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Dyaco XE295 Service Manual

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XE295
Service Manual
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Summary of Contents for Dyaco XE295

  • Page 1 XE295 Service Manual...

  • Page 2: Table Of Contents

    --------------------------------------------Table of Contents------------------------------------------- 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 7.
  • Page 3 11.5 Console Mast Replacement 11.6 Side Case Replacement 11.7 Cross Bar Replacement 11.8 Idler Wheel Replacement 11.9 Flywheel & Poly-V Belt Replacement...
  • Page 4 1. XE295 Outlines...
  • Page 5 Console Assembly Handle Bar Cover (L) Swing Arm Bushing Console Mast Cover Handle Bar Cover (R) Side Case (L) Pedal (L) Side Case (R) Round Disk Round Disk Cover Slide Wheel Cover Pedal Arm Cover (R) Pedal (R)
  • Page 6 Swing Arm (R) Swing Arm (L) Console Mast Lower Handle Bar (L) Lower Handle Bar (R) Drive Pulley Pedal Arm (L) Connecting Arm (L) Cross Bar Flywheel Adjustable Pedal (L) Main Frame Adjustable Pedal (R) Bushing Housing, Pedal Arm Connecting Arm (R) Pedal Arm (R) Rear Rail Assembly...

  • Page 7: Electronic Parts

    2. Electronic Parts...

  • Page 8: Upper Controllers

    Cooling FAN 2-1 Upper Controllers THUMB SWITCH DISPLAY...

  • Page 9: Lower Controller And Driver

    2-2 Lower Controller and Driver TENSION MOTOR SPEED SENSOR...

  • Page 10: Electrical Configurations

    3.Electrical Configurations...
  • Page 11 Console: Interface that controls all functions of the Elliptical. 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 ENSION MOTOR Work voltage:DC 4.5~7.5V Control resistance increases and decreases.
  • Page 13 4. XE295 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. 1.3 DATA window (7 segment display window) display RPM= 000，CALORIES= 000，TIME = 00:00，DISTANCE = 0.00，PULSE = - - -。...
  • Page 17 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” when the resistance level is “1”. The position of tension motor and ramp incline should back to the preset level before it pause when press “START”...
  • Page 18 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 99. WORK range is 0 to 20. LEVEL preset value is 1 to 20.
  • Page 19 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 20 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 21 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 22 RUN MODE STOP button: press “STOP” button to stop elliptical. 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 23 5. XE295 Unit Block Diagrams...
  • Page 24 Elliptical Configuration...
  • Page 25 6. XE295 Basic Connections and Wiring...

  • Page 26: Display Board Wire Connections

    6-1 Display Board wire Connections...

  • Page 27: Display Board Pcb Component Locations

    6-2 Display Board PCB Component Locations PCB Board Top...
  • Page 28 PCB Board Bottom...

  • Page 29: The Console Interface Board Wire Connections

    6-3 The console Interface Board wire Connections...
  • Page 30 Tension Motor connector definition function STEEL ROPE MAIN CONTROL 1.M+ 2.M- 3.+5V 4.VR 5.GND...

  • Page 31: Product Safety Instructions

    7. Product Safety Instructions...

  • Page 32: 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 120-volt, 15-amp grounded outlet with only the elliptical plugged into the circuit.

  • Page 33: Troubleshooting

    Error Messages / XE295 Troubleshooting...
  • Page 34  Error code items： Error Message Explain EEPROM ERR EEPROM failure Tension motor is failure  Prepare： Picture Tool name Multi-meter...
  • Page 35  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 36  Error Message ： - -  Definition：When you press the Level Up or Down key,the motor does not move.” --” appears on the display.  Configuration：...
  • Page 37  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 38 Place probes on the motor control wire(Red probe in palm wire,Black probe in black wire) on the drive board.
  • Page 39  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 40 XE295-01 Elliptical CIRCUIT DIAGRAM...
  • Page 41 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 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 Problem

    Console Problem 1. Display: When there is no display, check with following procedures. 2. Make sure power adaptor is properly inserted. 3. Check all connectors, including those in the console, on the controller and wire harness, are connected properly. Next, check if all the wires are inserted in the firmly and securely on to the console.

  • Page 45: Side Case & Round Disk Problem

    5. 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. Side case & Round Disk Problem The potential reason why there could be a problem here is due to the friction created causing abnormal sounds. However, to determine this, you will need to check to see if the large disk is not centered or offset.

  • Page 46: Flywheel Problem

    Flywheel Problem 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. If there is abnormal sound coming from the magnetic flywheel, first check if are any foreign objects or friction, make adjustments. If adjustments are not able to be made, replace with new part.

  • Page 47: Poly-V Belt Problem

    Poly-V Belt Problem 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 48 If the Poly-V Belt is slipping, simply adjust the cap the on hook-type screw with the #13 wrench to adjust. Refer to the disassembly procedures for adjustment. If the Poly-V Belt worn or damaged, replace with new part.

  • Page 49: Swing Arm Problem

    Swing Arm Problem 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. The solution is to add thick lubricant into the top ofØ 25x296L Swing Arm Axle.

  • Page 50: Connecting Arm And Slide Wheel Problem

    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 51 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 52: Q & A

    10. Q & A...

  • Page 53: Noise

    10-1. Noise 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 54 Bushing Housing, Pedal Arm: the CAP Socket Head Cap Bolt 3/8 "x2-1/4 on top and nyloc nut 3/8" x11T must be tightened securely, recommended weight is between 500~600Lbs. Cross Bar : CAP Socket Head Cap Bolt M8x40m/m on top of the Cross Bar on the must be tightened to recommend 550~600Lbs. Belt: This issue appears quite often, because after a period of time, most belts will become loose from use depending on usage time.
  • Page 55 10-3. Slip Problem Shaking is mainly due to loose screws, so check and tighten loose screws first. Check connection points to see if gaps have been created after prolong use causing wear and tear or improper assembly. For example, shaking of the foot pedal is caused by loose Carriage Bolts, from improper assembly.

