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Dyaco XBR95 Service Manual

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XBR95
Service Manual
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Summary of Contents for Dyaco XBR95

  • Page 1 XBR95 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 8-1. Console Disassembling and assembling 8-2.
  • Page 3 8-16. Console and Error Messages 8-17. Slippage and Drive Belt falling off 8-18. Noises...
  • Page 4 Outlines XBR95...
  • Page 5 Handgrip Foam Console Assembly Mesh Seat Back Console Mast Cover Pedal Handgrip Resistance Label Round Disk Aluminum Track Crank Arm Seat Drink Bottle Holder Front Shroud (L) Bottom Cover Drink Bottle Holder (R) 橢圓斜管塞 Handgrip End Cap...
  • Page 6 Mast Handle bar Assembly Seat Back Frame Console Mast Cover Seat Handle Bar Drive Pulley Seat Carriage Crank Arm Idler Wheel Assembly Console Display Board Flywheel Rear Stabilizer...

  • Page 7: Electronic Parts

    2. Electronic Parts...

  • Page 8: Upper Controllers

    Upper Controllers Speaker Cooling FAN DISPLAY...

  • Page 9: Lower Controller And Driver

    Lower Controller and Driver SPEED SENSOR Driver board HYBRID GENERATOR...

  • Page 10: Electrical Configurations

    3.Electrical Configurations...
  • Page 11 ONSOLE Interface that controls all functions of the Bike. AIN CONTROLLER The circuit board consist of the DC power supply for console. GENERATOR BRAKE 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 、driver control circuit.
  • Page 12 HYBRID GENERATOR BRAKE Work voltage:DC 0.4~14V Control resistance increases and decreases.

  • Page 13: Product Operation

    Product Operation XBR95...
  • 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 = - - -。...
  • Page 17 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 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 999. WORK range is 0 to 20. LEVEL preset value is 0 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, Strength, Interval,Calories,Fusion, 2 User, 2HR) 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 Bike, When pressing “START” button, 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 22 RUN MODE STOP button: press “STOP” button to stop Bike. START 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: Unit Block Diagrams

    Unit Block Diagrams XBR95...
  • Page 24 Bike Configuration...

  • Page 25: Basic Connections And Wiring

    Basic Connections and Wiring XBR95...
  • Page 26 Display Board wire Connections...
  • Page 27 Display Board PCB Component Locations PCB Board Top...
  • Page 28 PCB Board Bottom...
  • Page 29 The console Interface Board wire Connections...
  • Page 30 Amplifier Board wire Connections...
  • Page 31 Driver Board Wire Connections...
  • Page 32 Driver Board PCB Component Locations...
  • Page 33 Driver Board function GENERATOR GENERATOR SYSTEM BRAKE INPUT WIRE OUTPUT...

  • Page 34: Product Safety Instructions

    7. Product Safety Instructions...
  • Page 35 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 36: Error Messages / Troubleshooting

    Error Messages / XBR95 Troubleshooting...
  • Page 37  Error code items： Error Message Explain EEPROM ERR EEPROM failure  Prepare： Picture Tool name Multi-meter...
  • Page 38  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 39  Test configuration. The console to driver board connector pin define function The console to driver board connector pin define function: 1.12 VDC 2.GND 3.+6 VDC 4.NC 5.RES 6,5,4,3,2,1 6.RPM...
  • Page 40 Test Configuration. Driver board control function relate parts location  1.12 VDC 2.GND 3.+5 VDC 4.NC 5.PWM 6.SPD GENERATOR GENERATOR INPUT BRAKE OUTPUT...
  • Page 41 Troubleshooting Part Troubleshooting 1.Press UP key.The driver board CN2 OUTPUT. Display board 2.Press DOWN key.The driver board CN2 OUTPUT 3.If not as above,inspect the cable and connections. 1.Inspect whether the 8-PIN cable is connected well. 8-pin cable 2.Test by replacing the cable with a good one.
  • Page 42 XBR95 BIKE CIRCUIT DIAGRAM...
  • Page 43 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 44 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 power to console. 3. Replace lower controller. LCD displays not bright, incomplete or imperfect. 1. LCD displays are broken. 1.
  • Page 45 9. Troubleshooting...

  • Page 46: 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), as shown in figure 1 and 2. 2.
  • Page 47 Handlebar, Console Mast and Console Mast Cover 1. Follow Procedure 1 to take off the Console 2. Then use 12/14 m/m wrench (112) to release 2pcs of 5/16”x15 Hex Head Screws (68), 2pcs of o8x1.5T Split Washers and 2pcs of 5/16”x19x1.5T Flat Washers (76) and the Handlebar Assembly (3) can be released.) (figure 1) 3.

  • Page 48: Crank Arm And Pedal

    5. To resume, pull Computer Cables (44), Handgrip Sensor Wire, and Switch Cable (Upper)_(133) through the hole of Console Mast, and then use 12mm_Wrench to tight 6 pcs of 5/16” × 5/8”_Hex Head Bolts (68), 6 pcs of 5/16” × 18 × 1.5T_Washer (76), and 2 pcs of 5/16”...
  • Page 49 4. Use proper tool to secure Crank Arms (51L&51R) and release them with Hex Wrench. 5. To resume the Crank Arms (51L&51R), use power tool or hammer to secure them and return the Nut (108) back to the Crank Axle (8) tighten. Return Crank Arm End Cap (28) back to Crank Arms (51L&51R).
  • Page 50 Front Shroud (L) (R) and Round Disk dismounting (take off the crank and Console Mast cover ) 1. Follow procedure 3 to take off the Crank. 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 3.) 4.
  • Page 51 6. To release Right Front Chain Cover (30), on the mainframe, unscrew 2pcs of ø 3.5x20 Self Tapping Screws (107) with 2pcs of ø 5 x16x1.5Tflat Washers (78) then, on the Right Front Chain Cover, unscrew 2pcs of 5x16 Tapping Screws and unplug.

