Dyaco XE580s, Service Manual

Page 1: ...st Cover Console Covers Pedal L Chain Cover Handlebar Covers Front Rear Connecting Arm Covers L R Rear Stabilizer Covers L R Incline Cover Front Stabilizer Cover Round Disk Cover Crank Slide Wheel Cover Rear Bar Cover Pedal Arm Cover Incline Bottom Cover Front Bar Cover Round Disk Cover ...

Page 2: ...ecting Arm L Console Mast Assembly Adjustable Pedal Handle Bar L Handle Bar R InclinableRailAssembly PedalArm R IdlerWheelAssemblyDrivePulley MainFrame Rail Assembly Connecting Arm L Bushing Housing Cross Bar Incline Motor Flywheel Adjustable Pedal R ...

Page 3: ...el Assembly 8 Flywheel 9 Drive Pulley 10 Bushing Housing Assembly 11 Sliding Wheels 12 Incline Motor II Troubleshooting 1 Console Assembly 2 Left Right Chain Covers and Round Disk Cover Crank 3 Flywheel 4 The Belt 5 Left Right Handlebar 6 Bushing Housing 7 Pedal Arms Connecting Arms and Sliding Wheels 8 Incline Motor and Controller III Q A 1 Noises 2 Slippage 3 Wobble 4 Smoothness 5 Others ...

Page 4: ... of self tapping screws and 4pcs of M5 x 10 mm Phillips head screws which secure the Console as shown in figures 1 2 and 3 Unplug Computer Cables and Handlepulse Cables as shown in figure 4 2 To resume plug in Computer Cables and Handpulse Cables back to the Console and securethe Console with 4pcs of M5 x 10 mm Phillips head screws and return Front and Rear Console Covers 1 2 3 4 ...

Page 5: ...o release 5 16 x1 1 4 hex head bolt 5 16 x 20 x 1 5T flat washer and 5 16 x 7T nut which secure the Fish eye bearing as shown in figure 2 3 Use 12 mm wrench to release 5 16 x 15m m hex head bolt and 5 16 x 20 x1 5T flat washer to take apart the Connecting Arm Assembly as shown in figure 3 4 To take apart the Pedal Assembly Use C ring pliers to release 10 C ring and Locking Pin with spring as shown...

Page 6: ...5 Use Phillips head screwdriver to release 4pcs of M5x10mm Phillips head screws to take apart Locking Pin Holder as shown in figure 6 6 To resume return Locking Pin Holder with arrow heading the Pedal to Pedal Assembly and tighten with 4pcs of M5 x10m m Phillips head screws as shown in figure 7 8 Return Pedal Assembly and tighten with 4pcs of M5 x 10m m Phillips head screws together with the sprin...

Page 7: ...g backward and use C ring pliers to return C ring back to Locking Pin Assembly as shown in figure 9 8 Return the Connecting Arm Assembly now with Adjustable Pedal onto the Pedal Arm Assembly Return Carriage Bolt and tighten with 5 16 x 15m m hex head bolt with 5 16 x 23 x 1 5T flat washer Return the other end of the spring under the Pedal to the Locking Pin Assembly as shown in figures 10 and 11 1...

Page 8: ...gure 1 3 Use M6 and 13mm wrenches to release M8 x 50 socket head cap screw 2pcs of 5 16 20 1 5T flat washers and M8 x 7T Nyloc nut and pull Pedal Arm Assembly backward to release it as shown in figures 2 and 3 4 To resume use M8 x 50 socket head cap screw 2pcs of 5 16 20 1 5T flat washers and M8 x 7T Nyloc nut to secure the Pedal Arm Assembly with Bushing Housing Assembly 5 Follow procedure 2 5 to...

Page 9: ...n Covers as shown in figure 1 3 Use Phillips head screwdriver to release 7pcs of 4x19 self tapping screws and 3pcs of tapping screws to take Right Chain Cover apart as shown in figures 2 and 3 4 To take the Left Chain Cover apart release 4x15 self tapping screws with 1 4 x19 flat washer on the main frame and 3pcs of 5x16 Then disconnect two red jumpers and white grounding mark for red jumpers to r...

Page 10: ...e 4x15self tapping screw with 1 4 x19 flat washer to hold it not too tight temporarily then tighten with 3pcs of 5x16 tapping screws make sure Chain Cover matches with Round Disk Cover Crank Tighten 4x15 self tapping screw as shown in figures 7 and 8 6 Match both Chain Covers with each other and use 7pcs of 4x19 self tapping screws and 3pcs of 5x16 tapping screws to secure them 7 Follow procedures...

Page 11: ...wn 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 5Tflat washer and then use M6 wrench to release M8x30 socket head cap screw and the both the Cross Bar and Round Disk Cover Crank can be taken apart as shown in figures 2 and 3 4 Use Phillips head screwdriver to release 8pcs of 5x16 tapping screws with 1 4 x19flat washers to separate the Cross Bar from Round...

Page 12: ...xle align the Cross Bar with square hole and put 7x7x25L Woodruff Key in the hole and tighten the socket head cap screw until it reaches 600 Kg cm Return and tighten 5 16 x 15m m hex head bolt with 5 16 x 35 x 1 5T flat washer as shown in figures 5 and 6 6 Follow procedures 4 3 and 2 to resume Connecting Arm Pedal Arm and both left and right Chain Covers with Round Disk Cover 5 6 ...

