Technogym spin trainer, Maintenance Manual

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

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Page 3: ...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 res...

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Page 5: ...BLESHOOTING 6 1 6 1 THE DISPLAY DOES NOT ILLUMINATE 6 2 6 2 THE RESISTANCE IS NOT CORRECT 6 5 6 3 THE SPEED VALUE IS INCORRECT 6 8 6 4 THERE IS NO HEART RATE SIGNAL 6 11 6 5 THE HEART RATE SIGNAL IS I...

Page 6: ...TMENTS 8 1 8 1 WEAR OF BRUSHES 8 1 8 2 CALIBRATION 8 2 9 CONFIGURING THE MACHINE 9 1 9 1 ENABLE PRINTING 9 1 9 2 UNIT OF MEASURE 9 1 9 3 MESSAGES ON LED MATRIX 9 2 10 SCHEDULED MAINTENANCE 10 1 11 APP...

Page 7: ...servance 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 fo...

Page 8: ...e recommended 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 man...

Page 9: ...incorrect 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 ou...

Page 10: ...er to avoid puncturing or deforming the tire It is recommended to disassemble the rear brake shoes 2 5 CONFORMITY TO REGULATIONS The machine conforms to the following directives EMC Directive 89 336 E...

Page 11: ...ev 2 0 Page 2 3 2 6 WIRING DIAGRAM 2 6 1 CONNECTORS CPU board name type of connector connection CN1 AMP MATE N LOCK 12 pin F to alternator interface board CN2 AMP MODU II 6 pin M to serial connector C...

Page 12: ...3 AMP MODU I 4 pin M to power supply 2 6 2 WIRING Cable SP 1 consists of 3 sections terminating in a connector that plugs into CN1 on the CPU board In the interests of simplicity these 3 sections are...

Page 13: ...ctor 2 Tx Red 2 3 Rx Black 5 5 ground Orange 3 SP 7 Heart rate meter cable CPU Cardio receiver CPU CN4 Signal Color Receiver 1 5 V Red 1 2 Pulse per beat Blue 2 3 ground Black 3 SP 10 Fan power supply...

Page 14: ...istor 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 SP 3 High voltage power supply Power input socket Power...

Page 15: ...3 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 r...

Page 16: ...session on a serial printer 4 POWER SUPPLY Receives the mains voltage at its input and outputs the DC voltages 5 V 12 V and 12 V which supply the display and the alternator interface board 5 ALTERNAT...

Page 17: ...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 1 2 Tx brown 3 5 Rx white 2 6 ground green 5 To prevent interference...

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Page 19: ...wall outlet used should be reserved for the machine and have a rating of at least 60 Watt 9 The machine can be connected in cascade with other machines It is recommended to connect only machines of th...

Page 20: ...ll the LEDs At the end of the power on test the machine enters standby mode awaiting a keyboard command To check the correct operation of the machine start exercising check that the speed display vari...

Page 21: ...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 exec...

Page 22: ...the machine s input socket Replace blown fuses Replace mains lead Connect machine to a suitable electrical outlet Replace inlet socket on off switch block on the machine Replace cable SP 3 connecting...

Page 23: ...aph 7 10 Replace cable SP 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 paragr...

Page 24: ...nector 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 paragraph 2 6 2 Wiring 4 As for step 3 but on c...

Page 25: ...e correct Replace the power resistor see paragraph 7 10 Check and or replace cable SP 5 connecting the interface board to the alternator Replace the alternator see paragraph 7 13 YES NO YES NO NO YES...

Page 26: ...able V 13 Km h EXCITATION VOLTAGE VDC WAVEFORM FREQUENCY Hz INCLINE ALTERNATOR ALTERNATOR INTERFACE BOARD CPU BOARD 4 5 CN2 6 3 CN1 6 3 CN1 1 0 61 0 61 10 10 3 4 65 4 65 160 160 6 7 60 7 60 398 398 9...

Page 27: ...resistor is approximately 0 5 5 As for point 2 but with an oscilloscope if available between pins 6 probe and 3 ground of connector CN1 on the alternator interface board 6 As for point 5 but with the...

Page 28: ...cable correctly Replace the alternator see paragraph 7 13 Replace reconnect cable SP 5 which connects the alternator to the interface board Replace the alternator interface board see paragraph 7 10 Re...

Page 29: ...e table below SPEED Km h FREQUENCY Hz 10 81 6 15 122 20 164 25 204 30 245 The signal at the alternator output and on connector CN2 of the alternator interface board should be as shown below while on c...

Page 30: ...SPIN TRAINER Service Maintenance Manual rev 2 0 Page 6 10 5 As for step 2 but with the oscilloscope probes between pins 5 probe and 3 ground of connector CN1 on the display CPU board...

Page 31: ...ard see paragraph 7 4 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 32: ...necting 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...

Page 33: ...d 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 circui...

Page 34: ...age appear at the terminals of connector K2 on the fan control board Is the enable signal present on the fan control board Is the correct voltage present on connectors K1 and K3 of the fan control boa...

Page 35: ...trol board the measured voltage should be 12Vdc 2 Place the tester probes between pins 3 signal and 2 ground of connector K1 on the fan control board the measured voltage should be 5Vdc 3 Place the te...

Page 36: ...There is a problem with the printer or the PC serial port or their respective configurations YES NO YES NO YES Is cable SP 8 between the serial connector and the CPU board OK Replace or rewire cable S...

Page 37: ...ng program as soon as the last input is confirmed and training starts the machine will transmit the data through the serial port The RD LED should blink red 3 Use a tester to check the continuity of p...

