Dyaco XE330D Service Manual Download

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(2)Steel parts

Connecting Arm (L) Lower Handle Bar (L)

Cross Bar

Console Mast

Lower Handle Bar (R)

Bushing Housing, Pedal Arm

Rail Assembly

Pedal Arm(L)

Pedal Arm(R)

Rail Tube

Pedal Arm(R)

Connecting Arm (R)

Idler Wheel Assembly

Drive Pulley

Flywheel

Summary of Contents for XE330D

Page 1: ...XE330D TE006 Elliptical Service Manual ...

Page 2: ...nnections 6 2 Display Board PCB Component Locations 6 3 The Console Interface Board Wire Connections 6 4 Amplifier Board Wire Connections 6 5 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 E...

Page 3: ...9 8 Gear Motor Problem 10 Q A 10 1 Noise 10 2 Slip Problem 10 3 Resistance Incline Problem 10 4 Smooth Problem 11 Disassembling and Assembling of Parts 11 1 Console Replacement 11 2 Connecting Arm Replacement 11 3 Connecting Arm Replacement 11 4 Slide Wheel Replacement 11 4 Pedal Arm Replacement 11 5 Side Case Replacement 11 6 Cross Bar Replacement 11 7 Idler Wheel Replacement 11 8 Flywheel Poly V...

Page 4: ...S Se er rv vi ic ce e M Ma an nu ua al l 4 1 XE330D Elliptical Outlines ...

Page 5: ...ic parts Left Side Case Console Mast Cover Pedal R Right Side Case Drink Bottle Holder Rear Stabilizer Cover L Rear Stabilizer Cover R Slide Wheel Cover Round Disk Transportation Wheel Round Disk Cover Bushing Cover Pedal L Console Cover Swing Arm Axle ...

Page 6: ...l 6 2 Steel parts Connecting Arm L Lower Handle Bar L Cross Bar Console Mast Lower Handle Bar R Bushing Housing Pedal Arm Rail Assembly Pedal Arm L Pedal Arm R Rail Tube Pedal Arm R Connecting Arm R Idler Wheel Assembly Drive Pulley Flywheel ...

Page 7: ...S Se er rv vi ic ce e M Ma an nu ua al l 7 2 Electronic Parts ...

Page 8: ...S Se er rv vi ic ce e M Ma an nu ua al l 8 2 1 Upper Controllers DISPLAY Speaker ...

Page 9: ...S Se er rv vi ic ce e M Ma an nu ua al l 9 2 2 Lower Controller and Driver SPEED SENSOR TENSION MOTOR ...

Page 10: ...S Se er rv vi ic ce e M Ma an nu ua al l 10 3 Electrical Configurations ...

Page 11: ...upply for console tension motor driver link the console to output appropriate voltages for tension motor that control the elliptical functions TENSION MOTOR It can change to increase or decrease resistance level of brake GENERAL INFORMATION CONSOLE Contains Key controls and LCD Display TENSION MOTOR Work voltage DC 4 5 7 5V Control resistance increases and decreases ...

Page 12: ...S Se er rv vi ic ce e M Ma an nu ua al l 12 4 Elliptical Operation ...

Page 13: ...S Se er rv vi ic ce e M Ma an nu ua al l 13 Display Windows 5 5 LCD Display ...

Page 14: ...S Se er rv vi ic ce e M Ma an nu ua al l 14 LCD Layout ...

Page 15: ...SE MODE 3 1 Pressing STOP key during workout the unit enters PAUSE mode and the exercising parameters are saved 3 2 Under PAUSE mode the WM keeps displaying PRESS START BUTTON AFTER EXERCISING 3 3 PAUSE mode keeps for 4 minutes if there is no input in 4 minutes the unit enters SLEEP mode 3 4 The resistance level returns to level 1 Pressing START key again the gear motor returns the level before pa...

Page 16: ...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...

Page 17: ... workout DISPLAY range is 0 to 9999 WORK range is 0 to 9999 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 9999 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 P ...

Page 18: ...S Se er rv vi ic ce e M Ma an nu ua al l 18 Function Button Locations PROGRAM BUTTONS Quick_Start Manual CLIMBING Interval TEST WATT_CONTROL HRC User RECOVERY BODY FAT CONTROL KEYS ...

