Technogym Synchro Excite 500, Service Maintenance Manual

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

Page 2: ......

Page 3: ... PRESENT 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 responsible for any errors contained in this manual and declines all liability for accidents or damages resulting from the supply characteristics or use of this manual This document contains proprietary information that ...

Page 4: ......

Page 5: ...version 700WTV 2 10 2 8 WIRING 2 11 2 8 1 CBQ cables 2 11 2 8 2 CB cables 2 11 2 8 3 CU cables 2 12 2 8 4 ELT cables 2 14 3 PRINCIPLES OF OPERATION 3 1 3 1 BLOCK DIAGRAM 3 1 3 1 1 LED ARM Display boards 500 and 500SP 3 2 3 1 2 Led Arm Display Boards 700 and 700SP 3 3 3 1 3 Wellness TV Display boards Digital TV 700WTV 3 4 3 1 3 1 CPU board 3 4 3 1 3 2 Digital TV board 3 4 3 1 3 3 LCD Inverter 3 5 3...

Page 6: ...oard Test 6 7 6 3 THE DISPLAY FAILS TO ILLUMINATE 6 8 6 3 1 500 and 700 Models 6 8 6 3 2 500SP and 700SP Models 6 10 6 3 3 700WTV Wellness TV models 6 12 6 4 THE TOUCH SCREEN DOES NOT WORK IT S NOT CALIBRATED 6 16 6 5 NO AUDIO SOUND 6 17 6 6 NO TV PICTURE 6 18 6 7 THE RADIO DOES NOT PLAY 6 21 6 8 THE IPOD DOES NOT WORK 6 23 6 9 THE EQUIPMENT IS LOCKED COM MESSAGE ON DISPLAY 6 26 6 10 THERE IS NO R...

Page 7: ...SASSEMBLY 7 42 8 ADJUSTMENTS 8 1 8 1 BELT TENSION 8 1 8 2 SPEED SENSOR POSITION 8 2 8 3 BRAKE WINDING POSITION 8 3 8 4 THE MACHINE IS NOT FLAT 8 4 9 MACHINE CONFIGURATION 9 1 9 1 USER MENU CONFIGURATION FOR 500 MODELS 9 1 9 1 1 Language 9 2 9 1 2 Units of measurement 9 2 9 1 3 Maximum exercise time 9 2 9 1 4 Pause time 9 3 9 1 5 Cooldown time 9 3 9 1 6 Default age 9 3 9 1 7 Default weight 9 4 9 1 ...

Page 8: ...rite to low kit 9 22 9 4 1 3 Default Setting 9 23 9 4 1 4 Table of configuration parameters 9 23 9 4 2 Operating data 9 24 9 4 2 1 Read from low kit 9 24 9 4 2 2 Write to low kit 9 25 9 4 2 3 Machine usage data 9 25 9 4 3 Errors log 9 26 9 4 3 1 Read from low kit 9 26 9 4 3 2 Reset Errors 9 26 9 4 3 3 COM Fault 9 27 9 4 3 4 View Errors 9 27 9 4 4 Standard settings 9 28 9 4 5 Low kit menu 9 28 9 4 ...

Page 9: ...10 3 START UP CHECK 10 3 10 4 LIST OF CRITICAL SPARE PARTS 10 4 11 SCHEDULED MAINTENANCE 11 1 11 1 DAILY MAINTENANCE OPERATIONS 11 1 11 1 1 Setting up the operation 11 1 11 1 2 External cleaning operations 11 1 11 2 MONTHLY MAINTENANCE OPERATIONS 11 2 11 2 1 Checking the operation of the cardiotester receiver 11 2 11 2 2 Checking the operation of the hand sensor receiver 11 2 11 3 TWICE YEARLY MAI...

Page 10: ...SYNCHRO EXCITE Class Trend Service maintenance manual rev 2 0 Pagina vi Page intentionally left blank ...

Page 11: ...y ATTENTION non observance may cause damage to the machine Information about the operation in progress Observation about the operation in progress 1 2 RECOMMENDATIONS Technogym recommends the following steps for planning repair procedures Carefully evaluate the customer s description of the machine malfunction and ask all the necessary questions to clarify the symptoms of the problem Clearly diagn...

Page 12: ...cants of the recommended brands 3 Use special tools where specified 4 Consult the Technical Newsletters which may contain more up to date information on adjustments and maintenance than those contained in this manual 5 Before starting the repair procedure make sure that the recommended tools are available and in good condition 6 For the procedures described in this manual use only the specified to...

Page 13: ...ower supply 3 multi voltage 110 220 4 self powered 6 Type of Display L LED Display D Active W TV Digital TV 7 Integrated accessories N none T TGS I iPod A TGS iPod 8 9 Colour of the frame AL Silver Class AN Anthracite Trend 10 11 Colour of puddings 00 none 12 Guards colour 0 none G Flint grey Class R Dark grey Trend 13 Type of TV model 0 none D DVB T A ATSC I ISDB T 14 15 Language 00 WTV models BR...

Page 14: ...73DTAN00RDUKE which is interpreted as follows DA5 7 3 D T AN 00 R D UK E International Standard UK English language TV model DVB T Dark grey casing No upholsteries frame colour Anthracite Interfaced to TGS IPod key reader display Active Wellness TV CDA Mains powered supply with multi voltage inlet 700 model Synchro Excite 2 2 COLOUR OPTIONS The following table shows the possible combinations for o...

Page 15: ...20 VAC Self powered 43 7 VA 110 VAC 61 5 VA 220 VAC Self powered Difficultly levels 1 25 Resistance a 120 rpm 30 500 40 500 30 500 40 500 Max user weight 180 Kg 360 lbs Sub Maximal Test NO Fitness Test Fast Track Control NO SI HR Monitoring Telemetry Double Hand Sensor Telemetry Maintenance Maintenance not required upload Serial software Goal oriented display SI Coach Calories SI Language availabl...

Page 16: ...TE Class Trend Service maintenance manual rev 2 0 Pagina 2 4 2 4 MECHANICAL CHARACTERISTICS VERSION 500 700 700WTV 500SP 700SP Width 752 mm 30 Length 2042mm 80 Height 1609mm 63 Weight 148 Kg 326 lbs 150 Kg 330 lbs ...

Page 17: ...densing Humidity Storage from 5 to 85 non condensing 2 6 CONFORMITY TO REGULATIONS The machine conforms to the following standards EUROPA USA EMI EN 55014 1 2001 EN 55014 2 1998 EN 61000 3 2 2002 EN 61000 3 3 1997 Safety EN 60335 1 1998 EN 957 1 2000 EN 957 9 classe SA 2003 Directives 73 23 CE 89 336 CE 98 37 CE UL 1647 In addition Electrical isolation class Class I Protection rating IP21 ...

Page 18: ...owered version 500 DISPLAY ARM DISPLAY BOARD KEYBOARD CSAFE BOARD HFU RECEIVER CN8 CN1 CN9 CN1 CN3 CN2 BRAKE BRAKE BOARD CN4 CN3 CN1 CN2 SPEED SENSOR Patch conn CN7 Patch conn 2 Patch conn 1 POWER ENTRY MODULE VAC NTC Patch conn DUAL TGS READER CN1 Patch conn CU 132 CBQ 32 CBQ 13 ELT 16 ELT 04 ELT 06 ELT 05 ELT 07 ELT 00 ELT 02 ...

Page 19: ...LAY ARM DISPLAY BOARD KEYBOARD CSAFE BOARD HFU RECEIVER CN8 CN1 CN9 CN1 CN3 CN2 BRAKE BRAKE BOARD CN3 CN4 CN1 CN2 CN7 Patch conn 2 Patch conn 1 NTC Patch conn BATTERY ALTERNATOR Patch conn BATTERY CHARGER INPUT DUAL TGS READER CN1 Patch conn CU 132 CBQ 32 CBQ 13 ELT 16 ELT 04 ELT 06 ELT 05 ELT 07 ELT 02 ELT 01 ...

