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Dyaco SU136-YB02 Service Manual

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SU136-YB02 &
SR147-YB02
Service Manual
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Summary of Contents for Dyaco SU136-YB02

  • Page 1 SU136-YB02 & SR147-YB02 Service Manual...
  • Page 2 Product Operation Unit Block Diagrams Basic Connections and Wiring Product Safety Instructions Error Messages / Troubleshooting SU136-YB02 Troubleshooting 9-1 Console 9-2 Handle Bar and Console Mast 9-3 Seat and Sliding Seat Mount 9-4 Crank Arm and Pedal 9-5 Left and Right Shrouds...
  • Page 3 10. SR147-YB02 Troubleshooting 10-1 SR147 Console 10-2 Console Mast and Cover 10-3 Crank Arm and Pedal 10-4 Front Shroud 10-5 The Belt and Idler bracket 10-6 Crank Axle and Drive Pulley 10-7 Flywheel 10-8 Seat Back Bracket 10-9 The Seat, Seat Handle Bar and Handpulse Sensor 10-10 Seat Carriage and the Locking Knob 10-11 Rear Shrouds 10-12 Front and Rear Main Frame...
  • Page 4 1. Upper & Recumbent Controllers Outlines...
  • Page 5 SU136 Outlines Left Shroud Seat Saddle Cover Console Handgrip Console Mast Cover Foam Stabilizer End Cap (Front) Stabilizer End Cap (Rear) Pedal Right Shroud...
  • Page 6 SU136 Skeleton Sliding Seat Mount Inner Slide Handle Bar Console Mast Flywheel Drive Pulley Rear Stabilizer Front Stabilizer Idler Bracket Main Frame Flywheel Crank Arm Magnets Mounting Plate...
  • Page 7 SR147 Outlines Console Mast Seatback Seat Rear Shroud Console Cover Adjustme Front Shroud Transportation Seat Carriage Seat Handle Bar nt Base Wheel Cover...
  • Page 8 SR147 Skeleton Hand Pulse Seat Handle Bar Seat Carriage Sensor Arm Seat Back Bracket Console Mast Rear Main Frame Drive Pulley Crank Arm Rear Stabilizer Front Stabilizer Front Main Idler Frame Flywheel Flywheel Bracket Magnets Mounting Plate...
  • Page 9 2. Electronic Parts...
  • Page 10 SU136 Upper Controllers Cooling FAN Speaker Hand-Pulse DISPLAY...
  • Page 11 SR147 Recumbent Controllers Cooling FAN Speaker Hand-Pulse DISPLAY...
  • Page 12 SU136 Lower Controller and Driver SPEED SENSOR TENSION MOTOR...
  • Page 13 SR147 Lower Controller and Driver SPEED SENSOR TENSION MOTOR...
  • Page 14 3.Electrical Configurations...
  • Page 15 ONSOLE NTERFACE THAT CONTROLS ALL FUNCTIONS OF THE LLIPTICAL 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 16 4. Product Operation...

