Dyaco XE515SD-YE005, Service Manual

Page 1: ...XE515SD YE005 Elliptical Service Manual ...

Page 2: ...oller Indicator LED Debugging 6 9 Driver Board Function 6 10 Tension Motor Connector Definition Function 7 Product Safety Instructions 7 1 Important Safety Instructions 7 2 Important Electrical Instructions 7 3 Important Grounding Instructions 8 Elliptical Error Messages and Troubleshooting for electronic Issues 8 1 Error Message E1 8 2 Error Message E2 8 3 Error Message INCLINE E3 8 4 Circuit Dia...

Page 3: ...bling and Assembling of Parts 11 1 Console Replacement 11 2 Swing Arm Replacement 11 3 Connecting Arm Replacement 11 4 Pedal Arm Replacement 11 5 Console Mast Replacement 11 6 Side Case Replacement 11 7 Cross Bar Replacement 11 8 Idler Wheel Replacement 11 9 Flywheel Poly V Belt Replacement 11 10 Rear Frame Replacement 11 11 Rail Incline Motor Replacement ...

Page 4: ...1 Elliptical Outlines ...

Page 5: ... cover 1 Rear cover 2 Middle cover Pedal R Slide wheel cover R Bottom cover Pedal arm cover R Round disk cover Round disk Right side case Swing Arm Bushing Console Swing Arm Bushing Left side case Console mast cover Pedal L Front back handlebar cover L ...

Page 6: ...rts Main frame Flywheel Bushing Housing Pedal Arm Cross Bar Pedal arm R Drive Pulley Incline motor Rail assembly Connecting arm L Pedal arm L Connecting arm R Lower Swing arm L upper Swing arm L upper Swing arm R Console mast Lower Swing arm R Rear frame ...

Page 7: ...2 Electronic Parts ...

Page 8: ...S Se er rv vi ic ce e M Ma an nu ua al l 2 1 Upper Controllers DISPLAY Cooling FAN THUMB SWITCH Speaker ...

Page 9: ...2 2 Lower Controller and Driver SPEED SENSOR MOTOR CONTROLLER INCLINE MOTOR TENSION MOTOR ...

Page 10: ...S Se er rv vi ic ce e M Ma an nu ua al l 3 Electrical Configurations ...

Page 11: ...trol variable elevation by console within main controller GENERAL INFORMATION CONSOLE Contains Key controls and LCD Display Main controller Include power supply motor driver control circuit and incline control circuit TENSION MOTOR Work voltage DC 4 5 7 5V Control resistance increases and decreases INCLINE MOTOR This is a 120V volt AC motor Have four wires red black white and green Has one 3 pins ...

Page 12: ...S Se er rv vi ic ce e M Ma an nu ua al l 4 Elliptical Operation ...

Page 13: ...S Se er rv vi ic ce e M Ma an nu ua al l Display Windows 7 5 LCD Display ...

Page 14: ...S Se er rv vi ic ce e M Ma an nu ua al l LCD Layout ...

Page 15: ... 3 1 Child lock is preset off disable and may be set on or off in engineering mode 3 2 When child lock is on Turning on the power the message window will show CONSOLE LOCKED and flashes twice then scrolls CHILD LOCK ON PRESS START AND ENTER TO ENABLE OPERATION The user must press and hold both Start and Enter keys at the same time for 2 seconds to unlock and enter idle mode for use 3 3 When child ...

Page 16: ... for 3 seconds 6 2 2 The message window is followed by displaying CONGRATULATIONS YOU HAVE COMPLETED YOUR WORKOUT PRESS THE STOP KEY TO END OR A USER KEY TO SAVE with prompt of pressing start key to restart the program or pressing Stop key once to exit or pressing User key and follow the MW instructions to save the program which has been finished by the custom user 6 2 3 CAL will show the total ca...

Page 17: ... 0 to 99 WORK range is 0 to 20 LEVEL preset value is 0 to 20 Press UP or DOWN to adjust incline each increment and decrement is 1 TIME TIME is either COUNT UP or COUNT DOWN System preset is COUNT UP if user sets the time then timer is COUNT DOWN DISPLAY range is 0 00 to 99 99 WORK range is 0 00 to 99 59 COUNT DOWN setup range is 10 00 to 99 00 When TIME is set the count will go to zero In RUN Mode...

