Dyaco XT660B-A912, Service Manual

Page 1: ...XT660B A912 Treadmill Service Manual 110 120V 220 230V ...

Page 2: ...r Locations 6 7 Controller Indicator LED Debugging 6 8 Driver Board Function 7 Product Safety Instructions 7 1 Important Safety Instructions 7 2 Important Electrical Instructions 7 3 Important Grounding Instructions 8 Error Messages and Troubleshooting for Electronic Issues 8 1 Error Message LS1 LOW SPEED LOSE SPEED 8 2 Error Message E1 RAM ERROR 8 3 Error Message INCLINE E2 Err 8 4 Circuit Diagra...

Page 3: ...ller Replacement 12 2 Console Replacement 12 3 Motor Replacement 12 4 Breaker Replacement 12 5 AC Power Switch Replacement 12 6 Front Rear Roller Replacement 12 7 Running Deck Belt Cushion Replacement 12 8 Speed Sensor Replacement 12 9 Incline Motor Replacement ...

Page 4: ...S Se er rv vi ic ce e M Ma an nu ua al l 3 1 Treadmill Outlines ...

Page 5: ...S Se er rv vi ic ce e M Ma an nu ua al l 4 Console Hand Pulse Sensor Incline adjustment button Speed adjustment button ...

Page 6: ...S Se er rv vi ic ce e M Ma an nu ua al l 5 Incline Motor Lower Controller Driving Motor ...

Page 7: ...S Se er rv vi ic ce e M Ma an nu ua al l 6 2 Electronic Parts ...

Page 8: ...S Se er rv vi ic ce e M Ma an nu ua al l 7 2 1 Upper Controllers DISPLAY Cooling FAN Speaker ...

Page 9: ...S Se er rv vi ic ce e M Ma an nu ua al l 8 2 2 Lower Controller and Driver Driver System Motor Controller Incline Motor DC MOTOR Motor Controller INCLINE MOTOR ...

Page 10: ...S Se er rv vi ic ce e M Ma an nu ua al l 9 3 Electrical Configurations ...

Page 11: ...console to output appropriate voltages for motor that control the treadmill functions TREADMILL MOTOR This is a variable speed for DC motor To control the 0 90 or 0 180 for 220V model voltages on the main controller it can to increase or decrease speed of running belt INCLINE MOTOR This is an ac motor User can to control variable elevation by console within main controller GENERAL INFORMATION CONS...

Page 12: ...the treadmill motor will turn counter clockwise The higher the voltage the faster the motor turns The green wire is ground INCLINE MOTOR This is a 110 volt AC motor for 110V model 220 volt AC motor for 220V model Have four wires red black white and green Has one 3 pins cable of position sensor If there is AC voltage on the Red wire UP the incline motor will increase the incline If there is AC volt...

Page 13: ...S Se er rv vi ic ce e M Ma an nu ua al l 12 4 Product Operation ...

Page 14: ...S Se er rv vi ic ce e M Ma an nu ua al l 13 Display Windows 10 X 24 DOT MATRIX DISPLAY ...

Page 15: ... and enter OFF Mode Function SPEED Display the current speed in Kilometer mile per hour DISPLAY range is 0 0 to 99 9 WORK range is 1 0 18 0 kmph Press FAST or SLOW to adjust speed each increment and decrement is 0 1 km h mph Incline Display the incline position from 0 to 15 DISPLAY range is 0 to 99 WORK range is 0 to 15 INCLINE preset value is 0 to 15 Press UP or DOWN to adjust incline each increm...

Page 16: ...0 00 to 99 9 WORK range is 0 00 to 99 9 CALORIES Displays the cumulative calories burned at any given time during your workout DISPLAY range is 0 0 to 999 WORK range is 0 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 50 to 200 BPM In RUN Mode if the treadmill doesn t have a signal for ...

