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R5X-03
Service Manual
71 pgs7.95 Mb0

Matrix R5X-03 Service Manual

R 5 X - 0 3 B I K E
S E R V I C E M A N U A L
TABLE OF CONTENTS
CHAPTER 1: SERIAL NUMBER LOCATION ................................................................... 1
CHAPTER 2: IMPORTANT SAFETY INSTRUCTIONS
2.1 Read and Save These Instructions ........................................................................... 3
2.2 Electrical Requirements ............................................................................................ 4
CHAPTER 3: PREVENTATIVE MAINTENANCE
3.1 Recommended Cleaning Tips ................................................................................... 5
3.2 Check for Damaged Parts ......................................................................................... 5
3.3 Care and Maintenance Instructions .......................................................................... 6
CHAPTER 4: CONSOLE OVERLAY AND WORKOUT DESCRIPTION
4.1 Console Description .................................................................................................. 7
4.2 Workout Setup Steps - Manual .................................................................................. 8
4.3 Workout Setup Steps - Fat Burn ................................................................................ 8
4.4 Workout Setup Steps - Level Based .......................................................................... 8
4.5 Workout Setup Steps - Fitness Test ........................................................................... 9
CHAPTER 5: MANAGER MODE
5.1 Using Manager Mode ................................................................................................ 11
5.2 Manager Mode Overview ........................................................................................... 11
CHAPTER 6: ENGINEERING MODE
CHAPTER 7: SERVICE MODE
CHAPTER 8: TROUBLESHOOTING
CHAPTER 9: PART REPLACEMENT GUIDE
TABLE OF CONTENTS
9.18 Drive Belt Replacement .................................................................................................. 47
9.19 Generator Belt Replacement .......................................................................................... 48
9.20 Generator Replacement .................................................................................................. 49
9.21 Pulley Axle Set Replacement.......................................................................................... 50
9.22 Crank Axle Set Replacement .......................................................................................... 52
9.23 Testing the Bike ............................................................................................................... 53
CHAPTER 10: BIKE SPECIFICATIONS AND ASSEMBLY GUIDE
CHAPTER 11: SOFTWARE UPGRADE GUIDE
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1.1 SERIAL NUMBER LOCATION
CHAPTER 1: SERIAL NUMBER LOCATION
A serial number plate is located below the bottom of the console mast beneath a rubber boot. There is also a serial number tag on the middle of the main frame pointed towards the floor.
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1.1 SERIAL NUMBER LOCATION
CHAPTER 1: SERIAL NUMBER LOCATION
CONSOLE SERIAL NUMBER LOCATION
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CHAPTER 2: IMPORTANT SAFETY INSTRUCTIONS
2.1 READ AND SAVE THESE INSTRUCTIONS
To ensure your safety and protect the equipment, read all instructions before operating the MATRIX R5x-03 Bike.
To ensure proper use of the Matrix R5x-03 Bike, make sure that all users read this manual. Remind the users that before undertaking any fitness program, they should obtain complete physical examinations from their physicians. If, at any time while exercising, the user experiences dizziness, pain, or shortness of breath, nausea or feels faint, he or she must stop immediately.
* This bike is only to be used for its intended purpose described in this manual. Do not use attachments that have not been recom­mended by Matrix.
* Never drop or insert objects into any opening. Keep hands away from moving parts. If the item cannot be reached, contact a Matrix authorized dealer for assistance.
* Never operate the unit if it is damaged, not working properly, when it has been dropped, or has been dropped in water.
* Keep hands and feet clear at all times from moving parts to avoid injury.
* Do not use this product outdoors, near swimming pools or in areas of high humidity.
* Do not operate where aerosol (spray) products are being used or when oxygen is being administered.
* Do not use this product in bare feet. Do not wear shoes with heels, leather soles, cleats, or spikes while exercising.
CAUTION! If you experience chest pains, nausea, dizziness, or shortness of breath, stop exercising immediately and con­sult your physician before continuing.
CAUTION! Any changes or modifications to this equipment could void the product warranty.
* Do not remove the side covers. Service should only be done by an authorized service technician.
* Close supervision is necessary when used near children, invalids, or disabled people.
* When the bike is in use, young children and pets should be kept at least 3 meters / 10 feet away.