Page 20: ...N1 CN3 CN2 ELT 16 BRAKE POWER ENTRY MODULE VAC BRAKE BOARD CN4 CN3 CN1 CN2 SPEED SENSOR ELT 00 Patch conn ELT 04 CN4 J3 J2 RIGHT HAND SENSOR LEFT HAND SENSOR Patch conn 6 CN5 CN6 CONNECTOR BOARD LEFT LEVER RIGHT LEVER J1 J2 J4 Patch conn Patch conn J4 ELT 31 ELT 19 ELT 10 ELT 10 J3 Patch conn 5 ELT 09 ELT 23 CN7 Patch conn 2 Patch conn 1 ELT 06 ELT 05 ELT 07 NTC Patch conn ELT 02 DUAL TGS READER C...

Page 21: ...T 16 BRAKE BRAKE BOARD CN3 CN4 CN1 CN2 ELT 04 CN4 J3 J2 RIGHT HAND SENSOR LEFT HAND SENSOR Patch conn 6 CN5 CN6 CONNECTOR BOARD LEFT LEVER RIGHT LEVER J1 J2 J4 Patch conn Patch conn J4 ELT 31 ELT 19 ELT 10 ELT 10 J3 Patch conn 5 ELT 09 ELT 23 CN7 Patch conn 2 Patch conn 1 ELT 06 ELT 05 ELT 07 NTC Patch conn ELT 02 BATTERY ALTERNATOR Patch conn BATTERY CHARGER INPUT ELT 01 DUAL TGS READER CN1 Patch...

Page 22: ...TION CU167 DUAL TGS READER CN1 Patch Conn CU132 CN1 CBQ 32 CN8 CU240 DIGITAL TV BOARD ASSEMBLY J8 J7 Patch conn 3 J1 tuner ELT 32 CU169 J9 CU166 CU124 J10 CU164 CN26 CN21 CN19 CN27 HFU RECEIVER RIGHT LEFT HAND SENSOR BOARD J3 J2 CONNECTORS BOARD LEFT LEVER RIGHT LEVER J1 J2 J4 Pach Conn Pach Conn J4 ELT 10 ELT 10 J3 Pach Conn 5 ELT 09 ELT 23 RIGHT HAND SENSOR LEFT HAND SENSOR ELT 31 Pach Conn 6 EL...

Page 23: ...Board CN8 Signal Colour CSafe Board CN1 1 Digital 1 Flat cable 1 14 Digital 14 Flat cable 14 CBQ 32 TGS Cable Display CPU Board Patch connector Display Board CN7 CPU Board CN8 Signal Colour Patch conn 1 12 Vdc power supply Rosso 8 3 Rx Marrone 1 5 Tx Blu 2 9 Gnd Nero 6 2 8 2 CB CABLES CB 9 DVD video input cable Connectors Board Input AUX Board Scheda connettori CN1 Segnale Coloure Scheda input J2 ...

Page 24: ... signal Black 7 2 Video signal White 6 3 GND Left audio signal Black 3 4 Left audio signal White 2 5 Right audio signal White 4 6 GND right audio signal Black 5 CU160 CSafe iPod Video signals cable CPU board Digital TV board CPU board CN25 Signal Colour Digital TV board J7 1 Power supply 8 Vdc Black 1 2 Power supply 8 Vdc Black 2 3 Power supply 8 Vdc Black 3 6 RX TX Black 7 7 TX RX Black 6 8 CTS B...

Page 25: ...2 Power supply 8 Vdc Black 2 3 Power supply 8 Vdc Black 3 6 RX TX Black 7 7 TX RX Black 6 8 CTS Black 8 9 Power supply 5 Vdc Black 9 10 Power supply 5 Vdc Black 10 11 GND DTV board sensing Black 11 12 GND Play sensing Black 12 13 GND Black 13 14 GND Black 14 15 n c Black CU167 iPod signals cable AUX input board Docking Station AUX input cable Signal Colour Docking Station 1 V bus USB Black 14 2 GN...

Page 26: ...6 12Vdc Red 6 7 5 Vdc Red 1 8 sensing 5Vdc Red 3 CU240 LCD inverter power supply cable CPU Board Inverter LCD CPU board CN5 Signal Colour LCD Inverter CN1 1 Input voltage 12 Vdc Black 1 5 Input voltage 12 Vdc Black 2 2 GND Black 3 4 GND Black 4 3 Power system return 5Vdc ON 0Vdc OFF Black 5 7 n c Black 6 6 Lamp control Black 7 2 8 4 ELT CABLES ELT 00 High voltage cable Power entry module Brake boa...

Page 27: ...y charger Black soldered to external contact 6 Battery V Red Faston 7 Battery V Black Faston ELT 02 Brake supply cable Brake board Brake Speed sensor NTC Brake board CN2 Signal Colour Brake Speed sensor NTC 1 Brake supply Brown Faston 2 Brake supply Blue Faston 3 SPM Grey Faston connected to brown cable 4 SPM Reference Black eyelet 5 NTC White 2 6 NTC Brown 1 ELT 04 Power supply cable between uppe...

Page 28: ... and lower assemblies Brake board Patch connector 2 Brake board CN4 Signal Colour Patch connector 2 1 Digital Gnd Orange White 1 2 Digital Gnd Orange 2 3 NC Green White 3 4 Download Blue 4 5 Reset Blue White 5 6 NC Green 6 7 485 Tx Rx Brown White 7 8 485 Tx Rx Brown 8 ELT 07 Serial communication cable between upper and lower assemblies Patch connector 2 Display Board Patch connector 2 Signal Colou...

Page 29: ...d 3 Lever button signal Green 2 4 Sensor signal reference Black Faston 5 Reference Brown 4 6 5Vdc Power supply White 1 ELT 16 HFU Receiver cable Display Board HFU Receiver Display Board CN3 Signal Colour HFU Receiver 1 5 Vdc power supply White 2 7 Pulse beat to beat Black 4 8 Gnd Green 1 ELT 19 Hand sensor board cable Lever buttons Display Board Patch connector 6 Display Board CN4 CN5 CN6 Signal C...

Page 30: ...sor board cable Lever buttons Patch conn 6 Hand sensor board Lever connectors Connector Board Lever connector Connector board Patch connector 6 Signal Colour Hand Sensor Board J3 RH LH J2 J4 8 5Vdc Power supply Red 4 7 NA Green 1 1 NA Orange 2 3 Out pulse Blue 5 2 Reference Black 3 12 5Vdc Power supply White 6 11 Left lever button signal Brown 3 10 Reference Green 5 Gnd Braid 2 1 Reference Black 4...

Page 31: ...LE BRAKE BOARD VAC RIGHT TOUCH SENSORS LEFT TOUCH SENSORS HAND SENSOR BOARD CONNECTORS BOARD RIGHT LEVER LEFT LEVER SPEED SENSOR BRAKE NTC CORDLESS VERSION NTC BRAKE BATTERY BRAKE BOARD BATTERY CHARGER INPUT External power supply DISPLAY LED DISPLAY DISPLAY BOARD C SAFE BOARD DUAL TGS READER KEYBOARD WTV DISPLAY TOUCH SCREEN CONNECTORS BOARD L R C SAFE V iPOD DOCKING STATION DIGITAL TV BOARD ASSEM...

Page 32: ... functions of the board are Manages and process signals from Keyboard HR receiver CSafe Board TGS reader if present distributes the voltages received from the Brake Board to the display exchanges via the RS 485 serial link to the Brake Board the commands for controlling the brake controls the LEDs and the 7 segment displays which provide feedback about the exercise session The board includes the f...