Page 17: ... rv vi ic ce e M Ma an nu ua al l 16 Function Button Locations SPEED quick keys Incline quick keys Fan Key Cooling fan switch on or off Function Key Control operation Safety Key Emergency function PROGRAM keys ...

Page 18: ...nal profile ex Age and to change each function MANUAL can set using time Pre set PROGRAM can set using time and speed Heart Rate Control 1 2 can set time age and the value of heart rate User Program 1 2 can set time speed and incline FAST button If user doesn t enter a setting then this button is non functional SLOW button If user doesn t enter a setting then this button is non functional UP butto...

Page 19: ...ntinuously then speed decreases to MIN SPEED quickly UP button Press the button to raise position and each increase is 1 the maximum incline position is 15 DOWN button Press the button to lower position and each decrease is 1 the minimum incline position is 0 SPEED RAPID button To press SPEED then select 2 digits and treadmill will automatically adjust to that value INCLINE RAPID button To press I...

Page 20: ...S Se er rv vi ic ce e M Ma an nu ua al l 19 5 Unit Block Diagrams ...

Page 21: ...S Se er rv vi ic ce e M Ma an nu ua al l 20 Treadmill Configuration ...

Page 22: ...S Se er rv vi ic ce e M Ma an nu ua al l 21 6 Basic Connections and Wiring ...

Page 23: ...S Se er rv vi ic ce e M Ma an nu ua al l 22 6 1 Display Board wire Connections ...

Page 24: ...S Se er rv vi ic ce e M Ma an nu ua al l 23 6 2 Display Board PCB Component Locations PCB Board Top ...

Page 25: ...S Se er rv vi ic ce e M Ma an nu ua al l 24 PCB Board Bottom ...

Page 26: ...S Se er rv vi ic ce e M Ma an nu ua al l 25 6 3 Amplifier Board wire Connections ...

Page 27: ...S Se er rv vi ic ce e M Ma an nu ua al l 26 6 4 Driver Board Wire Connections ...

Page 28: ...S Se er rv vi ic ce e M Ma an nu ua al l 27 6 5 Driver Board PCB Component Locations ...

Page 29: ...S Se er rv vi ic ce e M Ma an nu ua al l 28 6 6 Driver Board LED Indicator Locations MOT_DRV PWM POWER SHUT_DOWN LIMIT INC_DW INC_UP ...

Page 30: ... 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 Shut_Down Controller shut down If controller has unusual shut down the Shut_Down light will be always bright Motor lock LIMIT light will be bright for 3 to 5 seconds previously Turn off power and reset the treadmill MOT_DRV Motor Drive...

Page 31: ...S Se er rv vi ic ce e M Ma an nu ua al l 30 6 8 Driver Board function ...

Page 32: ...S Se er rv vi ic ce e M Ma an nu ua al l 31 7 Product Safety Instructions ...

Page 33: ...bility to control This part is available through most electrical supply stores Examples Grainger part 1D237 or available online at www squared com part QO120HM 7 3 Important Grounding Instructions This product must be grounded If the treadmill should malfunction or breakdown grounding provides a path of least resistance for electric current reducing the risk of electric shock This product is equip...

Page 34: ...S Se er rv vi ic ce e M Ma an nu ua al l 33 8 Error Messages and Troubleshooting for Electronic Issues ...

Page 35: ...ror Message Explain LS1 LOW SPEED Display board CPU did not receive the RPM signal E 1 RAM ERROR EEPROM failure E2 INCLINE ERR 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 36: ...S Se er rv vi ic ce e M Ma an nu ua al l 35 8 1 Error Message LS1 LOW SPEED LOSE SPEED Definition Display board CPU did not receive the RPM signal Configuration ...

Page 37: ... Cause of LOW SPEED OR LOSE SPEED LS The motor doesn t turn LS1 LOW SPEED appears Explanation The drive board did not sent voltage to the motor so the motor didn t operate And the display board didn t receiver the RPM sensor signal Configuration ...