Page 13: ...e 13 mm wrench to loosen both M8 x 7T nuts on M8x170mm J bolt and on Idler Wheel respectively and the Belt can thus be released as shown in figures 1 2 and 3 3 To resume return the Belt on the Drive Pulley and Flywheel then tighten M8 x 7T nut until the acoustic gauge reads 170 Hz 10 Hz when it is played with finger as shown in figure 4 4 Follow procedures 5 4 3 and 2 to return other parts 1 2 3 4...

Page 14: ...bolt together with 5 16 x 23 x 1 5T flat washer until J bolt is released Use the same wrench to release M8 x 20 carriage bolt which secures Idler Wheel Assembly together with 5 16 x 20 x 1 5T flat washer and M8 x 7T nut to take Idler Wheel Assembly apart as shown in figures 1 and 2 3 To resume tighten M8x20 carriage bolt 5 16 x 20 x 1 5T flat washer and M8 x7T nut to secure Idler Wheel Assembly to...

Page 15: ...take apart Connecting Arm Pedal Arm both Chain Covers Cross Bar the Belt and Idler Wheel Assembly 2 Plug in the power and adjust the resistance to level 20 and release the cable 3 Use 15 mm wrench to release 2pcs of 3 8 UNF26 x 9T nuts which secure the Flywheel on the mainframe Pull out the Flywheel and take off the Belt 1 2 3 ...

Page 16: ...both 3 8 UNF26 x 9T nuts 5 Return the Cable onto the Flywheel with 45 degree and then return the Idler Wheel Assembly as shown in figure 4 6 Turn the Drive Pulley and check if the belt is secured Adjust either 3 8 UNF26 x 4Tnut to position the belt in the middle on the Drive Pulley and then tighten all other screws Adjust the Belt to a proper tension 7 Follow procedures 7 6 5 4 3 and 2 to return o...

Page 17: ...n the Crank Axle as shown in figures 1 and 2 and take off Crank Axle and Drive Pulley Use a hammer if necessary 3 To separate Crank Axle and Drive Pulley from each other use C ring pliers to release 25 C ring then use 11 mm wrench to release 4pcs of 1 4 x 3 4 hex head bolts with 1 4 nuts as shown in figure 3 4 To resume return Drive Pulley with one C ring onto the Crank Axle then return it to the ...

Page 18: ...ith 5 16 x 35 x 1 5T flat washer and the Bushing Housing can be released as shown in figure 1 3 To resume be sure that 25 wave washer is returned onto the shaft which is applied with thicker grease then return the Bushing Housing onto the shaft and tighten with 5 16 x15m m hex head bolt with 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 return Pedal Ar...

Page 19: ...r to take off Bushing Housing Cover as shown in figure 1 3 Use C ring Pliers to release 17 C ring and the Sliding Wheels can be released as shown in figure 2 4 To resume return one 17 wave washer Sliding wheels and another 17 wave washer in sequence and secure with C ring then return the wheel cover as shown in figure 3 5 Follow procedures 3 4 and 2 5 to return Pedal Arm and Connecting Arm 1 2 3 ...

Page 20: ...for incline motor and VR cables as shown in figure 4 and 5 3 Use two 14 mm wrenches to release 3 8 x 2 1 2 hex head bolt with 3 8 x 19 x 1 5T flat washer and 3 8 x 7T nut which secure incline motor and Incline Device Then use two 17 mm wrenches to M10x130m m hex head bolt with 3 8 x 19 x 1 5T flat washer and nut which secure Incline Motor and Incline Rail Assembly as shown in figures 6 and 7 Cut t...

Page 21: ... tighten with M10x130m m hex head bolt with 3 8 x 19 x 1 5T flat washer and M10 8T nut Then secure the Incline Motor on the Incline device with 3 8 x 2 1 2 hex head bolt together with 3 8 x 19 x 1 5T flat washer and 3 8 x 7T nut Tie up cables for the motor and connect the grounding then connect the power cables for the motor and VR cables 4 Return all Covers 5 6 7 ...

Page 22: ...n properly and AC breaker is not activated as shown in figure 1 3 Make sure that all connectors including cables for the console and AC power are connected properly Disassemble the console to check cables inside it if necessary 4 If all connections are fine then check to determine if cable breaks or console or lower controller fails as shown in figure 2 1 2 ...

Page 23: ...ve Pulley 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...

Page 24: ...e 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 25: ...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 26: ...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 17x 276L shaft on the mast as shown in figure 1 might resolve the problem 2 If the bearing makes noise or gets stuck replace this 6003 as shown in figures 2 and 3 1 2 3 ...

Page 27: ...ing Housing is rare However a few units might have noise problem as time lasts Applying some grease on 25 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 28: ...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 29: ...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 30: ...s 8 Incline Motor and Controller Board Rev Procedures 1 If the motor fails make sure that all cables are properly connected as shown in figures 1 and 2 Check if there is any sign of damages of controller board transformer or the console 1 2 ...

Page 31: ... 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 32: ...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 33: ...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 34: ...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 35: ...Model XE580s Work Q A Problem 5 Others 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 ...