Page 33: ...s of the board are Manages and process signals from Keyboard HS HR receiver Touch sensor CSafe Board TGS reader if present distributes the voltages received from the Brake Board to the display exchanges via the RS 485 serial link to the Brake Board the commands for controlling the brake controls the LEDs and the 7 segment displays which provide feedback about the exercise session The board include...

Page 34: ... Board to the display Exchanges via the RS 485 serial link to the Brake Board the commands for controlling the brake Manages the display of images on the LCD The board includes the following indicator LED LED name Colour Description D41 green if ON the 12 Vdc supply from the Brake Board correctly reaches the CPU board and a faston Nome Descrizione J2 denotes a ground node on the circuit board 3 1 ...

Page 35: ...e band The board manages also the functions of the CSafe Board detailed in the following pages and provides 3 RC connectors and the RJ45 connector for the CSafe communication 3 1 3 6 iPod docking station It is the device that allows to plug store iPod models in a safe docking station and to control it from the ACTIVE Wellness TV interface With the docking station developed for the full compatibili...

Page 36: ...es the machine to read the user s TGS key for performing workouts programmed with the propers SW of the Wellness System With Dual TGS reader it is possible to use both the Botom and the Mifare TGS keys 3 1 6 CARDIO RECEIVER This board manages the signal received from the telemetric transmitter used by the person exercising It receives the power supply signal from the display board and outputs a ne...

Page 37: ...selected on the display and the RPM value measured by the speed sensor angular velocity of the brake disk and is determined by the values stored in the braking table The board includes the following indicator LEDs LED name Colour Description LED1 green if ON the board is supplying the brake winding if BLINKING the Brake Board is in an error condition LED2 yellow if ON there is the 5 Vdc supply fro...

Page 38: ...tion by the movement of the pedals generating the voltage necessary for the machine s operation Depending on the rate of pedaling and the resulting speed of rotation it generates an alternating voltage which ranges from approximately 15 17 VAC at about 30 35 RPM to over 40 VAC for higher pedaling speeds The alternator has a built in speed sensor which provides to the Brake Board the speed signal 3...

Page 39: ...2 0 Page 3 9 3 1 13 EXTERNAL POWER SUPPLY INPUT Only for 500SP and 700SP versions This is a socket for plugging in the external power supply that comes with the machine which can be used to recharge the battery It is situated on the side of the front platform ...

Page 40: ...phase of the alternator 3 2 2 CONTROLS The control block diagram is as follows To obtain a given exercise effort level the Display Board sends the required value of electrical resistance to the Brake Board via the RS 485 serial link Based on the commands received and the feedback signal from the speed sensor the Brake Board will then apply the appropriate excitation current to the brake winding an...

Page 41: ... Board does not receive a speed signal which indicates that an exercise session is in progress the machine will not produce any resistance During the movement the Brake Board monitors for possible malfunctions The errors which can occur are Error Code Description 1 OVERHEATING this condition occurs when the temperature detected by the sensor on the circuit board exceeds 90 C 2 OVERCURRENT this con...

Page 42: ...e current supplied is a function of the adjustment algorithm Pulses This is the signal produced by the speed sensor and has the waveform shown in the figure below Figure 3 2 1 The signal enters the Brake Board pins 3 4 on connector CN2 where it is used to determine the speed value RPM that is sent to the Display Board via the RS 485 serial link This signal can also be measured qualitatively using ...

Page 43: ...The machine can be connected to the CardioTheater by means of the RJ45 connector on the CSafe board The CardioTheater unit must be provided with a power cable having the following pin out RJ45 Connector Signal 5 5 Vdc 7 Ground WARNING for the numbering of the pins on RJ45 connector please refer to the diagram below ...

Page 44: ...CSafe board WARNING for the numbering of the pins on RJ45 connector please refer to the diagram below When programming the machine sometimes it is necessary to fit plug into the free RJ 45 port on the back of the display to avoid any type of interference during the operation The wiring diagram of the RJ 45 plug is as follows Programming cable and plug can be ordered using the code H0002534AB ...

Page 45: ...machine to the other is effected via a special cable which plugs into the RJ45 connectors of the CSafe boards The cable to use code 0WC00644AA must be wired as follows Cable CSafe Periferic CSafe Board RJ45 Signal Colour CSafe Board RJ45 3 Tx White 4 4 Rx Brown 3 7 Digital Ground Green 7 8 Ground Shield Yellow 8 WARNING for the numbering of the pins on RJ45 connector please refer to the diagram be...

Page 46: ...s fitted into any one of the CSafe ports on the machine the corresponding LED should illuminate to indicate the presence of the 5 Vdc supply on the port During the CSafe port test function the plug connects the transmit channel directly to the receive channel thereby producing a positive test outcome if the port is functioning correctly ...

Page 47: ...HRAIN DVB T PAL B MOROCCO DVB T SECAM B BELGIUM DVB T PAL B G NETHERLANDS DVB T PAL B G BERMUDA DVB T NTSC M NEW ZEALAND DVB T PAL B G BRAZIL ISDB T PAL M NIGERIA DVB T BULGARY DVB T SECAM D K NORWAY DVB T PAL B G CANADA ATSC NTSC M OMAN DVB T COLOMBIA ATSC NTSC M PHILIPPINES DVB T NTSC M CYPRUS DVB T PAL B POLAND DVB T PAL D K CZECH REPUBLIC DVB T SECAM PAL D K PORTUGAL DVB T PAL B G DENMARK DVB ...

Page 48: ...SYNCHRO EXCITE Class Trend Service maintenance manual rev 2 0 Pagina 4 6 LIBYA DVB T ...

Page 49: ...SYNCHRO EXCITE Class Trend Service maintenance manual rev 2 0 Page 4 7 Page intentionally left blank ...

Page 50: ......

Page 51: ...positioned close to sources of heat sources of electromagnetic noise television sets electrical motors antennas high voltage lines household appliances etc or medical equipment 5 To eliminate any interference with the cardio receiver no transmitters should be placed less than 90cm from the display Only for the 500 700 and 700WTV models 6 The mains voltage must match the value specified on the mach...

Page 52: ...ble to receive a usable antenna signal for radio channel tuning RADIO FM SIGNAL On machines with Digital TV receiver it is possible only the tuning of the digital band and not the analogue one 5 2 1 DIGITAL SIGNAL DVB T Level Higher than 65 dBm 44 dBµV 16 dBmV Quality CH B E R 10 3 Channel Bit Error Rate Or C N Carrier to Noise ratio Modulation type 16 QAM 13 dB Modulation type 64 QAM 23 dB ATSC L...

Page 53: ...n have been met see paragraph 5 1 Specifications and requirements 2 Position the machine as specified above on a level surface that is free of vibrations and has sufficient carrying capacity for the combined weight of the machine and user 3 Depending on the destination country the machine may be shipped partially disassembled packed inside a special carton and fixed to a pallet or fully assembled ...

Page 54: ...rs the stand by state awaiting a command from the keyboard To check the correct operation of the machine get on the machine start exercising check that the displayed speed varies accordingly check that exercise resistance varies when the and effort level keys are pressed or the touch sensors on the 700 700 SP and 700WTV models are pressed and the effort level change from 1 to 25 put on the heart r...

Page 55: ...roubleshooting procedure where an ACTION must be carried out It typically contains a description of the ACTION necessary to resolve the problem Therefore after executing the specified ACTION 1 Check whether the problem has been resolved 2 If the problem persists it is recommended to resume the troubleshooting procedure from the point before the action was carried out A circled number such as that ...

Page 56: ...bottom left hand and the bottom right hand corner in sequence as shown in the picture below The machine display will shows a window from where you can access the different configuration menus using the proper password To access the menu type in the password 2411 and press ENTER key to confirm or BACK key to back forward At this point the machine display will shows the different parameters of the m...