* Assemble and operate the bike on a solid, level surface.
* Never face backward while using the Matrix R5x-03 Bike.
* Use the stationary handlebars when mounting or dismounting the bike.
* Do not wear clothing that might catch on any moving parts of this bike.
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CHAPTER 2: IMPORTANT SAFETY INSTRUCTIONS
2.2 ELECTRICAL REQUIREMENTS
The Matrix 5x Series Recumbent Bike is designed to be self powered. NOTE: If an add on TV (using a bracket) or Virtual Active is added to the unit, it must be plugged in, or the TV and Virtual Active will not operate correctly. If the Bike will be plugged in, follow the requirements below.
MATRIX DEDICATED CIRCUIT/ELECTRICAL REQUIREMENT INFO
All Matrix Bikes require the use of a 15 amp or 20 amp “dedicated circuit,” with a non-looped (isolated) neutral/ground, for the power requirement. Quite simply this means that each outlet you plug Bikes into should not have anything else running on that same circuit besides other Bikes (up to 3 per 15 amp circuit and 4 per 20 amp circuit). The easiest way to verify this is to locate the main circuit breaker box, and turn off the breaker(s) one at a time. Once a breaker has been turned off, the only thing that should not have power to it are the Bikes in question. No lamps, vending machines, fans, sound systems, or any other item should lose power when you perform this test.
Non-looped (isolated) neutral/grounding means that each circuit must have an individual neutral/ground connection coming from it, and terminating at an approved earth ground. You cannot “jumper” a single neutral/ground from one circuit to the next.
In addition to the dedicated circuit requirement, the proper gauge wire must be used from the circuit breaker box, to each outlet that will have the maximum number of units running off of it. If the distance from the circuit breaker box, to each outlet, is 100 ft or less, then 12 gauge wire may be used. For any distance greater than 100 ft from the circuit breaker box to the outlet, 10 gauge wire must be used.
For your safety and Bike performance, the ground on this circuit must be non-looped. Please refer to NEC article 210-21 and 210-23. Your Bike is provided with a power cord with a plug listed below and requires the listed outlet. Any alterations of this power cord could void all warranties for this product. Multiple Bikes can be powered on one dedicated circuit. (3 units per 15 Amp and 4 units per 20 Amp dedicated circuit.)
GROUNDING INSTRUCTIONS:
The Matrix R5x-03 Recumbent Bike must be grounded. If it should malfunction or break down, grounding provides a path of least resistance for electric current to reduce the risk of electric shock. The Bike is equipped with a cord having an equipment grounding conductor and a grounding plug. The plug must be plugged into an appropriate outlet that is properly installed and grounded in accordance with all local codes and ordinances. If the user does not follow these grounding instructions, the user could void the Matrix limited warranty.
DANGER: Improper connection of the equipment grounding conductor can result in the risk of electric shock. Check with a qualified electrician if the user is in doubt as to whether the product is properly grounded. Do not modify the plug provided with the product if it will not fit the outlet, have a proper outlet installed by an electrician.
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CHAPTER 3: PREVENTATIVE MAINTENANCE
3.1 RECOMMENDED CLEANING TIPS
Preventative maintenance and daily cleaning will prolong the life and look of your MATRIX R5x-03 Bike
Please read and follow these tips.
* Position the equipment away from direct sunlight. The intense UV
light can cause discoloration on plastics.
* Locate your equipment in an area with cool temperatures and low
humidity.
* Clean with a soft 100% cotton cloth.
* Clean with soap and water or other non-ammonia based all purpose
cleaners.
* Wipe seats, pedals, console, heart rate grips, and the handlebar clean
after each use.
* Do not pour liquids directly onto your equipment. This can cause dam-
age to the equipment and in some cases electrocution.
* Check pedal straps weekly for wear.
* Adjust leveling feet when equipment wobbles or rocks.
* Maintain a clean area around the equipment, free from dust and dirt.
3.2 CHECK FOR DAMAGED PARTS
DO NOT use any equipment that is damaged or has worn or
broken parts. Use only replacement parts supplied by Matrix Fitness Systems.
MAINTAIN LABELS AND NAMEPLATES. Do not remove labels for any reason. They contain important information. If unreadable or missing, contact Matrix Fitness Systems for a replacement at 866-693-4863 or www.matrixfitness.com.
