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Dyaco XE530s Service Manual

Elliptical trainer
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XE530s Service Manual
I.
Plastic Parts
Front/Rear Handlebar Cover (L)
Front/Rear Handlebar Cover (R)
Front/Rear Console Cover
Round Disk Cover, Crank
Console
Right Chain Cover
Console Mast Cover
Right Pedal
Round Disk Cover Left Chain Cover Left Pedal
Connecting Arm Cover B (L) Rail Cover (L)(metal)
Rail Cover (R)(metal)
Connecting Arm Cover A (L)
Rail Support Assembly (metal)
Front Stabilizer Cover
Pedal Arm Cover (L)

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Summary of Contents for Dyaco XE530s

  • Page 1 XE530s Service Manual Plastic Parts Front/Rear Handlebar Cover (L) Front/Rear Handlebar Cover (R) Front/Rear Console Cover Round Disk Cover, Crank Console Right Chain Cover Console Mast Cover Right Pedal Round Disk Cover Left Chain Cover Left Pedal Connecting Arm Cover B (L) Rail Cover (L)(metal)

  • Page 2: Connecting Arms

    Skeleton Left Handlebar Right Handlebar Bushing Housing Adjustable Pedal (L) Pedal Arm (L) Connecting Arm (R) Console Mast Adjustable Pedal (R) Fly Wheel Locking Pin Assembly Drive Pulley Pedal Arm (R) Cross Bar Slide Wheel Main Frame Connecting Arm (L) Rail Assembly...

  • Page 3: Table Of Contents

    CONTENTS . Disassembling and replacing of parts 1. Console 2. Connecting Arms 3. Pedal Arms 4. Left and Right Chain Covers 5. Cross Bar Assembly 6. The Belt 7. Idler Wheel Assembly 8. Fly Wheel 9. Drive Pulley 10. Bushing Housing 11.
  • Page 4 Model XE530s Work Disassembling parts 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 Model XE530s Work Disassembling parts Parts 2 Connecting Arm Procedures 1. Unscrew Connecting Arm Covers A with Phillips head screwdriver, as shown in figures 1 and 2. Use 12 mm and 13 mm wrenches to release 5/16" x1-1/4" hex head bolt together with 5/16"...
  • Page 6 Model XE530s Work Disassembling parts Parts 2 Connecting Arm Procedures 5. Use Phillips head screwdriver to release 4pcs of M5x10mm screws and take off the Pedal, as shown in figure 6. 6. Use Phillips head screwdriver to release 4pcs of M5x10mm screws to take off the Locking Pin Holder, as shown in figure 7.

  • Page 7: Pedal Arms

    Model XE530s Work Disassembling parts Parts 2 Connecting Arm Procedures 9. Put Adjustable Pedal and Connecting Arm together and return the Locking Pin with 13.5x 38.5L spring, pull it backward and return the C-ring by using C-ring pliers, as shown in figure 10.
  • Page 8 Model XE530s Work Disassembling parts Parts 3 Pedal Arm Procedures 1. Follow procedures take Connecting Arm apart. 2. Use Phillips head screwdriver to unscrew Pedal Arm Cover and Front Cover, top, as shown in figure 1 and 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 Disassembling and Replacing Model XE530s 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 Disassembling and Replacing Model XE530s Work Parts 4 Chain Covers Procedures 5. To resume, connect DC cable back on first. 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 Disassembling and Replacing Model XE530s 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 XE530s Work Parts 5 Cross Bar Procedures 5. 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...

  • Page 13: Cross Bar Assembly

    Disassembling and Replacing Model XE530s 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 XE530s 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. Use 13 mm wrench to loosen M8 x 7T nut and 5/16"...

  • Page 15: Idler Wheel Assembly

    Disassembling and Replacing Model XE530s 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 XE530s Work Parts 8 Fly Wheel Procedures 4. To resume the Fly Wheel, return the Belt onto the notches on the Fly Wheel pulley return Flywheel on the Main Frame. 5. Return and tighten 3/8" -UNF26 x 9T nuts at each side.

  • Page 17: Drive Pulley

    Disassembling and Replacing Model XE530s 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...

  • Page 18: Bushing Housing

    Disassembling and Replacing Model XE530s 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 XE530s Work Parts 11 Slide Wheels Procedures 1. Follow procedures 2 and 3 to take Connecting Arm and Pedal Arm apart. 2. Use C-ring pliers to take off C-ring and release Slide Wheel, as shown in figure 1.

  • Page 20: Console

    Model XE530s 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 are no damages with cables, as shown in figure 1.
  • Page 21 Model XE530s Work Troubleshooting Parts 2 Chain Covers and Round Disk Cover Rev Procedures The problems are usually grinding noises due to rubbing between two parts. cause normally misalignment or swing of the Drive Pulley, as shown in figures 1 and 2.

  • Page 22: Fly Wheel

    Model XE530s Work Troubleshooting Parts 3 Fly Wheel Procedures 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 release the Flywheel and cable to...

  • Page 23: The Belt

    Model XE530s Work Troubleshooting Parts 4 The Belt Procedures 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: Handlebars

    Model XE530s Work Troubleshooting Parts 5 Left and Right Handlebars Procedures 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: Bushing Housing

    Model XE530s Work Troubleshooting Parts 6 Bushing Housing Procedures The problem with Bushing Housing is rare. However, a few units might have noise problem as time lasts. Applying some grease on 25 x 111.5 shaft Cross Assembly, as shown in figure 1, may be helpful for solving this problem.
  • Page 26 Model XE530s Work Troubleshooting 7 Pedal Arm, Connecting Arm and Sliding Wheels Parts Procedures 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 XE530s Work Troubleshooting 7 Pedal Arm, Connecting Arm and Sliding Wheels Parts Procedures 3. Both Handlebars should connect properly with their corresponding connecting Arm and Sliding wheels should have real circle without slippage. During maintenance, start from sliding wheels by applying lubricant on wheels or replace if necessary, as shown in figures 3 and 4.
  • Page 28 Model XE530s Work Problem 1 Noises Procedures 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 Model XE530s Work Problem 2 Slippage Procedures There are 4 parts that may slip. M12 x P1.75 Fish-eye bearing: M12 nut must be firmly tightened with Connecting fish-eye bearing perpendicular to the bolt, as shown in figure 1. Bushing Housing: M8 x 50m/m socket head cap screw must be firmly tightened with M8 x 7T nut.

  • Page 30: Wobble

    Model XE530s Work Problem 3 Wobble Procedures 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

    Model XE530s Work Problem 4 Smoothness Procedures 1. Check tightness of screws and bolts if the unit clicks. 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: Other Problems

    Model XE530s Work Problem 5 Other Problems Procedure Contact DYACO for problems not covered in this service manual. Any problem solving on the unit is backed-up by DYACO technical team.

Table of Contents