Xterra XE570S, Service Manual

Page 1: ...Cover F R R Pedal Console Mast Cover L R R Side Case L Pedal L Side Case L Handle Bar Cover F R Connecting Arm Cover L R M Stabilizer Cover Incline Cover Round Disk Slide Wheel Cover Rear Bar Cove Pedal Arm Cover Incline Bottom Cover Inclinable Rail Cover Round Disk Cover ...

Page 2: ...Pedal Arm L Connecting Arm Console Mast L Swing Arm R Swing Arm Rear Rail Assembly R Pedal Arm Idler Wheel Drive Pulley Main Frame Rear Rail Assembly R Connecting Arm Bushing Housing Cross Bar Incline Motor Flywheel ...

Page 3: ...8 Idler Wheel Assembly 9 Flywheel 10 Bushing Housing Assembly 11 Sliding Wheels 12 Incline Motor II Troubleshooting 1 Console Assembly 2 Side Cases and Round Disk 3 Flywheel 4 The Belt 5 Swing Arms 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: ...e sensor cable as shown in figures 1 and 2 2 To resume plug in the Computer Cable Handle Resistance Wire and Handpulse sensor cable back to the Console and secure the Console with 4pcs of M5 x 10 mm Phillips head screws Make sure that cables are free from being pinched 3 If it is necessary to dismantle the console covers release Ø3 5 12m m_Sheet Metal Screws which secure the console to be open by ...

Page 5: ...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 and Pedal Carriage Bolt to take apart the Connecting Arm Assembly as shown in figure 3 4 To take apart the Pedal Assembly use Phillips head screwdriver to release 4pcs of M5x10mmPhullips head screws as shown in figure 4...

Page 6: ...rther two M5x15mm Phillips head screws and 3 5x12 Sheet Metal Screw as shown in figure 2 3 Use 12mm and 13mm wrenches to release 5 16 x1 1 4 Hex Head Bolt together with 5 16 x20x1 5 T flat washer and 5 16 x7T nut which secure swing arm and rod end bearing as shown in figure 3 4 Use 12mm wrench to release 5 16 x15 Hex Head Bolt and 5 16 x23x1 5T flat washer to take apart the swing arm as shown in f...

Page 7: ...Model XE570S Service Replacing Parts Parts 3 Swing Arms Rev Procedures 5 Reverse above steps to resume swing arm Make sure that ψ 17 wave washer is resumed at console mast shaft as shown in figure 5 5 ...

Page 8: ... as shown in figure 1 3 Use M8 and 14mm wrenches to release 3 8 x 2 1 4 socket head cap screw 2pcs of 3 8 19 1 5T flat washers and 3 8 x 11T Nylon nut and take apart Pedal Arm Assembly as shown in figures 2 and 3 4 To take the Bushing Housing apart use 12mm wrench to release 5 16 x 15m m hex head bolt and 5 16 x 35 x1 5T flat washer as shown in figure 4 5 Reverse above steps to resume all parts 1 ...

Page 9: ...rs as shown in figure 1 3 Use Phillips head screwdriver to release 7pcs of 4x19 self tapping screws and 3pcs of 5x16 x 3 tapping screws to take Right Side Case apart as shown in figures 2 and 3 4 To take the Left Side Case apart release 4x15 self tapping screws with 1 4 x19 flat washers on the main frame and 3pcs of 5x16 Tapping Screws Then disconnect two red jumpers and white grounding remember t...

Page 10: ... and use 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 Side Case matches with Round Disk Tighten 4x15 self tapping screws as shown in figures 7 and 8 7 Match both Side Cases with each other and use 7pcs of 4x19 self tapping screws and 3pcs of 5x16 tapping screws to secure them 8 Reverse above procedures ...

Page 11: ...re 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 and then use M6 and 13mm wrenches to release M8x40 socket head cap screws with M8x6 3T nuts so that the both the Cross Bar and Round Disk 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 B...

