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Dyaco CR900 Service Manual

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CR900
Service Manual
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Summary of Contents for Dyaco CR900

  • Page 1 CR900 Service Manual...
  • Page 2 CR900 Outlines Electronic Parts Electrical Configurations CR900 Product Operation CR900 Unit Block Diagrams CR900 Basic Connections and Wiring CR900 Error Messages /Troubleshooting Part Replacement Guide...
  • Page 3 Outlines CR900...
  • Page 4 Console Assembly Seat Back Pedal Seat Console Mast Cover Drink Bottle Holder Front Shroud Rear Shroud Front Shroud...

  • Page 6: Electronic Parts

    2. Electronic Parts...
  • Page 7 Upper Controllers Cooling FAN DISPLAY...
  • Page 8 Lower Controller and Driver SPEED SENSOR Driver board HYBRID GENERATOR...

  • Page 9: Electrical Configurations

    3.Electrical Configurations...
  • Page 10 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 LED Display. Main controller include power supply 、driver control circuit.

  • Page 11: Product Operation

    Product Operation CR900...
  • Page 12 Display Windows...

  • Page 13: Quick Start

    Operation POWER Spirit Fitness commercial fitness bikes have a built-in generator for power and do not need to be plugged into an AC outlet. To power up the fitness bike simply start to pedal, the console will turn on automatically. When initially powered on, the console will perform an internal self-test.

  • Page 14: Number Key Pad

    of the Message Window is a button labeled Scan. When the Scan button is pressed the next set of information will appear: METs, Time Remaining, Calories/Hour and Speed. Pressing the Scan button, the Scan mode is activated and the Message Window will show each set of data for four seconds then switch to the next set of data in a continuous loop.

  • Page 15: Programming The Console

    PROGRAMMING THE CONSOLE Each of the programs can be customized with your personal information and changed to suit your needs. Some of the information asked for is necessary to ensure the readouts are correct. You will be asked for your Age and Weight. Entering your Age ensures that the Heart Rate bar graph shows the correct number.
  • Page 16 6. The program automatically starts you at level one. This is the easiest level and it is a good idea to stay at level one for a while to warm up. If you want to increase the work load at any time press the Up key; the Down key will decrease the workload. 7.

  • Page 17: Unit Block Diagrams

    Unit Block Diagrams CR900...
  • Page 18 Bike Configuration...
  • Page 19 Basic Connections and Wiring CR900...
  • Page 20 Display Board wire Connections pin define J16→RPM： P-No Discription J7→INTERFACE： P-No Discription +12V BREAK J12→FAN： P-No Discription FAN-VCC FAN-GND J1→CSAFE： P-No CSAFE- Discription POWER J3→INTERFACE： P-No Discription Pulse HP/WP J8→MAIN KEY： P-No Discription J9→KEY PAD： P-No Discription J10→GND：...
  • Page 21 P-No Discription J17→USB： P-No Discription CAP_PWR...
  • Page 22 Display Board PCB Component Locations PCB Board Top...
  • Page 23 PCB Board Bottom...
  • Page 24 Driver Board PCB Component Locations...
  • Page 25 Driver Board function GENERATOR BRAKE OUTPUT SYSTEM WIRE GENERATOR INPUT...
  • Page 26 Error Messages / CR900/SU8800 Troubleshooting...
  • Page 27  Error code items： Error Message Explain EEPROM ERR EEPROM failure  Prepare： Picture Tool name Multi-meter...
  • Page 28  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 29 CR900/SU8800-SB008 BIKE CIRCUIT DIAGRAM...

  • Page 30: General Maintenance

    GENERAL MAINTENANCE 1. Wipe down all areas in the sweat path with a damp cloth after each workout. 2. If a squeak, thump, clicking or rough feeling develops the main cause is most likely one of two reasons: 1) The hardware was not sufficiently tightened during assembly. All bolts that were installed during assembly need to be tightened as much as possible.
  • Page 31 Troubleshooting procedure matrix Condition Reason Solve LEDs not bright, incomplete or imperfect. 1. LED light is broken. 1. Replace with new LED or console. 2. Power to console too low. 2. Check power to console. 3. Replace lower controller. LED displays not bright, incomplete or imperfect. 1. LED displays are broken. 1.