Page 57: ...the communication on CSafe ports The test can have two outcomes Test Successful This means that the test was completed successfully i e that serial communications on the selected port are correct Error COM1 This means that the outcome of the test was negative The CSafe COM test done on a machine which CSafe port is not plugged with the monitor plug described at chapter 4 of the Service Maintenance...

Page 58: ...that the outcome of the test was negative The TGS COM test done on machine not provided with the key reader gives a fail outcome 6 1 5 DVT BOARD TEST It s a command that allows to divert the serial communication usually between the Digital TV boardand the CPU board on the external CSafe port This function wich allows to connect an external device to the Digital TV board is not used at the moment O...

Page 59: ...t this point there are two options available Tech Config Troubleshooting Press numeric key to access the menu for configuring technical parameters the machine display will begin showing the current configuration structured as in the diagram below Accessing configuration of 700 models Simultaneously press the keys 369 for 700 LED models whereas on 700 Wellness TV models the keys 0369 must be presse...

Page 60: ... The tests grouped under this section conduct checks on the machine s operation in a fully automatic manner After selecting the desired test using the and effort level keys press ENTER to initiate the test and then await the result Press ENTER again to continue and use the CLEAR key to return to the higher menu level holding it down for a few seconds The various tests are described below 6 2 1 1 I...

Page 61: ...e outcome of the test was negative the message will specify COM1 in the case of the CSafe COM test COM2 in the case of communications with the low kit or COM3 in the case of the TGS COM test The TGS COM test done on machine not provided with the key reader gives a fail outcome The same if the CSafe COM test is done on a machine which CSafe port is not plugged with the monitor plug described at par...

Page 62: ...upper assembly 6 3 1 500 AND 700 MODELS Does the wall outlet supply the correct voltage Is the mains lead OK Are the LEDs on the Display board lit on Plug the machine into a working electrical outlet Replace the mains lead Replace the Display board THE DISPLAY DOES NOT ILLUMINATE NO YES NO YES NO YES A 1 Are the fuses OK Replace the fuses YES NO Continued on the following page ...

Page 63: ...e the tester probes across pins 3 and 1 of CN4 connectors on the Brake Board The measured value should be approximately 220 VAC or 110 VAC depending on the mains voltage 3 Slightly lift up the fast on on the machine power entry module Place the tester probes across the live and neutral pins on the same connector The measured value should be approximately 220 VAC or 110 VAC depending on the mains v...

Page 64: ...EDs on the Display board lit on Are the LEDs on the Brake board lit on while pedaling Correct operation after 30 seconds without pedaling the machine switches off Replace the Display board THE DISPLAY DOES NOT ILLUMINATE NO YES NO YES NO YES 2 1 B Replace the ELT 04 and or ELT 05 cables Are the DC voltages at the output of the brake board correct NO 3 Replace the Brake board YES 4 Continued on the...

Page 65: ...about 12Vdc recharge the battery for 8 hour with an external power pack without using the machine 2 Check the LEDs 1 and 2 green and yellow of the Display Board are correctly lit on 3 Check if the LEDs 1 and 2 green and yellow of the Brake Board are correctly lighting on as described in paragraph 3 1 7 Brake board 4 Using a tester check that all the output voltages on connector CN1 of the Brake bo...

Page 66: ...es the wall outlet supply the correct voltage Is the mains lead OK Are the LED on the Display board lit on Plug the machine into a working electrical outlet Replace the mains lead THE DISPLAY DOES NOT ILLUMINATE NO YES NO YES YES NO B 1 Are the fuses OK Replace the f uses YES NO Continued on the following page ...

Page 67: ...Start exercising by choosing Quick Start mode and press on the Touch Sensors Is the resistance change Do you hear beep sound NO Replace CPU board YES Replace the LCD inverter Does the problem persists YES Replace LCD A NO Defective LCD inveter Continued on the following page ...

Page 68: ...put of the Brake board correct NO Replace the Brake board 5 B Are the voltages on the patch connectors 1 and 3 are correct NO Replace ELT 04 and or ELT 05 cables Are the voltages at the input of the Digital TV board correct NO Replace CU169 cable YES YES YES 6 7 Are the voltages at the input of the CPU board correct YES Replace CPU board NO Replace CU169 cable 8 4 Is the voltage at the output of t...

Page 69: ...e same connector The measured value should be approximately 220 VAC or 110 VAC depending on the mains voltage 5 Using a tester check that all the output voltages on connector CN1 of the Brake board The measured value should be 12 Vdc between pins 6 2 5 Vdc between pins 7 3 6 As for step 5 but on patch connectors 1 and 3 of CU195 cable 7 Place the tester probes across pins 1 and 2 of J1 connectors ...

Page 70: ...en 2 Replace the Touch Screen Does it work correctly NO YES 1 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 detail below 1 It s recommended to upgrade the HW and SW of machine display to the last version due to the steady work on the product for its improvement Please refers to the prop...

Page 71: ...he CPU board 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 detail below 1 Carry out the configuration procedure as detailed at paragraph 9 5 6 TV Standard If you replace Display board Brake board check that its SW version is updated otherwise install the last version The TV and RADIO...

Page 72: ...tenna signal ATTENTION ONLY FOR JAPAN Before to carry out the following troubleshooting check that the B CAS card is correctly inserted on the TV Digital Board NO TV PICTURE Check if the antenna cable is properly connected Connect the cable NO 1 On the other machines you see the TV Check the antenna signal NO Connect the machines at one antenna soket sure working Replace the antenna soket NO A YES...

Page 73: ...ck the conditions of antenna cable It is CU 198 ok Replace the CU 198 cable NO A Is the TV standard correctly conf igured Conf igure the TV standard parameter NO 2 YES 3 Check the Antenna signal 4 YES YES YES YES 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 detail below ...

Page 74: ...h 5 2 Installation requirements and specifications for Wellness TV machines 4 Check the state of wear of the antenna cable CU198 and that it properly works If you replace Display board Brake board check that its SW version is updated otherwise install the last version The TV and RADIO channels is located in the Digital TV in the CPU Board and must necessarily be present This means that when even o...

Page 75: ...ible only the tuning of the digital band and not more the analogue one 1 Is the TV channel sound OK Replace the CPU board Does it work correctly Perf orm the Audio does not work procedure Def ective CPU board NO YES THE RADIO DOES NOT PLAY YES Check if the antenna signal is good NO Is the tuner connected to a terrestrial antenna cable without any type of interruption multiplexer TV distribution mo...

Page 76: ...tions for Wellness TV machines If you replace Display board Brake board check that its SW version is updated otherwise install the last version The TV and RADIO channels is located in the Digital TV in the CPU Board and must necessarily be present This means that when even one of the two boards will be replaced should be re stored channels through search or transferring from another machine via TG...

Page 77: ...es uploaded on the iPod Check the audio connection system NO Replace the Docking station board 2 3 YES Check the CU167 cable connection Is the iPod detected by the machine OK YES Is the voltage atthe inputofthe docking station correct Replace the docking station board YES 5 NO 6 NO A Update the iPod SWversion Has been the device enabled fromthe proper function in the user menu Enable the iPod NO 4...

Page 78: ...oard correct Replace CU166 cable YES 9 NO A Is the voltage at the output of the AUX board correct Replace CU167 cable YES NO 11 Is the v oltage on the patch connector correct 10 Replace Digital TV board NO Replace CU169 cable NO YES 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 detail b...

Page 79: ...nd then it can sometimes be connected the wrong way round Check that the connector marked with a blue sign is connected on the AUX connectors board 7 Place the tester probes across pins 8 9 of the connector on the docking station board where the CU167 cable is connected The measured value should be 5 Vdc 8 As for step 7 but across pins 6 7 of the connector on the AUX connectors board where CU167 i...

