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Model XE860

Work Troubleshooting

Part

4

The

belt

Rev

Procedures

1. If the Belt falls off, release right

Chain Cover and loosen Idler Wheel
Assembly and return the Belt on its
place. Then turn the Belt slowly and
watch for the shifting between the
Belt and Drive Pulley and the
alignment of the Belt, Drive Pulley
and Inductive Flywheel. Check
again at speed as high as 100 to 120
RPM. Resume the unit when
everything is fine, as shown in figure
1.

2. If there is a problem with the

alignment, Adjust the Flywheel to a
proper position, as shown in figure
2.

3. If the Belt slips, adjust the nut on

J-bolt with 13 mm wrench, as shown
in figure 2. (Follow procedure 6, as
shown in figure 3)

1

2

3

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Summary of Contents for 16117700

Page 1: ...over Crank Rear Handlebar cover L Chain Cover R Round Disk Cover front Stabilizer Cover Rear Stabilizer Cover Right Pedal Connecting Arm CoverA L R Left Pedal Left Rail Cover Metal Pedal Arm Cover Right Rail Cover Metal Connecting Arm Cover B L R Chain Cover L Rail Suppoert Assembly Metal Slide Wheel Cover Inside metal Rail Cover ...

Page 2: ...Bushing Housing Left Handlebar Left Pedal Console mast Left Pedal Arm Right handlebar Rail Assembly Inductive Flywheel Right Pedal Arm Cross Bar Right Connecting arm Idler Wheel Assembly Main Frame Drive Pulley ...

Page 3: ...t 7 Idler Wheel assembly 8 Inductive Flywheel 9 Drive Pulley 10 Bushing Housing 11 Slide Wheel II Troubleshooting 1 Console 2 Left Right Chain covers and Round Disk Cover Crank 3 Inductive Flywheel 4 The Belt 5 Left and right Handlebars 6 Bushing Housing 7 Pedal Arms Connecting Arms and Slide Wheels III Q A 1 Noises 2 Slippage 3 Wobble 4 Smoothness 5 Other Problems ...

Page 4: ...e 3pcs of M5x12mm screws 2pcs of self tapping screws and 4pcs of M5 x 10 mm screws Disconnect computer cables and handpulse cables and take apart the Console as shown in figure 1 and 2 2 To resume Connect the cables back on and tighten 4pcs of M5 x 10 mm to secure the Console Return and secure Fron Mast Covers 1 2 ...

Page 5: ...mm and 13 mm wrenches to release hex head bolt which secures the Fish eye bearing together with 5 16 x 18 x 1 5T flat washer and 5 16 x 7T nut as shown in figure 2 3 Use 12 mm wrench to release5 16 x 15m m hex head bolt and 5 16 x 23 x 1 5T flat washer which secure the Connecting Arm Then release the carriage bolt and take apart the Connecting Arm as shown in figures 3 and 4 1 2 3 4 ...

Page 6: ...n figure 5 5 To resume return and tighten the Pedal back on the Connecting Arm and joint it with Pedal Arm by inserting the carriage bolt and tighten with 5 16 x 15m m hex head bolt and 5 16 x 23 x 1 5T flat washer as shown in figure 6 6 Secure Fish eye bearing with 5 16 x1 1 4 hex head bolt 5 16 x 18 x 1 5T flat washer and 5 16 x 7T nut 7 Return Connecting Arm Covers A and B 5 6 ...

Page 7: ... 2 3 Use M6 and 13 mm wrenches to release M8 x 50 socket head cap screw which secures Pedal Arm and Bushing Housing together with 2pcs of 5 16 20 1 5T flat washer and M8 x 7T nut Pull Pedal arm backward to take it apart as shown in figures 3 and 4 4 To resume join Pedal Arm with Bushing Housing and secure with M8 x 50socket head cap screw 2pcs of 5 16 20 1 5T flat washer and M8 x7T nut and return ...

Page 8: ...gure 1 3 Use Phillips head screwdriver to release 7 4x19 self tapping screws and 3pcs of 5x16 tapping screws and take apart right Chain Cover as shown in figures 2 and 3 4 To release left Chain cover release 4x15 self tapping screw and 1 4 x19 flat washer which are on the main frame as well as 3pcs of 5x16 tapping screws Disconnect red and black power cables with grounding cable to release left Ch...

