764 x 764_CONNECTING CABLE (WHITE)

300m/m x 764 x 764_CONNECTING CABLE(BLACK)

800 m/m_COMPUTER CABLE (UPPER)

1150 m/m_COMPUTER CABLE (LOWER)

1300 m/m_COMPUTER CABLE (MIDDLE)

1000m/m_ GROUND WIRE

CONSOLE

TOP CONSOLE COVER

BOOK RACK (does not come as Set)

BEVERAGE HOLDER

FACE PLATE LENS

SPEAKER

SOUND BOARD W/CABLE - SPEAKER AMP

TOP MOTOR COVER

SPEED ADJUSTMENT SWITCH W/CABLE

INCLINE ADJUSTMENT SWITCH W/CABLE

M8 x ˜ 30 x 35_CUSHION (softer = 030060)

˜ 75_WHEEL(A)

˜ 62_WHEEL(B)

FOOT RAIL CAP (L)

FOOT RAIL CAP (R)

˜ 38_BUTTON HEAD END CAP

FRAME BASE CAP (L)

FRAME BASE CAP (R)

NON-SLIP RUBBER(L)

NON-SLIP RUBBER(R)

BOTTOM CONSOLE COVER

HANDGRIP SIDE CAP (R) Comes as SET

HANDGRIP SIDE CAP (L)

REAR ADJUSTMENT BASE (L)

REAR ADJUSTMENT BASE (R)

MOTOR COVER ANCHOR(D)

˜ 10 x ˜ 24 x 3T_NYLON WASHER (A)

˜ 50 x ˜ 13 x 3T_ NYLON WASHER (B)

˜ 30 x 3/8" _FOOT PAD

SENSOR RACK

SAFETY KEY

BELT GUIDE

˜ 14 x˜ 10 x 35_ WHEEL SLEEVE

MAGNET

FOOT RAIL

1/2" x 1-1/4" _CARRIAGE BOLT

1/2" x 1"_HEX HEAD SCREW

3/8" x 4-1/2"_SOCKET HEAD CAP SCREW

3/8" x 3-3/4"_BUTTON HEAD SOCKET SCREW

3/8" x 1-1/2"_HEX HEAD SCREW

3/8" x 1"_HEX HEAD SCREW

3/8" x 2"_FLAT HEAD SOCKET SCREW

5/16" x 1"_BUTTON HEAD SOCKET SCREW

20

022720

022721

022719

000619

000588

000591

000592

000598

022946

022940

000581

022558

022559

022482

022967

000127

000603

000604

022024

000586

000587

000313

000314

000596

000582

000593

000594

022484

022713

022989

022945

000595

023101

010041

000583

000062

000061

022885

000125

1

2

2

1

2

2

2

1

1

4

1

2

1

1

2

2

1

1

1

1

4

2

1

1

2

2

2

2

2

1

6

2

1

1

2

2

1

1

1

1

1

1

1

1

2

1

1

1

1

1

116

117

118

119

120

121

122

124

107

108

109

110

111

112

113

114

115

102

103

104

105

106

97

98

99

100

101

88

89

90

92

93

94

96

131

132

133

134

135

125

126

127

128

130

136

137

138

5/16" x 2-3/4"_BUTTON HEAD SOCKET SCREW

M8 x 60m/m_HEX HEAD SCREW

M8 x 80m/m_SOCKET HEAD CAP SCREW

M8 x 35m/m_FLAT HEAD COUNTERSINK SCREW

M3 x 10m/m_PHILLIPS HEAD SCREW

M5 x 15m/m_PHILLIPS HEAD SCREW

5/16" x 42 m/m _PHILLIPS HEAD SCREW

M5_ NYLON NUT

1/2" x 8T_ NYLON NUT

3/8" x 7T_ NYLON NUT

5/16" x 6T_ NYLON NUT

M8x 8T_ NYLON NUT

3/8" x 6.5T_ NUT (for Foot Pad)