  • Page 56: Smooth Problem

    10-4. Smooth Problem Check for loose screws if machine motion feels unsmooth. Check if there are foreign object on or around the sliding rail, use an alcohol wipe to remove and re-lubricate with lubricant.

  • Page 57: Disassembling And Assembling Of Parts

    11.Disassembling and assembling of Parts...

  • Page 58: Console Replacement

    11-1. Console Replacement Use Phillips head screwdriver to remove Phillips Head Screws M5x10mm (4pcs) securing the console. Unfasten all connected wires and remove console. Reassemble in the reverse order as disassembly (Be sure to not crush or damage wiring during process)

  • Page 59: Swing Arm Replacement

    11-2. Swing Arm Replacement Use a Phillips screwdriver to remove Sheet Metal Screws 3.5x12mm securing the swing arm covers (Front and Back) Disconnect the wiring connecting the upper and lower swing arms.
  • Page 60 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. 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.
  • Page 61 To take apart the swing arm assembly, use#12 and #13 open end wrenches to release three Hex Head Bolts 5/16" x 1-3/4" together with three nyloc nut 5/16" x 7T, and two curve washers 5/16"x 23 x 1.5T and separate upper Swing Arm and lower Swing Arm from each other.

  • Page 62: Connecting Arm Replacement

    11-3. Connecting Arm Replacement First, follow the procedure 2 to remove the handle bar (if you need the connecting bar only, just take apart the connection between handle bar and fish-eye bearing) Then use 12mm and 13mm wrenches to release 5/16" x1-1/4" hex head screw, 5/16" x 20 x 1.5T flat washer and 5/16"...
  • Page 63 Then use Phillips head screw driver to release M5x10mm Phillips Head Screws and Ø 19 × Ø 14 × Ø 10 × (5+4)T_ Bushing, as shown in figures 4, 5 and pull out Axle Of Locking Pin. Use C-ring pliers to release C-ring and pull out Locking Pin, as shown in figures 6, 7.
  • Page 64 Release four M5x10mm Phillips head screws, which secure the pedal, to take the pedal from the connecting arm, as shown in figure 4. Reverse above steps to resume parts.

  • Page 65: Pedal Arm Replacement

    11-4. Pedal Arm Replacement 1. Follow procedure 3 to take apart the connecting arm. 2. Disassemble Connecting Arm first and use Phillips head screw driver to release M5x10mm Phillips Head Screw to take apart Pedal Arm Cover, as shown in figure 1. 3.
  • Page 66 4. Use #12 hex wrench to remove hex head bolt 5/16”x15mm and flat washer 5/16”x35x1.5T, to remove Bushing Housing, Pedal Arm. 5. 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.
  • Page 67 7. Following the steps gradually as beginning of Ø 17 × 0.5T_Wave Washer, Ø 78_Slide Wheel, Urethane, Ø 17 × 0.5T_Wave Washer, and Ø 17_C Ring when assemble the Ø 78_Slide Wheel, Urethane.
  • Page 68 11-5. Console Mast Replacement ase 3 pcs of 3.5x16mm Sheet Metal Screws to take apart left and right console Use Phillips head screwdriver to rele mast covers, as shown in figure 1. Use 14mm wrench to remove hex head bolts 3/8”x3/4”, Curved Washers 3/8 "x23 x2T, external hex head bolts 3/8" x2-1/4 "and Spring Washer 3/8"...
  • Page 69 Remove Console Mast and Console Mast cover together, pull out control wires and incline wires and separate covers from Console Mast. To dismantle Handpulse Assembly, take the Round Cap apart first and use Phillips head screw driver to release two Tapping Screws_3x20mm.
  • Page 70 11-6. Side Case Replacement Remove Pedal Arm and Console Mast Assembly. (Refer to step 11.4 and 11.5) Unscrew left Chain Cover by releasing three Tapping Screws 5x19mm and disconnect Unscrew right Chain Cover on the mainframe by releasing three Tapping Screws 5x19mm.
  • Page 71 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. Unscrew right Chain Cover on the mainframe by releasing three Tapping Screws 5x19mm.
  • Page 72 Further release Sheet Metal Screw 3.5x16mm together with flat washer 1/4"x19 which is inside the right Chain Cover.
  • Page 73 Release the nut of DC power plug then pull out DC power cables and Chain Cover (L) can be released, as shown in figures 6 and 7. 7. Reverse the procedures to return (L)(R ) Chain Cover as above steps. Have to pay attention that DC cable doesn’t clip by (L)(R ) Chain Cover &...
  • Page 74 11-7. Cross Bar Replacement Remove left and right chain cover. (Refer to step 11.6) 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. 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 75 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 76 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. Reassemble parts in the reverse order as disassembly, tighten the nyloc nuts M8x9T on top of the hook screws, flick the belt for crisp sound to check tightness or use a sound measuring device to measure at 190HZ(±10), reassemble the remaining parts.
  • Page 77 11-9. Flywheel & Poly-V Belt Replacement Use the console to adjust the resistance lvl 20 and remove Steel Cable. Follow procedure 11-8 to take apart the Idler Wheel the Console and take apart the Steel Cable. Use #15 wrench to loosen nyloc nut 3/8”-UNF26x9T on flywheel and main-frame. Remove flywheel and belt.
  • Page 78 Reverse above steps to return all parts and adjust the position of the drive belt at the center on the drive pulley (according to idler wheel assembling procedures) and resume all parts.

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