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Dyaco XE515SD-YE005 Service Manual

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XE515SD-YE005
Elliptical
Service Manual

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Summary of Contents for Dyaco XE515SD-YE005

  • Page 1 XE515SD-YE005 Elliptical Service Manual...
  • Page 2 -----------------------------------------Table of Content----------------------------------------------- 1. 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 6.5 Driver Board Wire Connections...
  • Page 3 9.8 Tension Motor Problem 10. Q & A 10.1 Noise 10.2 Slip Problem 10.3 Shaking Problem 10.4 Smooth Problem 11. Disassembling and Assembling of Parts 11.1 Console Replacement 11.2 Swing Arm Replacement 11.3 Connecting Arm Replacement 11.4 Pedal Arm Replacement 11.5 Console Mast Replacement 11.6 Side Case Replacement 11.7 Cross Bar Replacement...
  • Page 4 1. Elliptical Outlines...
  • Page 5 (1) Plastic parts Front & back handlebar cover (L) Front & back handlebar cover (R) Swing Arm Bushing Console Left side case Swing Arm Bushing Console mast cover Pedal(L) Right side case Round disk cover Middle cover Rear cover(1) Round disk Pedal(R) Pedal arm cover(R) Rear cover(2)
  • Page 6 結構件 Steel parts Pedal arm (L) upper Swing arm (R) upper Swing arm (L) Console mast Connecting arm (L) Lower Swing arm (L) Connecting arm (R) Lower Swing arm (R) Rear frame Flywheel Drive Pulley Main frame Pedal arm (R) Bushing Housing, Pedal Arm Incline motor Cross Bar...
  • Page 7 2. Electronic Parts...
  • Page 8 2.1 Upper Controllers Cooling FAN THUMB SWITCH Speaker DISPLAY...
  • Page 9 2.2. Lower Controller and Driver TENSION MOTOR SPEED SENSOR MOTOR CONTROLLER INCLINE MOTOR...
  • Page 10 3. Electrical Configurations...
  • Page 11 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 12 4. Elliptical Operation...

  • Page 13: Display Windows

    Display Windows 7.5” LCD Display...
  • Page 14 LCD Layout...
  • Page 15 Operation Window Display Mode IDLE MODE 1.1 Dot matrix display shows program profiles page by page with each page lasts for 3 seconds for each program profile in order with message window showing each name of the program profile. SLEEP MODE 2.1 SLEEP MODE is preset ON（DISABLE）and can be set ON/OF under ENGINEER MODE.
  • Page 16 5.3 When pause mode lasts for 10 minutes without any key is activated, it enters idle mode automatically. 5.4 The resistance and ramp incline levels returns to 1. When “Start” is pressed again, the position of the gear motor resumes and the ramp incline return to the level just before pause.
  • Page 17 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 18 DISTANCE Display the current distance in kilometer or Mile. DISPLAY range is 00:00 to 99:00. WORK range is 00:00 to 9999. CALORIES Displays the cumulative calories burned at any given time during your workout. DISPLAY range is 00.0 to 999. WORK range is 00.0 to 999.
  • Page 19 Function Button Locations C O N T R O L K E Y S PROGRAM BUTTONS (Manual, Adventure, Fatburn, Fan Key Xtreme, Interval, Glute Blast, X Cooling fan switch on or off Country, Fitness, 2 User, 2HR)
  • Page 20 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 21 5. Elliptical Unit Block Diagrams...
  • Page 22 Elliptical Configuration...
  • Page 23 6. Elliptical Basic Connections and Wiring...
  • Page 24 6.1 Display Board wire Connections...
  • Page 25 6.2 Display Board PCB Component Locations PCB Board Top...
  • Page 26 PCB Board Bottom...
  • Page 27 6.3 The console Interface Board wire Connections...
  • Page 28 6.4 Amplifier Board wire Connections...
  • Page 29 6.5 Driver Board Wire Connections...
  • Page 30 Driver Board PCB Component Locations...
  • Page 31 6.7 Driver Board LED Indicator Locations INCLINE MOTOR DOWN INCLINE MOTOR UP POWER...
  • Page 32 6.8 Controller Indicator LED Debugging Indicator Function Condition Reason Solve Motion of incline motor LED1 Motion of incline motor is down. Transistor was broken. Replace controller. Relay failed. LED2 Motion of incline motor Motion of incline motor is up. Transistor was broken. Replace controller.
  • Page 33 6.9 Driver Board Function...
  • Page 34 6.10 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 35 7. Product Safety Instructions...

