Dyaco Canada XE528s, Service Manual

Page 1: ...er R Round Disk Cover Console Right Pedal Rear Console Cover Chain Cover R Front Handlebar Cover L Console Mast Cover Pedal Arm Cover L Rear stabilizer Cover A Connecting Arm Cover B L Slide Wheel Cover Rear Stabilizer Cover B Connecting Arm Cover A L Left Pedal Front Stabilizer Cover Chain Cover L ...

Page 2: ...ton Cross Bar Adjustable Pedal L Bushing Housing Connecting Arm R Console Mast Adjustable Pedal R Handlebar R Main Frame Rail Assembly Fly Wheel Pedal Arm L Pedal Arm R Drive Pulley Connecting Arm L Slide Wheel ...

Page 3: ...ss Bar 6 The Belt 7 Idler wheel Assembly 8 Fly Wheel 9 Drive Pulley 10 Bushing Housing 11 Slide Wheels II Troubleshooting 1 Console 2 Chain Covers and Round Disk Covers 3 Fly Wheel 4 The Belt 5 Handlebars 6 Bushing Housing 7 Pedal Arm Connecting arm and Slide Wheels III Q A 1 Noises 2 Slippage 3 Wobble 4 Smoothness 5 Others ...

Page 4: ... to take apart both Front and Rear Console Covers Then release 4pcs of M5 x 10 mm screws which secure the Console Disconnect computer cables and handpulse cables to take apart the Console as shown in figures 1 2 3 and 4 2 To resume connect the computer cables and handpulse cables and secure the Console with 4pcs of M5 x 10 mm screws Return both Cron and Rear Console Covers 1 2 3 4 ...

Page 5: ...ease 5 16 x1 1 4 hex head bolt together with 5 16 x 20 x 1 5T flat washer and 5 16 x 7T nut as shown in figure 3 3 Use 12 mm wrench to release 5 16 x 15m m hex head bolt with 5 16 x 20 x1 5T flat washer which secure the Connecting Arm then take off carriage bolt to release the Connecting Arm as shown in figure 4 4 Use C ring pliers to release ψ10 C ring in order to take off Adjustable Pedal as sho...

Page 6: ...illips head screwdriver to release 4pcs of M5x10mm screws to take off the Locking Pin Holder as shown in figure 7 3 To resume install the Locking Pin Holder with arrowhead pointing the Pedal on the Adjustable Pedal and secure with 4pcs of M5 x10m m screws as shown in figure 8 4 Secure the Pedal on the Adjustable Pedal with 4pcs of M5 x 10m m screws together with the spring as shown in figure 9 5 6...

Page 7: ...return the C ring by using C ring pliers as shown in figure 10 6 Return the Connecting Arm with Adjustable Pedal back to Pedal Arm and insert the carriage bolt and secure with 5 16 x 15m m hex head bolt and 5 16 x 23 x 1 5T flat washer and fasten the other end of the spring on the Locking Pin Holder as shown in figures 11 and 12 7 Return Connecting Arm Covers A and B with Phillips head screwdriver...

Page 8: ...re 1 3 Use M6 and 13 mm wrenches to release M8 x 50 socket head cap screw 2pcs of 5 16 20 1 5T flat washer and M8 x 7T nut and pull Pedal Arm backward to take it off as shown in figures 2 and 3 4 To resume join the Pedal Arm with Bushing Housing and secure with socket head cap screw 2pcs of 5 16 20 1 5T flat washer and M8 x7T nut Return Pedal Arm Cover 5 Follow procedure 2 5 to return Connecting A...

Page 9: ...ain Covers as shown in figure 1 3 Use Phillips head screwdriver to release 7pcs of 4x19 self tapping screws and 3pcs of 5x16 tapping screws which secure Right Chain Cover as shown in figure 2 and 3 4 To take apart left Chain Cover release 4x15 self tapping screw on the main frame and 1 4 x19 flat washer together with 3pcs of 5x16 tapping screws and disconnect DC cables as shown in figures 4 5 and ...

Page 10: ...ping screw together with a 1 4 x19 flat washer to hold not too tight temporarily Left Chain Cover on the Main Frame then tighten with 3pcs of 5x16 tapping screws be sure the Chain Cover matches with Round Dick Cover Crank Now tighten 4x15 self tapping screw as shown in figures 7 and 8 7 Match Right and Left Chain Covers and use 7pcs of 4x19 self tapping screws and 3pcs of 5x16 tapping screws to se...

