Dyaco XBR55 Service Manual
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Dyaco XBR55 Service Manual

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XBR55
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Summary of Contents for Dyaco XBR55

  • Page 1 XBR55 Service Manual...

  • Page 2: Table Of Contents

    --------------------------------------------Table of Contents------------------------------------------- Recumbent Controllers Outlines Outlines Skeleton Electronic Parts Upper Controllers Lower Controller and Driver Electrical Configurations Product Operation Unit Block Diagrams Basic Connections and Wiring Product Safety Instructions Error Messages / Troubleshooting Troubleshooting 9-1 Console Disassembling and assembling 9-2 Console Mast and Cover 9-3 Crank Arm and Pedal 9-4 Front Shroud &...
  • Page 3 9-16 Console 9-17 Belt Slipping and Falling-off 9-18 Noises...
  • Page 4 1. XBR55 Outlines...
  • Page 5 Console Mast Handle bar Assembly Assembly Mesh Seat Back Pedal (R) Crank Arm (L) Cable Assembly(L) Round Disk Seat Drink Bottle Holder (R) Pedal (L) Aluminum Track Front Shroud (L) Rear Shroud (R) Bottom Cover Handgrip End Cap...
  • Page 6 Handle Bar Cover Seat Back Bracket Console Mast Seat Carriage Crank Arm End Cap Seat Handle Bar Flywheel Idler Wheel Assembly Drive Pulley Main Frame Rear Stabilizer...

  • Page 7: Electronic Parts

    2. Electronic Parts...

  • Page 8: Upper Controllers

    Upper Controllers Cooling FAN DISPLAY...

  • Page 9: Lower Controller And Driver

    Lower Controller and Driver SPEED SENSOR TENSION MOTOR...

  • Page 10: Electrical Configurations

    3.Electrical Configurations...
  • Page 11 ONSOLE Interface that controls all functions of the Bike. ENSION MOTOR It can change to increase or decrease resistance level of brake. ENERAL NFORMATION ONSOLE Contains Key controls and LCD Display. Main controller Include power supply and motor driver control circuit .
  • Page 12 Tension motor Work voltage:DC 4.5~7.5V Control resistance increases and decreases.

  • Page 13: Product Operation

    4. XBR55 Product Operation...
  • Page 14 Display Windows 7.5” LCD Display...
  • Page 15 LCD Layout...
  • Page 16 Operation Window Display Mode IDLE MODE 1.1 Each program profile will be displayed on the MESSAGE WINDOW sequentially.And recycle display 『PRESS START FOR QUICK START OR PROGRAM BUTTON FOR SETUP』at the same time. 1.2 Heart rate bar LED and Track LED will be display stand light. DATA window (7 segment display window) display RPM= 000，CALORIES= 000，TIME = 00:00，DISTANCE = 0.00，PULSE = - - -。During 5 minutes no press any key will into IDEL MODE(no contain IDEL MODE) DISPLAY MODE...
  • Page 17 4.2 You could chose the program by pressing the key: MANUAL、PROGRAM、HRC . And then, press “START” key to start the workout. parameter will be the preset value. 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.
  • Page 18 END MODE 6.1 The message window will display “ WORKOUT SUMMARY ” after end workout and display workout data 1 minutes. 6.2 END MODE： 6.2.1 Display exercise data in message window each three seconds display 『TOTAL TIME XX:XX』 、 『AVG SPD XX.X』 、 『AVG WATT XXX』 、 『AVG HR XXX』...
  • Page 19 Function SPEED Display the current speed in mile per hour. DISPLAY range is 0.0 to 99.9 WORK range is 0.0~99.9 LEVEL Display the level position from 0 to 20. DISPLAY range is 0 to 999. WORK range is 0 to 20. LEVEL preset value is 0 to 20.
  • Page 20 DISTANCE Display the current distance in Mile. DISPLAY range is 00.0 to 99.9. WORK range is 00.0 to 99.9. 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. PULSE Displays the heart rate beat by using hand pulse or receiver.
  • Page 21 Function Button Locations PROGRAM BUTTONS (Manual, Hill, Fat Burn ,Cardio,Strength, Interval,User1~2, HR1~2) CONTROL KEYS Fan Key Cooling fan switch on or...
  • Page 22 Function Button In Main Mode READY MODE STOP button: Non-function. START button: Pressing “ START ” button to start Bike. In MANUAL, Bike starts at MIN LEVEL . LEVEL UP button: If user doesn’t enter a setting then this button is non-functional. LEVEL DOWN button: If user doesn’t enter a setting then this button is non- functional.
  • Page 23 RUN MODE STOP button: press “STOP” button to stop Bike. 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. Fan button: It can to control ON/OFF for the fan.