MAINTAIN ALL EQUIPMENT. Preventative maintenance is the key to smoothly operating equipment. Equipment needs to be inspected at regular intervals. Defective components must be kept out of use until they are repaired. Ensure that any person(s) making adjustments or performing maintenance or repair of any kind is qualified to do so. Matrix Fitness Systems will provide service and maintenance training at our corporate facility upon request or in the field if proper arrangements are made.
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CHAPTER 3: PREVENTATIVE MAINTENANCE
3.3 CARE AND MAINTENANCE INSTRUCTIONS
In order to maximize life span, and minimize down time, all MATRIX equipment requires regular cleaning, and maintenance items performed on a scheduled basis. This section contains detailed instructions on how to perform these items and the frequency of which they should be done. Some basic tools and supplies will be necessary to perform these tasks which include (but may not be limited to):
* Metric Allen wrenches * #2 Phillips head screwdriver * Adjustable wrench * Torque wrench (capability to read foot lbs and inch lbs) * Lint free cleaning cloths * Teflon based spray lubricant such as "Super Lube" or other Matrix approved products. * Mild water soluble detergent such as "Simple Green" or other Matrix approved products * Vacuum cleaner with an extendable hose and crevasse tool attachment.
You may periodically see addendums to this document, as the Matrix Technical Support Team identifies items that require specific attention, the latest version will always be available on the Matrix web site at www.matrixfitness.com.
DAILY MAINTENANCE ITEMS
1) Look and listen for loose fasteners, unusual noises, and any other indications that the equipment may be in need of service.
2) Clean the bike before and after each use, including: a. Use a damp, soft cloth with water or mild liquid detergent to clean all exposed surfaces. DO NOT use ammonia, chlorine, or any acid based cleaners. NOTE: Spray cleaner onto a cloth before using, never spray cleaner directly onto the equipment. b. Keep the console display free of fingerprints and salt build up caused by sweat.
3) Attempt to wobble the unit from side to side and front to back. Level if needed (see Section 10.5).
WEEKLY MAINTENANCE ITEMS
1) Frequently vacuum the floor beneath the unit to prevent the accumulation of dust and dirt which can affect the smooth operation of the unit.
2) Check the pedal straps for damage.
3) Clean the grooves on the foot pedals.
MONTHLY MAINTENANCE ITEMS
1) Inspect the console, seat, pedals, and shrouds for damage.
2) Tighten the pedals onto their respective cranks using a 15 mm wrench.
3) Adjust the leveling feet if equipment rocks or wobbles.
4) Check the seat for looseness. Tighten the seat rollers if needed.
YEARLY MAINTENANCE ITEMS
1) Remove the front shrouds and check the belt for damage, alignment, and proper tension.
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CHAPTER 4: CONSOLE OVERLAY AND WORKOUT DESCRIPTION
4.1 CONSOLE DESCRIPTION
WORKOUT KEYS: Simple program view and selection buttons.
GO: One touch Start.
UP / DOWN LEVEL: Easy information and level selection.
UP / DOWN TIME: Easy information and time adjustment.
STOP: Ends workout and shows workout summary data.
NUMBER KEYPAD: Workout data input for workout setup. Level adjustment during workout.
COOL DOWN: Puts bike into Cool Down mode.
FAN: Allows for fan speed selection (fan has 3 operating speeds).
TOGGLE DISPLAY: Allows user to select what information is displayed on the console.
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CHAPTER 4: CONSOLE OVERLAY AND WORKOUT DESCRIPTION
4.2 WORKOUT SETUP STEPS - MANUAL
GO - Press to immediately begin a workout. Workout, resistance
level, and time will automatically go to default settings. Pressing GO will not prompt user for age, weight, or level settings.
1) Start pedaling and press the GO key to begin your workout. 2) The display will read 3, 2, 1, Begin and then the program will start.
MANUAL - Manual allows the user to input more information
while defining their own workout. Calorie expenditure will be more accurate when inputting information in Manual than by pressing GO.
1) Start pedaling, press the MANUAL key.
2) Select Level by using the UP or DOWN LEVEL keys and press ENTER.
3) Select Time by using the UP or DOWN LEVEL keys and press ENTER.
