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Dyaco XBU55 Service Manual

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XBU55
Service Manual
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Summary of Contents for Dyaco XBU55

  • Page 1 XBU55 Service Manual...

  • Page 2: Table Of Contents

    --------------------------------------------Table of Contents------------------------------------------- 1. XBU55 Outlines 2. Electronic Parts 3. Electrical Configurations 4. Product Operation 5. Unit Block Diagrams 6. Basic Connections and Wiring 7. Product Safety Instructions 8. Error Messages / Troubleshooting 9. Troubleshooting 9-1. Console 9-2. Handle Bar and Console Mast(Take apart the console.) 9-3.

  • Page 3: Xbu55 Outlines

    1. XBU55 Outlines...
  • Page 4 Console Handgrip Side Assembly Drink Bottle Holder Console Mast Cover Seat Pedal(L) Seat Post Round Disk Cover Cover Chain Cover (L) Handgrip End Cap...
  • Page 5 Handle Bar Sliding Seat Mount Console Mast Seat Slider Crank Arm Drive Pulley Crank Axle Bearing Housing Main Frame Rear Stabilizer...

  • Page 6: Electronic Parts

    2. Electronic Parts...
  • Page 7 Upper Controllers Cooling FAN DISPLAY...
  • Page 8 Lower Controller and Driver TENSION MOTOR SPEED SENSOR...

  • Page 9: Electrical Configurations

    3.Electrical Configurations...
  • Page 10 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 11 Tension motor Work voltage:DC 4.5~7.5V Control resistance increases and decreases.

  • Page 12: Product Operation

    4. XBU55 Product Operation...
  • Page 13 Display Windows 7.5” LCD Display...
  • Page 14 LCD Layout...
  • Page 15 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 = - - -。...
  • Page 16 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. 5.2 In PAUSE MODE, it will display PAUSE.After 5 seconds,MW will show” PRESS START TO RESUME OR STOP TO END WORKOUT” 5.3 It will enter to IDLE MODE after waiting by five minutes without pressing any 5.4 The ramp incline level should back to “1”...
  • Page 17 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 incline position from 1 to 20. DISPLAY range is 0 to 999. WORK range is 1 to 20. LEVEL preset value is 1 to 20.
  • Page 18 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 19 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 20 Function Button In Main Mode READY MODE STOP button: Non-function. START button: Pressing “ START ” button to start Bike, When pressing “START” button, there will be 3 second final count down on window display, then machine starts running. In MANUAL, Bike starts at MIN LEVEL . LEVEL UP button: If user doesn’t enter a setting then this button is non-functional.
  • Page 21 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 22: Unit Block Diagrams

    5. XBU55 Unit Block Diagrams...
  • Page 23 Bike Configuration...

  • Page 24: Basic Connections And Wiring

    Basic Connections and Wiring XBU55...
  • Page 25 Display Board wire Connections...
  • Page 26 Display Board PCB Component Locations PCB Board Top...
  • Page 27 PCB Board Bottom...
  • Page 28 The console Interface Board wire Connections...
  • Page 29 Tension Motor connector definition function STEEL ROPE MAIN CONTROL 1.M+ 2.M- 3.+5V 4.VR 5.GND...

  • Page 30: Product Safety Instructions

    7. Product Safety Instructions...
  • Page 31 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 32: Error Messages / Troubleshooting

    Error Messages / XBU55 Troubleshooting...
  • Page 33 Error code items： Error Message Explain EEPROM ERR EEPROM failure Tension motor is failure  Prepare： Picture Tool name Multi-meter...
  • Page 34  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 35  Error Message ： - -  Definition：When you press the Level Up or Down key,the motor does not move.” --” appears on the display.  Configuration：...
  • Page 36  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 37 Place probes on the motor control wire(Red probe in palm wire,Black probe in black wire) on the drive board.
  • Page 38  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 39 XBU55 BIKE CIRCUIT DIAGRAM...
  • Page 40 MAINTENANCE MENU IN CONSOLE SOFTWARE The console has built in maintenance/diagnostic software. The software will allow you to change the console settings from English to Metric and turn off the beeping of the speaker when a key is pressed for example.
  • Page 41 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 42 9. Troubleshooting...

  • Page 43: Console

    9-1 Console 1. Use Phillips head screw driver to release four M5×12mm Phillips Head Screws(58) and disconnect computer(29) and both hand pulse sensor cables to take console(34) apart. 2. Reverse above step to resume console (34)

  • Page 44: Handle Bar And Console Mast(Take Apart The Console.)

    Handle Bar and Console Mast(Take apart the console.) 1. Take apart the console(34) 2. Take off the Handgrip Cap and use 12 mm wrench to release 2pcs of 5/16" × 5/8"_Hex Head Bolts (51), 2pcs of 5/16" × 18mm × 1.5T_Flat Washers (72) and 2pcs of 5/16" × 1.5T_Split Washers (103), which secure the Handlebar Assembly (3), and remove Handlebar Assembly (3) .
  • Page 45 4. Use Phillips head screw driver to release four 20m/m_Tapping Screws (62) securing Handpulse W/Cable Assembly(26) and separate Handpulse W/Cable Assembly(26) from each other and remove , as shown in figure . 5. Reverse above step to resume.