Page 9: ...llips head screwdriver to return 4x15 self tapping screw and 1 4 x19 flat washer on the main frame not too tight for now then tighten with 3pcs of 5x16 self tapping screws with Chain Cover and Crank Round Disk Cover match well Tighten 4x15 self tapping screw as shown in figures 7 and 8 7 Match right Chain Cover with left and secure with 7pcs of 4x19self tapping screws and 3pcs of tappinf screws 8 ...

Page 10: ... shown in figure 1 3 Use 12 mm wrench to release 5 16 x 15m m hex head bolt with 5 16 x 35 x 1 5T flat washer Then use M6 wrench to release M8x30 socket head cap screw and take apart Cross Bar with Round Disk Crank as shown in figures 2 and 3 4 Use Phillips head screwdriver to release 8pcs of 5x16 tapping screws with 1 4 x19 flat washers and take apart Round Disk Cover Crank from Cross Bar as show...

Page 11: ...le match with the square hole for 7x7x25L Woodruff Key to return it in the hole Return M8x30 socket head cap screw and tighten until it reads 600 Kgf cm Then tighten with 5 16 x 15m m hex head bolt and 5 16 x 35 x 1 5T flat washer as shown in figures 5 and 6 6 Follow procedures 4 3 and 2 to return Connecting Arm Pedal Arm Chain covers and Round Disk Cover 5 6 ...

Page 12: ...7T nut on M8x170mm J bolt Then use Phillips head screwdriver to loosen 3pcs of M6x15 screws on the Idler Wheel Assembly and take off the Belt as shown in figures 1 2 and 3 3 To resume return the Belt onto the Drive Pulley and Induction Flywheel then adjust M8 x 7T nut so tight the acoustic tension gauge reads 170 Hz 10 Hz as shown in figure 4 4 Follow procedures 5 4 3 and 2 to resume other parts 1...

Page 13: ...r on M8x170mm J bolt to release it Then use Phillips head screwdriver to release 3pcs of M6x15 screws with 1 4 spring washers and 1 4 x13x1T flat washers and take apart the Idler Wheel Assembly as shown in figures 1 and 2 3 To resume use 3pcs of M6x15 screws with 1 4 spring washers and 1 4 x13x1T flat washers to return Idler Wheel Assembly not too tight until the Belt has been returned Then return...

Page 14: ...the Cables as shown in figures 1 2 and 3 3 Use 11 mm wrench to release 4pcs of 1 4 x 3 4 hex head bolt with 1 4 spring washers and 1 4 x13x1T flat washers and take the Inductive Flywheel apart as shown in figure 4 4 To resume Return the Inductive Flywheel back on the Main Frame and secure with 4pcs of 1 4 x 3 4 hex head screws with 3pcs of 1 4 spring washer and 3pcs of flat washers then connect al...

Page 15: ... Axle together with Drive Pulley as shown in figures 1 and 2 Use a hammer if necessary 3 To separate Drive Pulley from the Crank Axle use C ring pliers to release ψ25 C ring and use two 11 mm wrenches to release 4pcs of 1 4 x 3 4 hex head bolt and 1 4 nuts as shown in figure 3 4 To resume Drive Pulley return one C ring back on the Crank Axle and put it back on the Main Frame then secure with remai...

Page 16: ...olt with 5 16 x 35 x 1 5T flat washer and take Bushing Housing apart as shown in figure 1 3 To resume return ψ25 wave washer on the shaft and place Bushing Housing back on the shaft which is applied with lubricant Secure Bushing Housing with 5 16 x15m mhex head bolt and 5 16 x 35 x 1 5T flat washer as shown in figures 2 and 3 4 Follow procedures 3 4 and 2 5 to resume Pedal Arm and Connecting Arm 1...

Page 17: ...screw Slide Wheel Cover as shown in figure 1 3 Use C ring pliers to release ψ17 C ring and take apart the Slide Wheel as shown in figure 2 4 To resume return ψ17 wave washer Slide Wheel ψ17 wave washer in sequence onto the wheel shaft and secure with C ring as shown in figure 3 Return the Slide Wheel Cover 5 Follow procedures 3 4 and 2 5 to return Pedal Arm and Connecting Arm 1 2 3 ...