4) Select Weight by using the UP or DOWN LEVEL keys and press ENTER.
5) The display will read 3, 2, 1, Begin and then the program will start.
4.3 WORKOUT SETUP STEPS - FAT BURN
FAT BURN - Fat burn is a level based program that is designed
to help users burn fat through various resistance level changes.
4.4 WORKOUT SETUP STEPS - LEVEL BASED
ROLLING HILLS - The Rolling Hills program is a level based
program that automatically adjusts the resistance level to simulate real terrain.
1) Start pedaling and press the ROLLING HILLS key.
2) Select Level by using the UP or DOWN LEVEL keys and press ENTER.
3) Select Time by using the UP or DOWN LEVEL keys and press ENTER.
4) Select Weight by using the UP or DOWN LEVEL keys and press ENTER.
5) The display will read 3, 2, 1, Begin and then the program will start.
INTERVAL TRAINING - The Interval Training program is a
level based program that automatically adjusts the resistance of the machine from low to high intensity settings at regular intervals.
1) Start pedaling and press the INTERVAL TRAINING key.
2) Select Level by using the UP or DOWN LEVEL keys and press ENTER.
3) Select Time by using the UP or DOWN LEVEL keys and press ENTER.
4) Select Weight by using the UP or DOWN LEVEL keys and press ENTER.
5) The display will read 3, 2, 1, Begin and then the program will start.
1) Start pedaling and press the FAT BURN key.
2) Select Level by using the UP or DOWN LEVEL keys and press ENTER.
3) Select Time by using the UP or DOWN LEVEL keys and press ENTER.
4) Select Weight by using the UP or DOWN LEVEL keys and press ENTER.
5) The display will read 3, 2, 1, Begin and then the program will start.
RANDOM - Random is a level based workout that randomly
adjusts the resistance of the machine.
1) Start pedaling and press the key next to RANDOM key.
2) Select Level by using the UP or DOWN LEVEL keys and press ENTER.
3) Select Time by using the UP or DOWN LEVEL keys and press ENTER.
4) Select Weight by using the UP or DOWN LEVEL keys and press ENTER.
5) The display will read 3, 2, 1, Begin and then the program will start.
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CHAPTER 4: CONSOLE OVERLAY AND WORKOUT DESCRIPTION
4.5 WORKOUT SETUP STEPS - FITNESS TEST
FITNESS TEST -The Cooper Fitness Test measures cardiovascular fitness and proves an estimated sub-maximal VO2 result. It is based
on power output according to ACSM standards and was developed by the Cooper Institute© (www.cooperinstitute.org). User RPMs must remain between 60-80 RPM during the test. The test will end when the user can no longer maintain this speed. Use of a heart rate strap is optional but provides more data.
The test starts at a low intensity level and gradually increases in intensity (difficulty) every 2 minutes. As it increases, the user must maintain 60-80 RPM to advance to the next level. The test could take upwards of 30+ minutes for very fit individuals. Once the test ends a recovery period (cool down) will begin and the user's results are calculated and displayed. Results are based on the number of stages completed. Incline will not be adjustable during the test.
1) Start pedaling and press the FITNESS TEST key.
2) Select Age by using the UP or DOWN LEVEL keys and press ENTER.
3) Select Gender by using the UP or DOWN LEVEL keys and press ENTER.
4) Select Weight by using the UP or DOWN LEVEL keys and press ENTER.
5) The display will read 3, 2, 1, Begin and then the program will start.
6) Once the workout is complete, the display will read the results of the Fitness Test.
STAGES COMPLETED:
1 Well Below Average 2 Well Below Average 3 Below Average 4 Below Average 5 Average 6 Average 7 Above Average 8 Above Average 9+ Well Above Average
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CHAPTER 4: CONSOLE OVERLAY AND WORKOUT DESCRIPTION
4.6 WORKOUT SETUP STEPS - TARGET HEART RATE
TARGET HEART RATE - The Matrix R5x-03 Bike comes with
standard digital contact heart rate sensors and are POLAR telemetry compatible. The heart rate control workout mode allows the user to program their desired heart rate zone, and the bike will automatically adjust the level based upon the user's heart rate. The heart rate zone is calculated using the following equation: (220-Age)8%=target heart rate zone. The user must wear a POLAR telemetric strap or continually hold onto the contact heart rate grips for this workout.