Page 18: ... cumulative calories burned at any given time during your workout DISPLAY range is 00 0 to 999 WORK range is 00 0 to 999 PULSE Displays the heart rate beat by using hand pulse or receiver When use receiver a chest belt must be worn DISPLAY range is 0 to 999 WORK range is 40 to 220 BPM In RUN Mode if the Elliptical doesn t have a signal for 8 seconds then display value will become ...

Page 19: ...r rv vi ic ce e M Ma an nu ua al l Function Button Locations Fan Key Cooling fan switch on or off PROGRAM BUTTONS Manual Adventure Fatburn Xtreme Interval Glute Blast X Country Fitness 2 User 2HR CONTROL KEYS ...

Page 20: ...thout pressing ENTER button the data is accepted Press this button to confirm the setting or the value entered RUN MODE STOP button press STOP button to stop Elliptical START button non functional ENTER button non functional LEVEL UP button Press the button to increase your level and each increase is 1 LEVEL DOWN button Press the button to decrease your level and each decrease is 1 INCLINE UP butt...

Page 21: ...S Se er rv vi ic ce e M Ma an nu ua al l 5 Elliptical Unit Block Diagrams ...

Page 22: ...S Se er rv vi ic ce e M Ma an nu ua al l Elliptical Configuration ...

Page 23: ...S Se er rv vi ic ce e M Ma an nu ua al l 6 Elliptical Basic Connections and Wiring ...

Page 24: ...S Se er rv vi ic ce e M Ma an nu ua al l 6 1 Display Board wire Connections ...

Page 25: ...S Se er rv vi ic ce e M Ma an nu ua al l 6 2 Display Board PCB Component Locations PCB Board Top ...

Page 26: ...S Se er rv vi ic ce e M Ma an nu ua al l PCB Board Bottom ...

Page 27: ...S Se er rv vi ic ce e M Ma an nu ua al l 6 3 The console Interface Board wire Connections ...

Page 28: ...S Se er rv vi ic ce e M Ma an nu ua al l 6 4 Amplifier Board wire Connections ...

Page 29: ...S Se er rv vi ic ce e M Ma an nu ua al l 6 5 Driver Board Wire Connections ...

Page 30: ...S Se er rv vi ic ce e M Ma an nu ua al l Driver Board PCB Component Locations ...

Page 31: ...S Se er rv vi ic ce e M Ma an nu ua al l 6 7 Driver Board LED Indicator Locations POWER INCLINE MOTOR DOWN INCLINE MOTOR UP ...

Page 32: ...ing Indicator LED Function Condition Reason Solve LED1 Motion of incline motor Motion of incline motor is down Transistor was broken Relay failed Replace controller LED2 Motion of incline motor Motion of incline motor is up Transistor was broken Relay failed Replace controller ...

Page 33: ...S Se er rv vi ic ce e M Ma an nu ua al l 6 9 Driver Board Function ...

Page 34: ...e er rv vi ic ce e M Ma an nu ua al l 6 10 Tension Motor connector definition function MAIN CONTROL 1 VIN 2 M 3 M 4 COUNT 5 ZERO 6 3V 7 GND 8 SPEED 1 2 3 4 5 6 7 8 1 2 SPEED SENSOR 1 GND 2 SPEED STEEL ROPE ...

Page 35: ...S Se er rv vi ic ce e M Ma an nu ua al l 7 Product Safety Instructions ...

Page 36: ...to control This part is available through most electrical supply stores Examples Grainger part 1D237 or available online at www squared com part QO230HM 7 3 Important Grounding Instructions This product must be grounded If the Elliptical should malfunction or breakdown ground ing provides a path of least resistance for electric current reducing the risk of electric shock This product is equipped w...

Page 37: ...S Se er rv vi ic ce e M Ma an nu ua al l 8 Elliptical Error Messages Troubleshooting ...

Page 38: ...al l Error code items Error Message Explain E1 EEPROM failure E2 Tension motor is failure INCLINE E3 The console board is not detecting the VR voltage value or the voltage value has exceeded the range Prepare Picture Tool name Multi meter ...