Page 11: ... in figure 1 3 Use 12 mm wrench to release 5 16 x 15m m hex head bolt with 5 16 x 35 x 1 5T flat washer then use M6 wrench to release M8x30 socket head cap screw and take off Cross Bar with Round Disk Cover Crank as shown in figures 2 and 3 4 Separate the Cross Bar apart from Round Disk Cover Crank by using Phillips head screwdriver to release 8pcs of 5x16 tapping screws and 1 4 x19 flat washers a...

Page 12: ...ss Bar and return and align it on the Crank Axle Return 7x7x25L Woodruff Key in the hole Tighten M8x30 socket head cap screw until it reads 600 Kg cm Return 5 16 x 15m m hex head bolt and 5 16 x 35 x 1 5T flat washer as shown in figures 5 and 6 5 Follow procedures 4 3 and 2 to resume Connecting Arm Pedal Arm and Round Disk Cover 5 6 ...

Page 13: ...s Bar Assembly 2 Use 13 mm wrench to loosen M8 x 7T nuts on M8x170mm J bolt and on Idler wheel Assembly The Belt can thus be released as shown in figures 1 2 and 3 3 To resume return the Belt onto the Drive Pulley and Fly wheel and tighten M8 x 7T nuts until the belt tension reads 170 Hz 10 Hz as shown in figure 4 4 Follow Procedures 5 4 3 and 2 to return other parts 1 2 3 4 ...

Page 14: ...on M8x170mm J bolt until J bolt is off Use the same wrench to release M8 x 20 carriage bolt 5 16 x 20 x 1 5T flat washer and M8 x 7T nut and take off Idler Wheel Assembly as shown in figures 1 and 2 3 To resume return Idler wheel Assembly and hold with M8x20 carriage bolt 5 16 x 20 x 1 5T flat washer and M8 x7T nut to be tighten after the belt tension being adjusted and return and tighten the J bo...

Page 15: ...Both Chain Covers Cross Bar Assembly the Belt and Idler Wheel Assembly 2 Turn on the power and set the resistance at level 20 Release the cable as shown in figure 1 3 Use 15 mm wrench to loosen 3 8 UNF26 x 9T nuts which secure the Fly Wheel at each side and pull out the Fly Wheel from the Main Frame Take off the Belt as shown in figures 2 3 and 4 1 2 3 4 ...

Page 16: ... 8 UNF26 x 9T nuts at each side 5 Return the Cable 45 degree onto the Fly Wheel and resume the Idler Wheel Assembly as shown in figure 5 6 Turn the Drive Pulley and make sure the Belt stays on the Pulley by adjusting 3 8 UNF26 x 4T nuts Tighten all screws when the Belt stays in the middle on the Drive Pulley Adjust the Belt for proper tension as shown in figure 6 7 Follow procedures 7 6 5 4 3 and ...

Page 17: ...nk Axle and Drive Pulley Use rubber hammer if necessary as shown in figures 1 and 2 3 To separate Drive Pulley from Crank Axle Use C ring pliers to release ψ 25 C ring on the Crank Axle and use 11 mm wrench to release 4pcs of 1 4 x 3 4 hex head bolts and 1 4 nuts as shown in figure 3 4 To resume return Drive Pulley and one C ring onto the Crank Axle Return both C rings after the returning the Cran...

Page 18: ...head bolt and 5 16 x 35 x 1 5T flat washer and take off Bushing Housing as shown in figure 1 3 To resume be sure to put ψ25 wave washer on the shaft and apply some lubricant prior to returning Bushing Housing onto the shaft Return and tighten 5 16 x15m m hex head bolt and 5 16 x 35 x 1 5T flat washer as shown in figures 2 and 3 4 Follow procedures 3 4 and 2 5 to resume Pedal Arm and Connecting Arm...

Page 19: ...f Slide Wheel Cover as shown in figure 1 3 Use C ring pliers to take off ψ17 C ring and release Slide Wheel as shown in figure 2 4 To resume return ψ17 wave washer Slide Wheel and ψ17 wave washer in sequence onto the shaft and use C ring to secure the Slide Wheel Finally return the Slide Wheel Cover as shown in figure 3 5 Follow procedures 3 4 and 2 5 to resume Pedal Arm and Connecting Arm 1 2 3 ...