Locate the metal sensors on the handlebars of the bike. Notice that there are two separate pieces of metal on each grip. You must be making contact with both pieces of each grip to get an accurate heart rate reading. You can grab these sensors in any program to view your current heart rate.
1) Start pedaling and press the HEART RATE key.
2) Select Age by using the UP or DOWN LEVEL keys and press SELECT.
3) Select Target HR Percentage by using the UP or DOWN LEVEL keys and press SELECT.
4) Select Time by using the UP or DOWN LEVEL keys and press SELECT.
5) Select Weight by using the UP or DOWN LEVEL keys and press SELECT.
6) The display will read 3, 2, 1, Begin and the program will start.
4.7 WORKOUT SETUP STEPS - CONSTANT WATTS
CONSTANT WATTS - Constant Watts is a unique program
that allows you to vary your cadence or RPM and the bike's resistance level will adjust accordingly to your selected goal. The quicker you pedal, the less resistance for the goal selected.
1) Start pedaling and press the CONSTANT WATTS key.
2) Select Watts by using the UP or DOWN LEVEL keys and press SELECT.
3) Select Time by using the UP or DOWN LEVEL keys and press SELECT.
4) Select Weight by using the UP or DOWN LEVEL keys and press SELECT.
5) The display will read 3, 2, 1, Begin and the program will start.
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CHAPTER 5: MANAGER MODE
5.1 USING MANAGER MODE
The Manager's Custom Mode allows the club owner to customize the bike for the club.
1) To enter Manager Mode, press and hold down the UP and DOWN LEVEL keys. Continue to hold down these two keys until the display reads Manager Mode and hit ENTER (Figure A).
2) To scroll through the list of options in Manager Mode, use the UP and DOWN LEVEL keys. Each of the custom settings will show on the display.
3) To select a custom setting, press the ENTER key when the desired setting is shown.
4) To change the value of the setting, use the UP and DOWN LEVEL keys.
5) To confirm and save the value of the setting, press the ENTER key.
6) To exit the setting without saving, press the BACK key.
7) Press and hold the STOP key for 3-5 seconds to return to normal operation.
5.2 MANAGER MODE OVERVIEW
CUSTOM SETTING DEFAULT MINIMUM MAXIMUM DESCRIPTION
Maximum Time 60 min 10 min 95 min Sets the total run time of any program.
Default Time 30 min 10 min Maximum
Default Level 1 1 20 Starting resistance when GO is pressed or when no resistance is
Default Age 30 10 100 Starting age when GO is pressed or when no age is selected during
Default User Weight 150 lbs /
75 kg
Accumulated Distance N/A 0 99,999
Accumulated Time N/A 0 999,999
Software Version N/A N/A N/A Current version of console software.
Timer Mode Up Up Down Determines whether the timer counts up or down.
Speed / Distance Mode Mile Mile Kilometer Displays distance in miles or kilometers.
Out of Order No No Yes Locks the machine when out of order.
Gender Male Male Female Determines the gender of the user when not selected during program
Language English English English Sets the language for the console. Select between English, Spanish,
Sound Mode On On Off Turns the chime on / off when a button is pressed.
80 lbs / 36 kg400 lbs /
Time Setting
181 kg
Miles
hours
Workout time when GO is pressed or when no time is selected during program set up.
selected during program set up.
program set up.
Weight used for program calorie expenditure calculations.
Total distance for all programs.
Total time for all programs displayed in hours.
set up.
German, French, Italian, and Dutch.
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CHAPTER 6: ENGINEERING MODE
6.1 USING ENGINEERING MODE
To enter Engineering Mode, hold the LEVEL UP and DOWN keys for 3-5 seconds until Manager Mode appears on the middle LED display. Press the LEVEL UP or DOWN key to scroll to Engineering Mode. Press ENTER to go into Engineering Mode.
CODE DEFAULT OPTIONS DESCRIPTION
Disable Errors No Yes or No No - Shows A-C class error
Speed Units Mile Mile or Kilometer Set for Mile or Kilometer.
Machine Type R5x H5x, R5x, U5x, E5x-02 or E5x-03 Set the Recumbent bike as R5x.
