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Dyaco SE578B-YE014 Service Manual

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SE578B-YE014
Elliptical
Service Manual

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Summary of Contents for Dyaco SE578B-YE014

  • Page 1 SE578B-YE014 Elliptical Service Manual...
  • Page 2 -----------------------------------------Table of Content----------------------------------------------- 1. SE578B Elliptical Outlines 2. Electronic Parts 2.1 Upper Controllers 2.2 Lower Controller and Driver 3. Electrical Configurations 4. Elliptical Operation 5. Elliptical Unit Block Diagrams 6. Elliptical Basic Connections and Wiring 6.1 Display Board Wire Connections 6.2 Display Board PCB Component Locations 6.3 The Console Interface Board Wire Connections 6.4 Amplifier Board Wire Connections...
  • Page 3 Troubleshooting 9.1 Console Problem 9.2 Side Case & Round Disk Problem 9.3 Flywheel Problem 9.4 Poly-V Belt Problem 9.5 Swing Arm Problem 9.6 Connecting Arm Problem 9.7 Controller & Incline Motor Problem 9.8 Tension Motor Problem 10. Q & A 10.1 Noise 10.2 Slip Problem 10.3 Resistance &...
  • Page 4 Circuit Diagram...
  • Page 5 1. Elliptical Outlines...
  • Page 6 (1) Plastic parts Front handlebar Console Front handlebar cover(R) Cover (L) Left side case Console mast cover Pedal(L) Connecting arm cover(B) Pedal(R) Rear cover(2) Round disk Rear cover(1) Connecting arm cover(A) Right side case Middle cover Bottom cover Round disk cover Slide wheel cover Front cover Pedal arm cover(R)
  • Page 7 (2) Steel parts Connecting arm (L) Swing arm (L) Pedal arm (L) Adjustable pedal Console mast Flywheel Tension motor Adjusting knob Swing arm (R) Controller Incline motor Drive Pulley Pedal arm (R) Cross Bar Rail assembly Main frame Rear frame Middle frame Connecting arm (R)
  • Page 8 2. Electronic Parts...
  • Page 9 2.1 Upper Controllers Cooling FAN THUMB SWITCH Speaker DISPLAY...
  • Page 10 2.2. Lower Controller and Driver SPEED SENSOR TENSION MOTOR MOTOR CONTROLLER INCLINE MOTOR...
  • Page 11 3. Electrical Configurations -10-...
  • Page 12 ONSOLE Interface that controls all functions of the Elliptical. AIN CONTROLLER The circuit board consist of the DC power supply for console、incline driver and tension motor driver, link the console to output appropriate voltages for tension motor that control the elliptical functions. ENSION MOTOR It can change to increase or decrease resistance level of brake.
  • Page 13 4. Elliptical Operation -12-...

