Dyaco XE515SD-YE005 Service Manual

XE515SD-YE005

Elliptical

Service Manual

-----------------------------------------Table of Content-----------------------------------------------

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

6.4 Amplifier Board Wire Connections

6.5 Driver Board Wire Connections

6.6 Driver Board PCB Component Locations

6.7 Driver Board LED Indicator Locations

6.8 Controller Indicator LED Debugging

6.9 Driver Board Function

6.10 Tension Motor Connector Definition Function

7. Product Safety Instructions

7.1 Important Safety Instructions

7.2 Important Electrical Instructions

7.3 Important Grounding Instructions

8. Elliptical Error Messages and Troubleshooting for electronic Issues

8.1 Error Message: E1

8.2 Error Message: E2

8.3 Error Message: INCLINE E3

8.4 Circuit Diagram

8.5 Calibration Procedure

8.6 Fuse Replacement

8.7 Troubleshooting Procedure Matrix for Electronic Issues

9. Troubleshooting

9.1 Console Problem

9.2 Side Case & Round Disk Problem

9.3 Flywheel Problem

9.4 Poly-V Belt Problem

9.5 Swing Arm Problem

9.6 Connecting Arm and Slide Wheel Problem

9.7 Controller & Incline Motor Problem

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9.8 Tension Motor Problem

10. Q & A

10.1 Noise

10.2 Slip Problem

10.3 Shaking Problem

10.4 Smooth Problem

11. Disassembling and Assembling of Parts

11.1 Console Replacement

11.2 Swing Arm Replacement

11.3 Connecting Arm Replacement

11.4 Pedal Arm Replacement

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

11.10 Rear Frame Replacement

11.11 Rail & Incline Motor Replacement

1. Elliptical Outlines

(1) Plastic parts

Front & back handlebar cover (R)

Rear cover(1)

Rear cover(2)

Middle cover

Pedal(R)

Slide wheel cover(R)

Bottom cover

Pedal arm cover(R)

Round disk cover

Round disk

Right side case

Swing Arm Bushing

Console Swing Arm Bushing

Left side case

Console mast cover

Pedal(L)

Front & back handlebar cover (L)

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結構件 Steel parts

Main frame

Flywheel

Bushing Housing, Pedal Arm

Cross Bar

Pedal arm (R)

Drive Pulley

Incline motor

Rail assembly

Connecting arm (L)

Pedal arm (L)

Connecting arm (R)

Lower Swing arm (L)

upper Swing arm (L)

upper Swing arm (R)

Console mast

Lower Swing arm (R)

Rear frame

2. Electronic Parts

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2.1 Upper Controllers

DISPLAY

Cooling FAN

THUMB SWITCH

Speaker

2.2. Lower Controller and Driver

SPEED SENSOR

INCLINE MOTOR

TENSION MOTOR

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3. Electrical Configurations

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ONSOLE:

Interface that controls all functions of the Elliptical.

AIN CONTROLLER

The circuit board consist of the DC power supply for console、incline driver and tension motor driver, link the console to output appropriate voltages for tension motor that control the elliptical functions.

ENSION MOTOR

It can change to increase or decrease resistance level of brake.

NCLINE MOTOR:

This is an ac motor. User can to control variable elevation by console within main controller.

ENERAL INFORMATION

ONSOLE

Contains Key controls and LCD Display.

Main controller Include power supply 、 motor driver control circuit and incline control circuit.

ENSION MOTOR

Work voltage:DC 4.5~7.5V

Control resistance increases and decreases.

NCLINE MOTOR

This is a 120V volt AC motor.

Have four wires, red, black, white and green.

Has one 3 pins cable of position sensor.

If there is AC voltage on the Red wire (UP) the incline motor will increase the incline.

If there is AC voltage on the Black wire (DOWN) the incline motor will decrease the incline.

The White wire (COM) is neutral. The green wire is ground.

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4. Elliptical Operation

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Display Windows

7.5” LCD Display

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LCD Layout

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Operation

Window Display Mode

IDLE MODE

1.1 Dot matrix display shows program profiles page by page with each page lasts for 3 seconds for each program profile in order with message

window showing each name of the program profile.

SLEEP MODE

2.1 SLEEP MODE is preset ON（DISABLE）and can be set ON/OF under ENGINEER MODE.

2.2 When SLEEP MODE is set OFF, the console won’t go to sleep mode except turning off the power. When it is set OFF and if there is no RPM input or no activation of any key button within 30 minutes, it enters SLEEP MODE.

2.3 In idle mode, hold and press “Enter”, “Stop” and “Display” keys for 2 seconds and use UP/DOWN keys to switch the sleep mode on and off th

press “Enter” key to return to idle mode.

2.4 W

hen in display mode LCD image clears and the background light turns off. Any key activation may wake up the console and reset and returns to

idle mode.

2.5 When in sleep mode, the resistance and incline levels are 1 and fan is turned off.

CHILD LOCK MODE

3.1 Child lock is preset off (disable) and may be set on or off in engineering mode.

3.2 When child lock is on: Turning on the power, the message window will show “CONSOLE LOCKED” and flashes twice then scrolls “CHILD

LOCK-ON PRESS START AND ENTER TO ENABLE OPERATION”. The user must press and hold both “Start” and “Enter” keys at the same time

for 2 seconds to unlock and enter idle mode for use.