Power Save Time 30 Seconds 30-60 Seconds Power saving time for the self
Pause Time 30 Seconds 15 - 120 Seconds For non self powered frames
Serial Number N/A N/A Serial Number input is available
Club ID N/A N/A This sets the club ID for clubs
Sleep Time Off Off or On (1-30 Minutes) If there is no use of the machine
Audio Source Off Off / TV / PC TV / Remote TV Manual setting that that sets
codes. Yes - Shows only C class error codes.
powered frame.
only. Not used on this model.
for both the Console and Frame. Use the number keys and UP / DOWN LEVEL keys to enter Engineering Mode. Due to the limited LED characters, 2 layers are used to enter the serial number. First Layer:
- PPPPP V
- PPPPP is the product name.
- V is the version. If the version is A, just leave this blank. Second Layer
- YY MM nnnnn.
- YY is the year (11, 12).
- MM is the month (e.g. 08, 09, 10).
- nnnnn is the actual serial number. Use the UP / DOWN LEVEL keys to navigate the layers and the number keys to input the serial number. The product name is dependent on the Machne Type setting. For example, the console is EP90 with ver. B and the manufactured date is 2011.08 with 98765. The frame is RB91 with ver. B and the manufactured date is 2011.06 with 12345. Their serial numbers are: Console SN: EP90B 1rst layer, 110898765 2nd layer. Frame SN: RB91B 1rst layer, 110612345 2nd layer.
using Asset Management.
over a period of time, the console LEDs will turn off (go into sleep mode).
which outside TV will have audio through the console audio ports.
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CHAPTER 7: SERVICE MODE
7.1 USING SERVICE MODE
To enter Service Mode, hold the LEVEL UP and DOWN keys for 3-5 seconds until Manager Mode appears on the middle LED display. Press the LEVEL UP or DOWN key to scroll to Service Mode. Press ENTER to go into Service Mode.
CODE DEFAULT OPTIONS DESCRIPTION
Service 1 Display Test Press the ENTER key repeatedly
Service 2 Keypad Test Press any key and the display
Service 3 Distance / Time Distance:
Mile 0 - 99999 Kilometer 0 - 160898 Time: 0 - 999999
Service 4 CSafe / RF Test Press the ENTER key to test
Service 5 Error Log Shows the last 10 errors. Press
Service 6 Set Date / Time Press the LEVEL keys to move
Service 7 Export and Import Parameter Export Parameter - Export all
Service 8 WiFi Function Automatically detects the
to check each set of LEDs on the display sequentially.
should show the corresponding message.
Manually sets the Accumulated Distance and Time.
CSAFE. Press the ENTER key again to test the RF.
and LEVEL UP and DOWN for 3 seconds to clear the errors.
cursor, the number keys to set date / time, and the ENTER key to save.
parameters to a USB device. Import Parameter 1 - Imports the engineer parameters to a USB device except serial number, accumulated distance and time. Import Parameter 2 - Imports the engineer parameters to a USB device.
available IP address and displays it.
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8.1 ELECTRICAL DIAGRAMS
CHAPTER 8: TROUBLESHOOTING
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CHAPTER 8: TROUBLESHOOTING
8.2 ERROR CODES ON THE CONSOLE
CODE CLASS DESCRIPTION SOLUTION
0x02AB C Machine type error. Set the correct machine type in
0x02B3 C Resistance type error. Set the correct machine type in
0x0201 A Low voltage on the battery
(voltage under 11.2V).
0x0247 B LCB failed (memory write error /
feedback ADC error).
0x0248 B Battery failure or disconnection
(Voltage under 8V or over 15V).
0x0441 B When the UCB implements
a command, the LCB is not receiving this command.
0x04A0 C Digital Communication Failure.
LCB has no return message for the UCB for 3 seconds.
0x04B0 C UCB No Response. Check the console cable
Engineering Mode.
Engineering Mode.
Charge by running or by plugging in the AC adapter.
Replace the LCB.
Check the wire connections at the battery. Replace the battery.
Check the machine type in Engineering Mode. Check the connections at the UCB and LCB.
Check the console cable connections at the UCB and LCB. Replace the UCB or LCB as needed.
connections at the UCB and LCB. Replace the UCB or LCB as needed.