Page 39: ...m of access all windows turn off and inputs stop Dot matrix shows E 1 and message window shows RAM ERROR Troubleshooting Since EEPROM fails the console board has to be replaced 8 2 Error Message E2 Definition When you press the Level Up or Down key the motor does not move E2 appears on the display Configuration ...

Page 40: ...he Level Up is 5VDC Level DOWN is 5VDC If there is power to the motor but the motor does not operate replace it If there is no power output inspect whether the drive board has power Tension Motor Voltage Test Procedure 1 Put multi meter to the 20VDC setting Place probes on the motor control wire Red probe in blue wire Black probe in green wire on the drive board 2 Turn on unit power The display li...

Page 41: ...S Se er rv vi ic ce e M Ma an nu ua al l Place probes on the motor control wire Red probe in blue wire Black probe in green wire on the drive board ...

Page 42: ... ic ce e M Ma an nu ua al l 8 3 Error Message INCLINE E3 Definition The console board is not detecting the VR voltage value or the voltage value has exceeded the range INCLINE E3 appears on the display Configuration ...

Page 43: ...S Se er rv vi ic ce e M Ma an nu ua al l LCD show INCLINE E3 ...

Page 44: ...value exceeds the range INCLINE E3 appears on the display Incline motor isn t operation up or down making the VR value exceed the range After turning on the unit the display board detects that the incline VR voltage exceeds the range so INCLINE E3 appears Action Flow Chart ...

Page 45: ...are broken or disconnected Display board 1 Inspect the incline wire and 11 pin cable connections 2 Test whether the VR voltage varies at the incline wire Elliptical 11 pin cable 1 Inspect the wire connections 2 Inspect whether wires are broken or crimped 3 Replace the wires and test again Driver board Inspect the display board 11 pin connections ...

Page 46: ...t configuration The console to driver board connector pin define function 11 10 9 8 7 6 5 4 3 2 1 The console to driver board connector pin define function 1 SPEED 2 GND 3 VCC 5V 4 ZERO 5 COUNT 6 MOTOR 7 MOTOR 8 VIN 9 INC UP 10 INC DOWN 11 INC VR ...

Page 47: ...ion RED UP BLACK DOWN White NEUTRAL INCLINE MOTOR DOWN LED INCLINE MOTOR UP LED The position sensor wires 1 Red Ground 2 White Position signal 3 Black 5vdc 0 5v depending on incline position 1 2 3 4 5 6 7 8 9 10 11 1 SPEED 2 GND 3 VCC 5V 4 ZERO 5 COUNT 6 MOTOR 7 MOTOR 8 VIN 9 INC UP 10 INC DOWN 11 INC VR 3 2 1 ...

Page 48: ...e loose If everything is tight then the potentiometer could be bad If there is no count then check the voltage at the potentiometer There should be 5vdc between the black and red wire and there should be a voltage between the red and white wire This voltage will be about 4 5 4 7 Vdc when the motor is at the lowest position the number isn t too critical as long as it s somewhere in this neighborhoo...

Page 49: ...S Se er rv vi ic ce e M Ma an nu ua al l Error Message INCLINE E3 Definition During incline action the display board CPU cannot read the VR value so INCLINE E3 appears Configuration ...

Page 50: ...splay Explanation Press the incline UP and DOWN key The driver board UP or DOWN indicator lights The incline operates moving the VR which changes the VR value The display board CPU reads the incline VR value If there is no VR value change to the CPU the incline is not operating when it should be INCLINE E3 appears on the display Action Flow Chart ...

Page 51: ...her the 11 PIN cable is connected well 2 Test by replacing the cable with a good one Driver board Inspect whether the driver board UP DOWN LED is lit 1 Press incline UP or DOWN key again making the incline motor return to its position 2 If INCLINE E3 still appears re calibrate the incline set Incline motor 1 Inspect whether the incline motor is stuck 2 Inspect whether the incline gears are cracked...

Page 52: ...S Se er rv vi ic ce e M Ma an nu ua al l 8 4 Circuit Diagram ...

Page 53: ...low you to test all the keys to make sure they are functioning B LCD Test Automatically tests all LCD s C Functions Press Enter to access settings use Level up down keys to scroll I Sleep Mode Turn on to have the console power down automatically after 30 minutes of inactivity II Motor Test Continually runs the tensioning gear motor III Manual Allows stepping of the gear motor IV Key Tone Turns off...

