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Dyaco CS800 Service Manual

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CS800( 2020)
Service Manual
Service Manual

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Summary of Contents for Dyaco CS800

  • Page 1 CS800( 2020) Service Manual Service Manual...

  • Page 2: Table Of Contents

    4-2-6 PROGRAMMABLE FEATURES ................................14 4-2-7 CSAFE FEATURE ....................................14 5. CS800(2020) Unit Block Diagrams ..................................16 6. CS800(2020) Basic Connections and Wiring ............................... 18 6-1 Display Board PCB Component Locations ..............................19 6-1-1 DISPLAY BOARD WIRE CONNECTIONS ............................... 19 6-1-2 PCB BOARD TOP ....................................
  • Page 3 7-5 Test configuration and the console to driver board connector pin define function ..................30 7-6 MAINTENANCE MENU IN CONSOLE SOFTWARE ............................31 7-7 Troubleshooting procedure matrix ................................32 8. Circuit diagram(CS800(2020)) .................................... 33 9. Troubleshooting(CS800(2020)) ..................................35 9-1 Troubleshooting for the console ................................36 9-2 Troubleshooting for the Flywheel................................

  • Page 4: Cs800(2020) Outlines

    1. CS800( 2020) Outlines Dyaco International Inc.
  • Page 5 Console Console Mast Cover (R) Console Mast Cover (R) Chain Cover (L) Handle Bar Cover (R) Pedal (L) Chain Cover (R) Pedal (R) Rear Side Case Left Slider Cover Right Slider Cover Handgrip CapCover (L) & (R) Dyaco International Inc.
  • Page 6 Console Mast Left Handgrip Right Handgrip Drive Pulley Crank Arm Assembly Swing Assembly Rail Tube Flywheel Idler Wheel Assembly Connecting Arm (L) Main Frame Connecting Arm (R) Linked Assembly ( R) Handgrip Connecting Tube Rear Stabilizer Dyaco International Inc.

  • Page 7: Cs800(2020) Electronic Parts

    2. CS800( 2020) Electronic Parts Dyaco International Inc.

  • Page 8: Upper Controllers

    2-1 Upper Controllers Console Cooling Fan Dyaco International Inc.

  • Page 9: Lower Controller And Driver

    2-2 Lower Controller and Driver Tension Motor Speed Sensor Dyaco International Inc.

  • Page 10: Electrical Configurations

    3. Electrical Configurations Dyaco International Inc.
  • Page 11 The circuit board consist of the DC power supply for console. ECB BRAKE It can change to increase or decrease resistance level of brake. GENERAL INFORMATION CONSOLE Contains Key controls and LED Display. Main controller include power supply、ECB driver control circuit. Dyaco International Inc.

  • Page 12: Cs800(2020) Product Operation

    4. CS800( 2020) Product Operation Dyaco International Inc.

  • Page 13: Display Windows

    4-1 Display Windows LED DATA DISPLAY WINDOWS SCAN BUTTON FOR LED WINDOW Dot-Matrix MESSAGE CENTER SCAN BUTTON FOR UP, DOWN Dot-Matrix PROGRAM CONTROL COOLONG FAN COOLING FAN SWITCH CHARGER START, STOP LEVEL CONTROLS Dyaco International Inc.

  • Page 14: Operation

    Vertical Distance ,Watts ,METs and Time Remaining. 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. Pressing the Scan button again will bring you back to the beginning. Dyaco International Inc.

  • Page 15: 1/4 Mile Track

    Pulse values are displayed anytime the computer is receiving a Grip Pulse signal. You may use the Grip Pulse feature while in Heart Rate Control. The CS800 will also pick up wireless heart rate transmitters that are Polar compatible, including coded transmissions.
  • Page 16 (about the same as your TV when it is turned off) and it is perfectly fine to leave the main power switch on in sleep mode. Of course you may also remove the safety button or turn off the main power switch to power down the stepper. Dyaco International Inc.

  • Page 17: Cs800(2020) Unit Block Diagrams

    5. CS800( 2020) Unit Block Diagrams Dyaco International Inc.
  • Page 18 Dyaco International Inc.

  • Page 19: Cs800(2020) Basic Connections And Wiring

    6. CS800( 2020) Basic Connections and Wiring Dyaco International Inc.

  • Page 20: Display Board Pcb Component Locations

    6-1 Display Board PCB Component Locations 6-1-1 DISPLAY BOARD WIRE CONNECTIONS Dyaco International Inc.

  • Page 21: Pcb Board Top

    6-1-2 PCB BOARD TOP Dyaco International Inc.