  • Page 46: Main Frame And Console Mast Cover

    Main Frame and Console Mast Cover 1. Take apart the Computer Cable(29) and Handle Bar(3) 2. Slightly press the Console Mast Cover to separate it from left and right Chain covers. Then use 12 wrench to release 7pcs of 5/16" × 5/8"_Hex Head Bolt (51), 6pcs of 5/16" × 18mm × 1.5T_Flat Washer(72) and 1pcs of 5/16" × 19 × 1.5T_Curved Washer (99) and the Handle Bar (3) can be released as shown in figures.。...

  • Page 47: The Seat And Sliding Seat Mount

    The Seat and Sliding Seat Mount 1. Use 14 mm wrench to loosen both hex head bolts to remove Seat(19) , as shown in figure . 2. Turn to take Brake Tension Knob(86) apart from Fix Plate(8) and remove Sliding Seat Mount (7) , as shown in figure . 3.

  • Page 48: Inner Slide

    Inner Slide 1. Remove Locking Knob(106) , as shown in figure . 2. Separate seat post cover (39) and chain cover (R/L) (36.37), and pull seat slider (6) and seat post cover (39) up. Take Center spatial wrap (107) apart from Main Frame (1) with a rubber hammer (refer to photo 2), and then use Phillips Head Screw Driver (93) to release 2 pcs of 4 ×...

  • Page 49: Crank Arm And Pedal

    Crank Arm and Pedal 1. Use 13/15mm open end wrench to take apart pedals by turning left pedal(45) clockwise and right pedal(46) counterclockwise, as shown in figure. 2. To resume pedals, turn pedals with reversed directions respectively. 3. Take Crank Arm End Cap(96) apart and use plug wrench to release the nut(83), as shown in figures 1 and 2. 4.
  • Page 50 5. To resume the crank (16L,16R), use air crank tool or rubber hammer to fix the crank (16L,16R) on the axle (11) and tighten the nut on the crank axle and plug in the Crank Arm End Cap (96).

  • Page 51: Chain Cover (L)(R)

    Chain Cover (L)(R) 1. Take apart pedals and crank arm. Separate both Console Mast Cover and Saddle Cover from left and right Shrouds and use Phillips head screw driver to release seven Ø 3.5 × 16m/m_Sheet Metal Screw(63) and three 5 × 16m/m_Tapping Screw(61), which secure left shroud, to take left shroud apart, as shown in figures 1 and 2) 2.

  • Page 52: Handgrip End Cap

    Handgrip End Cap 1. Put Handgrip End Cap (41) on the button of front and Rear Stabilizer. 2. Use rubber hammer when assembling. The Belt and Drive Pulley 1. Remove Chain Cover (L)( R) (36)(37). Use 11 mm open end wrench to release 1/4" × 8T_Nyloc Nut(130) to the end and use 6 mm Allen wrench to remove to remove M10 ×...
  • Page 53 3. Use C Ring tweezers to remove Ø 20 C Ring(67) on Crank Arbor(11) as shown in figure to take down Crank Arbor (11) and Drive Pulley(15) which can be knocked by rubber hammer. 4. Use two 11 mm open end wrenches to remove four 1/4" × 3/4"_Hex Head Bolts (54) together with four 1/4" × 8T_Nyloc Nuts (79) on Crank Arbor(11) and Drive Pulley(15) to take Drive Pulley(15) apart as shown in figure.

  • Page 54: Flywheel, Drive Belt And Bearing Housing

    9-10 Flywheel, Drive Belt and Bearing Housing 1. Take apart left and right shrouds and the belt. 2. Use 11 mm open end wrench to release 1/4" × 8T_Nyloc Nut(130) to the end and use 6 mm Allen wrench to remove to remove M10 ×...
  • Page 55 Use 15mm & 14 mm open end wrench to release two nuts which secure the flywheel by turning counterclockwise and take apart the flywheel. 7. Reverse above step to resume, but notice to follow step 7 to adjust the elastic and position of belt (14); besides, notice the direction of Bearing Housing(9) and Nut Stopper (128) when assemble Bearing Housing(9) on main frame (1) (refer to photos 3.4)

  • Page 56: Console And Error Messages

    9-11 Console and Error Messages 1. When there is no display, check as below: 2. Make sure the console(34) and computer Cables(29) are connected properly, as shown in figure . 3. If all are connected properly, take measurements of power outputs to find out the problem. Q: No heart rate is displayed: 1.

  • Page 57: Noises

    9-12 Noises Q: Noises A:大 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(45)(46) must be replaced, as shown in figure.
  • Page 58 Noises caused by Chain covers Most cases are caused by Chain Covers (36.37)deforms so that crank arms (16L.R) scratch Chain Covers. The deform is because of the requirement by safety regulations of minimum gaps. The solution for deformation is to replace Chain covers (36.37). In some cases, there is noises caused by the deformed Drive Pulley (15) that rubs the right Chain Cover (37).

  • Page 59: Flywheel, Steel Cable And Gear Motor

    9-14 Flywheel, steel cable and gear motor. Q: Resistance can’t be adjusted: Please take chain cover (L) (36) down to see if steel cable comes off. If yes, please reassemble it. As steel cable is fastened on both sides, this situation will happen rarely. If steel cable is no problem, check gear motor (21) is workable.

  • Page 60: Other

    9-15 Other Noises coming from left and right pedals. This is mostly pedals wear causing noises and not moving smoothly. The worn out pedals(45)(46) must be replaced, as shown in figure. Left and right crank. Sometimes crank gets loose causing noises and not moving smoothly. Tightening the crank fixes the problem, as shown in figure.
  • Page 61 If sway happens on Console Mast (2) or Handle Bar (3), it almost results from unlocked screw. Please fasten it.

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