  • Page 14: Display Windows

    Display Windows 7.5” LCD Display -13-...
  • Page 15 LCD Layout -14-...
  • Page 16 Operation Window Display Mode IDLE MODE 1.1 Each program profile will be displayed on the MESSAGE WINDOW sequentially. 1.2 Heart rate BAR will light up from the bottom and move up. Level, HR% Profile and Track loop will light up from bottom middle and move counterclockwise.
  • Page 17 PAUSE MODE 5.1 Press “STOP” key enter to PAUSE MODE, and exercise parameters will be recorded. Message window will display “PAUSE”, and upper window will display the recorded exercise parameter. 5.2 In PAUSE MODE, it will display PAUSE by five seconds, and then display by transit string ”PRESS START TO RESUME OR STOP TO END” serially.
  • Page 18 Function SPEED Display the current speed in Kilometer mile per hour. DISPLAY range is 0.0 to 99.9 WORK range is 0.0~99.9 Incline Display the incline position from 0 to 20 DISPLAY range is 0 to 99. WORK range is 0 to 20. INCLINE preset value is 0 to 20.
  • Page 19 LAPS Display the total working laps quantity. DISPLAY range is 0 to 99. WORK range is 0 to 99. Displays total laps quantity. PACE 1 KM/MILE DISPLAY range is 00:00 to 99:99. WORK range is 00:00 to 99:99. DISTANCE Display the current distance in kilometer or Mile. DISPLAY range is 00.0 to 99.9.
  • Page 20 Function Button Locations Level quick keys Incline quick keys 1/3/6/9/12/15 1/3/6/9/12/15 PROGRAM BUTTONS (Manual, Hill, Fat Burn, Strength, Interval, 2 User, 2HR) Fan Key Cooling fan switch on or off D I S P L A Y C O N T R O L K E Y S -19-...
  • Page 21 Function Button In Main Mode READY MODE STOP button: Non-function. START button: Pressing “ START ” button to start treadmill, When pressing “START” button, there will be 3 second final count down on window display, then machine starts running. In MANUAL, treadmill starts at MIN LEVEL . LEVEL UP button: If user doesn’t enter a setting then this button is non-functional.
  • Page 22 RUN MODE STOP button: press “STOP” button to stop treadmill. 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 button: Press the button to raise position and each increase is 1, the maximum incline position is 20.
  • Page 23 5. Elliptical Unit Block Diagrams -22-...
  • Page 24 Elliptical Configuration -23-...
  • Page 25 6. Basic Connections and Wiring -24-...
  • Page 26 6.1 Display Board wire Connections -25-...
  • Page 27 6.2 Display Board PCB Component Locations PCB Board Top -26-...
  • Page 28 PCB Board Bottom -27-...
  • Page 29 6.4 The console Interface Board wire Connections -28-...
  • Page 30 6.4 Amplifier Board wire Connections -29-...
  • Page 31 6.5 Driver Board Wire Connections -30-...
  • Page 32 6.6 Driver Board PCB Component Locations -31-...
  • Page 33 6.7 Driver Board LED Indicator Locations INCLINE MOTOR DOWN INCLINE MOTOR UP POWER -32-...
  • Page 34 6.8 C Controller Indicator LED debugging Indicator Function Condition Reason Solve LED3 Controller power If DC voltage is normal, it would be Voltage is not correct. Check the supply voltage is 110-120V. POWER always ON. If off, fault condition Fuse is blown. Replace Fuse.
  • Page 35 6.9 Driver Board Function -34-...
  • Page 36 6.10 Tension Motor connector definition function STEEL ROPE SPEED SENSOR 1. GND 2. SPEED -35-...
  • Page 37 7. Product Safety Instructions -36-...

