Dyaco 1612735, Service Manual

Page 1: ...1 16 61 12 27 73 35 5 T Tr re ea ad dm mi il ll l S Se er rv vi ic ce e M Ma an nu ua al l M Ma au ur ri ic ce e P Pi in nc co of ff fs s 1 1 8 88 88 8 7 70 07 7 1 18 88 80 0 ...

Page 2: ...WARNING ALWAYS UNPLUG THE TREADMILL FROM THE ELECTRICAL OUTLET BEFORE SERVICING THE UNIT ...

Page 3: ...ription 4 A ELECTRICAL CONFIGURATION 4 1 1612735 Treadmill components 4 B GENERAL INFORMATION 5 1 Console 5 2 Main controller 5 3 Treadmill motor 5 4 incline motor 5 Operation 7 A WINDOW DISPLAY MODE 7 1 OFF Mode 7 2 READY Mode 7 3 SLEEP Mode 7 4 RUN Mode 7 B FUNCTION 8 1 SPEED 8 2 TIME 8 3 DISTANCE 8 4 CALORIES 9 5 INCLINE 9 6 PULSE 10 C FUNCTION BUTTON IN MAIN MODE 11 1 READY MODE 11 2 SLEEP MOD...

Page 4: ...8 7 70 07 7 1 18 88 80 0 T Ta ab bl le e o of f C Co on nt te en nt ts s 2 2 1 General 16 2 Troubleshooting Matrix 17 3 controller debugging form 25 Diagrams and Schematics 26 APPENDIX A 30 1 TREADBELT ADJUSTMENT 30 APPENDIX B 32 1 TREADMILL LUBRICATION 32 APPENDIX C 33 1 RESET SWITCH RESETTING 33 APPENDIX D 34 1 FUSE REPLACEMENT 34 APPENDIX E 35 1 SPEED SENSOR ADJUSTMENT 35 2 SERVICE QUESTIONS 35...

Page 5: ...TABLE OF FIGURES Figure 1 Operational Flowchart 6 Figure 2 Console Layout 26 Figure 3 Mechanical Layout 26 Figure 4 Main Controller information voltages 27 Figure 5 Function JK1 connector on Main Controller 27 Figure 6 Wiring Diagram 28 Figure 7 Schematic Diagram 29 Figure 8 If Treadbelt slips 30 Figure 9 If tread belt shifts too far to the Right 30 Figure 10 If tread belt shifts too far to the Le...

Page 6: ...ard level replacement 1 1612735 TREADMILL COMPONENTS a Safety key Magnetic key that fits in the Console to activate all functions b Console Interface that controls all functions of the treadmill c Main controller A circuit board that incorporates the DC power supply and takes input from the console and sends out appropriate voltages that control the treadmill functions d Treadmill motor A variable...

Page 7: ...s three wires red black and green c If there is DC voltage on the Red wire M the treadmill motor will turn clockwise d If there is DC voltage on the Black wire M the treadmill motor will turn counter clockwise e The higher the voltage the faster the motor turns f The green wire is ground 4 INCLINE MOTOR a Reversing 110 V AC motor b Have four wires red black white and green c Has one 3PIN cable of ...

Page 8: ... l 1 16 61 12 27 73 35 5 T Tr re ea ad dm mi il ll l M Ma au ur ri ic ce e P Pi in nc co of ff fs s D De es sc cr ri ip pt ti io on n 1 1 8 88 88 8 7 70 07 7 1 18 88 80 0 D De es sc cr ri ip pt ti io on n 6 6 Figure 1 Operational Flowchart ...

Page 9: ...N and the SAFETY KEY is inserted in console TIME window display 0 00 CALORIES window display 0 0 DISTANCE window display 0 00 INCLINE window display current incline position MANUAL light will flash and the PROGRAM light will go off b TIME DISTANCE and CALORIES Values will all be saved when RUN Mode enters READY Mode c In READY Mode if user doesn t press any button for 4 minutes it will then enter ...