  • Page 24: Unit Block Diagrams

    5. XBR55 Unit Block Diagrams...
  • Page 25 Bike Configuration...

  • Page 26: Basic Connections And Wiring

    Basic Connections and Wiring XBR55...
  • Page 27 Display Board wire Connections...
  • Page 28 Display Board PCB Component Locations PCB Board Top...
  • Page 29 PCB Board Bottom...
  • Page 30 The console Interface Board wire Connections...
  • Page 31 Tension Motor connector definition function STEEL ROPE MAIN CONTROL 1.M+ 2.M- 3.+5V 4.VR 5.GND...

  • Page 32: Product Safety Instructions

    7. Product Safety Instructions...
  • Page 33 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 115-volt, 15-amp grounded outlet with only the Bike plugged into the circuit.

  • Page 34: Error Messages / Troubleshooting

    Error Messages / XBR55 Troubleshooting...
  • Page 35 Error code items： Error Message Explain EEPROM ERR EEPROM failure Tension motor is failure  Prepare： Picture Tool name Multi-meter...
  • Page 36  Error Message：EEPROM ERR  Definition: All screens are off, and outputs are stop when EEPROM damaged or malfunction.Display message will show “ ”. EEPROM ERR  Troubleshooting: Replace upper controller.
  • Page 37  Error Message ： - -  Definition：When you press the Level Up or Down key,the motor does not move.” --” appears on the display.  Configuration：...
  • Page 38  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 ...
  • Page 39 Place probes on the motor control wire(Red probe in palm wire,Black probe in black wire) on the drive board.
  • Page 40  Test configuration. The console to driver board connector pin define function The console to driver board connector pin define function: 1. MTR- 2. MTR+ 3. +5V 4. MPOS 5. GND 6. RPM1 7. GND 8. RPM2 9. GND 10. +12V 11.N/A 12.
  • Page 41 XBR55 BIKE CIRCUIT DIAGRAM...
  • Page 42 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 43 9. Troubleshooting...

  • Page 44: Console Disassembling And Assembling

    Console Disassembling and assembling 1. Use Phillips Head Screw Driver (114) to release four pcs of M5 × 12 m/m_Phillips Head Screw (99) and unplug Computer Cable (44), 2100m/m_Handpulse Wire, Coiled (133) and 2100m/m_Switch Cable (Upper)_(148), and then replace the Console Assembly (19). 2.

  • Page 45: Console Mast And Cover

    Console Mast and Cover (Take the console apart first.) 1. Take the console apart first. 2. Then use 12/14 m/m wrench (112) to release 2pcs of 5/16" x5/8" Hex Head Screws (68), 2pcs of 5/16"x1.5T Split Washers and 2pcs of 5/16”x18x1.5T Flat Washers (76) and the Handlebar Assembly (3) can be released, as shown in figure. 3.
  • Page 46 5. To resume Console Mast (2), guide the Computer Cable (44) and Hand Pulse Sensor Assembly W/Cable (45) through the Console Mast (2) and out of console securing plate (2~3) then tighten 6pcs of 5/16"×5/8"Hex Head Bolts (68), 6pcs of 5/16"×18×1.5T Flat Washers (76) and 2pcs of 5/16"×19×1.5T Curved Washers (83) with 12m/m open wrench.