CLASS C ERRORS WILL DISPLAY ON THE CONSOLE.
CLASS A OR B ERRORS WILL ONLY DISPLAY IN SERVICE MODE 5.
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CHAPTER 8: TROUBLESHOOTING
8.3 LCB LED INSTRUCTIONS
LED INDICATOR DESCRIPTION
LED 1 RPM (AC Plug In).
LED 2 +5V
LED 3 +15V
LED 4 Bus Voltage
LED 5 RPM (Generator).
LED 6 Status 1 (Program operation).
LED 7 Status 2 (Resistance value in middle 1/2 VCC).
LED 8 Status 3 (Digital Communication).
LED 9 +12V (Console Power).
WITHOUT AC PLUG - NORMAL
LED 2 - LED 9 - On. LED 1 - Off (No AC plug detected). LED 5 - On (Generator power detected),
WITH AC PLUG - NORMAL
LED 2 - LED 9 - On. LED 1 - On (AC plug detected). LED 5 - Off (No Generator power detected).
LED 1
LED 5
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CHAPTER 8: TROUBLESHOOTING
8.4 TROUBLESHOOTING - DISPLAY ISSUES
NO DISPLAY ON THE CONSOLE OR THE DISPLAY IS DIM WHEN RUNNING
LED 1
LED 9
LED 5
LED 8
SYMPTOM: The console will not power up or the display is dim.
CHECK POINT POSSIBLE ISSUE SOLUTION
LEDs 2, 3, 4, 6, and 7 should be ON. If they are OFF, the LCB is damaged. Replace the LCB.
If LED1 is OFF. No AC power cord plugged in. Normal for an unpowered unit.
If LED 5 is OFF. Generator has no RPM output. Normal for a powered unit. If unpowered and
If LED 8 is OFF. Bad communication between UCB and LCB. Reconnect the console cable at the LCB and
If LED 9 is OFF. LCB is not providing 12V power to the UCB. Replace the LCB.
issue is still present, replace the generator.
UCB and check for kinks.
SOLUTION IF LEDS ARE NORMAL:
1) If the LEDs are lit normally, replace the UCB and console cable.
2) if the issue is still present after the UCB and console cable are replaced, replace the LCB.
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CHAPTER 8: TROUBLESHOOTING
8.5 TROUBLESHOOTING - ERROR 0x04A0
ERROR 0x04A0 (DIGITAL COMMUNICATION FAILURE)
LED 1
LED 8
SYMPTOM: Error code 0x04A0 is displayed on the console.
CHECK POINT POSSIBLE ISSUE SOLUTION
LEDs 2, 3, 4, 6, and 7 should be ON. If they are OFF, the LCB is damaged. Replace the LCB.
If LED1 is OFF. No AC power cord plugged in. Normal for an unpowered unit.
If LED 8 is OFF. Bad communication between UCB and LCB. Reconnect the console cable at the LCB and
UCB and check for kinks.
SOLUTION IF LEDS ARE NORMAL:
1) If the LEDs are lit normally, replace the UCB and console cable.
2) if the issue is still present after the UCB and console cable are replaced, replace the LCB.
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CHAPTER 8: TROUBLESHOOTING
8.6 TROUBLESHOOTING - KEYPAD ISSUES
ALL OR SOME OF THE FUNCTION KEYS DO NOT RESPOND
POSSIBLE CAUSES:
1) The keypad connection ribbon cable has not been plugged in correctly.
2) The keypad is damaged.
3) The UCB is damaged.
SOLUTION:
1) Perform a keypad test in Service Mode: a. Press and hold both the UP and DOWN LEVEL keys until Manager Mode appears on the display. b. Use the UP and DOWN LEVEL keys to scroll to Service Mode 5 and press ENTER. c. Test the affected keypad. If the keypad works in the keypad test it may not be a functioning key in the program used for testing it.
2) Check the connections of the keypad at the UCB. a. Remove the console from the console mast. b. Remove the 6 screws holding the back of the console to the front (Figure A). c. Inspect the keypad ribbon cable connection at the UCB (Figure B). d. Even if the keypad ribbon cable appears to be connected correctly, unplug and re-seat the cable.
3) Replace the affected keypad.
4) Replace the UCB.
FIGURE A FIGURE B
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