Page 54: ...If your elliptical loses power or will not start check the fuse located on the motor controller DANGER Turn the power switch off and unplug the elliptical to reduce the risk of an electric shock Remove FUSE holder Remove and replace the fuse on the holder FUSE 5A ...

Page 55: ...c field disturbance 3 Receiver is broken 1 Check for other chest belt use around elliptical 2 Change the position or direction of elliptical 3 Replace with new receiver 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 press DOWN can t press UP 1 The connector of INCLINE CABLE and CONSOLE not connected properly 2 The...

Page 56: ... 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 3 feet 3 Replace with new lithium battery type is ...

Page 57: ...S Se er rv vi ic ce e M Ma an nu ua al l 9 Troubleshooting ...

Page 58: ...e console screen will display if there is no display first check AC adapter to make sure it is in the correct position 2 Next check if all the wires are inserted in the firmly and securely on to the console 3 Then remove the AC adapter fuse to check for damage replace if damaged ...

Page 59: ...ot centered causing friction remove the left and right chain cover and reassemble Refer to the assembly and disassembly procedures 3 If the disc is offset causing friction remove the left and right chain cover use Phillips screwdriver and remove the 5x16mm Tapping Screw as well as the 1 4 x19mm flat washer Placed the round disk and the Cross Bar on a flat surface to check if either is deformed If ...

Page 60: ...stments or improper assembly causing offset creating abnormal sounds Please follow the magnetic flywheel and cable disassembly procedures to commence adjustments 2 If there is abnormal sound coming from the magnetic flywheel first check if are any foreign objects or friction make adjustments If adjustments are not able to be made replace with new part ...

Page 61: ... not aligned in a straight line Lastly rotate at high speed 100 120RPM and test with abrupt stops to check for abnormalities If everything is ok restore to fully assemble 2 If the three parts are not aligned in a straight line adjust the magnetic flywheel to the proper place Adjustments are always made to product ensuring alignment before shipment from factory 3 If the Poly V Belt is slipping simp...

Page 62: ...o the top ofØ17x276L Swing Arm Axle If the noise is emitting from the bottom bracket then the 6203 bearings needs to be replaced 2 When the keys on the handrails are not functioning first remove the stickers use a Phillips head screw driver and remove the M5x20mm screws securing the keys to the Swing Arm Check to see if the wires for the keys and swing arm are connected properly 3 Next check the w...

Page 63: ...any things that may affect or create problems with the footing The main issue is if the sliding wheel of the linked structure slides smoothly and parallel on top of the Inclinable Rail Assembly In short the main cause would be side Inclinable Rail Assembly and the Inclinable Rail Assembly are not parallel side Inclinable Rail Assembly and the main frame bottom bracket rotating sleeve do not come t...

Page 64: ...t from the sliding wheels replacing the sliding wheels or adding lubrication to the top of the sliding wheel arcs Check the main structure for abnormalities abnormalities in parallel parts make sure that the problem is with the parts and not assembly before replacing the parts ...

Page 65: ...n check incline controller and power adaptor is damaged or broken Replace damaged or broken parts 2 To return the incline motor make sure it has been reset then turn the tubing clockwise to the end as shown in figures 1 and 2 Turn the tubing again but counterclockwise two and half circles or let the center between two holes be 204 1 mm as shown in figure 3 ...

Page 66: ... there is no resistance first check to see if console is functioning normally Next check the Gear Motor cable if worn or damaged remove the Steel Cable Use Phillips screw driver to remove the Tapping Screw w 5x19 securing the Gear Motor cable and replace cable with new ...

Page 67: ...S Se er rv vi ic ce e M Ma an nu ua al l 10 Q A ...

Page 68: ...disk sleeve Cross Bar Belt and belt pulley Idler Wheel Plate Swing Arm Swing Arm Axle Flywheel Steel Cable Slide Wheel and Crank Arm during assembly along with side Inclinable Rail Assemblys as well as pedals The main reasons are usually not enough lubrication unsmooth rotations and loose screws Because the product is designed based on linked designs resolving noise issue will vary from machine to...