Page 80: ...layed by a massage and stored in the Errors Log section To reinstate communications between the lower and upper assemblies 1 Check that cables ELT 06 and ELT 07 are correct using the Test Box Excite and replace if necessary 2 Try replacing the brake board and the display board in turn and check whether the communication works If you replace Display board Brake board check that its SW version is up...

Page 81: ...e Does the brake board supply tension at the brake THERE IS NO RESISTANCE Are the Watt and SPM values shown on the display dif f erent f rom zero NO YES 1 Carry out the The speed signal is incorrect troubleshooting procedure Replace the brake board YES Does the input of brake receive tension f rom the brake NO Replace the brake YES Replace ELT 02 cable NO 3 YES Is the resistance on the Brake windi...

Page 82: ...1 Place the tester probes across pins 1 2 of the connector CN2 on the brake board and exercise at a speed of 60 RPM You should measure a Vdc which increases according to the exercise level 2 As for step 1 but across the two fast on at the input of the brake 3 As for step 1 but with everything reconnected and across the brake winding If you replace Display board Brake board check that its SW versio...

Page 83: ...ement is incorrect the brake board is defective the brake is defective Are the mechanics of the machine in good condition Does the brake board output the correct current to the brake winding Replace the brake board NO Replace the Brake winding YES THE RESISTANCE IS INCORRECT 2 Repair the faulty mechanical parts NO Carry out the Speed signal is Incorrect troubleshooting procedure 3 Carry out the St...

Page 84: ...tting procedure as detailed at paragraph 9 5 5 Standard settings 2 Check that the mechanical system consisting of the pedals belt and brake moves smoothly and without higher than normal friction or resistance 3 Measure the voltage supplied by the brake board to the winding In Quick Start mode select the effort level and check that the value is different from 0 If you replace Display board Brake bo...

Page 85: ...speed sensor send the correct signal to the brake board 3 Replace the speed sensor generator on SP models NO Replace the Brake board YES THE SPEED SIGNAL IS INCORRECT 1 YES YES Update the brake board SW Is the speed signal correct Def ective SW NO Carry out the Standard Setting procedure 2 Follow the procedure step by step to correctly diagnose the problem Take particular care with the checks high...

Page 86: ... be 136 Hz Self Powered models Check the signal on ELT 01 cable The measured signal should be that indicated in Figure 3 2 1 In addition when pedaling at 80 RPM the frequency of the signal should be 136 Hz The speed signal can also be observed qualitatively using a multimeter The value should be 0 Vdc when the machine is stopped and gradually increase as the speed increases 3 Update the low kit SW...

Page 87: ...output to the Display board correct Replace cable CBQ 32 1 2 YES NO YES Replace the display board NO A Is the serial communication link between the display board and the TGS reader OK Replace the TGS reader Is the communication link between the display board and the TGS reader OK TGS reader def ective 3 3 YES NO YES Replace the display board NO A Replace the TGS reader Follow the procedure step by...

Page 88: ...CN1 of the TGS reader The measured value should be 12 Vdc 2 As for step 1 but across pins 1 and 9 of connector CN8 on the display board 3 Use the serial communications test described at paragraph 6 2 1 3 Serial Ports Test If you replace Display board Brake board check that its SW version is updated otherwise install the last version ...

Page 89: ... receiver Is the supply voltage correct at the output of the display board Replace the receiver Replace ELT 16 cable 2 3 YES NO YES Replace display board NO Carry out the troubleshooting procedure THE TELEMETRIC SIGNAL IS INCORRECT 1 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 detail ...

Page 90: ... functions of Test Box Excite THERE IS NO HR SIGNAL Arethesensors correctly connectedtotheconnectors board Reinstatetheconnection 2 YES NO Is thesupply voltagecorrectat theinputtotheHSinterface board ReplacetheHSinterface board 3 YES NO Is theconnectors board correctly connectedtotheHS interfaceboard Reinstatetheconnection YES NO Is thesupply voltagecorrecton thepatchconnector 6 Replacethe ELT 31c...

Page 91: ...l below 1 Check the earth connection of the machine using a tester to measure the resistance between the ground pin on the power supply cable and the ground node to which the receiver is connected inside the display The value must be less than 1 Ω Ohm 2 Check the connections referring to paragraph 2 7 Wiring diagrams 3 Place the tester probes across pins 2 and 1 of connector J3 on the HS interface...

Page 92: ...paced by the required minimum distance Is the receiv er correctly positioned and are the connecting cables properly routed Are there sources of electromagnetic noise near the receiver Reposition the machines so they are adequately spaced Correct the position of the receiver and the routing of the cables Move the machine away f rom the noise source or attenuate the power of the noise NO YES NO YES ...

Page 93: ... YES NO 5 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 detail below 1 Check the earthing of the machine using a tester to measure the resistance between the ground pin on the power supply cable and the ground node to which the receiver is connected inside the display The value must be ...

Page 94: ...romagnetic noise near the machine use Test Box Excite as detailed here below You can use one of the following cables ELT16 0WC00518AB CBQ28 0WC00390AC or TRM28 0WC00336AC as connection cable The circuit lights the LED for each heart beat and or disturbance received in this way it is possible to determine whether there is any interference and identify its sources 5 Check the battery power level usi...

Page 95: ...and unplug the mains lead from the wall outlet Only for 500 2 Back off the 4 screws a using a medium Phillips screwdriver Figure 7 1 2 3 Unplug the connectors as indicated in the figure at left CN9 CN1 CN3 4 Remove the display Figure 7 1 3 5 Back off the 2 screws b using an 8mm Hex wrench to remove the rear display support To reassemble the display carry out the above steps in reverse order ...

Page 96: ...m the wall outlet Only for 700 2 Back off the 4 screws a using a medium Phillips screwdriver Figure 7 1 5 3 Unplug the connectors as indicated in the figure at left CN9 CN1 CN6 CN5 CN4 4 Remove the display Figure 7 1 6 5 Back off the 2 screws b using an 8mm Hex wrench to remove the rear display support To reassemble the display carry out the above steps in reverse order ...

Page 97: ...he wall outlet 1 Back off the 4 screws a using a medium Phillips screwdriver Figure 7 1 8 2 Unplug the connectors as indicated in the figure at left CN30 CN26 CN27 CN19 CN21 CN22 CN25 3 Remove the display Figure 7 1 9 4 Back off the 2 screws b using an 8mm Hex wrench to remove the rear display support To reassemble the display carry out the above steps in reverse order ...

Page 98: ...le its circuit boards The Display Board A The C Safe Board B Figure 7 2 2 Display Board A 1 Disconnect connectors a CN2 of the keyboard and b CN8 of the CSafe board from the Display board 2 Back off the 5 screws c with a medium Phillips screwdriver 3 Remove the circuit board Figure 7 2 3 CSafe Board B 1 Disconnect connector d CN8 of the C Safe from the Display board 2 Remove the circuit board e sl...

Page 99: ... boards The Display Board A The C Safe Board B Figure 7 2 5 Display Board A 1 Disconnect connectors a CN2 of the keyboard and b CN8 of the CSafe board from the Display board 2 Back off the 5 screws c with a medium Phillips screwdriver 3 Remove the circuit board Figure 7 2 6 CSafe Board B 1 Disconnect connector d CN8 of the C Safe from the Display board 2 Remove the circuit board e slipping it off ...

Page 100: ...bench It is now possible to disassemble its circuit boards The LCD inverter A The CPU Board B And the circuit boards mounted on the rear display support Digital TV Board Input AUX Board Figure 7 2 8 LCD inverter A 1 Back off the 2 screws a with a medium Phillips screwdriver Figure 7 2 9 2 Remove the covering plate b of the LCD inverter 3 Disconnect the connectors c CN2 CN3 CN5 4 Back off the 2 scr...