Page 19: ...OWN button If user doesn t enter a setting then this button is non functional MODE button While in program setting pressing this button goes to next setting parameter RUN MODE START STOP button press START STOP button to stop Elliptical MODE button non functional UP button Press the button to increase your level and each increase is 1 DOWN button Press the button to decrease your level and each de...

Page 20: ...S Se er rv vi ic ce e M Ma an nu ua al l 20 5 Elliptical Unit Block Diagrams ...

Page 21: ...S Se er rv vi ic ce e M Ma an nu ua al l 21 Elliptical Configuration ...

Page 22: ...S Se er rv vi ic ce e M Ma an nu ua al l 22 6 Basic Connections and Wiring ...

Page 23: ...S Se er rv vi ic ce e M Ma an nu ua al l 23 6 1 Display Board wire Connections ...

Page 24: ...S Se er rv vi ic ce e M Ma an nu ua al l 24 6 2 Display Board PCB Component Locations PCB Board Top ...

Page 25: ...S Se er rv vi ic ce e M Ma an nu ua al l 25 PCB Board Bottom ...

Page 26: ...S Se er rv vi ic ce e M Ma an nu ua al l 26 6 3 The console Interface Board wire Connections ...

Page 27: ...S Se er rv vi ic ce e M Ma an nu ua al l 27 6 4 Amplifier Board wire Connections ...

Page 28: ...S Se er rv vi ic ce e M Ma an nu ua al l 28 6 5 Tension Motor connector definition function STEEL ROPE 1 2 3 4 5 MAIN CONTROL 1 M 2 M 3 VR P 4 AD IN 5 GND ...

Page 29: ...S Se er rv vi ic ce e M Ma an nu ua al l 29 7 Product Safety Instructions ...

Page 30: ... to control This part is available through most electrical supply stores Examples Grainger part 1D237 or available online at www squared com part QO120HM 7 3 Important Grounding Instructions This product must be grounded If the Elliptical should malfunction or breakdown grounding provides a path of least resistance for electric current reducing the risk of electric shock This product is equipped w...

Page 31: ...S Se er rv vi ic ce e M Ma an nu ua al l 31 8 Error Messages Troubleshooting ...

Page 32: ...S Se er rv vi ic ce e M Ma an nu ua al l 32 Error code items Error Message Explain E2 EEPROM failure E1 Tension motor is failure Prepare Picture Tool name Multi meter ...

Page 33: ...nu ua al l 33 8 1 Error Message E2 Definition All screens are off and outputs are stop when EEPROM damaged or malfunction Display message will show E 1 and message window will show RAM ERROR Troubleshooting Replace upper controller ...

Page 34: ...S Se er rv vi ic ce e M Ma an nu ua al l 34 8 2 Error Message E1 Definition When you press the Level Up or Down key the motor does not move E1 appears on the display Configuration ...

Page 35: ...the cable and connections Tension Motor Inspect Display board output to the motor Press the Level Up is 5VDC Level DOWN is 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 drive board has power Tension Motor Voltage Test Procedure 1 Put multi meter to the 12VDC setting Place probes on the motor control wire Red probe in p...

Page 36: ...S Se er rv vi ic ce e M Ma an nu ua al l 36 Place probes on the motor control wire Red probe in black wire Black probe in palm wire on the Tension Motor ...

Page 37: ...ng Part Troubleshooting Display board 1 Inspect the 13 pin cable connections 10 pin cable 1 Inspect the wire connections 2 Inspect whether wires are broken or crimped 3 Replace the wires and test again Tension Motor Inspect the display board 5 pin connections ...

Page 38: ...t configuration The console to driver board connector pin define function The console to Tension Motor connector pin define function 1 NONE 2 NONE 3 NONE 4 GND 5 GND 6 VCC 7 SPEED 8 GND 9 GND 10 AD IN 11 VR P 12 M 13 M 1 2 3 4 5 6 7 8 9 10 11 12 13 ...

Page 39: ...S Se er rv vi ic ce e M Ma an nu ua al l 39 8 3 Circuit Diagram ...