Page 69: ... securely tightened with Pedal Bar Assembly and Rod End Bearing needs to be vertical 1 2 Bushing Housing Pedal Arm the CAP Socket Head Cap Bolt 3 8 x2 1 4 on top and nyloc nut 3 8 x11T must be tightened securely recommended weight is between 500 600Lbs 1 3 Cross Bar CAP Socket Head Cap Bolt M8x40m m on top of the Cross Bar on the must be tightened to recommend 550 600Lbs ...

Page 70: ... l 2 Belt This issue appears quite often because after a period of time most belts will become loose from use depending on usage time Solution will depend on weight and adjustment methods refer to belt disassembly procedures for references ...

Page 71: ...xample shaking of the foot pedal is caused by loose Carriage Bolts from improper assembly 10 4 Smooth Problem 1 Check for loose screws if machine motion feels unsmooth 2 Check if there are foreign object on or around the sliding rail use an alcohol wipe to remove and re lubricate with lubricant Although this manual can not cover all of elliptical problems it describes most of it Whatever the probl...

Page 72: ...S Se er rv vi ic ce e M Ma an nu ua al l 11 Disassembling and assembling of Parts ...

Page 73: ...eplacement 1 Use Phillips head screwdriver to remove Phillips Head Screws M5x10mm 4pcs securing the console Unfasten all connected wires and remove console 2 Reassemble in the reverse order as disassembly Be sure to not crush or damage wiring during process ...

Page 74: ...crewdriver to remove Sheet Metal Screws 3 5x12mm securing the swing arm covers Front and Back 2 Disconnect the wiring connecting the upper and lower swing arms 3 Use 12mm open end wrench to remove the hex head bolt 5 16 x15mm and flat washer 5 16 x23x1 5T securing the swing arm assembly ...

Page 75: ...elease three Hex Head Bolts 5 16 x 1 3 4 together with three nyloc nut 5 16 x 7T and two curve washers 5 16 x 23 x 1 5T and separate upper Swing Arm and lower Swing Arm from each other 6 To take apart the Handle Switch Bracket tear off Handle Switch sticke first then use Phillips head screw driver to release two Flat Head Socket Screws M5 20mm and the Handle Switch Bracket handlebar resistance cab...

Page 76: ...simply remove swing arm with Rod End Bearing attached 2 Use 12 and 13 open end wrenches to release Hex Head Bolt 5 16 x1 1 4 flat washer 5 16 x 20 x 1 5T and nut 5 16 x 9T which secure the Rod End Bearing 3 Use 12mm open end wrench to remove hex socket screw 5 16 x15mm and flat washer 5 16 x20 Pull out the pedal carriage bolts to remove the Pedal Bar Assembly ...

Page 77: ...S Se er rv vi ic ce e M Ma an nu ua al l 5 Use Phillips screwdriver to remove Phillips Head Screw M5x10mm securing the pedal and remove pedal 6 Reassemble in the reverse order as disassembly ...

Page 78: ...uring the cover to pedal arm joint and remove pedal arm joint cover 3 Use M8 hex wrench and 14wrench to remove Gap socket screw 3 8 x2 1 4 two flat washer 3 8 x19x1 5T and nyloc nut 3 8 x11T connecting the Inclinable Rail Assembly and rotating block to remove Inclinable Rail Assembly 4 Use 12 hex wrench to remove hex head bolt 5 16 x15mm and flat washer 5 16 x35x1 5T to remove Bushing Housing Peda...

Page 79: ...to release two Phillips head screws M5x15mm and take the slide wheel cover first 4 Use circlip pliers to remove circlip Ø17 and remove sliding wheels 5 Reassemble in the reverse order as disassembly Reverse above steps to resume the pedal arm and return wavy washes Ø 17 back to left and right slide wheels ...

Page 80: ... gently pulling back with your hands separate left and right cover 3 Use 14mm wrench to remove hex head bolts 3 8 x3 4 Curved Washers 3 8 x23 x2T external hex head bolts 3 8 x2 1 4 and Spring Washer 3 8 x2T that secures the Console Mast 4 Remove Console Mast and Console Mast cover together pull out control wires separate covers from Console Mast ...