Page 101: ...isconnect the cable s connectors coming from TTL and Touch screen CN3 CN28A on CPU Board On the inverter those direct to the LCD inverter indicated in the figure CN2 CN3 ATTENTION to disconnect the cable coming from the touch screen bend lightly back the protection plate if necessary 2 Back off the 5 screws f which fix the plate with all the Display Boards to the front covering Figure 7 2 12 3 Bac...

Page 102: ...screws i using a small Phillips screwdriver 8 Remove the touch screen protection plate l Figure 7 2 14 9 Shift touch screen m on one side paying attention to the cable which connect it to the CPU Board Figure 7 2 15 10 Back off the 4 screws n using a small Phillips screwdriver 11 Lift up and remove the LCD ...

Page 103: ...X Board and the antenna cable highlighted in the figure and the power supply cable 3 Back off the 4 screws o with a medium Phillips screwdriver 4 Remove the Digital TV Board Figure 7 2 17 5 Slip off the AUX Input Board p from its housing ATTENTION During the reassembly of the Digital TV Board pay attentions to not squash the cables under it To reassemble the circuit boards carry out the above step...

Page 104: ...3 2 Use a sharp tool to lift up and detach a corner of the keyboard To assemble a 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 toward the right without bending the keyboard 3 Insert the connector in the special slot on the display and connect it to the display board 4 Remove the protective fil...

Page 105: ... lift up and detach a corner of the keyboard To assemble a 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 toward the right without bending the keyboard 3 Insert the connector in the special slot on the display and connect it to the display board 4 Remove the protective film ATTENTION When reasse...

Page 106: ...E Class Trend Service maintenance manual rev 2 0 Pagina 7 12 7 3 3 700WTV VERSION WELLNESS TV To disassemble the Touch Screen please refer to the Display Board disassembly procedure 7 2 3 700WTV version Wellness TV ...

Page 107: ...e mains lead from the wall outlet 1 Back off the 6 screws a using a medium Phillips screwdriver 2 Lift up the upper tray bracket Figure 7 4 2 3 Unplug the connector indicated in the figure 4 Remove the receiver Figure 7 4 3 To assemble the new receiver 1 On the HFU receiver there are the receiving coil b and the connector c Continued on following page ...

Page 108: ...in the sponge d as shown in the picture to side 4 Use a cable tie to secure the receiver in the sponge ATTENTION The receiving coil must be oriented upwards and toward the user Figure 7 4 6 5 Place on top of the receiver inside the plastic housing a thick sponge Figure 7 4 7 6 Secure the cardio receiver and the sponges with a sticker To reassemble the cardio receiver carry out the above steps in r...

Page 109: ...g a medium Phillips screwdriver 3 Remove the upper tray Figure 7 5 2 4 Back off the 4 screws b using a 4mm hexagonal wrench 5 Remove the lower tray bracket Figure 7 5 3 6 Back off the three screws c using a 6mm hexagonal wrench back off the three screws on the left or right depending on which handgrip is being disassembled 7 Remove the handgrips To reassemble the handgrips carry out the above step...

Page 110: ...00WTV Figure 7 6 1 Turn off the machine and unplug the mains lead from the wall outlet For each handle sensor 1 Back off the 2 screws a using a small Phillips screwdriver Figure 7 6 2 2 Lift up the top sensor 3 Remove the lower sensor 4 To disconnect the sensors unplug the two Fast on indicated in the figure Continued on following page ...

Page 111: ... 1 Back off the 4 screws b using a small Phillips screwdriver Figure 7 6 4 2 Lift up the top sensor 3 Remove the lower sensor 4 To disconnect the sensors unplug the two faston and the connector c of the touch sensor indicated in the figure To reassemble the sensors carry out the above steps in reverse order ...

Page 112: ...g the mains lead from the wall outlet 1 Back off the screws a on both sides of the machine using a 4mm hexagonal wrench 2 Remove the top cover b Figure 7 7 2 3 Back off the 4 screws c using an 8mm hexagonal wrench Figure 7 7 3 4 Back off the screw d on both sides of the machine using a 4mm hexagonal wrench 5 Remove the rear guard Continued on following page ...

Page 113: ... maintenance manual rev 2 0 Page 7 19 Figure 7 7 4 6 Back off the 5 screws e on both sides of the machine using a medium Phillips screwdriver for the three top screws and a 4mm hexagonal wrench for the two lower ones 7 Remove the guard ...

Page 114: ...ides of the machine using a medium Phillips screwdriver 2 Lift the top cover along the display column Figure 7 7 6 3 Back off the 4 screws g using a 4mm hexagonal wrench 4 Back off the 2 screws ga using a medium Phillips screwdriver 5 Remove the front casing h Figure 7 7 7 6 Back off the 2 screws i using a 4mm hexagonal wrench 7 Remove the rear frame ...

Page 115: ...d back off the screw l on each side of the machine using a Phillips screwdriver Figure 7 7 9 2 Remove the guard n by pushing the tabs in the direction indicated by the arrows and simultaneously lifting it upward Figure 7 7 10 3 Back off the screws o on either side of the machine using a 4mm hexagonal wrench Continued on following page ...

Page 116: ... 22 Figure 7 7 11 4 Back off the screws p on either side of the machine using a 4mm hexagonal wrench Figure 7 7 12 5 Back off the 4 screws q using a 4mm hexagonal wrench 6 Remove the two front half guards To reassemble the guards carry out the above steps in reverse order ...

Page 117: ...cover guard 1 Back off the 2 screws a using a 4mm hexagonal wrench Figure 7 8 2 2 Back off the screw b using a medium Phillips screwdriver 3 Remove the cover plate from the electrical box Figure 7 8 3 4 Unplug the 4 connectors indicated in the figure at left 5 Remove the electrical box To reassemble the electrical box carry out the above steps in reverse order ...

Page 118: ...rations described in paragraph 7 7 2 Brake box cover guard and 7 7 3 Front guards 1 Back off the 4 screws with a small Phillips screwdriver that fix the support plate at the frame 2 Unplug connectors shown in the figure at the side 3 Release the clipsand to remove the board and replace if necessary To reassemble the hand sensor board carry out the above steps in reverse order ...

Page 119: ...o force it outward Figure 7 10 2 2 Unplug the connector indicated in the figure 3 Back off the 4 screws b using a 6mm Allen wrench 4 Pull out the lever from the machine frame To reassemble the lever carry out the above steps in reverse order ATTENTION During reassembly apply a drop of Loctite thread compound and lock down the screws b using a torque wrench setting of 37 Nm ...

Page 120: ...Nm Figure 7 11 2 2 Back off the nut b on the lower part of the lever using a 17mm hexagonal wrench 3 Back off the screw c using a 8mm hexagonal wrench ATTENTION During reassembly lock down the screw c using a torque wrench setting of 40 Nm and lock down nut b using a setting of 30 Nm Figure 7 11 3 4 Using a 6mm hexagonal wrench back off the 6 screws d securing the bushing assembly that connects to...

Page 121: ...crewdriver Figure 7 11 5 7 Back off the two screws g which secure the guard covering the lever accessing them from below 8 Remove the guard e Figure 7 11 6 9 Back off the ring nut h using a 17mm ring nut spanner if necessary holding the pin in place with an 8mm hexagonal wrench 10 Remove the pin in the direction indicated by the arrow Continued on following page ...

Page 122: ...It is now possible to disassemble the various levers and handles backing off the ring nuts l and m with a 20mm and 15mm ring nut spanner respectively if necessary holding the pins in place with an 8mm hexagonal wrench ATTENTION During reassembly lock down the rings l using a torque wrench setting of 70 Nm ATTENTION During reassembly lock down the ring m using a torque wrench setting of 50 Nm To re...