  • Page 17: Display Windows

    Display Windows 6.5” LCD Display...
  • Page 18 LCD Layout...
  • Page 19 Operation Window Display Mode IDLE MODE 1.1 Each program profile and name will be displayed on the MESSAGE WINDOW sequentially. SLEEP MODE 2.1 Pre-set: DISPLAY ON(DISABLE). You could set the DISPLAY ON/OFF by ENGINEERING MODE. 2.2 The console will not get into SLEEP MODE when the set up is “ON”, unless turn off the power. There is no RPM input in IDEL MODE, and enter to SLEEP MODE after 20 minutes without pressing any key.
  • Page 20 END MODE 6.1 The message window will display “ END OF WORKOUT” . 6.2 END MODE workout information 6.2.1 Display exercise data in message window each three seconds. 6.3 When the time counting is end, and END MODE display is finished without pressing any key in 30 seconds.The system will enter IDLE MODE. RESET MODE 7.1 In IDLE MODE, press STOP key for more than three seconds will enter to RESET MODE and reset the system.
  • Page 21 Function SPEED Display the current speed in Kilometer mile per hour. DISPLAY range is 0.0 to 99.9 (message bar) WORK range is 0.0~99.9 LEVEL Display the level position from 0 to 20 DISPLAY range is 0 to 999. (message bar) WORK range is 0 to 20.
  • Page 22 CALORIES Displays the cumulative calories burned at any given time during your workout. DISPLAY range is 00.0.0 to 9999. WORK range is 000.0 to 9999. 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.
  • Page 23 Function Button Locations Manual, Program Up,Program Down, User 1,User 2,HR1,HR2,Enter,Level up,Start,Level down,Stop,Fan...
  • Page 24 Function Button In Main Mode READY MODE STOP button: Non-function. START button: Pressing “ START ” button to start Elliptical, When pressing “START” button, there will be 3 second final count down on window display, then machine starts running. In MANUAL, Elliptical starts at MIN LEVEL . LEVEL UP button: If user doesn’t enter a setting then this button is non-functional.
  • Page 25 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. PROGRAM UP Button:select a program PROGRAM DOWN Button:select a program USER 1: non-functional.
  • Page 26 5. Unit Block Diagrams...
  • Page 27 Bike Configuration...
  • Page 28 6. Basic Connections and Wiring...

  • Page 29: Display Board Wire Connections

    Display Board wire Connections...
  • Page 30 Display Board PCB Component Locations PCB Board Top...
  • Page 31 PCB Board Bottom...
  • Page 32 SU136 The console Interface Board wire Connections...
  • Page 33 SR147 The console Interface Board wire Connections...
  • Page 34 Amplifier Board wire Connections...
  • Page 35 Tension Motor connector definition function MAIN CONTROL 1. VIN 2. M+ 3. M- 4. COUNT STEEL ROPE 5. ZERO 6. 3V 7. GND 8. SPEED SPEED SENSOR 1. GND 2. SPEED...
  • Page 36 7. Product Safety Instructions...

  • Page 37: Important Safety Instructions

    Important Safety Instructions - To reduce the risk of electric shock disconnect your Bike 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 Bike on a flat level surface with access to a 220-volt, 10-amp grounded outlet with only the Bike plugged into the circuit.
  • Page 38 8. Error Messages / Troubleshooting...
  • Page 39 Error code items： Error Message Explain RAM ERROR EEPROM failure MOTOR ERROR Tension motor is failure Prepare： Picture Tool name Multi-meter...
  • Page 40 Error Message： ： ： ： RAM ERROR Definition: All screens are off, and outputs are stop when EEPROM damaged or malfunction. Display message will show “RAM ERROR”, and message window will show “RAM ERROR” Troubleshooting: Replace upper controller.
  • Page 41 Error Message ： ： ： ： MOTOR ERROR Definition：When you press the Level Up or Down key,the motor does not move.” MOTOR ERROR” appears on the display. Configuration：...
  • Page 42 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. Tension Motor receives the signal and responds by putting Tension Motor out power to the motor.Level UP:+5VDC;Level DOWN:-5VDC Tension Motor Troubleshooting Part...
  • Page 43 Place probes on the motor control wire(Red probe in blue wire,Black probe in green wire) on the drive board.