  • Page 38: Important Safety Instructions

    7.1 Important Safety Instructions - To reduce the risk of electric shock disconnect your treadmill from the electrical outlet prior to cleaning and/or service work. - To reduce the risk of burns, fire, electric shock, or injury to persons, install the treadmill on a flat level surface with access to a 230-volt, 10-amp grounded outlet with only the treadmill plugged into the circuit.
  • Page 39 8. Error Messages / Troubleshooting -38-...
  • Page 40 Error code items： Error Message Explain EEPROM failure Tension motor is failure The console board is not detecting the VR voltage value,or the voltage value has exceeded the range. Prepare： Picture Tool name Multi-meter -39-...
  • Page 41 8.1 Error Message： ： ： ： E1 Definition: All screens are off, and outputs are stop when EEPROM is damaged or malfunction. Display message will show “E-1”, and message window will show “RAM ERROR” Troubleshooting: Replace upper controller. -40-...
  • Page 42 Error Message ： ： ： ： E2 Definition：When you press the Level Up or Down key, the motor does not move.” E2” appears on the display. Configuration： -41-...
  • Page 43 Tension Motor Operation Part Description Key signal travels to the display. The main program IC then Display sends a command signal to the drive board. Drive board receives the signal and responds by putting out Drive Board power to the motor. Level UP:+5VDC;Level DOWN:-5VDC Tension Motor Troubleshooting Part Description...
  • Page 44 Place probes on the motor control wire (Red probe in blue wire, Black probe in green wire) on the drive board. -43-...
  • Page 45 Error Message： ： ： ： E3 Definition：The console board is not detecting the VR voltage value, or the voltage value has exceeded the range.” E3” appears on the display. Configuration： -44-...
  • Page 46 LCD show E3 Case of E3 Incline VR value exceeds the range. 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 E3 appears. Action Flow Chart -45-...
  • Page 47 -46-...
  • Page 48 Troubleshooting Part Troubleshooting 1.Reconnect VR wires. Incline VR 2.Inspect whether the incline wires are broken or disconnected. 1.Inspect the incline wire and 12-pin cable connections. Display board 2.Test whether the VR voltage varies at the incline wire terminal. 1.Inspect the wire connections. 12-pin cable 2.Inspect whether wires are broken or crimped.
  • Page 49 Test configuration. The console to driver board connector pin define function 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 11,10,9,8,7,6,5,4,3,2,1 -48-...
  • Page 50 Test Configuration. Incline motor control function relate parts location INCLINE MOTOR DOWN LED The position sensor wires 1.Red = Ground, 2.White = Position signal, INCLINE MOTOR 3.Black = 5vdc, (0~5v depending on incline position) UP LED BLACK-DOWN 1.SPEED White-NEUTRAL 2.GND 3.VCC+5V 4.ZERO 5.COUNT...
  • Page 51 Test Procedure： ： ： ： Run calibration again. Does the incline motor move at all? If no, do the Up/down lights on the incline board light? If they light, do the relays click on? If the relay clicks on but the motor doesn’t move: with the incline light and relay activated check the voltage between the neutral (white) wire and the Up (red) or down (black) wire, depending on which direction the motor is supposed to travel according to Up/Down lights on the board.
  • Page 52 Error Message： ： ： ： E3 Definition：During incline action, the display board CPU cannot read the VR value, so E3 appears. Configuration： -51-...
  • Page 53 Cause of E3 Press the incline UP/DOWN key. The incline doesn’t operate. E3 appears on the 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.
  • Page 54 Troubleshooting Part Troubleshooting 1.Press incline UP key. The driver board UP LED lights. Display board 2.Press incline DOWN key. The driver board DOWN LED lights. 3.If not as above, inspect the cable and connections. 1.Inspect whether the 11-PIN cable is connected well. 11-pin cable 2.Test by replacing the cable with a good one.
  • Page 55 8.4 Circuit Diagram -54-...
  • Page 56 CALIBRATION PROCEDURE Incline Calibration: If there is a problem with the incline, try running the calibration. Press the Incline ▲ key and the Start key at the same time. Hold them down for 5 seconds and the Incline calibration will start and run automatically. If the problem persists contact service department. MAINTENANCE MENU IN CONSOLE SOFTWARE The console has built in maintenance/diagnostic software.
  • Page 57 8.6 Fuse replacement FUSE 5A 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.
  • Page 58 8.7 Troubleshooting procedure matrix Condition Reason Solve LCDs not bright, incomplete or imperfect. 1. LCD light is broken. 1. Replace with new LCD or console. 2. Power to console too low. 2. Check AC power is 110-120V. 3. Check power to console. 4.Replace lower controller.
  • Page 59 properly. 3. Replace with new cable. 3. The wires got damaged when connecting the HANDPULSE W/WIRE 4. Replace console or Hand pulse board. and Console. 4. Hand pulse board is broken. Wireless lost its function. 1. Chest belt not worn properly. 1.
  • Page 60 9. Troubleshooting -59-...
  • Page 61 9.1 Console Problem Under normal use console screen will display, if there is no display, first check AC adapter to make sure it is in the correct position. Next, check if all the wires are inserted in the firmly and securely on to the console. Then remove the AC adapter fuse to check for damage, replace if damaged.
  • Page 62 Remove console cover, left and right chain covers, check if all the wires are inserted in the correct positions and check if whether the wires broken. -61-...
  • Page 63 9.2 Side case & Round Disk Problem The potential reason why there could be a problem here is due to the friction created causing abnormal sounds. However, to determine this, you will need to check to see if the large disk is not centered or offset.
  • Page 64 9.3 Flywheel Problem This problem is very rare, most of the time the problem is caused by incorrect cable adjustments 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.
  • Page 65 9.4 Poly-V Belt Problem If the Poly-V Belt falls off, first remove the right chain cover and Idler Wheel Plate, and then reinstall the Poly-V Belt. Once reinstalled, rotate at low speed to observe if the Drive Pulley or Poly-V Belt is offset or deformed. Check if the belt pulley is offset or if the belt, Drive Pulley, Magnetic flywheel are not aligned in a straight line.
  • Page 66 9.5 Swing Arm Problem To make assembly easier for consumers, there will be minor difference in size (0.05mm~0.07mm). Therefore, it is normal for a little shake/wobble to exist, but after prolonged use, small parts due to friction wear will generate noise. The solution is to add thick lubricant into the top of Ø25x296L Swing Arm Axle.
  • Page 67 9.6 Connecting Arm Problem The elliptical uses linked structure design, thus if there is a problem in the link it will affect other parts of the structure. Therefore, every part of the elliptical structure is important, more importantly, asides from resolving and replacing problem parts, it is also important to lubricate frequently.
  • Page 68 9.7 Controller & Incline Motor Problem When incline motor is not functioning, check all the wire for secure connection, check incline controller and power adaptor is damaged or broken. Replace damaged or broken parts. (2) Incline motor needs to be calibrated to the correct distance (242mm) -67-...
  • Page 69 9.8 Gear Motor Problem If 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. -68-...
  • Page 70 10. Q & A -69-...
  • Page 71 10.1 Noise (1) There are potentially many locations where noise can originate from, but it is not easy to isolate the location specifically. In the front, the chain cover and the round disk, EPE, round 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.
  • Page 72 10.2 Slip Problem (1) Slipping problems can be verified by the following steps. 1-1 M12 x P1.75 Rod End Bearing : M12 Nut on top must be securely tightened with Pedal Bar Assembly, and Rod End Bearing needs to be vertical. Bushing Housing, Pedal Arm: the CAP Socket Head Cap Bolt 3/8 "x2-1/4 on top and nyloc nut 3/8"...
  • Page 73 10.3 Resistance & Incline Problem Shaking is mainly due to loose screws, so check and tighten loose screws first. Check connection points to see if gaps have been created after prolong use causing wear and tear or improper assembly. For example, shaking of the foot pedal is caused by loose Carriage Bolts, from improper assembly.
  • Page 74 11. Disassembling and assembling of Parts -73-...