M3_ NUT

˜ 35 x ˜ 5/16" x 1.5T_ FLAT WASHER

˜ 25 x ˜ 10 x 1.5T_ FLAT WASHER

˜ 19 x ˜ 10 x 1.5T_ FLAT WASHER

˜ 5 x ˜ 10 x 1.0T_ FLAT WASHER

˜ 5/16" x ˜ 18 x 1.5T_ FLAT WASHER

˜ 5 x ˜ 12 x 1.0T_ FLAT WASHER

˜ 5 x ˜ 15 x 1.0T_ FLAT WASHER

˜ 6 x ˜ 23 x ˜ 13 x 5.5T x 3T_NYLON DISHED WASHER

˜ 6.5 x 25 x 50 x 1.5Tx2.5H_CONCAVE WASHER

˜ 10 _SPRING WASHER

M3_SPRING WASHER

M5_RAISED WASHER

4x12m/m_SELF TAPPING SCREW

5x16m/m_TAPPING SCREW - Black

5x19m/m_TAPPING SCREW

3.5 x 6 m/m_SELF TAPPING SCREW

5 x 16m/m_TAPPING SCREW - Black

3 x10m/m_SELF TAPPING SCREW

3.5 x 12 m/m_SELF TAPPING SCREW

3x10 m/m_TAPPING SCREW

4x38m/m_SELF TAPPING SCREW

3.5 x 16 m/m_TAPPING SCREW

3 x 10 m/m_SELF TAPPING SCREW

M5_ IRON PLATE NUT

5/16" x 1/2"_BUTTON HEAD SOCKET SCREW

022314

023082

000913

023102

000080

030039

010125

000126

000077

000070

010110

010125

COMBINATION M5 ALLEN WRENCH & PHILLIPS HEAD SCREW DRIVER

M6 ALLEN WRENCH 022973

3 x 10 m/m _SELF TAPPING SCREW

3x 8m/m_SELF TAPPING SCREW

023082

PLASTIC WASHER

FRONT MOTOR COVER

TOP MOTOR COVER PLATE

000590

000589

0.8T_SPRING FOR CONSOLE

HARDWARE KIT

FAN ASSEMBLY

DECAL (SIDE)

DECAL (CONSOLE)

022680

000616

000623

000624

010110

023082

010113

010115

000325

022979

023082

010109

000085

21

4

59

1

2

13

2

16

12

1

4

4

4

1

2

2

1

4

2

4

3

1

4

4

3

1

4

1

1

1

2

8

1

2

1

2

6

2

6

12

000089 1

1

2

6

6

2

1

1

1

1

1

1

Z900 Exploded View

22

Z900A-A82 Part List_SPIRIT

7

8

5

6

9

2

3

NO.

DESCRIPTION

1

MAIN FRAME

4

INCLINE BRACKET

HANDRAIL SUPPORT

RIGHT HANDRAIL

LEFT HANDRAIL

CONSOLE SUPPORT

%20x40x1.5Tx680L_DECK CROSS BRACE

˜ 10_MAGNET

DRIVE BELT - 240J/610J

10

˜ 110 x 75_FRONT ROLLER W/ PULLEY

11

˜ 75_REAR ROLLER

12

1410 x 680 x 25T_RUNNING DECK

13

560 x 3250 x 2.5T_RUNNING BELT

14

˜ 38 x 225m/m x 3T_HANDGRIP FOAM

15

˜ 38 x 295 m/m x 3T_CONSOLE SUPPORT FOAM

16

0.6T_SPRING

17

WIRE TIE MOUNT

18

LUBRICANT

19

765x390L_BOTTOM FRAME COVER

20

MOTOR - 3.0hp YC

21

INCLINE MOTOR

22

CONTROLLER

23

1000 mm_SENSOR W/CABLE

24

15A_BREAKER

25

POWER SOCKET

26

ON / OFF SWITCH

27

POWER CORD

28

100mm x 764 x 764_CONNECTING CABLE (BLACK)

29

150mm x 764 x 764_CONNECTING CABLE (WHITE)

30

150mm x 764 x 764_CONNECTING CABLE (BLACK)

31

800 mm_COMPUTER CABLE (UPPER)

32

800 mm_COMPUTER CABLE (LOWER)

33

1300 mm_COMPUTER CABLE (MIDDLE)

34

800 mm_SPEED CABLE (UPPER)

35

800 mm_INCLINE CABLE (UPPER)

36

TRANSFORMER

37

CONSOLE

37~1

TOP CONSOLE COVER

37~2

BOOK RACK (does not come as set)

37~3

BEVERAGE HOLDER OF CONSOLE

37~4

FACE PLATE LENS

37~13

AUDIO CABLE - Speaker Amp. Harness

37~14

SPEAKER

37~16 2.3x6 m/m_SELF TAPPING SCREW

38

290 m/m_SPEED ADJUSTMENT SWITCH W/CABLE

39

290 m/m_INCLINE ADJUSTMENT SWITCH W/CABLE

40

FRAME BASE CAP (R)

23

022720

000503

022719

022754

022755

022791

000621

000588

000591

000592

000598

000565

022946

023105

022558

022559

000608

PART #

000562

000634

000632

000631

000633

000611

000507

022553

000499

000500

000492

000495

000606

000605

010083

022271

000866

000602

022696

022882

022561

022448

022658

022476

022812

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

41

5

1

2

2

1

1

1

1

1

2

1

2

1

1

1

QTY.

1

1

1

1

41

FRAME BASE CAP (L)

42

FAN ASSEMBLY

42~1

BOTTOM FAN COVER

42~2

TOP FAN COVER

42~3

FAN SWITCH

000607

000616

42~4

DEFLECTOR FAN GRILL

42~5

FAN GRILL ANCHOR

42~6

FAN

43

M8 x ˜ 30 x 35 58°±3_CUSHION Softer = 30060

44

˜ 81 x35_WHEEL 023016

45

TOP MOTOR COVER

47

1400m/m_FOOT RAIL

48

BEVERAGE HOLDER

49

˜ 38 _BUTTON HEAD END CAP

50

HANDPULSE ASSY.