Page 12: ...ith square hole and put 7x7x25L Woodruff Key in the hole and tighten M8x40 socket head cap screw together with two M8x6 3T nuts until it reaches 500 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 above procedures to resume Connecting Arm Pedal Arm and both left and right Side Cases with Round Disk Cover 5 6 ...

Page 13: ...sen M8 x 9T nut on M8x170mm J bolt and on Idler Wheel and another M8 x 7T nut 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 9T nut until the acoustic gauge reads 190 Hz 10 Hz when it is played with finger then tighten M8 x 7T nut as shown in figure 4 4 Follow above procedures to return other parts 1 2 ...

Page 14: ...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 be tighten after the belt...

Page 15: ...Side Covers Cross Bar the Belt and Idler Wheel Assembly 2 Plug in the power and adjust the resistance to level 20 and release the steel cable as shown in figures 1 and 2 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 as shown in figures 3 and 4 1 2 3 4 ...

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

Page 17: ... m hex head bolt with 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 thatψ25 wave washer is returned onto the shaft 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 4 Follow procedures 3 4 and 2 5 to return Pedal Arm and Connecting Arm 1 2 ...

Page 18: ...take off Slide Wheel Cover as shown in figure 1 2 Use C ring Pliers to release ψ 17 C ring and the Sliding Wheels can be released as shown in figure 2 and 3 3 To resume apply some lubricant on the wheel shaft and return oneψ17 wave washer sliding wheels and another ψ 17 wave washer in sequence and secure with C ring then return the wheel cover 1 2 3 ...

Page 19: ...o release M5x15mm Phillips head screws to take apart Incline Cover Incline Bottom Cover Inclinable Rail Cover and Rear Bar Cover as shown in figure 1 2 and 3 3 Use two 14 mm wrenches to release two 3 8 x 2 1 2 hex head bolts together with one 3 8 x 19 x 1 5T flat washer and two 3 8 x 7T nuts which secure incline motor and Incline Device as shown in figures 4 and 5 1 2 3 4 ...

Page 20: ...hex head bolt together with 3 8 x 19 x 1 5T flat washer and 3 8 x7T nut which secure Incline Motor as shown in figure 6 5 Use Phillips head screw driver to release 5x16 Tapping Screw which secure the grounding wire of the incline motor Cut the wire tie and the Incline Motor can be taken apart as shown in figures 7 and 8 5 6 7 8 ...

Page 21: ...be and take apart the rail assembly as shown in figure 9 7 Rif taking apart aluminum rails is necessary release M5x15mm Phillips head screws which secure aluminum rails as shown in figure 10 8 To replace slide wheels use Phillips head screw driver to release two M6x10m m Phillips head screws together with 1 4 x 19 x 1 5T flat washers as shown in figure 11 9 Reverse above steps to resume parts 9 10...

Page 22: ...is plug in 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 and 3 1 2 3 ...

Page 23: ...lley which causes rubbing noises then taking apart of both Side Cases if necessary Refer to procedure 4 3 If the Drive Pulley swings and causes rubbing noises then take apart both Side Cases and 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 warp The s...

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: ...ving 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 ψ17x 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: ...hing 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 plastic Bushing has been worn out replace it with a new one as shown in figure 2 1 2 ...

Page 28: ...ry important to lubricate each moving parts and joints with high viscosity lubricant 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...

Page 29: ...ev procedures 3 Both Handlebars should connect properly with their corresponding connecting Arm and Sliding wheels should have real circle without slippage 4 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: ...Parts 8 Incline Motor and Controller 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: ...om 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: ...cular to M12x P1 75 bolt as shown in figure 1 3 Bushing Housing 3 8 x 2 1 4 socket head cap screw must be firmly tightened with 3 8 x 11T nut 4 Cross Bar M8x40m 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 t...

Page 33: ...ighten 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: ...ness 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 XE570S Service Q A Problem 5 Others Rev Procedures 1 Contact DYACO for problems not covered in this service manual Any problem solving on the unit is backed up by DYACO technical team ...