  • Page 22: Pcb Board Bottom

    6-1-3 PCB BOARD BOTTOM Dyaco International Inc.

  • Page 23: The Console Interface Board Wire Connections

    6-1-4 THE CONSOLE INTERFACE BOARD WIRE CONNECTIONS Dyaco International Inc.

  • Page 24: Generator Flywheel Definition Function

    6-1-5 GENERATOR FLYWHEEL DEFINITION FUNCTION MAIN CONTROL STEEL ROPE 1. M- 2. M+ 3. +5 4. VR 5. GND Dyaco International Inc.

  • Page 25: Cs800(2020) Error Messages / Troubleshooting

    7. CS800( 2020) Error Messages / Troubleshooting Dyaco International Inc.

  • Page 26: Error Codes

    7-1 Error Codes Error Code CAUSE EEPROM ERROR EEPROM failure Tension Motor failure 7-2 Prepare tools Multi-meter Dyaco International Inc.

  • Page 27: Error Messageļ¼šeeprom Error

    When the tension motor feedback signal is abnormal or no feedback to the console, all the outputs will stop and all the display windows are blank but the LEVEL window will show “Err”. Troubleshooting 1. Check the control cable and replug it. 2. Check the tension motor. Dyaco International Inc.

  • Page 28: Tension Motor Operation

    DISPLAY BOARD LEVEL +/- KEYS +/- KEYS LEVEL VR LEVEL +/- SIGNAL SIGNAL TENSION MOTOR Dyaco International Inc.

  • Page 29: Tension Motor Troubleshooting

    2. Inspect console power output to the motor. Press the Level Up is +4~5VDC;Level DOWN is -4~5VDC.If there is power to the motor, but the motor does not operate, replace it. If there is no power output, inspect whether the transformer has power. Data cable Inspect the cable and connections. Dyaco International Inc.

  • Page 30: Tension Motor Voltage Test Procedure

    Press LEVEL DOWN. Normal reading: -4~5VDC.Motor operates. Resistance decreases. If there is no voltage, check the transformer, if there is no output, replace it. Place probes on the motor control wire(Red probe in palm wire, Black probe in black wire) on the drive board. Dyaco International Inc.

  • Page 31: Test Configuration And The Console To Driver Board Connector Pin Define Function

    3. 5V 4. MTR_AD 5. GND 6. RPM 7. GND 8. N/A 9. GND 10. 12V 11. N/A 12. N/A 13. N/A 14. N/A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Dyaco International Inc.

  • Page 32: Maintenance Menu In Console Software

    -Units (Sets the display to read out in English or Metric display measurements) -Pause mode (have five minutes) -Odometer Reset (Resets the odometer) -Sleep mode -Beep sound(Control Beep) -CAB Protocol or CSAFE Protocol Service -Motor test -Csafe test -Sensor test(Test the speed sensor function) Exit Dyaco International Inc.

  • Page 33: Troubleshooting Procedure Matrix

    2. User chest belt in front of console within 3 feet. 3. Chest belt battery is weak or dead. 3. Replace with new lithium battery type is CR2032. Chest belt too close to the Stepper. Weak battery. Replace with new lithium battery with type CR2032. Dyaco International Inc.

  • Page 34: Circuit Diagram(Cs800(2020))

    8. Circuit diagram( CS800( 2020) ) Dyaco International Inc.
  • Page 35 Dyaco International Inc.

  • Page 36: Troubleshooting(Cs800(2020))

    9. Troubleshooting( CS800( 2020) ) Dyaco International Inc.

  • Page 37: Troubleshooting For The Console

    Check the power supply or test with a new one. Check all computer cables are plug well. Check all wires inside the console and the chain cover are plug well. And check there are no pinched wires. Dyaco International Inc.

  • Page 38: Troubleshooting For The Flywheel

    There is a noise when the flywheel is spinning. Solve: Check the noise is from the flywheel friction drive pulley or idle wheel. If so follow the replacement steps to reinstall those parts. If the noise comes from flywheel, please do the replacement. Dyaco International Inc.

  • Page 39: Troubleshooting For Drive Belt

    If the drive pulley, flywheel pulley, and idle wheel assembly are not aligned, to adjust the flywheel to appropriate locate can fix it. Situation: Drive Belt is Skidding. Solve: To use a 13mm open-end wrench to adjust the nut of J-Bolt can fix it. If Drive Belt is worn please do the replacement. Dyaco International Inc.

  • Page 40: Troubleshooting For Swing Assembly

    9-4 Troubleshooting for Swing Assembly Situation: There is a clearance between bushing and axle. Solve: The bushing may be worn after a long time of usage requires replacement. Dyaco International Inc.

