Dyaco Canada XE528s Service Manual

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XE528s Service Manual

Plastic Parts

Round Disk Cover, Crank

Round Disk Cover

Rear Console Cover

Front Handlebar Cover (L)

Pedal Arm Cover (L)

Connecting Arm Cover B (L)

Connecting Arm Cover A (L)

Front Stabilizer Cover

Front Console Cover Front Handlebar Cover (R)

Console

Slide Wheel Cover Rear Stabilizer Cover B

Left Pedal

Chain Cover (L)

Right Pedal

Chain Cover (R)

Console Mast Cover

Rear stabilizer Cover A

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Summary of Contents for Dyaco Canada XE528s

Page 1 XE528s Service Manual Plastic Parts Round Disk Cover, Crank Front Console Cover Front Handlebar Cover (R) Round Disk Cover Console Right Pedal Rear Console Cover Chain Cover (R) Front Handlebar Cover (L) Console Mast Cover Pedal Arm Cover (L) Rear stabilizer Cover A...
Page 2 Skeleton Cross Bar Adjustable Pedal (L) Bushing Housing Connecting Arm (R) Console Mast Adjustable Pedal (R) Handlebar (R) Main Frame Rail Assembly Fly Wheel Pedal Arm (L) Pedal Arm (R) Drive Pulley Connecting Arm (L) Slide Wheel...
Page 3: Table Of Contents
CONTENTS I. Disassembling and replacing of parts 1. Console 2. Connecting Arms 3. Pedal Arms 4. Left and right Chain Covers 5. Cross Bar 6. The Belt 7. Idler wheel Assembly 8. Fly Wheel 9. Drive Pulley 10. Bushing Housing 11.
Page 4 Disassembling and Replacing Model XE528s Work Parts 1 Console Procedures 1. Use Phillips head screw driver to release 3pcs of M5x12mm screws and 2pcs of 3.5x12 self tapping screws to take apart both Front and Rear Console Covers. Then release 4pcs of M5 x 10 mm screws which secure the Console.
Page 5 Disassembling and Replacing Model XE528s Work Parts 2 Connecting Arms Procedures： 1. Unscrew Connecting Arm Covers A and B with Phillips head screwdriver, as shown in figures 1 and 2. 2. Use 12 mm and 13 mm wrenches to release 5/16" x1-1/4" hex head bolt together with 5/16"...
Page 6 Disassembling and Replacing Model XE528s Work Parts 2 Connecting Arms Procedures： 1. Use Phillips head screwdriver to release 4pcs of M5x10mm screws and take off the Pedal, as shown in figure 6. 2. Use Phillips head screwdriver to release 4pcs of M5x10mm screws to take off the Locking Pin Holder, as shown in figure 7.
Page 7 Disassembling and Replacing Model XE528s Work Parts 2 Connecting Arms Procedures： 5. Put Adjustable Pedal and Connecting Arm together and return the Locking Pin with ψ13.5x 38.5L spring, pull it backward and return the C-ring by using C-ring pliers, as shown in figure 10.
Page 8 Disassembling and Replacing Model XE528s Work Parts 3 Pedal Arms Procedures 1. Follow procedures 2 to take Connecting Arm apart. 2. Use Phillips head screwdriver to unscrew Pedal Arm Cover, as shown in figure 1. 3. Use M6 and 13 mm wrenches to release M8 x 50 socket head cap screw, 2pcs of 5/16"×20×1.5T flat...
Page 9: Console
Disassembling and Replacing Model XE528s Work Parts 4 Chain Covers Procedures 1. Follow procedures 2 and 3 to take apart Connecting Arm and Pedal Arm. 2. Slightly press Console Mast Cover to separate from Chain Covers, as shown in figure 1.
Page 10: Connecting Arms
Disassembling and Replacing Model XE528s Work Parts 4 Chain Covers Procedures 5. To resume, connect DC cable back on first. 6. Return Left Chain Cover back on the Main frame (be sure to put a 5/16" x 23 x 1.5T flat washer between the...
Page 11: Pedal Arms
Disassembling and Replacing Model XE528s Work Parts 5 Cross Bar Procedure 1. Follow procedures 2, 3 and 4 to take apart Connecting Arm, Pedal Arm and both Chain Covers. 2. Use a sharp stick to take off Round Disk Cover, as shown in figure 1.
Page 12 Disassembling and Replacing Model XE528s Work Parts 5 Cross Bar Procedures 4. To resume, secure Round Disk Cover, Crank onto the Cross Bar and return and align it on the Crank Axle. Return 7x7x25L Woodruff Key in the hole. Tighten M8x30 socket head cap screw until it reads 600 Kg-cm.
Page 13: Cross Bar
Disassembling and Replacing Model XE528s Work Parts 6 The Belt Procedures 1. Follow procedures 2, 3, 4 and 5 to take apart Connecting Arm, Pedal Arm, both Chain covers and Cross Bar Assembly. 2. Use 13 mm wrench to loosen M8 x 7T nuts on M8x170mm J-bolt and on Idler wheel Assembly.
Page 14: The Belt
Disassembling and Replacing Model XE528s Work Parts 7 Idler Wheel Assembly Procedures 1. Follow procedures 2, 3, 4, 5 and 6 to take Connecting arm, Pedal Arm, both Chain Covers, Cross Bar Assembly and the Belt. 2. Use 13 mm wrench to loosen M8 x 7T nut on M8x170mm J-bolt until J-bolt is off.