Page 40: ... Another chest belt in use around Elliptical 2 Other magnetic field disturbance 3 Receiver is broken 1 Check for other chest belt use around elliptical 2 Change the position or direction of elliptical 3 Replace with new receiver Hand pulse lost its function No pulse displayed on monitor 1 Hands not on the hand pulse sensors or only one hand on sensor 2 The connector of HANDPULSE W WIRE and Console...

Page 41: ...S Se er rv vi ic ce e M Ma an nu ua al l 41 9 Troubleshooting ...

Page 42: ...following procedures 2 Make sure power adaptor is properly inserted Check all connectors including those in the console on the controller and wire harness are connected properly 3 Check continuity of wire harness and the console 4 Use multi meter to check DC voltage Replace the adaptor if there is no DC voltage ...

Page 43: ...assemble Refer to the assembly and disassembly procedures 3 If the disc is offset causing friction remove the left and right chain cover use Phillips screwdriver and remove the 5x16mm Tapping Screw as well as the 1 4 x19mm flat washer Placed the round disk and the Cross Bar on a flat surface to check if either is deformed If deformed check to see if the deformity can be fixed manually The deformit...

Page 44: ...justments or improper assembly causing offset creating abnormal sounds Please follow the magnetic flywheel and cable disassembly procedures to commence adjustments 2 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 45: ...e not aligned in a straight line Lastly rotate at high speed 100 200RPM and test with abrupt stops to check for abnormalities If everything is ok restore to fully assemble 2 If the three parts are not aligned in a straight line adjust the magnetic flywheel to the proper place Adjustments are always made to product ensuring alignment before shipment from factory 3 If the Poly V Belt is slipping sim...

Page 46: ...l 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 lubrantic into the top of ψ17x276L Swing Arm Axle If the bearing makes noises or get stuck change the bearing ...

Page 47: ...el of the linked structure slides smoothly and parallel on top of the Inclinable Rail Assembly In short the main cause would be side Inclinable Rail Assembly and the Inclinable Rail Assembly are not parallel side Inclinable Rail Assembly and the main frame bottom bracket rotating sleeve do not come together as 90 degrees 3 Check to see if left Right connecting arm and left right step is connected ...

Page 48: ... Few problems occur at this part but it may make noises after a certain of time of usage Applying of thicker lubricant on Ø22 x Ø17 x 111 5 L on the axle is recommended to eliminate noises 2 If the noise is emitting from the bushings then the bushings 47 needs to be replaced ...

Page 49: ... no sign motor operating the open the Chain Covers to make sure wire harnesses are connected properly If motor still does not work use multi meter to check black and red wires for DC power If power is OK then the motor is bad otherwise wire harnesses are bad Follow the procedures to replace defective parts 3 If there is no problem with the gear motor then check if the sliding end where the cable c...

Page 50: ...S Se er rv vi ic ce e M Ma an nu ua al l 50 10 Q A ...

Page 51: ...round disk sleeve Cross Bar Belt and belt pulley Idler Wheel Plate Swing Arm Swing Arm Axle Flywheel Steel Cable and Slide Wheel during assembly along with side Inclinable Rail Assemblys as well as pedals The main reasons are usually not enough lubrication unsmooth rotations and loose screws Because the product is designed based on linked designs resolving noise issue will vary from machine to mac...

Page 52: ...t be securely tightened and Rod End Bearing needs to be vertical 1 2 Cross Bar CAP Socket Head Cap Bolt M8x30m m on top of the Cross Bar on the must be tightened 2 Belt This issue appears quite often because after a period of time most belts will become loose from use depending on usage time Solution will depend on weight and adjustment methods refer to belt disassembly procedures for references ...

Page 53: ... 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 10 4 Smooth Problem 1 Check for loose screws if machine motion feels unsmooth 2 Check if there are foreign object on or around the sliding rail use an alcohol wipe to remove and re lubricate with lubricant ...

Page 54: ...S Se er rv vi ic ce e M Ma an nu ua al l 54 11 Disassembling and assembling of Parts ...

Page 55: ...M5x10mm 4pcs securing the console Unfasten all connected wires and remove console 2 Reassemble in the reverse order as disassembly Be sure to not crush or damage wiring during process 3 To remove both upper and lower console cover remove the Sheet Metal Screws 3 5x12 that is securing the console Should only be done by a professional ...

