Technogym BIKE XT, Service Maintenance Manual

Page 1: ...SERVICE MAINTENANCE MANUAL REV 2 0...

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Page 3: ...EN THE MACHINE IS TURNED OFF NOTE The information contained in this document is subject to change without notice Technogym does not guarantee this documentation in any way Technogym shall not be held...

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Page 5: ...6 1 6 1 THE DISPLAY DOES NOT ILLUMINATE 6 2 6 2 THE RESISTANCE IS NOT CORRECT 6 5 6 3 THE RPM VALUE IS INCORRECT 6 7 6 4 THERE IS NO HEART RATE SIGNAL 6 9 6 5 THE HEART RATE SIGNAL IS INCORRECT 6 10 7...

Page 6: ...ction keys 9 2 9 1 6 Enabling the ENTER key 9 2 9 2 MAINTENANCE INFORMATION 9 3 9 2 1 Hours on 9 3 9 2 2 Hours of use 9 3 9 3 CHANGING THE MAINTENANCE INFORMATION 9 3 9 3 1 Hours on 9 3 9 3 2 Hours of...

Page 7: ...vance may cause damage to the machine Information about the operation in progress OBSERVE observation about the operation in progress 1 2 RECOMMENDATIONS Technogym recommends the following steps for p...

Page 8: ...ecommended brands 3 Use special tools where specified 4 Consult the technical circulars which may contain more up to date information on adjustments and maintenance than those contained in this manual...

Page 9: ...voltage setting can cause irreversible damage to the power supply unit Before changing the mains voltage setting the machine must be turned off and the mains lead unplugged from the wall output 2 3 AM...

Page 10: ...aintenance manual rev 2 0 Page 2 2 2 5 WIRING DIAGRAM 2 5 1 CONNECTORS CPU board name type of connector connection CN1 AMP MATE N LOCK 12 pin F to alternator interface board CN4 AMP MODU II 4 pin M to...

Page 11: ...cable CPU Alternator interface board CPU CN1 Signal Color Alternator interf board CN1 1 12 V Red 1 2 5 V Orange 2 3 ground Black 3 4 12 V Blue 13 5 Alternator RPM X 6 Violet 5 6 Alternator control fr...

Page 12: ...or Blue Yellow Blue eyelet 6 Yellow eyelet 4 3 Resistor Red Yellow Red eyelet 6 Yellow 5 ground Black eyelet 4 4 Excitation Orange Red Faston BX 3 High voltage supply cable Power input socket Power su...

Page 13: ...PRINCIPLES OF OPERATION 3 1 BLOCK DIAGRAM The block diagram of the machine is shown in the figure below 1 CARDIO TRANSMITTER It is worn by the person using the machine and transmits to the cardio rec...

Page 14: ...workload data Watt and RPM It controls the difficulty level selected with the keys or according to the chosen training program 4 POWER SUPPLY Receives the mains voltage at its input and outputs the DC...

Page 15: ...eader The serial port is connected to the CPU by the cable described below which is supplied in the upgrade kit TGSRN2XT Internal cable CPU 9 pin connector CPU CN2 Signal Color DB9 male 1 12 V yellow...

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Page 17: ...t 9 The machine can be connected in cascade with other machines It is recommended to connect only machines of the same type in cascade up to a maximum of 5 machines In this case make sure that the wal...

Page 18: ...by mode awaiting a keyboard command To check the correct operation of the machine get on the machine start exercising check that the RPM display changes accordingly check that the intensity of the exe...

Page 19: ...e This type of box is a step in the troubleshooting procedure where an ACTION must be carried out It typically contains a description of the ACTION necessary to resolve the problem Therefore after exe...

Page 20: ...tput of the machine s input socket Replace blown fuses Replace mains lead Connect machine to a suitable electrical output Replace input socket on off switch unit on the machine Replace cable BX 3 conn...

Page 21: ...ph 7 8 Replace cable BX 1 connecting the alternator interface board to the display YES NO NO YES NO YES 4 5 6 Are DC output voltages of the power supply correct 3 Replace the power supply see paragrap...