  • Page 36: Important Safety Instructions

    7.1 Important Safety Instructions - To reduce the risk of electric shock disconnect your Elliptical 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 Elliptical on a flat level surface with access to a 220-volt, 15-amp grounded outlet with only the Elliptical plugged into the circuit.
  • Page 37 8. Elliptical Error Messages / Troubleshooting...
  • Page 38 Error code items： Error Message Explain EEPROM failure Tension motor is failure The console board is not detecting the VR voltage value,or the INCLINE E3 voltage value has exceeded the range. Prepare： Picture Tool name Multi-meter...
  • Page 39 8.1 Error Message： ： ： ： E1 Definition：When EEPROM is damaged or with problem of access, all windows turn off and inputs stop. Dot matrix shows “E-1” and message window shows ”RAM ERROR”. Troubleshooting: Since EEPROM fails, the console board has to be replaced. Error Message ：...
  • Page 40 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 41 Place probes on the motor control wire(Red probe in blue wire, Black probe in green wire) on the drive board.
  • Page 42 8.3 Error Message： ： ： ： INCLINE E3 Definition ： The console board is not detecting the VR voltage value,or the voltage value has exceeded the range.” INCLINE E3” appears on the display. Configuration：...
  • Page 43 LCD show INCLINE E3...
  • Page 44 Case of INCLINE E3 Incline VR value exceeds the range. INCLINE 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 INCLINE E3 appears. Action Flow Chart...
  • Page 45 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 11-pin cable connections. Display board 2.Test whether the VR voltage varies at the incline wire Elliptical. 1.Inspect the wire connections. 11-pin cable 2.Inspect whether wires are broken or crimped.
  • Page 46 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...
  • Page 47 Test Configuration. Incline motor control function relate parts location INCLINE MOTOR The position sensor wires DOWN LED 1.Red = Ground, 2.White = Position signal, 3.Black = 5vdc, (0~5v depending on incline position) BLACK-DOWN INCLINE MOTOR UP LED White-NEUTRAL RED-UP 3,2,1 1.SPEED 2.GND 3.VCC+5V...
  • Page 48 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 49 Error Message： ： ： ： INCLINE E3 Definition：During incline action, the display board CPU cannot read the VR value, so INCLINE E3 appears. Configuration：...
  • Page 50 Cause of INCLINE E3 Press the incline UP/DOWN key. The incline doesn’t operate. INCLINE 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 51 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 52: Circuit Diagram

    8.4 Circuit Diagram...
  • Page 53 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 54 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 55 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 for 110V model(or 220V-230V for 220V model) 3.
  • Page 56 (No pulse displayed on monitor) or only one hand on sensor. 2. The connector of HANDPULSE 2. Connect the cable again. W/WIRE and Console not connected properly. 3. Replace with new cable. 3. The wires got damaged when connecting the HANDPULSE W/WIRE 4.
  • Page 57 9. Troubleshooting...
  • Page 58 9.1 Console Problem (1) 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. (2) Next, check if all the wires are inserted in the firmly and securely on to the console. (3) Then remove the AC adapter fuse to check for damage, replace if damaged.
  • Page 59 (4) 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. 9.2 Side case & Round Disk Problem (1) The potential reason why there could be a problem here is due to the friction created causing abnormal sounds.
  • Page 60 9.3 Flywheel Problem (1) 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.
  • Page 61 9.4 Poly-V Belt Problem (1) 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 62 9.5 Swing Arm Problem (1) 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. solution is to add thick lubricant into the top ofØ17x276L Swing Arm Axle.
  • Page 63 9.6 Connecting Arm and Slide Wheel Problem (1) 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 64 (4) Generally maintenance should start from the sliding wheels, replacing the sliding wheels or adding lubrication to the top of the sliding wheel arcs. Check the main structure for abnormalities, abnormalities in parallel parts, make sure that the problem is with the parts and not assembly before replacing the parts.
  • Page 65 9.7 Controller & Incline Motor Problem (1) 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) To return the incline motor, make sure it has been reset then turn the tubing clockwise to the end as shown in figures 1 and 2.
  • Page 66 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.
  • Page 67 10. Q & A...
  • Page 68 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 69 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. 1-2 Bushing Housing, Pedal Arm: the CAP Socket Head Cap Bolt 3/8 "x2-1/4 on top and nyloc nut 3/8"...
  • Page 70 (2) Belt: This issue appears quite often, because after a period of time, most belts will become loose from use depending on usage time. Solution will depend on weight and adjustment methods, refer to belt disassembly procedures for references.
  • Page 71 (2) Check if there are foreign object on or around the sliding rail, use an alcohol wipe to remove and re-lubricate with lubricant. Although this manual can not cover all of elliptical problems, it describes most of it. Whatever the problem occurs, fixing the problem is back up by Dyaco technical service.
  • Page 72 11. Disassembling and assembling of Parts...

  • Page 73: Console Replacement

    11.1 Console Replacement (1) Use Phillips head screwdriver to remove Phillips Head Screws M5x10mm (4pcs) securing the console. Unfasten all connected wires and remove console. (2) Reassemble in the reverse order as disassembly (Be sure to not crush or damage wiring during process)

  • Page 74: Swing Arm Replacement

    11.2 Swing Arm Replacement (1) Use a Phillips screwdriver to remove Sheet Metal Screws 3.5x12mm securing the swing arm covers (Front and Back) (2) Disconnect the wiring connecting the upper and lower swing arms. (3) Use 12mm open end wrench to remove the hex head bolt 5/16"x15mm and flat washer 5/16"x23x1.5T securing the swing arm assembly.
  • Page 75 (4) 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. Remove swing arm assembly. (5) To take apart the swing arm assembly, use#12 and #13 open end wrenches to release three Hex Head Bolts 5/16"...
  • Page 76 11.3 Connecting Arm Replacement (1) Remove swing arm assembly and swing arm Refer to step 11.2 (If removal of pedal tube, simply remove swing arm with Rod End Bearing attached) (2) Use 12 and #13 open end wrenches to release Hex Head Bolt 5/16" x1-1/4", flat washer 5/16"...
  • Page 77 (5) Use Phillips screwdriver to remove Phillips Head Screw M5x10mm securing the pedal and remove pedal. (6) Reassemble in the reverse order as disassembly...