  • Page 44: Troubleshooting

    Troubleshooting Part Troubleshooting Display board 1.Inspect the 8-pin cable connections. 1.Inspect the wire connections. 8-pin cable 2.Inspect whether wires are broken or crimped. 3.Replace the wires and test again. Tension Motor Inspect the display board 8-pin connections.
  • Page 45 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 4.ZERO 5.COUNT 6.MOTOR- 7.MOTOR+ 8.VIN ,8,7,6,5,4,3,2,1...
  • Page 46 SU136-YB02 Circuit Diagram AA-00830-K2...
  • Page 47 SR147-YB02 Circuit Diagram...
  • Page 48 General Maintenance 1. Wipe down all areas in the sweat path with a damp cloth after each workout. 2. If a thump, clicking or wobbly feeling develops, the main cause is usually the pedals and/or crank arms being loose. Engineering Mode The console has built in maintenance/diagnostic software.
  • Page 49 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 220V. 3. Check power to console. 4.Replace lower controller.
  • Page 50 9. SU136-YB02 Troubleshooting...
  • Page 51 9-1 Console Use Phillips head screw driver to release four M5×12mm Phillips head screws and disconnect Sensor Cable and two Hand pulse Sensor in order to take apart the Console. To resume console, plug in sensor cable and two Hand pulse sensor cable back onto the console and secure with four M5×12mm Phillips head screws.
  • Page 52 Handle Bar and Console Mast Take the console apart and pull out two hand pulse cables which had been tied on the mast tube. Separate handlebar assembly from the mast tune by using L-Allen wrench to release two 5/16"×5/8" Button Head Socket Bolts.
  • Page 53 Slightly slap console mast cover to separate it from left and right shrouds and use 5mm Allen wrench to release five 5/16"x1-3/4" Button Head Socket Bolts, four 5/16"x18mmx1.5T flat washers, four 5/16"x1.5T split washers and one 5/16"×19 x1.5T curved washer and pull out the console mast. To resume console mast, slide the console mast cover through the computer cable and further slide the computer cable through the console mast and out of the console mounting plate.
  • Page 54 Seat and Sliding Seat Mount Turn the knob counterclockwise to separate and take apart the Sliding Seat Mount. To resume, place the Sliding Seat Mount on the Inner Slide and secure with the knob from the bottom.
  • Page 55 Crank Arm and Pedal Use 15mm open end wrench to turn left pedal clockwise, right pedal counterclockwise, to loosen, and take them apart. Turn left and right pedals reversely to resume them. Release the Crank Arm End Cap and use T-wrench or plug wrench to take the nut apart.
  • Page 56 Applying the tool to secure it onto the crank arm and use hex wrench to turn the crank arm and take it apart. To resume, use air apparatus to shake the crank arm back to the crank axle. If air apparatus is not available, use rubber hammer to hit.
  • Page 57 Left and Right Shrouds First remove the pedal and the crank arm. Separate Mast Cover and Mast Rear Cover from left and right Side Cases and use Phillips head screw driver to unscrew lest Side Case with seven ø4×12mm × 7 Sheet Metal Screws and three 5×16mm Tapping Screws to take left Side Case apart.
  • Page 58 Inner Slide Inner Slide 1. Follow procedures 3 to take the seat apart and turn Lock Knob counterclockwise to take it apart. Separate console mast cover from left and right shrouds and pull out Inner Slide together withø40×80 Center spatial wrap from the main frame. Hit Inner Slide with rubber hammer to take apart Slide Spacer and thus the Inner Slide, ø40×80 Center spatial and Seat Post Cover can be taken apart from each other.
  • Page 59 Twin Crank Arms, Belt, Idler Bracket and Drive Pulley 1. Take apart left and right shrouds. 2. Use nose pliers to release the spring and use 13mm open end wrench to turn 5/16” ×6T nut, with 5/16” ×18×1.5T flat washer, counterclockwise to take Idler Bracket and the belt apart 3.
  • Page 60 Flywheel 1. Take apart left and right shrouds and the belt. 2. Use 8mm open end wrench and Phillips head screw driver to release M5x75mm Phillips head adjustment screw, which is on magnet mount. 3. Use nose pliers to take magnet mount from the flywheel cable. 4.