  • Page 32: Part Replacement Guide

    8. Part Replacement Guide...
  • Page 33 1. Serial Number Location 2. Component Description Change drawing. Add table that can be modified so I can write English descriptions..
  • Page 34 Console Assembly Console Assembly Book Rack Deflector Fan Grill End Cap Console Chin Cover End Cap Seat Back Cover Console Mast Cover-L Console Mast Cover-R Rear Shroud (L) Rear Shroud (R) Beam Cover Rear Shroud (L) Rear Shroud (R) Block Front Stabilizer Cover Rear Stabilizer Cover (L) Rear Stabilizer Cover (R)
  • Page 35 3. Preventative Maintenance Check Pedals are tight As shown in Figure 3.1.1, 3.1.2, check whether the pedals are tight every week. The left pedal tightens counter-clockwise and the right pedal tightens clockwise. Figure 3.1.1 Figure 3.1.2 Check for Console Mast Figure 3.2.1, Figure 3.2.2, check that all mounting screws are tight.
  • Page 36 Periodic Cleaning: Wipe down all surfaces with a clean damp cloth. Mild detergents may be used on most areas. Do not use abrasives or caustic cleaning materials unless otherwise indicated. Figure 3.3.1, Figure 3.3.2, regular cleaning of aluminum seat track rails for continued smooth seat operation and life of wheels.
  • Page 37 6. Part Replacement Guide Console Replacement 6.1.1 Remove the rear Console Cover In Figure 6.1.1, Figure 6.1.2, Figure 6.1.3, remove the four screws of the rear cover and remove it. Figure 6.1.1 Figure 6.1.2 Figure 6.1.3 6.1.2 Remove Electronic Console As shown in Figure 6.1.4, Figure 6.1.5, remove the four screws from the rear of the electronic console.
  • Page 38 6.1.3 Electronic console assembly: Follow steps 6-1-1 and 6-1-2 in reverse order. 6.2 Front Handlebar Replacement 6.2.1 Refer to Figure 6-1-1 for the removal of the rear console cover. As shown in Figure 6.2.1 and Figure 6.2.2, remove the M8 socket screws and handle bar. Figure 6.2.1 Figure 6.2.2 6.2.2 Refer to 6-2-1 and follow the procedure in reverse order for handle bar assembly.
  • Page 39 6.3 Rear Handle bar Replacement 6.3.1 Remove Rear Handle bar Cover (Need picture of cover from top. Difficult to know what cover from these pictures.) As shown in Figure 6.3.1, Figure 6.3.2, remove the 2 screws underneath the rear handle bar cover and remove it.
  • Page 40 6.3.2 Remove Left and Right Cup holders Figure 6.3.3 and Figure 6.3.4 show the left and right cup holders. Remove the two screws from each (total of 4 screws) and remove cup holders. Figure 6.3.3 Figure 6.3.4 6.3.3 Remove Rear Handle bars As shown in Figure 6.3.5, remove the rear handle bars by removing the 8 bolts.
  • Page 41 6.3.4 Disconnect hand pulse Wires As shown in Figure 6.3.6, disconnect the hand pulse wires then remove the handle bar assembly. Figure 6.3.6 6.3.5 Please refer to 6-3-1 ~ 6-3-4 and follow the procedure in reverse order for handle bar assembly.
  • Page 42 Pedal/Crank Arm Replacement 6.4.1 Remove Pedals As shown in Figure 6.4.1, 6.4.2: Using a 15 mm open end wrench remove the right pedal counterclockwise and remove the left pedal clockwise. Figure 6.4.2 Figure 6.4.2 6.4.2 Remove Crank Arm Retaining Bolt As shown in Figure 6.4.3, Use an 8 mm Allen wrench to remove the crank arm bolt.
  • Page 43 6.4.3 Remove Crank As shown in Figure 6.4.4, Use a standard bicycle crank arm removal tool to extract the crank arm Figure 6.4.4 6.5 Front Shroud Replacement 6.5.1 Remove Mast Covers Figure 6.5.1, Figure 6.5.2, Remove the 3 self tapping screws from the left hand side mast cover. Both covers can now be removed.