Page 38: ...S Se er rv vi ic ce e M Ma an nu ua al l 37 LS LS1 LOW SPEED solution follow chart ...

Page 39: ...S Se er rv vi ic ce e M Ma an nu ua al l 38 Terminals for motor cable Red for M Black for M PWM LED POWER LED ...

Page 40: ...S Se er rv vi ic ce e M Ma an nu ua al l 39 LS LS 1 LOW SPEED solution follow chart check RPM sensor device procedure ...

Page 41: ...he good connection for cables The speed sensor didn t detect signal completely Check the gap between speed sensor and magnet To keep the gap distance less than 3 mm Defective sensor or bad cable connection Check if the sensor and cables are circuit short damaged Change the sensor or cables The motor can not move The motor can not work Check if the motor wire is plug well and the controller is norm...

Page 42: ... EEPROM damaged or malfunction Display message will show E 1 and message window will show RAM ERROR Troubleshooting Replace upper controller 8 3 Error Message INCLINE E2 Err Definition The console board is not detecting the VR voltage value or the voltage value has exceeded the range INCLINE E2 appears on the display Configuration ...

Page 43: ... value exceeds the range INCLINE E2 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 E2 appears Action Flow Chart ...

Page 44: ...es are broken or disconnected Display board 1 Inspect the incline wire and 12 pin cable connections 2 Test whether the VR voltage varies at the incline wire terminal 12 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 12 pin connections ...

Page 45: ...sole to driver board connector pin define function The console to driver board connector pin define function 1 Controller S W 2 Incline down output 3 Incline up output 4 Vin 5 Speed up output 6 Speed down output 7 GND 8 GND 9 Speed sensor input 10 VCC 11 ADC input 12 GND ...

Page 46: ...CK DOWN White NEUTRAL The position sensor wires Red Ground White Position signal Black 5vdc 0 5v depending on incline position UP DOWN LED 12 11 10 9 8 7 6 5 4 3 2 1 1 Controller S W 2 Incline down output 3 Incline up output 4 Vin 5 Speed up output 6 Speed down output 7 GND 8 GND 9 Speed sensor input 10 VCC 11 ADC input 12 GND ...

Page 47: ...cket could be 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...

Page 48: ...S Se er rv vi ic ce e M Ma an nu ua al l 47 Error Message INCLINE E2 OR Err Definition During incline action the display board CPU cannot read the VR value so INCLINE E2 appears Configuration ...

Page 49: ...he display 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 E2 appears on the display Action Flow Chart ...

Page 50: ... whether the 12 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 ERR 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 3...

Page 51: ...S Se er rv vi ic ce e M Ma an nu ua al l 50 8 4 Circuit diagram 120V 230V ...

Page 52: ...display to show Metric or English settings Miles vs Kilometers To do this press the key to show which you want then press Enter 4 Make sure the wheel size diameter is 2 83 then press Enter 5 Adjust the minimum speed if needed to 1 0 and then press Enter 6 Adjust the maximum speed if needed to 12 0 and then press Enter 7 Adjust the maximum elevation if needed to 15 and then press Enter 8 Press Star...

Page 53: ...the keys to make sure they are functioning c Display test Test all the windows display c Functions Press Enter to access settings and Up arrow to scroll i Sleep Mode Turn on to have the console power down automatically after 20 minutes of inactivity ii Pause Mode Turn on allow 5 minutes of pause turn off to have the console pause indefinitely iii Maintenance To indicate lubrication iv Units Sets t...

Page 54: ... properly 4 12 PIN computer cable is broken 5 Fuse on controller is blown 6 Varistor on controller is blown 7 Safety device is broken open 8 Other components are faulty 1 Switch the AC switch 2 Insert the safe key on right position 3 Please check the wire and connect again 4 Replace 12 PIN computer cable 5 Replace fuse or controller 6 Replace varistor or controller 7 Replace safety key device 8 Re...