  • Page 75: Console Replacement

    11.1 Console Replacement (1) Use Phillips head screw driver to remove the Phillips Head Screws M5x15mm (3pcs) securing the bottom cover (front and back) of the console as well as the Sheet Metal Screws 3.5x12mm (2pcs). Remove bottom console cover. (2) Use Phillips head screwdriver to remove Phillips Head Screws M5x10mm (4pcs) securing the console.

  • Page 76: Swing Arm Replacement

    11.2 Swing Arm Replacement Use a Phillips screwdriver to remove Sheet Metal Screws 3.5x12mm securing the swing arm covers (Front and Back) Disconnect the wiring connecting the upper and lower swing arms. Use Phillips head screwdriver to the Phillips Head Screws M5x15mm and Sheet Metal Screw 3.5x12mm to remove Connecting Arm Cover A (left and right) -75-...
  • Page 77 Use Phillips head screwdriver to the Phillips Head Screw M5x15mm and Sheet Metal Screw to remove Connecting Arm Cover B (left and right) Use 14mm open end wrench to remove the hex head bolt 3/8”x3/4” and flat washer 3/8”x30x1.5T securing the swing arm assembly. Use #12 and #13 open end wrench affix swing arm assembly and remove hex head bolt 5/16”x1-1/4”, flat washer 5/16”x20x1.5T and nyloc nut 5/16”x7T.
  • Page 78 11.3 Connecting Arm Replacement Remove swing arm assembly and swing arm (If removal of pedal tube, simply remove swing arm with Rod End Bearing attached) Use 12mm open end wrench to remove hex head bolts 5/16”x15mm and flat washer 5/16”x23. Pull out the pedal carriage bolts to remove the Pedal Bar Assembly.
  • Page 79 (4) Use Phillips screwdriver to remove Phillips Head Screw M5x10mm and Bushing 19×14×10×(5+4)T. Pull out Axle of locking pin and use circlip pliers to remove circlip Ø10. Remove Locking Pin Assembly. (5) Use Phillips screwdriver to remove Phillips Head Screw M5x10mm securing the pedal and remove pedal.