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Page 39: ...s lead from the wall outlet 2 Unscrew 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 Open the DI...

Page 40: ...ing an integrated circuit extractor tool Figure 7 2 2 To reassemble the EPROM 1 Make sure that reference index b on the EPROM coincides with reference notch c on the socket 2 Be careful to center the...

Page 41: ...1 Carry out the procedure described in paragraph 7 1 Disassembling the display With the display on a work bench 1 Remove the two fixing screws a of the fan control board using a 5 5 mm socket wrench 2...

Page 42: ...the display placed on a work bench 1 Disconnect keyboard connector a 2 Remove the 5 screws b using a small Phillips screwdriver 3 Remove the CPU board These procedures must be carried out on a work be...

Page 43: ...assemble 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 bending th...

Page 44: ...e machine and unplug the mains lead from the wall outlet 2 Remove the CARDIO RECEIVER housing from its support on the machine 3 Unscrew the 2 screws a using a small Phillips screwdriver 4 Open the hou...

Page 45: ...rge Phillips screwdriver 3 Remove the rear cover b of the display 4 Remove the fan cable Figure 7 7 2 5 Unscrew the 4 screws c fixing the instruction lexan d to the FAN ASSEMBLY bracket 6 Unscrew the...

Page 46: ...lug the mains lead from the wall outlet 2 Unscrew the 3 self tapping screws a fixing the GUARD with a large Phillips screwdriver Figure 7 8 2 3 Unscrew the two rear hub supports using a 3 mm hex T wre...

Page 47: ...THE FOOTBOARD Figure 7 9 1 1 Turn off the machine and unplug the mains lead from the wall outlet 2 Unscrew the 3 screws a which hold the FOOTBOARD in place using a 6 mm Allen wrench 3 Remove the FOOTB...

Page 48: ...late using a 7 mm socket wrench 3 Remove the circuit board To disassemble the ALTERNATOR INTERFACE BOARD b 1 Disconnect the 3 connectors CN1 CN2 and CN3 2 Unscrew the 4 fixing screws on the support pl...

Page 49: ...ling the guard 1 Disconnect alternator cables a Figure 7 11 2 2 Unscrew the 4 screws b which fix the REAR GROUP to the machine frame using a 6 mm hex T wrench 3 Remove the REAR ASSEMBLY To reassemble...

Page 50: ...rews a using a 6 mm hex T wrench 2 Remove the SECOND ROLLER To reassemble the SECOND ROLLER carry out the above procedure in reverse order When reassembling the SECOND ROLLER ensure that it doesn t fu...

Page 51: ...e flywheel using a 2 5 mm hex T wrench 3 Remove flywheel a 4 Remove tab b 5 Remove the flywheel side spacer c 6 Unscrew the four nuts of the pins which fix the support on alternator d using a 10 mm wr...

Page 52: ...the procedure described in paragraph 7 8 Disassembling the guard 1 Unscrew the two screws a fixing the limit stop bracket to the machine frame using 4 mm hex T wrench 2 Remove the bracket 3 Pull the...

Page 53: ...ing the rear hub supporting frame With the rear hub frame placed on a bench and working from both sides 1 Remove the snap ring a securing the BUSHINGS with the special pliers 2 Remove the first BUSHIN...

Page 54: ...igure 7 16 1 Carry out the procedure described in paragraph 7 14 Disassembling the rear hub supporting frame For both RUNNER BARS 1 Remove the screws which clamp the RUNNER BARS to the machine frame u...

Page 55: ...the wall outlet 2 Disassemble bicycle fork clamp a 3 Remove snap ring b using the special pliers 4 Remove pin c 5 Working through the slot in support d use a pointed tool to push out the 2 SHOCK ABSO...

Page 56: ...clamp f 3 Remove circlip g using the circlip pliers 4 Pull out pin h 5 Unscrew screw l using a 5 mm hex T wrench 6 Working through the slot in support i use a pointed tool to push out the 2 SHOCK ABSO...

Page 57: ...NG THE ALTERNATOR BRUSHES Figure 7 18 1 Carry out the procedure described in paragraph 7 8 Disassembling the guard 1 Disconnect alternator cable a 2 Unscrew BRUSH group fixing screw b 3 Remove the BRU...

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Page 59: ...1 Carry out the procedure described in paragraph 7 18 Disassembling the alternator brushes The brush shown in A is correctly worn The brush shown in B is irregularly worn and may result in noise and w...

Page 60: ...elow 1 Turn on the machine and wait for it to enter standby mode 2 Simultaneously press the 314 keys 3 The machine will display the message PSI or ATM as a reminder to check the pressure of the rear t...

Page 61: ...p switches on the CPU board Dip switch configuration 1 enables the printout function 9 1 ENABLE PRINTING On the SW release not TGS it is possible to enable the printing using dip switch 1 Printing ena...

Page 62: ...TRIX Starting from release 2 2 TGS it is possible to select how some messages will be shown on the LED matrix IP or PI stands for Performance index and PSI or ATM is a reminder to check the pressure o...

Page 63: ...en the chain guards see paragraph 7 8 remove the footboard see paragraph 7 9 and use a vacuum cleaner or compressed air to thoroughly clean the interior taking special care with the alternator and the...

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Page 65: ...n which 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...

Page 66: ...n 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...

Page 67: ...n in sensitivity must be verified experimentally taking great care not to excessively reduce the reception distance WARNING if there is already a 15 KOhm resistor mounted in parallel with the coil not...

Page 68: ...must be folded immediately after the connection on the receiver so that it does not pass near the coil the receiver must be directed in such a way that its axis of reception shown in the figure below...

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