Page 15: Idler Wheel Assembly
Disassembling and Replacing Model XE528s Work Parts 8 Fly Wheel Procedures 1. Follow procedures 2, 3, 4, 5, 6 and 7 to take apart Connecting Arm, Pedal Arm, Both Chain Covers, Cross Bar Assembly, the Belt and Idler Wheel Assembly.
Page 16: Fly Wheel
Disassembling and Replacing Model XE528s Work Parts 8 Fly Wheel Procedures 3. To resume the Fly Wheel, return the Belt onto the notches on the Fly Wheel pulley and return the Flywheel on the Main Frame. 4. Return and tighten 3/8" -UNF26 x 9T nuts at each side.
Page 17: Drive Pulley
Disassembling and Replacing Model XE528s Work Parts 9 Drive Pulley Procedures： 1. Follow procedures 2, 3, 4, 5 and 6 to take apart Connecting Arm, Pedal Arm both Chain Covers Cross Bar Assembly and the Belt. 2. Use C-ring Pliers to release both ψ...
Page 18: Bushing Housing
Disassembling and Replacing Model XE528s Work Parts 10 Bushing Housing Procedures： 1. Follow procedures 2 and 3 to take apart Connecting Arm and Pedal Arm. 2. Use 12 mm wrench to release 5/16" x 15m/m hex head bolt and 5/16" x 35 x 1.5T flat washer and take off...
Page 19: Slide Wheels
Disassembling and Replacing Model XE528s Work Parts 11 Slide Wheels Procedures： 1. Follow procedures 2 and 3 to take Connecting Arm and Pedal Arm apart. 2. Use Phillips head screwdriver to take off Slide Wheel Cover, as shown in figure 1.
Page 20 Model XE528s Work Troubleshooting Parts 1 Console Procedures 1. Follow the procedure below to diagnosis when the display is blank. 2. Make sure that power is plugged in properly and check the continuity of the cables. Make sure there is no damages with cables., as shown in...
Page 21: Noises
Model XE528s Work Troubleshooting Parts 2 Chain Covers and Round Disk Cover Rev Procedures 1. The problems are usually grinding noises due to rubbing between two parts. The cause is normally misalignment or swing of the Drive Pulley, as shown in figures 1 and 2.
Page 22 Model XE528s Work Troubleshooting Parts 3 Fly Wheel Procedures 1. The problem with Flywheel is rare and usually the noise is caused by the cable is not adjusted correctly or not assembled properly that causes shifting. Follow the procedures to...
Page 23 Model XE528s Work Troubleshooting Parts 4 The Belt Procedures 1. If the Belt drops off, release right Chain cover and loosen the Idler Wheel Assembly and return the Belt. Turn the Belt slowly and watch for the swing and the alignment of the Belt, Drive Pulley and Flywheel.
Page 24 Model XE528s Work Troubleshooting Parts 5 Left and Right Handlebars Procedures： 1. There is a 0.05mm~0.07mm tolerance for the Handlebar on its shaft for moving 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.
Page 25 Model XE528s Work Troubleshooting Parts 6 Bushing Housing Procedures： 1. The problem with Bushing 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.
Page 26 Model XE528s Work Troubleshooting 7 Pedal Arm, Connecting Arm and Sliding Wheels Parts Procedures： 1. Since ellipticals a lot of levers to connect and move parts, Parts interact and affect others a lot. It is very important to lubricate each moving parts and joints, as shown in figures 1 and 2.
Page 27: Slippage
Model XE528s Work Troubleshooting 7 Pedal Arm, Connecting Arm and Sliding Wheels Parts Procedures： 1. Both Handlebars should connect properly with their corresponding connecting Arm and Sliding wheels should have real circle without slippage. 2. During maintenance, start from sliding wheels by applying lubricant on wheels or replace if necessary, as shown in figures 3 and 4.
Page 28 Q＆A Model XE528s Work Problem 1 Noises Procedures： 1. The part making noises is hard to identify. From 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.
Page 29 Q＆A Model XE528s Work Problem 2 Slippage Procedures： 1. There are 4 parts that may slip. M12 x P1.75 Fish-eye bearing: M12 nut must be firmly tightened with Connecting Arm and fish-eye bearing perpendicular to the bolt, as shown in figure 1.
Page 30: Wobble
Q＆A Model XE528s Work Problem 3 Wobble Procedures： 1. Wobble is usually caused by loose screw. When there is wobble, try to tighten 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.
Page 31: Smoothness
Q＆A Model XE528s Work Problem 4 Smoothness 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,...
Page 32 Q＆A Model XE528s Work Problem 5 Other Problems Procedure： 1. Contact DYACO for problems not covered in this service manual. Any problem solving on the unit is backed-up by DYACO technical team.