  • Page 47: Crank Arm And Pedal

    Crank Arm and Pedal 1. Use 13/15mm Wrench to turn the left pedal clockwise and the right pedal counterclockwise to take off those pedals. 2. Turn Pedals reversely respectively to return them. 3. Take off the Crank Arm End Cap (28), and then use T-Wrench or Plug Wrench to release the Nut, as shown in figure 3 and 4.

  • Page 48: Front Shroud & Round Disk

    Front Shroud & Round Disk 1. Dismantle and take apart Crank Arm (51L. 51R) 2. Remove the round disk (34) with fingers. 3. When assemble the round disk pay attention to the direction, because latch has different size, FRONT facing forward and then assemble.( figures 4.) 4.

  • Page 49: Gear Motor, Steel Cable And Reed Switch Sensor

    Gear Motor, Steel Cable and Reed Switch Sensor 1. Take both left and right front shrouds apart. (29)。 2. Remove the Steel Cable (62) on the Flywheel (55). Be careful to treat the aluminum plate gently as it deforms easily to cause scratching noises as shown in figure.
  • Page 50 4. Use Phillips head screw driver to remove M5 × 12m/m_Phillips Head Screw (99) and take the Reed Switch Sensor (46) apart, as shown in figure. 5. To adjust the cable range with the Console (19) when reassembling the Steel Cable (62), increase the resistance to max. level with the console and tighten the Steel Cable with screw.

  • Page 51: Drive Pulley Axle And Drive Pulley

    Drive Pulley Axle and Drive Pulley 1. Disassemble Front Shrouds (29.30) and the Drive Belt (54). 2. Use C-ring pliers to release Ø 20_C-ring (86) to take apart Crank Axle (8), as shown in figure 1. 3. Use 11mm_wrench to to unscrew Crank Axle (8) and Drive Pulley (20), 4 pcs of 1/4" × 3/4"_Hex Head Bolts (66) together with 8 pcs of 1/4"...

  • Page 52: Flywheel And Drive Pulley

    Flywheel and Drive Pulley 1. Take both left and right front shrouds(29)(30). 2. Use 13 mm open end wrench to loosen the Nyloc Nut (88) on the J Bolt (87) and remove the J Bolt (87), as shown in figure. 3.
  • Page 53 4. Remove the Drive Belt (54), as shown in figure. 5. Remove the steel cable on the Flywheel (55) and use 15 mm open end wrench to release 3/8"-UNF26_Nut (121) on the Flywheel (55) to remove the Flywheel (55), as shown in figure.
  • Page 54 6. To resume, hang the Drive Belt (54) on the Flywheel (55) then install the Flywheel on the Mainframe (1). Try to align the Flywheel with the Pulley (20) in line and turn the Nut (120) outward till it touches the Mainframe (1) then use 15 mm and 17 mm open end wrenches to tighten the Nut (120) and 3/8"-UNF26_Nut (121).
  • Page 55 8. Return the Drive Belt (54) back to Drive Pulley (20) and the Flywheel (55), then turn the Drive Pulley to make sure the belt turns smoothly in the center. Loosen the 3/8"-UNF26_Nut (121) on the Flywheel (55) and adjust both Nuts (119) and (120) if the Belt is not in the center.

  • Page 56: Disassembling/Assembling Of Seat Carriage Cover And Seat Back Bracket

    Disassembling/Assembling of Seat Carriage Cover and Seat Back Bracket 1. Use Phillips Head Screw Driver to release 4 pcs of Ø 4 × 16m/m_Sheet Metal Scre (105). 2. Use two 14mm_Wrenchs to release 2 pcs of 3/8" × 4"_Hex Screw (67) and 2 pcs of 3/8" × 7T _Nyloc Nut(89).
  • Page 57 3. Use a 12 mm and 13 mm Wrench to release a 5/16" × 1- 1/4"_Hex Screw (70) and a 5/16" × 18mm × 1.5T_Flat Washer (76), and then you could take Seat Back Assembly (5) and Mesh Seat Back (63) off. Loose the cable from the Mesh Seat Back (63).