Page 56: ...16 x15mm and flat washers 5 16 x1 1 4 at rod ends of both sides 3 Use 12 mm wrench to unscrew the Connecting Arms 5 16 x3 4 hex head screw and 5 16 x23x1 5T flat washer and pull out Pedal Axle to separate Connecting Arm from Pedal Arm 4 Use Phillips screwdriver to remove Phillips Head Screw M5x10mm securing the pedal and remove pedal 4 To resume match the connecting Arm and Pedal Arm holes for Ped...

Page 57: ...S Se er rv vi ic ce e M Ma an nu ua al l 57 5 Secure to Connecting Arm with the Lower Handle Bar ...

Page 58: ...a al l 58 11 3 Pedal Arm Replacement 1 First remove the Pedal Bar Assembly then use 12 mm wrench to remove the Hex Head Bolts 5 16 x 3 4 securing bushing housing and remove bushing washer 2 Reassemble in the reverse order as disassembly ...

Page 59: ...ps head screwdriver M5x15mm 2 Use 12 mm wrench to release hex head screw 5 16 x3 4 with flat washer 5 16 x20x1 5T and pull out Slide wheel axle to take apart the slide wheel 3 To resume put a wave washer on the slide wheel slide in the Wheel axle and tighten the hex head screw 5 16 x3 4 with flat washer 5 16 x20x1 5T ...

Page 60: ...hing Cover from the Bushing Washer 2 Use 12 mm wrench to remove Hex Head Bolts 5 16 x 1 1 4 flat washers 5 16 x35x1 5T securing the Rod End Assembly 3 Use 12 mm wrench to remover Hex Head Bolts 5 16 x3 4 securing the bushing housing and remove bushing Washer 4 Take off right Pedal Arm ...

Page 61: ...12mm x 9 self tapping screws 5x16mm x 3 by using Phillips head screw driver and release it 7 Reassemble in the reverse order as disassembly 8 Disassemble Chain Cover L by following previous procedures 9 Release self tapping screw 4x16mm and flat washer 1 4 x19 on the Console Mast by using Phillips head screw 10 Release tapping screws 5x16mm ...

Page 62: ...S Se er rv vi ic ce e M Ma an nu ua al l 62 11 Release the nut of DC power plug then pull out DC power cables and Chain Cover L can be released 12 Reassemble in the reverse order as disassembly ...

Page 63: ...ove hex head bolt 5 16 x3 4 flat washer 5 16 x35x1 5T securing the cross bar 3 Use Allen wrench to loosen the Socket Head Cap Bolt M8x30 steel lvl 10 and remove the cross bar assembly 4 To resume the Cross Bar put it on the Crank Axle and secure the Woodruff Key by tightening M8x30 Socket Head Cap Screw 5 CM Be sure to tighten Socket Head Cap Screw M8x30 as tight as 600 Kgf cm 6 Resume the unit wi...

Page 64: ... to remove belt Use 13 wrench Double Open End Wrench to remove screws M8x20 nyloc nut M8x7T and flat washer 5 16 x23x1 5T to remove the Idler wheel 3 Reassemble parts in the reverse order as disassembly tighten the nyloc nuts M8x7T on top of the hook screws flick the belt for crisp sound to check tightness or use a sound measuring device to measure at 170HZ 10 reassemble the remaining parts ...

Page 65: ...osen nyloc nut 3 8 UNF26x9T on flywheel and main frame Take apart the steel cable connected to flywheel Remove flywheel and belt 4 Reassemble parts in the reverse order as disassembly and adjust belt and center the belt wheel Turn Drive Pulley to make sure the belt stays on it Adjust nuts 3 8 UNF26 x 4T to make sure the belt stays in the middle and tighten all screws Adjust the belt for proper ten...

Page 66: ...lywheel and the Belt 2 Take apart the Woodruff Key and Ø25 circlip by using circlip pliers 3 Pull out the Drive Pulley and Crank Axle use a soft hammer if necessary 4 To separate Drive pulley from Crank Axle use 12 mm wrench to release hex head screws 1 4 x3 4 and nuts 1 4 5 Reverse above steps to resume Be sure to include Spacer Bushing on Crank Axle ...

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