Page 22: ...ctor CN2 on the power supply to access the pins with the tester probes Check that all the output voltages of the power supply are correct referring to 2 5 2 Wiring diagrams 4 As for step 3 but on conn...

Page 23: ...he power resistor see paragraph 7 8 Check and or replace cable BX 5 connecting the interface board to the alternator Replace the alternator see paragraph 7 9 YES NO YES NO NO YES NO YES 2 3 4 Does the...

Page 24: ...equencies specified above are nominal values 3 As for point 2 but with the tester between pins 4 positive and 5 negative of connector CN2 on the alternator interface board 4 Disconnect all the cables...

Page 25: ...e correctly Replace the alternator see paragraph 7 9 Replace reconnect cable BX 5 which connects the alternator to the interface board Replace the alternator interface board see paragraph 7 8 Replace...

Page 26: ...l at the alternator output and on connector CN2 of the alternator interface board should be as shown below while on connectors CN1 of the alternator interface board and CN1 of the CPU board the follow...

Page 27: ...ard see paragraph 7 3 1 2 YES NO YES NO Follow the procedure step by step to correctly diagnose the problem Take particular care with the checks highlighted by circled numbers which are described in d...

Page 28: ...ting cables correctly routed If the TGS is present is the TGSRN2ST cable correctly routed Are there sources of electromagnetic noise near the receiver Move the machines to the minimum distance see par...

Page 29: ...by the circled numbers which are described in detail below 1 To check for electromagnetic noise near the machine use a frequency signal monitor constructed as shown in the schematic below The circuit...

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Page 31: ...ug the mains lead from the wall output 2 Remove the 7 self tapping screws a which fix the DISPLAY using a large Phillips screwdriver Support the DISPLAY before removing the last screw Figure 7 1 2 3 O...

Page 32: ...g an integrated circuit extractor tool Figure 7 2 2 To reassemble the EPROM 1 Make sure that reference notch b on the EPROM coincides with reference notch c on its socket 2 Be careful to center the EP...

Page 33: ...ling the display With the display on a work bench 1 Disconnect keyboard connector a 2 Unscrew the 5 screws b using a small Phillips screwdriver 3 Disconnect the cardio receiver connector if it is stil...

Page 34: ...semble the new KEYBOARD with the display on a work bench 1 Remove the backing film from the adhesive 2 Apply the adhesive part starting from the left and working towards the right without folding the...

Page 35: ...e above steps in reverse order Before securing the screws make sure the cable is correctly positioned in order to avoid squeezing it Version B receiver situated inside display secured by a strap Figur...

Page 36: ...IVER housing box i using a small Phillips screwdriver 2 Disconnect connector h of cable BK 7 from the RECEIVER To reassemble the new RECEIVER with the display on a work bench 3 Connect connector h of...

Page 37: ...E SADDLE STEM GUARD Figure 7 6 1 1 Turn off the machine and unplug the mains lead from the wall output 2 Unscrew the 2 Allen screws a using a 4 mm hex T wrench 3 Remove the SADDLE STEM GUARD b To reas...

Page 38: ...to hold the opposing screw on the RIGHT SIDE CASING in place 3 Unscrew the 7 self tapping screws which fix the RIGHT SIDE CASING using a large Phillips screwdriver Figure 7 7 2 4 Push the right pedal...

Page 39: ...Remove the fixing screws on the plate support using a 7 mm socket wrench 3 Manually unscrew the fixing studs on the plate support 4 Remove the circuit board To disassemble ALTERNATOR INTERFACE BOARD...

Page 40: ...17 mm wrench Figure 7 9 2 4 Loosen dowel f using a 4 mm hex T wrench 5 Move the ALTERNATOR until belt g can be removed To facilitate the operation the belt can first be removed from the pulley 6 Loos...

Page 41: ...paragraph 7 7 Disassembling the right and left side casings 1 Back off nut b of belt tension rod a using a 17 mm wrench Figure 7 10 2 2 Back off dowel c with a 4 mm hex T wrench 3 Move the alternator...

Page 42: ...move cam e Figure 7 10 4 7 Remove BELT g from the guide of pulley h 8 Remove snap ring i using the special pliers 9 Use a pointed tool to push pin l inward taking care to recover the Teflon spacer and...