3.3 When child lock is on, all key functions are disabled and unusable before unlock.

EXERCISE MODE（QUICK START）

4.1 When in idle mode, pressing “Start” key enters manual mode. Age and weight are with preset values and time will count up from 00:00. All

parameters will count up from 0 with resistance starts from 1.

4.2 Press program key （MANUAL、PROGRAM、USER1、USER2、HRC1、HRC2）to select a program then press “Start” key begin the selected

mode with preset parameters.

PAUSE MODE

5.1 Pressing “Stop” key during the workout enters pause mode and the exercise parameters will be recorded. Message window will show ”PAUSE”

with upper windows displaying the last moment parameters.

5.2 In pause mode when “PAUSE” has been shown for 5 seconds, it switches to scroll “PAUSED - PRESS START TO RESUME OR PRESS

BUTTON AGAIN TO END WORKOUT” once and recycles.

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5.3 When pause mode lasts for 10 minutes without any key is activated, it enters idle mode automatically.

5.4 The resistance and ramp incline levels returns to 1. When “Start” is pressed again, the pos

ition of the gear motor resumes and the ramp incline

return to the level just before pause.

END MODE

6.1 At the end of the program, message window will display “CONGRATULATIONS YOU HAVE COMPLETED YOUR WORKOUT PRESS THE

STOP KEY TO END OR A USER KEY TO SAVE” showing the workout data for 1minutes.

6.2 END MODE workout information：

6.2.1 In message window,『AVG SPD XX.X』、『AVG WATT XXX』、『AVG HR XXX』、『LAPS XX』、『ALT XXXX FT』each lasts for 3 seconds.

6.2.2 The message window is followed by displaying “CONGRATULATIONS YOU HAVE COMPLETED YOUR WORKOUT PRESS THE STOP

KEY TO END OR A USER KEY TO SAVE” with prompt of pressing start key to restart the program or pressing “Stop” key once to exit or

pressing “User” key and follow the MW instructions to save the program which has been finished by the custom user.

6.2.3 CAL will show the total calorie value of the workout, time window the total workout time and DIST window the total distance of the workout.

6.3 When TIME ends the count down to the end with end mode displayed for 1 minute without any key activation, it returns to idle mode automatically.

RESET MODE

7.1 Under idle mode (except console has been locked that must be unlocked prior to having the reset function), press “Stop” key for 3 seconds to enter reset function and restart the system.

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Function

SPEED

Display the current speed in Kilometer mile per hour. DISPLAY range is 0.0 to 99.9 WORK range is 0.0~99.9

Incline

Display the incline position from 0 to 20 DISPLAY range is 0 to 99. WORK range is 0 to 20. INCLINE preset value is 0 to 20. Press “UP” or ”DOWN” to adjust incline, each increment and decrement is 1.

LEVEL

Display the incline position from 0 to 20 DISPLAY range is 0 to 99. WORK range is 0 to 20. LEVEL preset value is 0 to 20. Press “UP” or ”DOWN” to adjust incline, each increment and decrement is 1.

TIME

TIME is either COUNT UP or COUNT DOWN. System preset is COUNT UP; if user sets the time then timer is COUNT DOWN. DISPLAY range is 0:00 to 99:99. WORK range is 0:00 to 99:59. COUNT DOWN setup range is 10:00 to 99:00. When TIME is set, the count will go to zero. In RUN Mode, press “STOP” button to save value of time and enter “RUN Mode” again that value will continue count up time.

LAPS

Display the total working laps quantity. DISPLAY range is 0 to 99. WORK range is 0 to 99. Displays total laps quantity.

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DISTANCE

Display the current distance in kilometer or Mile. DISPLAY range is 00:00 to 99:00. WORK range is 00:00 to 9999.

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. When use receiver, a chest belt must be worn. DISPLAY range is 0 to 999. WORK range is 40 to 220 BPM. In RUN Mode, if the Elliptical doesn’t have a signal for 8 seconds then display value will become “- - - ”.

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Function Button Locations

Fan Key

Cooling fan switch on or off

PROGRAM BUTTONS

(Manual, Adventure, Fatburn, Xtreme, Interval, Glute Blast, X Country, Fitness, 2 User, 2HR)

CONTROL KEYS

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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. LEVEL DOWN button: If user doesn’t enter a setting then this button is non- functional. INCLINE UP button: If user doesn’t enter a setting then this button is non- functional. INCLINE DOWN button: If user doesn’t enter a setting then this button is non- functional. FAN button: It can to control ON/OFF for the fan.

ENTER KEY：：：：

Press this button to set data. If only START button is pressed without pressing ENTER button, the data is accepted. Press this button to confirm the setting or the value entered.

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. INCLINE UP button: Press the button to raise position and each increase is 1, the maximum incline position is 20. INCLINE DOWN button: Press the button to lower position and each decrease is 1, the minimum incline position is 0. Fan button: It can to control ON/OFF for the fan.

DISPLAY KEY：

：：

：

During the workout, press “Enter” key to switch the workout data. If the message displayed is the last data, pressing “Enter” key will light on

the scan icon and begin a 4-second cycling mode. The cycling mode will begin with “PROGRAM NAME” followed by the items below：

『SPEED XX.XKPH』『WATT XXX』『LAPS XX』『ALT XXXX FT』『LEVEL XX』