  • Page 78: Pedal Arm Replacement

    11.4 Pedal Arm Replacement First remove the Pedal Bar Assembly (Refer to step 11.3), 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. (3) Use M8 hex wrench and #14wrench to remove Gap socket screw 3/8”x2-1/4”, two 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 79 To take the slide wheel apart, use Phillips head screw driver to release two Phillips head screws M5x15mm and take the slide wheel cover first. Use circlip pliers to remove circlip Ø17 and remove sliding wheels Reassemble in the reverse order as disassembly. Reverse above steps to resume the pedal arm and return wavy washes Ø...

  • Page 80: Console Mast Replacement

    11.5 Console Mast Replacement Remove the Swing Arms. Refer to step 11.2 Separate Console Mast cover by gently pulling back with your hands, separate left and right cover Use 14mm wrench to remove hex head bolts 3/8”x3/4”, Curved Washers 3/8 "x23 x2T, external hex head bolts 3/8"...
  • Page 81 To dismantle Handpulse Assembly, take the Round Cap apart first and use Phillips head screw driver to release two Tapping Screwsψ3x20mm. Pull out Handpulse W/Cable from the bottom and pull Handpulse Top Cover upward. Reassemble in the reverse order as disassembly -------------------------------------------------------------------------...
  • Page 82 11.6 Side Case Replacement Remove Pedal Arm and Console Mast Assembly. Refer to step 11.4 and 11.5 Use Phillips head screwdriver to remover four Sheet Metal Screws 3.5x16 mm and remove right chain cover. (3) Use Phillips head screwdriver to remover three Sheet Metal Screws 3.5x16 mm and remove left chain cover.
  • Page 83 Unscrew left Chain Cover by releasing three Tapping Screws 5x19mm and disconnect two red Connecting Wires and one green Ground Wire to take left Chain Cover apart. (5) Unscrew right Chain Cover on the mainframe by releasing three Tapping Screws 5x19mm.
  • Page 84 (7) To take AC power switch assembly apart, use Phillips head screw driver to release two Phillips Head Screws M4×12mm and two nuts M4×5T . (6) Reassemble in the reverse order as disassembly (Flat Washer 5/16 "x23x1.5T is to be placed on the left chain cover)
  • Page 85 11.7 Cross Bar Replacement (1) Remove left and right chain cover. (Refer to step 11.6) (2) Remove elliptical side cover Round Disk Cover, use 12mm 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 bolt M8x6.3T (steel lvl 10). Use #13 wrench and hex wrench (M6) to loosen the inner bolt and remove the cross bar.
  • Page 86 (4) Use Phillips head screw driver to release Tapping Screws which secure the Round Disk and separate Cross Bar and Round Disk from each other. (5) When reassembling, place the cross bar into the center of the rotating mandrel. Next place the Woodruff Key with the rounded part facing inwards. Reassemble remaining parts in the reverse order as disassembly...
  • Page 87 11.8 Idler Wheel Replacement Remove the cross bar. (Refer to step 11.7) Use #13 wrench to loosen nyloc nut M8x9T on the hook screws to remove belt. Use #13 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 step 11.8) (2) Use the console to adjust the resistance lvl 20 and remove Steel Cable. 3) Use #15 wrench to loosen nyloc nut 3/8”-UNF26x9T on flywheel and main-frame. Remove flywheel and belt.
  • Page 89 11.10 Rear Frame Replacement 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 wrench and 12mm 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 step 11.10) (2) Use Phillips head screwdriver to remove screws M5x15mm from Rear Bar Cover, Inclinable Rail Cover and Incline Cover, then remove parts.
  • Page 91 (3) Use two 14mm wrenches to remove hex head bolt 3/8”x2-1/2” together with flat washer 3/8"x19x1.5T, nyloc nut 3/8"x7T and two Nylon Washers Ø3/8'' x Ø35 x5T which secure Incline tube and Incline Device. (4) Use two 14mm wrenches to release Hex Head Bolt M10 × 130m/m, Flat Washer x19x1.5T and Nyloc Nut 3/8 x7T which secure the Incline Motor on Rail Base "...
  • Page 92 (5) Use Phillips head screwdriver to remove tapping screw 5x16 from incline motor grounding wire. Cut the wire and remove incline motor. (6) Use 12mm 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 (7) If removal of aluminum rail is needed, remove Phillips head screws M5x15mm from aluminum rail to proceed.