Page 43: ...is threaded the one on the right is not Figure 7 10 6 Working from the right side 7 Remove bracket o which clamps adjuster pin p 8 Use a 4 mm hex T wrench to unscrew adjusting pin p until the right h...

Page 44: ...he pulley cams to facilitate the operation Figure 7 11 2 5 Using a hammer and screwdriver open the locking tabs to release the left ring nuts of the pedal crank group from the snap ring clamps Figure...

Page 45: ...he procedure described in paragraph 7 7 Disassembling the right and left side casings for the left side casing only 1 Disconnect cable a from the alternator 2 Unscrew BRUSH group fixing screw b using...

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Page 47: ...alternator pivot b using a 4 mm hex T wrench 3 Placing a straight reference rod d against pulley f verify the alignment of belt e by checking that the reference rod d is parallel with belt e 4 Adjust...

Page 48: ...casings 1 Back off lock nut a of alternator pivot b using a 19 mm wrench 2 Back off dowel c of alternator pivot b Figure 8 2 2 3 Back off nut e of belt tension rod d using a 17 mm wrench 4 Rotate the...

Page 49: ...he 2 screws b which clamp cam a to the frame using a 4 mm hex T wrench Figure 8 3 2 3 Remove snap ring c using the special pliers 4 Remove the cam 5 Use a pointed tool to push pin d inward until the s...

Page 50: ...from the right hand side 1 Disassemble locking bracket g 2 Using a 4 mm hex T wrench rotate pivot h in a clockwise or anticlockwise direction to shift the pulley to the left or to the right To ensure...

Page 51: ...to the frame using a 4 mm hex T wrench 2 Turn the cams in a clockwise or anticlockwise direction to loosen or tighten the chain until the vertical play at point A is approximately 1 cm 3 Check the amo...

Page 52: ...PLAY OF SADDLE STEM Figure 8 5 1 Carry out the procedure described in paragraph 7 6 Disassembling the saddle stem guard 1 Back off the locking nut using a 17 mm wrench 2 Regulate the amount of play w...

Page 53: ...isassembling the alternator brushes Inspect the 2 brushes for wear referring to the figures at left and the descriptions below The brush shown in A is correctly worn The brush shown in B is irregularl...

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Page 55: ...rocedure will show on the LED matrix the actual settings 9 1 1 LANGUAGE USED When a language is chosen from the list of languages available all the messages on the display are automatically shown in t...

Page 56: ...TION KEYS The function keys can be disabled so that exercise sessions can be started only using the TGS portable memory To change the current setting when the setting is actually in use will scroll on...

Page 57: ...INFORMATION To set the maintenance information at the desired values for example after replacing the CPU board with the equipment in the standby mode press number keys 314 at the same time The follow...

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Page 59: ...l never to spray the product directly onto the machine use it to moisten a cloth B INTERNAL CLEANING Carry out every month Open the side casings see paragraph 7 7 and use a vacuum cleaner or compresse...

Page 60: ...out every 6 months Open the side casings see paragraph 7 7 and lubricate the chain using spray grease cod 0V021 spray the grease while simultaneously turning the pedal crank H CHECK PLAY ON SADDLE STE...

Page 61: ...ich a 15 KOhm resistor is sometimes mounted The following paragraphs contain various suggestions regarding the cardio receivers which may be useful for improving the reception of the cardio signal 11...

Page 62: ...the presence of electromagnetic interference use the frequency signal monitor shown in the schematic below to determine the presence intensity and effect of the fields This circuit causes the LED to l...

Page 63: ...ensitivity must be verified experimentally taking great care not to excessively reduce the reception distance OBSERVE if there is already a 15 KOhm resistor mounted in parallel with the coil note that...

Page 64: ...mediately after the connection on the receiver in order not to pass near the coil the receiver must be directed in such a way that its axis of reception shown in the figure below is parallel to that o...

Page 65: ...Therefore particularly in cases where the receiver is housed inside the display it is recommended to Route cable a behind the studs which fix the display on its support and not on top of the CPU boar...

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