Page 123: ...g 2 Unplug the connector circled in the figure at left Figure 7 12 2 3 Back off the 2 screws b using an 8mm hexagonal wrench supporting the entire brake winding group c to avoid damaging the copper disk 4 Remove the brake winding assembly To reassemble the brake winding carry out the above steps in reverse order ATTENTION After completing the reassembly adjust the position of the winding group as ...

Page 124: ...move the cap a Figure 7 13 2 2 Back off the nut b on the lower part of the lever using a 17mm hexagonal wrench 3 Back off the screw c using a 8mm hexagonal wrench Figure 7 13 3 4 Back off the lock nut d and back off the screw e of the front tensioning mechanism using a 17mm wrench 5 Back off the screw f using a 8mm hexagonal wrench 6 Remove the front tensioning mechanism Continued on following pag...

Page 125: ...ning mechanism assembly Figure 7 13 5 9 Back off the screws l securing the two bridge bearings on which the secondary shaft is assembled using an 8mm hexagonal wrench for the screws and a 17mm wrench to hold the corresponding nuts in place 10 Remove the secondary shaft assembly pulling it out from the belt Only for 500SP and 700SP models Figure 7 13 6 11 Cut the strip tie and unplug the three fast...

Page 126: ...imary shaft is assembled using an 8mm hexagonal wrench for the screws and a 17mm wrench to hold the corresponding nuts in place 13 Remove the primary shaft assembly from the machine 14 Remove the belts ATTENTION During reassembly lock down the screws m using a torque wrench setting of 40 Nm To reassemble the belts follow the above instructions in reverse order ...

Page 127: ...a work bench 1 Back off the screw a using a 5mm hexagonal wrench and remove the washer b 2 Remove the crank c using an extractor tool ATTENTION During reassembly lock down the screw a using a 35 Nm torque wrench applying a drop of Loctite thread compound Figure 7 14 2 3 Back off the 2 grub screws d using a 3mm hexagonal wrench 4 Remove the key e 5 Remove the bearing from the shaft Figure 7 14 3 6 ...

Page 128: ...f the screw and remove part b 5 Pull the components out of the assembly Figure 7 14 1 To reassemble the shaft group look at the picture at the side and proceed as follows 1 Place all the components on the shaft respecting the correct order and the direction of insertion as shown on the side 2 Place the spacer the seeger and the seeger s covering piece 3 Insert the special tool x on the shaft locki...

Page 129: ... Remove the key e 5 Remove the bearing from the shaft 6 Remove the stator assembly f from the shaft Figure 7 14 7 To disassemble the shaft you need to have the kit R0003810AA 1 Insert the special tool x on the shaft 2 Lock down the screw y on the shaft using 13 mm wrench until the pressure is removed from the snap ring 3 Using the special pliers remove the snap ring from its seat sliding it upward...

Page 130: ...4mm hexagonal wrench WARNING Take particular care with the copper disk as it can bends easily ATTENTION During reassembly lock down the screws h using a torque wrench setting of 6 Nm Figure 7 14 10 To disassemble the plastic pulley 1 Back off the screw i using a 5mm hexagonal wrench and remove the washer l 2 Remove the crank m using an extractor tool ATTENTION During reassembly lock down the screw...

Page 131: ...nal wrench holding the corresponding nuts in place using a 13mm wrench 7 Remove the pulley from the shaft ATTENTION During reassembly lock down the screws p using a torque wrench setting of 22 Nm Figure 7 14 12 To reassemble the primary shaft assembly carry out the above steps in reverse order ATTENTION Screw the grub screws indicated in the picture by the arrows which are fixing the bearings keep...

Page 132: ...scribed in paragraph 7 13 Disassembling the belts as far as step 10 Place the secondary shaft assembly on a work bench 1 Back off the ring a using a 25mm ring nut spanner and remove the support b Figure 7 15 2 2 Remove the three spacers c and the pulley assembly d To reassemble the secondary shaft assembly carry out the above steps in reverse order ...

Page 133: ...e two cable ties a 2 Back off the 2 screws b using a 3mm hexagonal wrench 3 Remove the speed sensor and its support Figure 7 16 2 4 Unplug the Faston indicated in the figure 5 Back off the two screws c using a Phillips screwdriver and remove the sensor d To reassemble the speed sensor carry out the above steps in reverse order ATTENTION After completing the reassembly adjust the position of the se...

Page 134: ...over on one side 2 Back off the screws a for the front covers and or the screws b for the rear covers Figure 7 17 2 Underneath the front platforms at left in the figure there are housings for Power entry module 500 700 and 700WTV or battery charger socket 500SP and 700SP connector of the cable leading to the CSafe board At this point it is possible to 1 Back off the two screws c using a 4mm hexago...

Page 135: ...anual rev 2 0 Page 7 41 Figure 7 17 3 Disassembling the wheels 1 To disassemble the wheels e remove the snap ring f and pull out the pin on which they rotate To reassemble the platforms connectors and wheels carry out the above steps in reverse order ...

Page 136: ...SASSEMBLY Only for self powered version 500SP e 700SP Figure 7 18 1 Carry out the operations described in paragraph 7 7 3 Front guard as far as step 4 1 Unplug the two faston a 2 Cut the strip tie b and remove the battery To reassemble the battery carry out the above steps in reverse order ...

Page 137: ...aragraph 7 7 Guards for removing the upper guard Working on the front or rear belt tensioning mechanism 1 Back off the lock nut a using a 17mm wrench 2 Make the adjustment by turning the screw b with a 17mm wrench 3 Tighten the lock nut again ATTENTION The correct belt tension is 200Hz 20Hz To reassemble the bel carry out the above steps in reverse order ...

Page 138: ... Only for powered version 500 700 e 700WTV Figure 8 2 1 Carry out the operations described in paragraph 7 7 Guards for removing the rear guard 1 Back off the 2 screws a and shift the speed sensor support to the side so that it is 0 7 mm from the screws on the copper disk 2 Lock the screws back down ...

Page 139: ... 3 8 3 BRAKE WINDING POSITION Figure 8 3 1 Carry out the operations described in paragraph 7 7 1 Rear guard 1 Back off the 2 screws a and position the brake winding support so that it is centred on the copper disk using a 1mm thickness gauge 2 Lock the screws back down ...

Page 140: ...to the positioning of the machine on a not flat surface To resolve this problem is necessary to act on foot adjustment Figure 8 4 1 The equipment is levelled by adjusting the two front feet and the central foot 1 Screw the foot a in or out until the frame is in a stable position 2 Adjustment made to tighten the counter nut b ...

Page 141: ...SWORD To access the procedure type in the password 2406 and press ENTER to confirm To enter the password increase or decrease the displayed value using the and keys or use the GOAL keys to scroll through and modify the individual digits At this point the machine display begins showing the current configuration structured as in the diagram below USER MENU Language MAX time Cooldown time Distance Pa...

Page 142: ...shows the current setting UNITS xxx Press the GOAL keys to select the desired unit of measurement from the options listed in the table below UNITS KG default POUNDS Press ENTER to confirm the operation use the or effort level keys to move to the next or preceding parameter 9 1 3 MAXIMUM EXERCISE TIME It is possible to set a maximum duration for each exercise ranging from 1 to 9999 minutes To chang...

Page 143: ...OWN TIME xxx Press the ENTER key to change the value The current parameter value starts to blink on the display use the and keys to increase or decrease the value or use the GOAL keys to scroll through and modify the individual digits Press ENTER to confirm the operation use the or effort level keys to move to the next or preceding parameter The default value of this parameter is 60 If you are exe...