  • Page 44 Figure 6.5.1 Figure 6.5.2 6.5.2 Remove Left Front Cover 6.5.2.1 First remove the crank arms (See Procedure 6.4). Remove the 9 screws from the left cover and take off the cover as shown below in Figure 6.5.3, Figure 6.5.4. Figure 6.5.3 Figure 6.5.4...
  • Page 45 6.5.3 Remove Right Front Cover 6.5.3.1 Remove the 4 screws as shown below in figures 6.5.5 & 6.5.6 and take off the right side cover. Figure 6.5.5 Figure 6.5.6 6.5.4 Reverse the process to re-install the covers.
  • Page 46 6.6 Drive System Replacement 6.6.1 Release tension on idler Loosen the adjustment nut on the J-bolt until the tension spring can be removed. Figure 6.6.1 Figure 6.6.2 6.6.2 Remove Belt After the idler is removed you can then remove the Poly-V drive belt. When re-installing the belt make sure the belt tension is set to 220 ~ 240 Newtons (50-55 Lbs.).
  • Page 47 6.6.3 Remove Idler Assembly As shown in Figure 6.6.5, Figure 6.6.6, loosen the 3 screws and remove the idler assembly. When re-installing the idler assembly, make sure the bracket is rotated fully clockwise so the screws are at the end of travel in the slots as shown. Figure 6.6.5 Figure 6.6.6 6.6.4 Remove Brake...
  • Page 48 6.6.5 Replacing the Bearing Cartridge Assembly As shown in Figure 6.6.9, loosen the nut with a spanner wrench or screw driver and hammer if necessary. When installing the new assembly be sure to align the key in the cartridge with the slot in the frame housing.
  • Page 49 Insert picture of reed switch alignment Figure 6.6.10 6.7 Rear Cover/Bottom Cover Replacement 6.7.1 Remove Bottom Cover Refer to Figure 6-5 for the removal of the front covers. As shown in Figure 6.7.1 and Figure 6.7.2, remove the 4 screws of the left and right bottom covers. Figure 6.7.1 Figure 6.7.2 6.7.2 Remove Rear Stabilizer Cover...
  • Page 50 Figure 6.7.3, Figure 6.7.4, remove the four screws from the left and right covers and remove covers. Figure 6.7.3 Figure 6.7.4 6.7.3 Remove Left Rear Cover Figure 6.7.5, Figure 6.7.6, remove the 9 screws as shown and take off cover.. Figure 6.7.5 Figure 6.7.6 6.7.4 Remove Right Rear Cover...
  • Page 51 as shown. Figure 6.7.7 Figure 6.7.8...
  • Page 52 6.8 Lower Controller Replacement 6.8.1 Remove Lower Controller Refer to Figure 6-7 for the removal of the covers. Unplug the wiring connectors then remove the four Phillips head screws that secure the lower controller. Figure 6.8.1...
  • Page 53 6.9 Sliding Seat Assembly Replacement 6.9.1 Remove Cable Ties In Figure 6.9.1 cut the cable tie on the inside of the seat carriage that restrains the seat release cable. In Figure 6.9.2 cut the cable tie that restrains the hand pulse wiring. Figure 6.9.1 Figure 6.9.2 6.9.2 Remove the Seat Track Cover and Plastic Sweat Protector (New Picture..too many hands)
  • Page 54 6.9.3 Remove Release Lever and Cable Remove the release lever assembly from the seat frame by unscrewing the two mounting bolts (Figure 6.9.4). Remove the cable by loosening the jam nut, as shown in Figure 6.9.5, then unscrew the barrel until the inside nut is removed from the thread end of the barrel.
  • Page 55 6.9.5 Remove Iron Plate As shown in Figure 6.9.8, remove the four screws on the iron plate and remove them. Figure 6.9.8 6.9.6 Remove Seat Carriage Remove the release lever (6.9.3) then remove the two center, bottom screws on both sides of the carriage (Figure 6.9.9) and slide the carriage off the back of the unit (Figure 6.9.10) Figure 6.9.9 Figure 6.9.10...