Page 55: ... with new controller 7 Replace with new motor 8 Replace with new console The speed of the belt doesn t match console display 1 Console is not calibrated 1 Calibrate the console The incline position doesn t match console 1 Console is not calibrated 1 Calibrate the console INCLINE ERR INCLINE window displays INCLINE E2 1 Position sensor value of incline motor is wrong 1 Turn off the AC switch and tu...

Page 56: ... press DOWN can t press UP 1 The connector of INCLINE CABLE and CONSOLE not connected properly 2 The connector of INCLINE CABLE and INCLINE ADJUSTMENT SWITCH W CABLE not connected properly 3 The connector of INCLINE CABLE or INCLINE ADJUSTMENT SWITCH CABLE got damage 4 Button of INCLINE ADJUSTMENT SWITCH is broken 5 The connector of INCLINE CABLE or INCLINE ADJUSTMENT SWITCH CABLE got damage 6 The...

Page 57: ...ithium battery with type CR2032 Tread belt does not run in center Tread belt tension not even across tread belt See treadmill belt adjustment Tread belt hesitates while being stepped on Insufficient lubricant on tread belt Tread belt tension insufficient See treadmill belt lubrication Black particles collecting under treadmill Drive belt is breaking in Vacuum under treadmill periodically Noise und...

Page 58: ...S Se er rv vi ic ce e M Ma an nu ua al l 57 9 Treadmill Folding Unfolding and Transport ...

Page 59: ...eck until it is secured by the locking telescoping tube assembly in center back of base TO UNFOLD THE TREADMILL Apply slight forward pressure on the treadmill running deck with one hand Pull down on the unlocking lever and slowly lower the running deck to the floor The deck will lower unassisted when it reaches about waist high At the rear roller area to relieve pressure on the locking system TRAN...

Page 60: ...S Se er rv vi ic ce e M Ma an nu ua al l 59 10 General Maintenance ...

Page 61: ...lt Allow the belt to dry before using Belt Dust This occurs during normal break in or until the belt stabilizes Wiping excess off with a damp cloth will minimize buildup General Cleaning Dirt dust and pet hair can block air inlets and accumulate on the running belt On a monthly basis vacuum underneath your treadmill to prevent buildup Once a year you should remove the black motor hood and vacuum o...

Page 62: ...in use It is normal for some belts to drift near one side while the belt is running with no one on it After a few minutes of use the tread belt should have a tendency to center itself If during use the belt continues to move toward one side adjustments are necessary TO SET TREADBELT TRACKING A 10 mm Allen wrench is provided to adjust the rear roller Make tracking adjustments from the left side onl...

Page 63: ...of Lube and extra tubes can be ordered directly from or your authorized dealer You may also use a Lube n Walk kit that can be purchased through both aforementioned sellers Keeping the deck lubricated at the recommended intervals ensures the longest life possible for your treadmill If the lubricant dries out the friction between the belt and deck rises and places undue stress on the drive motor dri...

Page 64: ...odel wall outlet 4 Breaker panel circuit breaker may be tripped 5 Treadmill defect Contact your dealer Tread belt does not stay centered The user may be walking while favoring or putting more weight on either the left or right foot If this walking pattern is natural track the belt slightly off center to the side opposite from the belt movement Treadmill belt hesitates when walked run on See Genera...

Page 65: ...noise is coming from the rollers 2 If the noise is coming when the user is running on the treadmill with lowest level of incline it could be due to too much pressure with the incline cylinder only in case of the lowest incline level 3 If there is knocking noise during the workout check and make sure all bolts are tightened 4 When there is thumping noise while the belt is running This happens with ...

Page 66: ...S Se er rv vi ic ce e M Ma an nu ua al l 65 11 Installation of the Incline Motor ...

Page 67: ...S Se er rv vi ic ce e M Ma an nu ua al l 66 225 Incline Range must be adjusted to 225mm minimum prior to installation ...