  • Page 80: Pedal Arm Replacement

    11.4 Pedal Arm Replacement (1) First remove the Pedal Bar Assembly, then use Phillips head screwdriver to remove the Phillips Head Screws M5x10mm securing the cover to pedal arm joint and remove pedal arm joint cover. (2) Use #8 hex wrench and #14 open end wrench to remove Gap socket screw 3/8”x2-1/4”, 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.
  • Page 81 Use circlip pliers to remove circlip Ø17 and remove sliding wheels (5) Reassemble in the reverse order as disassembly -80-...

  • Page 82: Console Mast Replacement

    11.5 Console Mast Replacement Remove the Swing Arms. (refer to 11.2 above) (2) Separate Console Mast cover by gently pulling back with your hands, separate left and right cover (3) Use # 14 open end wrench to remove hex head bolts 3/8”x3/4”, Curved Washers 3/8 "x23 x2T, external hex head bolts 3/8"...
  • Page 83 (5)Remove Console Mast and Console Mast cover together, pull out control wires and incline wires and separate covers from Console Mast. (6) Reassemble in the reverse order as disassembly -82-...
  • Page 84 11.6 Side Case Replacement (1) Remove Swing Arm and Inclinable Rail Assembly. Use Phillips hear screwdriver to remove Phillips Head Screws M5x15mm securing the Front Stabilizer Cover and remove cover. (3) Use Phillips head screw to remover left cover self securing screw 4x19 and Tapping Screw 5x16, remove left chain cover.
  • Page 85 (5) Remove grounding wire and console wiring from AC base terminal (remember wire connection points), remove right chain cover. (6) Reassemble in the reverse order as disassembly (Flat Washer 5/16 "x23x1.5T is to be placed on the right cover) -84-...
  • Page 86 11.7 Cross Bar Replacement (1) Remove left and right chain cover. (refer to 11.6 above) (2) Remove elliptical side cover Round Disk Cover, use 12mm Open End Combination Spanner 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 Nut M8x6.3T (steel lvl 10).
  • Page 87 11.8 Idler Wheel Replacement (1) Remove the cross bar. (refer to 11.7 above) (2) Use #13 Double Open-End Wrench to loosen nyloc nut M8x9T on the hook screws to remove belt. Use #13 wrench Double Open-End Wrench to remove screws M8x20, nyloc nut M8x7T and flat washer 5/16”x20x1.5T to remove the Idler wheel.
  • Page 88 11.9 Flywheel & Poly-V Belt replacement (1) Remove idler wheel . (refer to 11.8 above) (2) Use the console to adjust the resistance lvl 20 and remove Steel Cable. (3) Use #15 Double Open-End Wrench to loosen nyloc nut 3/8”-UNF26x9T on flywheel and main-frame.
  • Page 89 11.10 Rear Frame Replacement (1) Use Phillips head screw driver to remove the Phillips Head Screws M5x15mm below Incline Bottom Cover. Disconnect the power and VR wirings for the incline motor. (2) Use two 14mm Double Open-End Wrench and 12mm Double Open-End 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"...
  • Page 90 11.11 Rail & Incline Motor replacement (1) Remove rear frame. (refer to 11.10 above) (2) Use Phillips head screwdriver to remove screws M5x15mm from Rear Bar Cover, Inclinable Rail Cover and Incline Cover, then remove parts. (3) Use two 14mm Open-End Wrench to remove hex head bolt 3/8”x2-1/2” from Rear Rail Assembly and Incline Motor Holder including flat washer 3/8"x19x1.5T and nyloc nut 3/8"x7T.
  • Page 91 (4) Use 12mm Double Open-End Wrench to 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. (5) Use two 14mm Open-End Wrench to remove head hex bolt 3/8"x1-1/2", flat washer 3/8"x19x1.5T and nyloc nut 3/8"x7T from incline motor (6) Use Phillips head screwdriver to remove tapping screw 5x16 from incline motor grounding wire.
  • Page 92 (7) Use 12mm wrench to remove head hex bolt 5/16"x1 and flat washer 5/16"x 35x2T from rail assembly, remove the rail assembly. If removal of aluminum rail is needed, remove Phillips head screws M5x15mm from aluminum rail to proceed. If removal of incline wheel is needed, use Phillips head screwdriver to remove thumb head socket screw M6x10mm*2 (nylock screw), flat washer ¼”x19x1.5T-2 to proceed.

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Se598b-ye016

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