  • Page 61 5. Use 14mm open end wrench to release two nuts which secure the flywheel on the mainframe, to take the flywheel apart, as shown in figure 3. 6. Reverse above steps to resume parts.
  • Page 62 9-9 Console and Error Messages 9-9-1 The console without display When there is no display, check as below: 1. Make sure the console and computer cables are connected properly. 2. 如 If all are connected properly, take measurements of power outputs to find out the problem. 9-9-2 No heart rate is displayed: 1.
  • Page 63 9-10 Slipping Belt and Belt falling Off 9-10-1 Slipping Belt: Take apart both left and right shrouds. Check the value of the belt tension with sound wave gauge. The value should be in the range of 250±50HZ. Check if the spring and the belt are getting loose if the value is out of range. If they are getting loose, parts require to be replaced.
  • Page 64 9-10-2 Belt falling off: Follow the assembly procedure to install the driving belt and test by revolving forward and backward after adjustment. If the belt falls off, adjust it one groove toward the direction the belt falling off and test again. If the belt still falls off, the machine might be so heavily dropped that part dimension deviates.
  • Page 65 9-11 Noises The causes of noises are mostly loose screws. Sometimes it is because of parts being deformed or shifting causing rubbing or unsmooth moving. Most causes are as follows: Noises coming from left and right pedals. This is mostly pedals wear causing noises and not moving smoothly. The worn out pedals must be replaced.
  • Page 66 10. SR147-YB02 Troubleshooting...
  • Page 67 10-1 SR147 Console 1. Use Phillips head screw driver to release four M5 x 12mm Phillips head screws which secure the console and disconnect the computer cable and hand pulse sensor cable to take the console apart. 2. Reverse above step to resume.
  • Page 68 10-2 Console Mast and Cover Take the console apart first. Slight slap console mast cover to separate it front shroud, as shown in figure 1, and use 6mm Allen wrench to release five 5/16" x 3/4"L Button Head Socket Bolts, four 5/16" x 18 x 1.5T flat washers, five 5/16" x 1.5T split washers and 5/16" x19x 1.5T curved washer in order to take apart the console mast.
  • Page 69 10-3 Crank Arm and Pedal 1. Use 15mm open end wrench to turn left pedal clockwise, right pedal counterclockwise to take them apart. 2. Turn pedals reversely against the above step to resume both pedals. 3. Take apart crank arm end cap and use T-shape wrench or plug wrench to release the nut.
  • Page 70 4. Use crank fixing tool to hold the crank and release the crank with Allen wrench. 5. To return the crank, use compressed air tool to fix the crank in the crank axle then tighten the nut on the axle and plug in the crank arm end cap.
  • Page 71 10-4 Front Shroud 1. Take apart the crank arm and console mast cover 2. Use Phillips head screw driver to release eightØ4x12 Sheet Metal Screws and two 5x16 Phillips Head Screws which secure left front shroud and take the shroud apart. 3.
  • Page 72 10-5 The Belt and Idler bracket 1. Take both left and right front shrouds apart 2. Use nose pliers to release the spring and take the drive belt apart from the drive pulley. 3. Release 3/8"x7T nut to take apart idler bracket. 4.
  • Page 73 10-6 Crank Axle and Drive Pulley 1. Take apart both left and right shrouds and the drive belt. 2. Use C-ring pliers to releaseØ20 C-ring on crank axle to take the axle apart. 3. Use two 11mm open end wrenches to release four 1/4" x 3/4" hex head bolts, four 1/4"x13x1T flat washers and four 1/4" x 8T nuts and which are on the crank axle and drive pulley to take the pulley apart.
  • Page 74 10-7 Flywheel 1. Take both left and right front shrouds and the belt apart. 2. Use 8mm open end wrench and Phillips head screw driver to release M5x75mm Phillips head screws which adjust resistance magnets. 3. Use nose pliers to separate magnet stripe from the mounting mechanism.