Page 68: ...S Se er rv vi ic ce e M Ma an nu ua al l 67 12 Disassembling and assembling of Parts ...

Page 69: ...e M Ma an nu ua al l 68 12 1 Lower Controller Replacement 1 Remove motor cover 2 Disconnect all lower controller wirings 3 Use Phillips head Screwdriver to remove replace with new lower controller and reconnect all wirings ...

Page 70: ...use Phillips Head Screw Driver to remove 6 Phillips Head Screw Bolt Access Caps and the left and right handlebar covers 2 Use M5 L Allen wrench to remove 4 button head socket bolts 2 flat Washers and 2 star Washers from the console support Disconnect console wirings and replace with new console ...

Page 71: ...c ce e M Ma an nu ua al l 70 12 3 Motor Replacement 1 Use Phillips head screwdriver to remove 5 Tapping screw securing the motor cover 2 Remove motor grounding wire greenish yellow motor wire red and motor wire black ...

Page 72: ...ble in reverse order of disassembly re hook belt readjust belt to be parallel with main frame after re hooking Do not tighten 4 securing screws yet 5 Use 14mm open end wrench to adjust belt tension using tension measuring device Adjust to white LBS area between 70 75LBS Use 14mm T shaped socket wrench to secure and tighten 4 securing screws 6 Connect grounding wires and motor wires red M black M ...

Page 73: ...S Se er rv vi ic ce e M Ma an nu ua al l 72 12 4 Breaker Replacement Remove Breaker connection wiring replace part and reconnect wiring ...

Page 74: ...S Se er rv vi ic ce e M Ma an nu ua al l 73 12 5 AC Power Switch Replacement 1 Disconnect wiring to AC power switch replace AC power switch and reconnect wiring ...

Page 75: ...v vi ic ce e M Ma an nu ua al l 74 12 6 Front Rear Roller Replacement 1 Use Phillips head screwdriver to loosen 2 screws on the rear adjustment base 2 Use M6 L Allen wrench to loosen 2 screws on the rear roller ...

Page 76: ...wrench to loosen 1 belt tension screw and loosen drive belt 4 Use 13mm wrench to loosen front roller screws remove front and back rollers and replace with new Reassemble in reverse order of disassembly 5 When reassembled running belt tension needs to be adjusted and centered Belt tension also needs to be adjusted refer to 12 3 5 above ...

Page 77: ... Allen wrench and 12m m wrench to remove securing screws on cylinder and remove the cylinder 2 Perform step 12 6 and remove front and rear rollers 3 Remove left and right Foot Rail Caps then use Phillips head screw driver to release six Concave Washers w Screws and take apart Concave washers which secure the Foot Rail Follow the direction shown to slide apart the Foot rails ...

Page 78: ...S Se er rv vi ic ce e M Ma an nu ua al l 77 ...

Page 79: ...unning board Remove the running board and replace running board or running belt If cushions need to be replaced remove 6 cushions and replace Reassemble in the reverse order as disassembly 5 When reassembled center and adjust running belt tension Belt tension also needs to be adjusted Refer to step 12 3 5 ...

Page 80: ...a al l 79 12 8 Speed Sensor Replacement including the wire 1 First remove motor top cover 2 Remove speed sensor wiring and proceed with parts replacement 3 After replacement a test to check if the sensor registers the magnet is required ...

Page 81: ... 9 Incline Motor Replacement Zeroing the incline motor before take it apart from the machine or assemble it onto the frame The zeroing distance is 225mm 1 First adjust treadmill to folded position then proceed with old incline motor replacement 225 ...

Page 82: ...S Se er rv vi ic ce e M Ma an nu ua al l 81 2 Use M6 Allen wrench M8 Allen wrench and 14mm wrench to assemble new incline motor ...

Page 83: ...S Se er rv vi ic ce e M Ma an nu ua al l 82 3 Connect incline motor wiring with controller Red wire Connect to UP White wire Connect to COM Black wire Connect to DOWN ...