Page 18: ...roperly and AC breaker is not activated as shown in figure 1 3 Make sure that all connectors including computer cables vs Console are connected properly Disassemble the Console to check computer cables inside the Console if necessary 4 If cables are all connected properly then check for cable damage or Console lower Controller failure as shown in figure 2 1 2 ...

Page 19: ...which is causing the noise release both left and right Chain Covers and re assemble them again Follow procedure 4 3 If it the swing of the Round Disk Crank which is causing the noise then release both Chain Covers and Round Disk Crank then use Phillips head screwdriver to release 16pcs of 5x16m m tapping screws with 1 4 x19m m flat washers on Round Disk Crank Put Cross Bar with Round Disk Crank on...

Page 20: ...eel is rare If there is no resistance take off both Chain Covers and check for disconnection or breakage for electric cables as shown in figure 1 2 If there is no power generated check AC power switch for fuse blown Replace with a new AC switch if necessary follow procedure 8 as shown in figure 2 and 3 1 2 3 ...

Page 21: ...een the Belt and Drive Pulley and the alignment of the Belt Drive Pulley and Inductive Flywheel Check again at speed as high as 100 to 120 RPM Resume the unit when everything is fine as shown in figure 1 2 If there is a problem with the alignment Adjust the Flywheel to a proper position as shown in figure 2 3 If the Belt slips adjust the nut on J bolt with 13 mm wrench as shown in figure 2 Follow ...

Page 22: ...e between 0 05 mm and 0 07 mm for easy to assemble to the end user It is normal for handlebars to shift a little bit However noises may be caused as time lasts because parts wear The solution for the noise is to apply some grease on ψ25x296Lmast shaft as shown in figure 1 2 If Bushing Housing has been worn out replace it with a new one 1 ...

Page 23: ...ng Housing is rare However a few units might have noise problem as time lasts Applying some grease on ψ25 x 111 5 L shaft on Cross Bar Assembly as shown in figure 1 may be helpful for solving this problem 2 If the Copper Bushing has been worn out replace it with a new one as shown in figure 2 1 2 ...

Page 24: ...lot It is very important to lubricate each moving parts and joints as shown in figures 1 and 2 2 There are many factors which affect the feeling of smoothness The most important key point is to make sure that sliding wheels move parallel and smoothly on the rails In brief Pedal Arm should keep parallel with Connecting Arm and both Pedal Arm and mainframe keep perpendicular to the bushings 1 2 ...

Page 25: ...Procedures 3 Both Handlebars should connect properly with their corresponding connecting Arm and Sliding wheels should have real circle without slippage 4 During maintenance start from sliding wheels by applying lubricant on wheels or replace if necessary as shown in figures 1 and 2 1 2 ...

Page 26: ... Chain Cover rubbing Crank Round Disk Cover Bushing Housing and Cross Bar Belt and Drive Pulley Idler Wheel Assembly Handlebar and Mast shaft Flywheel and Cable to Sliding Wheels and Rail Assembly even Pedals etc Insufficient lubrication smoothness or loose screws are major causes as shown in figure 1 1 ...

Page 27: ...ndicular to the bolt as shown in figure 1 3 Bushing Housing M8 x 50m m socket head cap screw must be firmly tightened with M8 x 7T nut 4 Cross Bar M8x30m msocket head cap screw on the Cross Bar must be firmly tight 5 The Belt Belt slipping is quite usual because the belt gets less tensioned as time lasts Time duration and user weight are major factors Follow procedure 6 to adjust the belt tension ...

Page 28: ...ten all screws and check for installation faults or worn out of parts when time lasts Like a wobble pedal is usually caused by carriage bolt not installed properly If the unit wobbles adjust the screws for footpad beneath Front Stabilizer as shown in figures 1 and 2 Be sure to apply some lubricant after replacing the parts 1 2 ...

Page 29: ...ss Rev Procedures 7 Check tightness of screws and bolts if the unit clicks 8 Otherwise there might be foreign materials on either the rail or Slide Wheel Use rubbing alcohol to wipe and apply some lubricant both parts as shown in figure 1 1 ...

Page 30: ...Model XE860 Work Q A Problem 5 Other Problems Rev Procedures 1 Contact DYACO for problems not covered in this service manual Any problem solving on the unit is backed up by DYACO technical team ...

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