Page 20: ...continuity of the cables Make sure there is no damages with cables as shown in figure 1 3 Make sure all wires including computer cables and which are in the Console are connected properly Disassembling the Console and check cables inside if necessary 4 If cables are all connected properly check for any damages for cables or malfunction of the Console or the Gear Motor as shown in figure 2 1 2 ...

Page 21: ...y which causes rubbing noises then taking apart of both Chain covers is necessary Refer to procedure 4 3 If the Drive Pulley swings and causes rubbing noises then take apart both Chain covers and Crank Round Disk and use Phillips head screwdriver to release 16pcs of 5x16m m tapping screws with 1 4 x19m m flat washers which are on the Crank Round Disk Check the Crank Round Disk on the level for war...

Page 22: ... is not adjusted correctly or not assembled properly that causes shifting Follow the procedures to release the Flywheel and cable to make adjustment as shown in figure 1 2 If the Flywheel is making noises check if noises are due to foreign materials or rubbing If adjustment is impossible replace the Flywheel with a new one as shown in figure 2 1 2 ...

Page 23: ...ive Pulley and Flywheel Then revolve the Drive Pulley with speed between 100 and 120 RPM and stop abruptly to see if there is anything abnormal Resume the unit if there is nothing wrong as shown in figure 1 2 If there is misalignment adjust the Flywheel to a proper position which had been done prior to shipping as shown in figure 2 3 If the Belt slips adjust the nut on J bolt with 13 mm wrench as ...

Page 24: ...for moving smoothly of the Handlebar so that a small amount of play is normal However as time lasts there might be noises which are caused by parts wearing out Applying some grease on ψ25x 296L shaft on the mast as shown in figure 1 might resolve the problem 2 If the bearing makes noise or gets stuck replace this 6005 as shown in figures 2 and 3 1 2 3 ...

Page 25: ...ing Housing is rare However a few units might have noise problem as time lasts Applying some grease on ψ25 x 111 5 L shaft on Cross Bar Assembly as shown in figure 1 may be helpful for solving this problem 2 If the Copper Bushing has been worn out replace it with a new one as shown in figure 2 1 2 ...

Page 26: ...a lot It is very important to lubricate each moving parts and joints as shown in figures 1 and 2 2 There are many factors which affect the feeling of smoothness The most important key point is to make sure that sliding wheels move parallel and smoothly on the rails In brief Pedal Arm should keep parallel with Connecting Arm and both Pedal Arm and mainframe keep perpendicular to the bushings 1 2 ...

Page 27: ...v Procedures 1 Both Handlebars should connect properly with their corresponding connecting Arm and Sliding wheels should have real circle without slippage 2 During maintenance start from sliding wheels by applying lubricant on wheels or replace if necessary as shown in figures 3 and 4 3 4 ...

Page 28: ... Chain Cover rubbing Crank Round Disk Cover Bushing Housing and Cross Bar Belt and Drive Pulley Idler Wheel Assembly Handlebar and Mast shaft Flywheel and Cable to Sliding Wheels and Rail Assembly even Pedals etc Insufficient lubrication smoothness or loose screws are major causes as shown in figure 1 1 ...

Page 29: ...ndicular to the bolt as shown in figure 1 3 Bushing Housing M8 x 50m m socket head cap screw must be firmly tightened with M8 x 7T nut 4 Cross Bar M8x30m msocket head cap screw on the Cross Bar must be firmly tight 5 The Belt Belt slipping is quite usual because the belt gets less tensioned as time lasts Time duration and user weight are major factors Follow procedure 6 to adjust the belt tension ...

Page 30: ...hten all screws and check for installation faults or worn out of parts when time lasts Like a wobble pedal is usually caused by carriage bolt not installed properly If the unit wobbles adjust the screws for footpad beneath Front Stabilizer as shown in figures 1 and 2 Be sure to apply some lubricant after replacing the parts 1 2 ...

Page 31: ...ess Rev Procedures 1 Check tightness of screws and bolts if the unit clicks 2 Otherwise there might be foreign materials on either the rail or Slide Wheel Use rubbing alcohol to wipe and apply some lubricant both parts as shown in figure 1 1 ...

Page 32: ...Model XE528s Work Q A Problem 5 Other Problems Rev Procedure 1 Contact DYACO for problems not covered in this service manual Any problem solving on the unit is backed up by DYACO technical team ...