  • Page 58: Release Lever And Steel Cable

    Release Lever and Steel Cable Steel Cable (58): Use the 8m/m_Wrench to fix the Nut of Gas Cylinder (See figure 1). Use the Wrench to release the Head Bolt of Release Lever (40) (See figure 2) and also remove the Steel Cable (280L) (58). Reverse above steps to resume. Release Lever (40): Remove the Steel Cable (280L) (58) first and use 12/13m/m_Wrench to release the 5/16"...

  • Page 59: Gas Cylinder (Remark 8)

    9-10 Gas Cylinder (Remark 8) 1. Use Phillips Head Screw Driver to loosen 2 pcs of M5 × 12_Phillips Head Screw (99), and then take off the Seat Carriage Cover (125), as shown in figure 1. 2. Use 2 pcs of 13mm_wrenchs to release a 5/16" × 2- 1/2"_Hex Head Screw (69), a 5/16" × 18mm × 1.5T_Flat Washer (76), and a 5/16"_Nyloc Nut (91), as shown in figure 2.
  • Page 60 3. Use a 12 mm and a 13mm wrench to release a 5/16" × 1- 1/4"_Hex Head Screw (70), a 5/16" × 18mmx1.5T_Flat Washer (76), and a 5/16"_Nyloc Nut (91), as shown in figure 3. 4. Use 8 mm Wrench to release the screws Secured on the steel cable, and then take Steel Cable (58) and Gas Cylinder (57) apart, and take Gas Cylinder (57) off, as shown in figure 4.

  • Page 61: Seat, Seat Handle Bar And Handpulse W/Cable

    9-11 Seat, Seat Handle Bar and Handpulse W/Cable Assembly 1. Take Left and Right Bottle Holder (38, 39) and Release Lever (40) off. 2. Use Phillips Head Screw Driver to release four M6 × 15m/m_Phillips Head Screws (98) and take the Seat (61) apart, as shown in figure 1.
  • Page 62 4. Take apart HGP Wire Grommet (126) which secure Handpulse Assemblies (27). Use Phillips Head Screw Driver to release four Ø 3 × 20m/m_Tapping Screws and take Handpulse Assemblies (27) apart, as shown in figure 3 and 4. 5. Reverse above steps to return parts.
  • Page 63 Buttons on The Handle Bar (Remark 9) 9-12 1. Use your hand or the tool with flat bead to take the Handgrip End Cap (144) off and get Resistance Button W/Cable (145) out, as shown in figure 1. 2. Take apart Resistance Button W/Cable (145) and Switch Cable (lower) (151), as shown in figure2. 3.

  • Page 64: Rear Shrouds And Harness

    4. Pay attention to reverse the Headgrip End Cap’s direction. Must match the rasied part on Handlegrip End Cap (144) with the concave part on Handbar (6). 9-13 Rear Shrouds and Harness 1. Use Phillips Head Screw Driver to release 7 pcs of Ø 3.5 × 16m/m_Sheet Metal Screws (103) and 2 pcs of 5 × 16m/m_Tapping Screws (101) which are on left Rear Shroud (35).
  • Page 65 2. On the Right Rear Chain Cover (36), unscrew Ø 3.5x16 Self Tapping Screws (103) with 3/16" × 15mm × 1.5T_Flat Washers (78) and 2pcs of 5x16 Tapping Screws (101) and the Right Rear Chain Cover (36) can be released as shown in figure)。...