  • Page 41: Troubleshooting For Connecting Arm

    9-5 Troubleshooting for Connecting Arm Situation: The broken pedal. Solve: To do the pedal replacement. Situation: There is a vibration feeling from feet when pedaling. Solve: It’s maybe the bearing of Slide wheel is defective require replacement. Dyaco International Inc.

  • Page 42: Parts Replacement Guide

    10. Parts Replacement Guide Dyaco International Inc.

  • Page 43: Console Replacement

    Step 1: Use a screwdriver to remove 4 screws (5*10mm) which locking console on console mast. Step 2: Unplug wires then take off the console. Step 3: Plug wires back before install the console then tighten 4 screws back. Note: Do not pitch the wires. Dyaco International Inc.

  • Page 44: Chain Cover Replacement

    Step 1 : Use a screwdriver to remove both side handle bar cover. Step 2: Use a screwdriver to remove 3 screws(ψ4*15mm) then take off console mast covers. Step 3: Use a screwdriver to remove 7 screws(ψ4*15mm). Dyaco International Inc.
  • Page 45 Step 4: Remove a screw which locking both left and right chain covers. Step 5: Remove 5 screws(ψ5*19mm) of right side chain cover then take off it. Step 6: Remove 5 screws(ψ5*19mm) of left side chain cover then take off it. Dyaco International Inc.
  • Page 46 Step 7: Use a Needle nose plier to remove DC socket nut, then unmount DC power wire from chain cover. Step 8: To do the reverse of above steps to install both side chain cover back. Dyaco International Inc.

  • Page 47: Swing Assembly Replacement

    Step 1: Follow the steps of Chain Cover Replacement to take off both chain covers. Step 2: Use a 12mm open-end wrench to remove inside bolt and washer of swing assembly axle. Step 3: Unmount axle and separate the swing assembly and connecting arm. Dyaco International Inc.
  • Page 48 Step 4: Use a 12mm open-end wrench to remove bolt and washer which locking swing assembly with mainframe, then take off swing assembly. Step 5: To do the reverse of above steps to install swing assembly back. Note: Make sure axle and U-plate alignment before tighten the bolt. Dyaco International Inc.

  • Page 49: Linked Assembly Replacement

    Step 3: Remove the bolt which locking the linked assembly with the crank, then take off the linked assembly. Step 4: To do the reverse of above steps to install back. Note : Make sure axle and U bracket alignment before tightening the bolts. Dyaco International Inc.

  • Page 50: Connecting Arm Replacement

    Step 3: Use a circlip plier to remove the circlip Ø 17 then remove the slide wheel. Step 4: Use a screwdriver to remove 4 screws(M5*10mm) then take off pedal. Step 5: To do the reverse of above steps to install back. Dyaco International Inc.

  • Page 51: Console Mast Replacement

    Step 3: Put out the Handle pulse wires from under the tube. Step 4: Use a screwdriver to remove 2 screws(ψ3x20mm) then remove the handle pulse with wire. Step 5: To do the reverse of above steps to install back. Note : Do not pinch the wires. Dyaco International Inc.

  • Page 52: Rail Tube Replacement

    Step 2: Use a screwdriver to remove a screw(M5*10mm) of Slider Cover then take off it. Step 3: Use 2 14mm open-end wrenches to remove the bolts and nuts which locking the Rail tube then take off it. Step 4: To do the reverse of above steps to install back. Dyaco International Inc.

  • Page 53: Crank Arm Assembly Replacement

    Step 3: Use a M6 L-Allen wrench and a 13mm wrench to loose the bolt(M8*35L) then take off the Crank Arm Assembly. Step 4: To do the reverse of above steps to install back. Note: The direction of the woodruff key, the round head direct to the axle. Dyaco International Inc.

  • Page 54: Idle Wheel Assembly Replacement

    Step 3: Use a 13mm open-end wrench to remove the nut which locking on the J-bolt then unmount the drive belt from drive pulley. Step 4: To do the reverse of above steps to install back. Use the nut of J-bolt to adjust drive belt tension then use Sonic belt tension meter to measuring belt tension. Dyaco International Inc.
  • Page 55 Step 5: Operate the crank to make sure the belt is aligned with drive pulley, flywheel pulley, and idle wheel, and then install back all other parts. Dyaco International Inc.

  • Page 56: Flywheel And Drive Belt Replacement

    If not, use a 17mm open-end wrench to adjust the nuts of flywheel to center the belt on the drive pulley. Step 5: Adjust the drive belt tension with the idle wheel assembly, and then install back all other parts. Dyaco International Inc.

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