  • Page 52: The Belt And Idler Wheel Assembly

    The Belt and Idler Wheel Assembly 1. Disassemble Front Shroud(29)(30). 2. Use 13mm_wrench to loosen M8 × 7T_Nut (88) on the J-bolt (87) until it comes off. 3. Use Phillips Head Screw Driver to release 3 pcs of M6 × 15_screws (98) on Idler Wheel Assembly (10) to take off the Belt (54).
  • Page 53 4. To resume, secure the Idler Wheel Assembly (10) with 3 pcs of M6 × 15_screws (98) together withØ 1/4"_Spring Washers (80) and 1/4" × 13 × 1T_Flat Washers (72) onto the Induction Brake (55) by using Phillips Head Screw Driver. Return the Belt (54) on Drive Pulley (20) and on the Induction Brake (55).

  • Page 54: 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 55: Induction Brake

    Induction Brake 1. Disassemble Front Shroud(29)(30) and Drive Belt (54). 2. Unplug harnesses on the induction Brake (55) and use 11mm_wrench to release 4 pcs of 1/4" × 3/4"_Hex Head Bolts (66) together with 4 pcs of 1/4" × 13 × 1T_Flat Washers (72) and Ø 1/4"_Spring Washers (80), which are on Induction Brake (55), as shown in figures 1.

  • Page 56: Seat Back Assembly And Mesh Seat Back

    Seat Back Assembly and Mesh Seat Back 1. Use Phillips Head Screw Driver to release 4 pcs of Ø 4 × 16m/m_Sheet Metal Scre (105), as shown in figure 1. 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), as shown in figure 2.
  • 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. 4.

  • 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 (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

    Gas Cylinder (Remark 8) 9-10 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). 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).
  • 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). 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.

  • Page 61: Seat, Seat Handle Barand Handpulse W/Cable Assembly

    Seat, Seat Handle Bar and Handpulse W/Cable Assembly 9-11 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. 3.

  • Page 62: Buttons On The Handle Bar

    Take apart HGP Wire Grommet (126) which secure Handpulse Assemblies (27). Use Phillips Head Screw Driver to release four O3 × 20m/m_Tapping Screws and take Handpulse Assemblies (27) apart. 5. Reverse above steps to return parts. Buttons on The Handle Bar (Remark 9) 9-12 1.
  • Page 63 3. Tear Up/Down Handgrip Resistance Lable (146 and 147), and then take off Handgrip Button W/Cable (145). 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).

  • Page 64: Rear Chain Covers

    Rear Chain Covers 9-13 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). Unplug 300m/m_Handpulse Wire, Coiled (26), 2100m/m_Handpulse Wire, Coiled (133), and 2100m/m_Switch Cable (Upper)_(148), and then left Rear Shroud (35) can be taken apart.
  • Page 65 3. Use special tools to remove nut from hand pulse cable sensor assembly(26) and handle switch bracket and then could separate right/left rear shroud. 4. When reserve the rear shroud use flat washer 5/16"×16×1T(127) place on rear shroud (R) plastic column and then through a hole of plastic column to main frame (1) and use Ø...

  • Page 66: Sear Carriage And Parts

    Sear Carriage and Parts 9-14 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. Use Phillips Head Screw Driver to release four M6 ×...
  • Page 67 4. Use M4 Allen wrench and 10m/m Wrench open end wrench to release M5×45m/m Socket Head Cap Bolt (171) and M5×5T Nyloc Nut (173). 5. 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).
  • Page 68 7. 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 69 9. Then install Seat Carriage (4) on Aluminum Axle (14) and use 11/13 mm Open End Wrenches to adjust the positions of Seat Wheel Adjustment Plates (9L, 9R) by turning 11mm Wrench counterclockwise at left front side, and then use 13mm Wrench to tighten M8 ×...

  • Page 70: Alluminum, Step Cover, And Induction Brake Controller

    Alluminum, Step Cover, and Induction Brake Controller 9-15 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 71 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. Console and Error Messages 9-16 Q Display won’t come on:...
  • Page 72 3. Use multi-meter to check output voltage at each connect contact. Q No speed readout: 1. If the display is on but without speed readout, disassemble Front Shroud (29) and make sure 9P computer cable (44) and Hall Sensor (46) are properly connected, as shown in figure 2. 2.
  • Page 73 2. If step 1 is OK, disassemble left Rear Shroud (35) and check if Handpulse Wires (26) are connected properly with Handpulse Wire (133) at the Console. 3. If all are connected properly, use multi-meter to check cable continuity. Remark: Console and related parts were factory tested and it is rare that the unit fails at this part.
  • Page 74 Slippage and Drive Belt falling off 9-17 Q. Slippage 1. Disassemble Front Shrouds (29, 30). 2. Use 13mm Open End Wrench to turn M8 × 7T_Nyloc Nut (88) clockwise to tighten until as shown in figure 1. sound wave tension gauge reads 180±10Hz. 3.
  • Page 75 Q Drive Belt falling off: Follow Procedure #5 in section I to install, Drive Belt (54) requires to turn back and forth to see if it falls off. Adjust Drive Belt (54) on notch beyond against the side it falls off. If it still keeps falling off, try to replace Drive Pulley (20), Idler Wheel Assembly (10) or Induction Brake (55).
  • Page 76 Noises 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 77 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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