50~2

650 m/m_HANDPULSE CABLE

50~3

HANDPULSE ASSEMBLY TOP

50~4

HANDPULSE ASSEMBLY BOTTOM

50~5

HANDLE BAR END CAP

51

FRAME FRONT COVER

000557

000532

000635

022024

022672

022756

022757

022758

022759

000599

000596

000610

52

BOTTOM CONSOLE COVER

53 HANDGRIP SIDE CAP (R) Comes as SET

54 HANDGRIP SIDE CAP (L) Comes as SET

55

REAR ADJUSTMENT BASE (L)

56

REAR ADJUSTMENT BASE (R)

57

MOTOR COVER ANCHOR

58

˜ 24 x ˜ 10 x 3T_NYLON WASHER(A)

59

˜ 50 x ˜ 13 x 3T_NYLON WASHER(B)

60

˜ 38 x 3/8"_FOOT PAD

61

25 x 50_SQUARE END CAP

000612

000613

000922

22713

000630

000636

022945

000595

62

1/2" x 4 (13m/m)_BOLT CAP

63

SAFETY KEY

64

BELT GUIDE

65

1/2" x 57m/m_HEX HEAD SCREW

66

3/8" x 4-1/2"_SOCKET HEAD CAP SCREW

67

3/8" x 4"_SOCKET HEAD CAP SCREW

68

3/8" x 1-3/4"_HEX HEAD SCREW

69

M8 x 60m/m_HEX HEAD SCREW

70

M8 x 80m/m_SOCKET HEAD CAP SCREW

71

M8 x 50m/m_FLAT HEAD COUNTERSINK SCREW

72

M8 x 30m/m_FLAT HEAD COUNTERSINK SCREW

73

3/8" x 3/4"_BUTTON HEAD SOCKET SCREW

74

3/8" x 1"_HEX HEAD SCREW

75

1/2" x 15T_NYLON NUT

76

3/8" x 7T_NYLON NUT

77

M8_NYLON NUT

78

˜ 19 x ˜ 10 x 1.5T_FLAT WASHER

79

˜ 25 x ˜ 10 x 1.5T_FLAT WASHER

80

˜ 5 x ˜ 15 x 1.0T_FLAT WASHER

81

˜ 6.5 x 25 x 1.5T x 2.5H_CONCAVE WASHER

000580

020349

022999

000061

000080

24

4

2

2

2

1

4

2

6

2

6

1

2

4

1

1

2

2

1

4

1

2

2

1

2

1

1

2

1

2

2

022482

2

2

4

4

1

1

1

1

1

4

2

2

2

4

2

1

1

2

1

6

82

M5 RAISED WASHER

83

˜ 6.5 x 25 x 1.5T x 5.8H_CONCAVE WASHER

84

M5 IRON PLATE NUT

85

˜ 10 x1.5T_SPRING WASHER

86

5 x19 m/m_TAPPING SCREW

87

5 x16 m/m_TAPPING SCREW - Black

88

4x12 m/m_SELF TAPPING SCREW

89

3.5x12 m/m_SELF TAPPING SCREW

90

3.5x43 m/m_SELF TAPPING SCREW

91

3x10 m/m_SELF TAPPING SCREW

92

5x16 m/m_ TAPPING SCREW - Black

93

3x10 m/m_ TAPPING SCREW

94

4x38 m/m_SELF TAPPING SCREW

95

3x10 m/m_SELF TAPPING SCREW

96

3.5 x16m/m_TAPPING SCREW

98

3/8" _NUT

99

5/16" x 3/4"_BUTTON HEAD SOCKET SCREW

100

5/16" x 1/2"_BUTTON HEAD SOCKET SCREW

101

3/8" x 2"_BUTTON HEAD SOCKET SCREW

102

3/8" x 2T_SPRING WASHER

010109

030057

010110

000070

010113

023082

010110

010115

000325

023082

022979

000100

000085

023090

000053

103

M3 x 18 m/m_TAPPING SCREW 022248

104

COMBINATION M5 ALLEN WRENCH & SCREWDRIVER 000089

105

M6 ALLEN WRENCH

106

3 x 10 m/m_SELF TAPPING SCREW

107

3x 8m/m_SELF TAPPING SCREW

022973

023082

108

PLASTIC WASHER

109

NON-SLIP RUBBER(L)

110

NON-SLIP RUBBER(R)

111

112

SENSOR RACK

MOTOR FAN for CONTROLLER

113

M4x35 m/m_TAPPING SCREW

114

NYLON NUT

115

˜ 4 x ˜ 10 x 1.0T_FLAT WASHER

000313

000314

022989

000876

116

250m/m_ BLACK CONNECTING CABLE OF MOTOR FAN 000637

117

250m/m_ WHITE CONNECTING CABLE OF MOTOR FAN 000538

HARDWARE KIT

DECAL (SIDE)

DECAL (CONSOLE)

000614

000615

000624

21

2

2

5

3

4

16

8

2

13

4

10

4

1

39

3

6

6

2

2

1

2

1

1

1

2

2

1

1

2

6

1

2

6

1

3

1

1

25