Page 10: ...just speed each increment and decrement is 0 1MPH KPM 2 TIME a TIME and INCLINE value display in same window and pressing MODE button will toggle between them b TIME is either COUNT UP or COUNT DOWN System preset is COUNT UP if user sets the time then timer is COUNT DOWN c DISPLAY range is 0 00 to 99 59 d WORK range is 0 00 to 99 59 e COUNT DOWN setup range is 10 00 to 99 00 f When TIME is set the...

Page 11: ...nd save all data If RUN Mode is entered the distance will count up again 4 CALORIES a CALORIES and PULSE value display in same window and pressing MODE button will toggle between them b CALORIES divides into COUNT UP and COUNT DOWN System preset is COUNT UP if user sets the time then timer is COUNT DOWN c DISPLAY range is 0 00 to 999 9 d WORK range is 0 00 to 999 9 e COUNT DOWN setup range is 1 0 ...

Page 12: ... Op pe er ra at ti io on n 1 1 8 88 88 8 7 70 07 7 1 18 88 80 0 O Op pe er ra at ti io on n 1 10 0 6 PULSE a PULSE and CALORIES value display in same window and pressing MODE button will toggle between them b DISPLAY range is 0 to 999 c WORK range is 40 to 240 d If the treadmill doesn t have a signal for 8 seconds then value will become P ...

Page 13: ...ANCE and CALORIES that can press FAST or SLOW to set count down If MODE button is pressed for 2 seconds the treadmill will clear all value to zero e FAST button If user doesn t enter a setting then this button is non functional f SLOW button If user doesn t enter a setting then this button is non functional g UP button If user doesn t enter a setting then this button is non functional h DOWN butto...

Page 14: ...on non functional f SLOW button non functional g UP button non functional h DOWN button non functional i LOW SPEED 3 mph 4 km button non functional j MIDDLE SPEED 5 mph 7 km button non functional k HIGH SPEED 7 mph 10 km button non functional 3 RUN MODE a PROGRAM button non functional b START button non functional c STOP button press STOP button to stop and enter READY Mode d MODE button press MOD...

Page 15: ... SPEED quickly g SLOW button Press the button to decrease your speed and each decrease is 0 1mph km If button is pressed continuously then speed decreases to MIN SPEED quickly h UP button Press the button to raise position and each increase is 1 the MAX INCLINE position is 10 i DOWN button Press the button to raise position and each increase is 1 the MIN INCLINE position is 0 j LOW SPEED 3 mph 4 k...

Page 16: ...FAST or SLOW button to adjust maximum speed value to 10 0 mph in SPEED window g Set WHEEL size Press UP or DOWN button to adjust wheel size value to 2 30 in SPEED window h Press START button to memorize above setting and enter next section of setting mode i Set Max INCLINE position Press UP or DOWN button to adjust maximum incline value to 10 in PULSE INCLINE window j Press START button to memoriz...

Page 17: ... Power on treadmill b Press START and SLOW button at the same time c Insert SAFETY KEY the window display all data for 1second then enter section 1 of surveying mode d PULSE INCLINE window displays INCLINE MAX value SPEED window displays WHEEL SIZE value e Press any button to enter next section f PULSE INCLINE window displays SPEED MAX value SPEED window displays SPEED MIN value g Press any button...

Page 18: ... 0 T Tr ro ou ub bl le es sh ho oo ot ti in ng g 1 16 6 TROUBLESHOOTING WARNING ALWAYS UNPLUG THE TREADMILL FROM THE ELECTRICAL OUTLET BEFORE SERVICING THE UNIT 1 GENERAL a Do a visual check of all wiring and connections looking for chafed wires or lose connections b Make sure any wiring is safely positioned and or secured away from moving parts c If you find a fuse blown on a circuit board replac...