  • Page 75 4. Use 5mm Allen wrench and 13mm open end wrench to release 5/16"x 2-1/2L Button Head Socket Bolt which secures the magnet to take magnet stripe apart. 5. Use 14mm open end wrench to turn two nuts, which secure the flywheel, counterclockwise, to take the flywheel apart. 6.
  • Page 76 10-8 Seat Back Bracket 1. Use L Allen Wrench to release two 3/8" × 3/4"_Button Head Socket Bolts and 3/8" × 19 × 1.5T flat washers then use 14.15m/m_Wrench to take both 3/8" × 7T_Nyloc Nuts apart and remove Seat Back Bracket. 2.
  • Page 77 10-9 The Seat, Seat Handle Bar and Handpulse Sensor 1. Take seatback assembly apart. 2. Unplug stereo headphones on handpulse sensor and rear shroud before taking seat handle bar apart. 3. Use 5mm Allen wrench and 13mm open end wrench to release four 3/8"x 1-3/4L Button Head Socket Bolts to take seat handle bar apart.
  • Page 78 4. To take handpulse sensor apart, use Phillips head screw drive to release two 4 x 20 L Sheet Metal Screws. If changing the circuit is necessary, disconnect the sensor cable from the connector and replace. 5. Use Phillips head screw driver to release four M6 x 35 L Phillips head screws to take seat cushion apart. 6.
  • Page 79 10-10 Seat Carriage and the Locking Knob 1. Take apart seatback assembly, seat cushion and seat handle bar respectively. 2. Use Phillips head screw driver to unscrew Track Endcap with four M5 X 16 L Phillips Head Screws and take them apart. 3.
  • Page 80 5. Use L Allen Wrench to release 5/16" × 3/4"_Socket Head Cap Bolt and remove Seat Carriage from Sliding Assembly. 6. Reverse above steps (5 to 2) to return Locking Knob and Seat Carriage.
  • Page 81 10-11 Rear Shrouds 1. Use Phillips head screw driver to release threeØ4x12 Sheet Metal Screws and two 5x16 tapping screws to take apart left rear shroud. Release two 5x16 tapping screws to take right rear shroud apart. To resume rear shrouds, secure right rear shroud first on the main frame with two 5x16 tapping screws and then match both left and right rear shrouds and secure with three ψ4x12 Sheet Metal Screws together with two 5x16 tapping screws.
  • Page 82 10-12 Front and Rear Main Frame 1. Use 5mm Allen wrench to release six 5/16" x 3/4"L Button Head Socket Bolts, six 5/16" x 18 x 1.5T flat washers and six 5/16" x 1.5T split washers which secure front and rear main frame to separate front and rear main frames, from each other. 2.
  • Page 83 10-13 Front and Rear Stabilizers and End Caps 1. To take apart front and rear stabilizers, use 5mm Allen wrench to release four 5/16" x 3/4"L Button Head Socket Bolt, four 5/16" x 18 x 1.5T flat washers and four 5/16" x 1.5T split washers which secure front and rear stabilizers. 2.
  • Page 84 10-14 Console and Error Messages When there is no display, check as below: 1. Make sure the console and computer cables are connected properly. 2. If all are connected properly, take measurements of power outputs to find out the problem. No heart rate is displayed: The console is displaying but there is no HR shown.
  • Page 85 If they are all connected well, check all point contacts. Replace the wire cable if necessary. Error messages and fix: 1. MW shows with blinking “MOTOR ERROR” and motor is not operative normally or the feedback signal is abnormal. Fix: Replacing gear motor; replacing the controller or the console; replacing harness. 2.
  • Page 86 10-15 Belt Slipping and Falling-off 1. Take apart both left and right front shrouds. 2. Check the value of the belt tension with sound wave gauge. The value should be in the range of 250±50HZ. Check if the spring and the belt are getting loose if the value is out of range. If they are getting loose, parts require to be replaced, as shown in figure 1.
  • Page 87 10-16 Noises The causes of noises are mostly loose screws. Sometimes it is because of parts being deformed or shifting causing rubbing or unsmooth moving. Most causes are as follows 1. Noises coming from left and right pedals. This is mostly pedals wear causing noises and not moving smoothly. The worn out pedals must be replaced.

This manual is also suitable for:

Sr147-yb02