  • Page 56 6.9.7 Remove the Seat Lock Mechanism As shown in Figure 6.9.12, 6.9.13, remove the two axles from the barrel of the locking mechanism. Figure 6.9.12 Figure 6.9.13 6.9.8 Remove Mechanical Lift Arm As shown in Figure 6.9.14, loosen the nut on the lift arm to remove the replacement. (Moving column removal reference 6-9-8) As shown in Figure 6.9.15, the direction of the key in the installation is in the direction of the electronic watch.
  • Page 57 Figure 6.9.14 Figure 6.9.15 6.9.9 Remove Seat Slide As shown in Figure 6.9.16, Figure 6.9.17, relax the 8 screws to pull out the seat rails (the screws do not need to be removed), and do not lock them first (see 6-9-13). Figure 6.9.16 Figure 6.9.17 6.9.10 Install Seat Slide Group...
  • Page 58 6.9.11 Install Cable As shown in Figure 6.9.19, Figure 6.9.20, the round end is mounted on the lift arm and the nut end is pierced from the side notch, with the handle shown in 6-9-3. Figure 6.9.20 Figure 6.9.21 6.9.12 Adjust Seat Slide Group As shown in Figure 6.9.22, move the carriage to the front and lock the front two screws;...
  • Page 59 6.9.13 Combine Slide and Lift Arm See Figure 6.9.24 and refer to the 6-9-6 removal procedure to replace the parts and, as shown in Figure 6.9.25, the outer screws are locked to the bottom and fixed to the inner braces. (Both sides are the same) Figure 6.9.24 Figure 6.9.25 6.9.14 Adjust Mechanical Lift Arm...
  • Page 60 6.9.15 Install Iron Plate and Plastic Plate Make the heartbeat thread back and tie the strap and set the 8 screws as shown in Figure 6.9.28, Figure 6.9.29, and 6-9-1, 6-9-2. Figure 6.9.28 Figure 6.9.29 6.10 Seat Bottom / Seat Back Replacement 6.10.1 Remove Seat Bottom As shown in Figure 6.10.1, 6.10.2, Remove the four screws from the under-side of seat cushion.
  • Page 61 6.10.2 Remove Seat Back Cover and Retaining Strap As shown in Figure 6.10.3, 6.10.4, remove the two screws that hold on the retaining strap. Remove the cover by grabbing the edge with your fingers and pull (Fig. 6.10.4) until cover un-snaps from the seat back. Figure 6.10.3 Figure 6.10.4 6.10.3 Remove Seat Back...
  • Page 62 6.11 Foot Pad/Transport Wheel Replacement 6.11.1 Remove Transport Wheel As shown in Figure 6.11.1 loosen the screw and nut and remove the wheel. Figure 6.11.1 6.11.2 Remove Foot Pad As shown in Figure 6.11.2 Loosen the locking nuts with a 15 mm wrench and turn the footpad counterclockwise to remove.
  • Page 63 7. Trouble Shooting Belt Slips While Pedaling Under High Load 7.1.1 If you find the belt is slipping please refer to 6-5, 6-6-1, 6-6-2 to gain access to the belt adjustment. Loosen the bottom jam nut and back it off a few turns on the J-Bolt then tighten the top nut to increase tension on the spring until the slipping stops.
  • Page 64 7.2 Noise and/or rough feeling at the pedals 7-2-2 If there is a clicking sound, or feeling that something is loose, first check that the pedals are tight. Then check that the crank arm bolts are tight. Check for play in the axle. It is also possible that the bearing assembly nuts are loose, check those.
  • Page 65 7-3 Noise or unstable feeling 7-3-1 If the front handle bars are shaking during pedaling or feel loose when grabbing them check the bolts securing the handle bar to the mast and/or the mast bolts at the main frame. 7-3-2 If the seat is shaking during use check the wheels are tightened properly. It may be necessary to eliminate play between the wheels and the seat track.

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