Page 19: ... Breaker is broken 9 A C switch is broken 1 Plug the power cord into outlet 2 Plug the power cord into unit 3 Check the voltage of outlet 4 Replace with new power cord 5 Replace with new power cord 6 Check if wire is disconnected connect it again 7 Press the small red button to return to original status 8 Replace with new breaker 9 Replace with new A C switch After turning on power treadmill has a...

Page 20: ...lace with new console With no safe key but treadmill could display or operate 1 Reed switch of console is broken Short 2 Have other magnetic components on console 1 Replace with new reed switch or console 2 Remove magnetic component beside safe key When press START treadmill doesn t start 1 Motor M or M wire isn t connected into right position 2 Controller is broken No power to motor 3 Motor is br...

Page 21: ...t displays are broken 1 Replace with new console and calibrate it When press START button to start treadmill running belt isn t running and window displays LS error message after 8 seconds 1 Controller experienced unusual shut down the S_D light will be always bright Controller debugging form 2 Motor wires red black aren t plugged into controller 3 Computer cables not connected properly 4 Computer...

Page 22: ...cable is broken 7 Console is broken speed sensor and magnet 2 Replace with new magnet 3 Use metal material to test the magnet 4 Replace with new sensor cable 5 Plug the cable again on controller connector and console 6 Gray and purple cable got damage replace with new cable 7 Replace with new console SPEED windows display is not 1 0 to 10 0 mile Monitor is not calibrated Calibrate the monitor INCL...

Page 23: ...2 Other magnetic field disturbance 3 Receiver is broken 1 Check for other chest belt use around treadmill 2 Change the position or direction of treadmill 3 Replace with new receiver After pressing START button the treadmill stop immediately Controller was broken Replace with new controller and calibrate it FAST SLOW button of SPEED ADJUSTMENT SWITCH can t be used 1 The connector of SPEED CABLE UPP...

Page 24: ... new cable 6 Replace with new cable UP DOWN button of INCLINE ADJUSTMENT SWITCH can t be used Incline button just can press UP can t press DOWN Incline button just can 1 The connector of INCLINE CABLE UPPER and CONSOLE not connected properly 2 The connector of INCLINE CABLE UPPER and INCLINE ADJUSTMENT SWITCH W CABLE not connected properly 3 The connector of INCLINE CABLE UPPER or INCLINE ADJUSTME...

Page 25: ...the hand pulse 2 Connect the cable again 3 Replace with new cable 4 Replace console or Hand pulse board Wireless lost its function No pulse displayed on monitor 1 Chest belt not worn properly 2 Distance is too far and exceeds range of receiver 3 Chest belt battery is weak or dead 1 Check chest belt has proper contact with skin and is oriented correctly 2 User chest belt in front of console within ...

Page 26: ...rticles collecting under treadmill Drive belt is breaking in Vacuum under treadmill periodically Noise under motor cover 1 Worn brushes or bearings on motor 2 Front roller bearings are defective 3 Drive belt is misadjusted too tight or too loose 1 Replace with new motor 2 Replace with new front roller 3 Adjust motor position Noise in the rear of the treadmill 1 Rear roller bearings are defective 2...

Page 27: ...ontroller LIMIT Limit the current of DC motor When current of motor exceed 30A the LED will turn on If LIMIT light is bright for 3 to 5 seconds the S_D light will turn on Loading is too high on belt Operation is not correct motor lock Check mechanical drive system is not locked or jammed Replace controller Replace motor S_D Controller shut down If controller has unusual shut down the S_D light wil...

Page 28: ...Ma au ur ri ic ce e P Pi in nc co of ff fs s D Di ia ag gr ra am ms s a an nd d S Sc ch he em ma at ti ic cs s 1 1 8 88 88 8 7 70 07 7 1 18 88 80 0 D Di ia ag gr ra am ms s a an nd d S Sc ch he em ma at ti ic cs s 2 26 6 DIAGRAMS AND SCHEMATICS Figure 2 Console Layout Figure 3 Mechanical Layout ...