Page 81: ...tle Handpulse Assembly take the Round Cap apart first and use Phillips head screw driver to release two Tapping Screwsψ3x20mm Pull out Handpulse W Cable from the bottom and pull Handpulse Top Cover upward 6 Reassemble in the reverse order as disassembly ...

Page 82: ...e Pedal Arm and Console Mast Assembly Refer to step 11 4 and 11 5 2 Use Phillips head screwdriver to remover four Sheet Metal Screws 3 5x16 mm and remove right chain cover 3 Use Phillips head screwdriver to remover three Sheet Metal Screws 3 5x16 mm and remove left chain cover ...

Page 83: ...x19mm and disconnect two red Connecting Wires and one green Ground Wire to take left Chain Cover apart 5 Unscrew right Chain Cover on the mainframe by releasing three Tapping Screws 5x19mm 6 Further release Sheet Metal Screw 3 5x16mm together with flat washer 1 4 x19 which is inside the right Chain Cover ...

Page 84: ...o take AC power switch assembly apart use Phillips head screw driver to release two Phillips Head Screws M4 12mm and two nuts M4 5T 6 Reassemble in the reverse order as disassembly Flat Washer 5 16 x23x1 5T is to be placed on the left chain cover ...

Page 85: ...er to step 11 6 2 Remove elliptical side cover Round Disk Cover use 12mm wrench to remove hex head bolt 5 16 x15mm flat washer 5 16 x35x1 5T securing the cross bar 3 Use 13 wrench and loosen the outer bolt M8x6 3T steel lvl 10 Use 13 wrench and hex wrench M6 to loosen the inner bolt and remove the cross bar ...

Page 86: ...crews which secure the Round Disk and separate Cross Bar and Round Disk from each other 5 When reassembling place the cross bar into the center of the rotating mandrel Next place the Woodruff Key with the rounded part facing inwards Reassemble remaining parts in the reverse order as disassembly ...

Page 87: ...ws to remove belt Use 13 wrench to remove screws M8x20 nyloc nut M8x7T and flat washer 5 16 x20x1 5T to remove the Idler wheel 3 Reassemble parts in the reverse order as disassembly tighten the nyloc nuts M8x9T on top of the hook screws flick the belt for crisp sound to check tightness or use a sound measuring device to measure at 190HZ 10 reassemble the remaining parts ...

Page 88: ...wrench to loosen nyloc nut 3 8 UNF26x9T on flywheel and main frame Remove flywheel and belt 4 Reverse above steps to return all parts and adjust the position of the drive belt at the center on the drive pulley according to idler wheel assembling procedures and resume all parts Reassemble parts in the reverse order as disassembly and adjust belt and center the belt wheel Reassemble the remaining pa...

Page 89: ...irings for the incline motor 2 Use two 14mm wrench and 12mm wrench to remove hex head bolt 3 8 x1 1 2 flat washer 3 8 x19x1 5T nyloc nut 3 8x7T outer hex head bolt 5 16 x2 1 4 spring washer 5 16 x1 5T flat washer 5 16 x20x1 5T and star washer Ø5 16 Remove rear frame 3 Reassemble parts in the reverse order as disassembly and make sure wirings are connected correctly same color wire to same color so...

Page 90: ...a an nu ua al l 11 11 Rail Incline Motor replacement 1 Remove rear frame Refer to step 11 10 2 Use Phillips head screwdriver to remove screws M5x15mm from Rear Bar Cover Inclinable Rail Cover and Incline Cover then remove parts ...

Page 91: ...2 together with flat washer 3 8 x19x1 5T nyloc nut 3 8 x7T and two Nylon Washers Ø3 8 x Ø35 x5T which secure Incline tube and Incline Device 4 Use two 14mm wrenches to release Hex Head Bolt M10 130m m Flat Washer 3 8 x19x1 5T and Nyloc Nut 3 8 x7T which secure the Incline Motor on Rail Base Assembly ...

Page 92: ... remove from Rail Assembly hex head bolt 5 16 x1 flat washer 5 16 x 35x2T and pull out locking tube assembly and remove rail assembly 7 If removal of aluminum rail is needed remove Phillips head screws M5x15mm from aluminum rail to proceed 8 Reassemble in the reverse order as disassembly Be sure that the grounding wire of the incline motor is firmly secured on the frame tube of the Rear Frame ...