  • Page 66: Seat Carriage

    9-14 Seat Carriage 1. Disassemble Rear Shrouds (35, 36). 2. Use Phillips Head Screw Driver to 2 pcs of M6 × 15_screws (98) and Seat Stop Axles (11) can be taken apart, as shown in figure 1. Pull up Release Lever (40) to take Seat Carriage (4) apart. 3.
  • Page 67 6. Use Phillips Head Screw Driver to release four M6 × 10L_Flat Phillips Head Screws (161), 4 pcs of 1/4" × 16 × 1.0T_Flat Washer and four Sleeve (162). Then use 13 mm Open End Wrench to release four M8 ×7T _Nyloc Nuts (88) and four Ø...
  • Page 68 8. Use Phillips Head Screw Driver to release two M5×25m/m Flat Head Socket Screws (169) then pull out Lever Anchor (168) to take apart Seat Front/Aft Adjustment Lever (167) as shown in figure. 9. Use M5 Allen wrench and 11mm Open End Wrench to take apart M6 × 38m/m_Socket Head Cap Bolt (93), 1/4" × 13 × 1T_Flat Washer (72) and M6_Nyloc Nut (129), and then take off Seat Position Latch (12), as shown in figure 5.
  • Page 69 10. To install Seat Front/Aft Adjustment Lever (167), consolidate Seat Front/Aft Adjustment Lever (167) and Lever Anchor (168) and secure with two M5×25m/m Flat Head Socket Screws (169) then place Spring (104) in Seat Position Latch (12) and secure with a M5×45m/m Socket Head Cap Bolt (171) by going through Seat Position Latch (12), Spring (104), ø...
  • Page 70 13. To test the smoothness, if seat carriage is too tight, reversely adjust four screws until the smoothness is acceptable. Tighten four Sleeves (163) with four 1/4" × 16 ×1.0T_Flat Washers, M6 × 10L_Flat Phillips Head Screws (161) to secure. Seat Stop Axle (11) and Rear Shrouds (35, 36) can be installed.

  • Page 71: Aluminum Trail And Stabilizer Cover

    9-15 Aluminum Trail and Stabilizer Cover Induction Brake Controller After taking Rear Chain Cover (L/R)_(35, 36), unplug the cables on the Induction Brake controller (43), and then use Phillips Head Screw Driver to release 2 pcs of 5 ×19_Tapping Screws and take apart Induction Brake Controller (43), as shown in figure 1.
  • Page 72 Step Cover Take apart Rear Shroud (35, 36) and Front Shroud (29, 30), and then use Phillips Head Screw Driver to release 4 pcs of M5 ×12_Head Screws (99), and then take apart Step Cover (33), as shown in figure 3.
  • Page 73 9-16 Console Q Display won’t come on: 1. Follow procedures below for checking when your display couldn’t show anything. 2. Make sure that Console (19) and computer cable (44) are connected properly, as shown in figure 1. 3. Use multi-meter to check output voltage at each connect contact. Q No speed readout: 1.
  • Page 74 9-17 Belt Slipping and Falling-off Q:Slippage 1. Disassemble Front Shrouds 2. Use 13m/m Wrench to turn M8×7T Nyloc Nut (88) clockwise until sound wave frequency falls between 450N. However, since the machine is with drive belt, slippage is possible depending on the weight of the user or the way the user uses.
  • Page 75 9-18 Q: Noises A: Noises are mostly caused by loose screws/bolts, sometimes rubbing or poor smoothness due to mechanical deformity/shifting may also causes noises: 1. Noises at Seat Carriage (4) are mostly caused by loose Seat Wheel Adjustment Plate due to long time usage and usually accompanied with serious play.
  • Page 76 3. Crank Arm (51L.R) loose can also cause poor smoothness and noises, although the chance is low. Tighten, as shown in figure 3, to remedy noises 4. If noises still persists after disassembling Front Shrouds (29, 30), find the spot where noises initiate and replace parts when necessary.

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