Page 29: ... ic ce e P Pi in nc co of ff fs s D Di ia ag gr ra am ms s a an nd d S Sc ch he em ma at ti ic cs s 1 1 8 88 88 8 7 70 07 7 1 18 88 80 0 D Di ia ag gr ra am ms s a an nd d S Sc ch he em ma at ti ic cs s 2 27 7 Figure 4 Main Controller information voltages Figure 5 Function JK2 connector on Main Controller ...

Page 30: ...tch Red Wire Motor Black Wire Controller Green Wire JK1 10CM Black Wire 12PIN 700mm Upper Connection Core 12PIN 2300mm Bottom Connection S 100mm Green Wire Green with yellow CONNECTOR CONNECTOR PLUG 250 mm Black Wire AC2 0 120V JK2 JK3 Incli DOWN COM 0 UP 0 12 M 0 110V AC1 0 120V 1 2 3 JK3 ensor Wire 1000mm Green Wire Incline Motor Incline VR White Wire Black Wire Red Wire ne VR 0 120V 120V 0V VR2...

Page 31: ...e ea ad dm mi il ll l M Ma au ur ri ic ce e P Pi in nc co of ff fs s D Di ia ag gr ra am ms s a an nd d S Sc ch he em ma at ti ic cs s 1 1 8 88 88 8 7 70 07 7 1 18 88 80 0 D Di ia ag gr ra am ms s a an nd d S Sc ch he em ma at ti ic cs s 2 29 9 Figure 7 Schematic Diagram ...

Page 32: ...usted however if during the operation 1 4 TURN Figure 8 If Treadbelt slips The treadbelt is too loose Tighten both rear roller adjusting bolts 1 4 turn clockwise using allen wrench 1 4 TURN Figure 9 If tread belt shifts too far to the Right a Set the treadmill speed to 3 5 mph 5 6 km b Tighten the right adjusting bolt a 1 4 turn clockwise using allen wrench c Wait 15 seconds if no change turn the ...

Page 33: ...elt shifts too far to the Left a Set the treadmill speed to 3 5 mph 5 6 km b Tighten the left adjusting bolt a 1 4 turn clockwise using allen wrench c Wait 15 seconds if no change turn the right adjusting bolt a 1 4 turn counter clockwise using allen wrench e Repeat steps b and c until belt is centered IMPORTANT DO NOT OVERTIGHTEN TREADBELT If treadbelt is overtightened edges of treadbelt will beg...

Page 34: ...f the surface is slick to the touch then no further lubrication is required If the surface is dry to the touch apply one packet of lubricant HOW TO APPLY LUBRICANT 1 Lift one side of treadbelt 2 Pour one half of the lubricant bottle under the center of the treadbelt on the top surface of the treadboard 3 Walk on the treadmill at a slow speed for 3 to 5 minutes to evenly distribute lubricant NOTE D...

Page 35: ...C C 1 1 8 88 88 8 7 70 07 7 1 18 88 80 0 APPENDIX C Tripped Normal Figure 11 Resetting Reset switch 1 RESET SWITCH RESETTING a If the red button of reset switch is tripped it will protrude out from the face of the switch b Press in the red button of the switch c If the red button of reset switch is not tripped that means normal A AP PP PE EN ND DI IX X C C 3 33 3 ...

Page 36: ...18 88 80 0 APPENDIX D Figure 12 Fuse replacement 1 FUSE REPLACEMENT If your treadmill loses power or will not start check the fuse located on the motor controller DANGER Turn the power switch off and unplug the treadmill to reduce the risk of an electric shock Remove the motor cover Remove and replace the fuse on the motor controller Replace the motor cover A AP PP PE EN ND DI IX X D D 3 34 4 ...

Page 37: ... 3 35 5 If the monitor does not display speed or distance the speed sensor and magnet may be misaligned Follow these steps to check and realign Remove the motor cover Check the spacing and alignment between the magnet on the right side of the front roller and the speed sensor on the frame The spacing must be 1 8 Loosened screw and slide speed sensor in or out of clamp Retighten screw Replace the m...