Page 144: ...e display shows the current duration DEFAULT DURATION MIN xxx Press the ENTER key to change the parameter The current parameter value starts to blink on the display use the and keys to increase or decrease the value or use the GOAL keys to scroll through and modify the individual digits Press ENTER to confirm the operation use the or effort level keys to move to the next or preceding parameter The...

Page 145: ... value of this parameter is 10 9 1 11 ENABLE TGS It is possible to enable or disable the use of the TGS reader To change the selection when the display shows the current setting TGS xxx Press the GOAL keys to select the desired option out of those listed in the table below TGS ENABLED default DISABLED Press ENTER to confirm the operation use the or effort level keys to move to the next or precedin...

Page 146: ...possible to reset the user menu parameters to their default values To select the function when the display shows DEFAULT CONFIG Press ENTER to confirm the operation use the or effort level keys to move to the next or preceding parameter If the ENTER key is pressed the display will show CONFIRM press ENTER to confirm or cancel by pressing the CLEAR key for a few seconds 9 1 15 FORMAT P P KEY This f...

Page 147: ... TV models the keys 0369 must be pressed one after the other The following prompt appears on the display ENTER PASSWORD To access the procedure type in the password 2406 and press ENTER to confirm At this point the machine display begins showing the current configuration structured as in the diagram below USER MENU Language Pause time MAX time Distance TGS Keys HR Edit Messages Default config Form...

Page 148: ...s the current setting DISTANCE xxx Press the GOAL keys to select the desired unit of measurement from the options listed in the table below DISTANCE KM default MLS Press ENTER to confirm the operation use the or effort level keys to move to the next or preceding parameter 9 2 3 MAXIMUM EXCERCISE TIME It is possible to set a maximum duration for the exercise in minutes with a value ranging from 1 t...

Page 149: ... change the setting when the display shows the currently selected maximum time COOLDOWN TIME xxx Press the ENTER key to change the value The current parameter value starts to blink on the display use the and keys to increase or decrease the value or use the GOAL keys to scroll through and modify the individual digits Press ENTER to confirm the operation use the or effort level keys to move to the ...

Page 150: ...ring a constant heart rate exercise To change the selection when the display shows the current setting HR xxx Press the GOAL number keys to select the desired option out of those listed in the table below HR MODIFIABLE default NOT MODIFIABLE Press ENTER to confirm the operation use the or effort level keys to move to the next or preceding parameter 9 2 9 ENABLE CUSTOM MESSAGES It is possible to co...

Page 151: ...ned custom standby messages when the LED display is showing the current selection CHANGE MESS LANGUAGE Press ENTER to confirm the operation use the or effort level keys to move to the next or preceding parameter 9 2 12 ENABLE MULTI LANGUAGE MODE The machine can be configured to allow selection of the language at each session To change the selection when the display shows the current setting LANGUA...

Page 152: ...ion when the display shows FORMAT P P press ENTER to confirm or cancel by pressing the CLEAR key for a few seconds At the end of the configuration procedure hold down the CLEAR key for a few seconds to exit The CLEAR key can be pressed at any time to interrupt the procedure and revert to standby mode 9 2 15 SN This parameter shows the serial number of the machine SN xxxx ...

Page 153: ...u can access the different configuration menus using the proper password To access the menu type in the password 2406 and press ENTER key to confirm or BACK key to back forward At this point the machine display will shows the different parameters of the menu collected in different pages which can be scrolled with the FORWARD and BACK keys To exit the configuration press HOME key Pressing HOME in a...

Page 154: ...equently displayed by the machine will be in the chosen language To change the selection select the desired option among the ones in the list directly touching on the Touch Screen Press HOME to confirm and save FORWARD or BACK to scroll the pages 9 3 3 MEASURE It is possible to choose between EUROPEAN units kg and km or IMPERIAL units pounds and miles To change the selection select the desired opt...

Page 155: ...confirm and save FORWARD or BACK to scroll the pages 9 3 6 MAXIMUM EXCERCISE TIME It is possible to set a maximum duration for the exercise in minutes with a value ranging from 1 to 9999 To change the setting press the MODIFY key and insert the value using the numeric keyboard Press ENTER key to confirm or BACK key to back forward The default value of this parameter is 9999 Press HOME to confirm a...

Page 156: ...operation use the or effort level keys to move to the next or preceding parameter The default value of this parameter is 60 If you are exercising with a TGS key the cooldown will be stopped if you extract the key 9 3 9 TOP EXERCISE PROGRAMS FOR YOU SHORTCUT It is possible to choose 2 extra training programs from the list of those available which will be displayed in the main page with the fixed on...

Page 157: ... the Touch Screen STANDBY TV ON default TV OFF Press HOME to confirm and save FORWARD or BACK to scroll the pages 9 3 12 LANGUAGE The machine can be configured to allow selection of the language at each session To change the selection select the desired option among the ones in the list directly touching on the Touch Screen LANGUAGE FIXED default OPTIONAL Press HOME to confirm and save FORWARD or ...

Page 158: ...ing the numeric keyboard Press ENTER key to confirm or BACK key to back forward The default value of this parameter is 10 Press HOME to confirm and save FORWARD or BACK to scroll the pages 9 3 16 DISPLAY IN THE WORKOUT It is possible to configure the size of the exercise data during the workout To change the selection select the desired option among the ones in the list directly touching on the To...

Page 159: ...ON OPTION DOCKING STATION default NOTHING Press HOME to confirm and save FORWARD or BACK to scroll the pages 9 3 19 STANDBY CHANNEL It is possible to set the channel which is displayed on the TV when the TV is in standby To change the setting press the MODIFY key and insert the value using the numeric keyboard Press ENTER key to confirm or BACK key to back forward Press HOME to confirm and save FO...

Page 160: ...digits At this point there are two options available Tech Config Troubleshooting Press numeric key to access the menu for configuring technical parameters the machine display will begin showing the current configuration structured as in the diagram below Accessing configuration of 700 models Simultaneously press the keys 369 for 700 LED models whereas on 700 Wellness TV models the keys 0369 must b...

Page 161: ...ss the or effort level keys to display the next or the preceding item To modify a parameter value it is necessary to press the ENTER key when the current parameter value starts to blink press the CLEAR key to erase the current value and then use the number keys to enter the desired new value Save the changes made by pressing the ENTER key To cancel the operation press the CLEAR key for a few secon...

Page 162: ...this function also includes the 3 sub functions described below 9 4 1 1 Read from low kit To read the parameter values from the low kit memory and view them on the display scroll using the keys until the display shows READ FROM LOW KIT press ENTER to read the errors from the low kit and return to the upper menu level by pressing CLEAR for a few seconds 9 4 1 2 Write to low kit To write the values ...

Page 163: ...e the Write to low kit function 9 4 1 4 Table of configuration parameters Parameter Description Defaultvalues Par 01 Transmission ratio 141 Par 02 Speed ratio integer part 1 Par 03 Minimum braking current standby pos mA 0 Par 04 Maximum continuous power W 200 Par 05 Machine torque correction coefficient constant torque 100 Par 06 User friction torque 60 Par 07 Maximum coil temperature C 125 Par 08...

Page 164: ...ows OPERATING DATA Life Kit H Life Brake WRITE TO LOW KIT READ FROM LOW KIT Life Kit L Tot Km KJ In addition to the machine usage data this function also includes the 2 sub functions described below 9 4 2 1 Read from low kit To read the parameter values from the low kit memory and view them on the display scroll using the keys until the display shows READ FROM LOW KIT press ENTER to read the error...

Page 165: ... machine is switched off any data modified after the last memory update will be lost MESSAGE ON DISPLAY DESCRIPTION Life Brake Minutes x 10 of operation of the brake Life Kit H Minutes x 10 of operation of the upper assembly Life Kit L Minutes x 10 of operation of the lower assembly Tot Km Total km traveled KJ Total KJ during exercise By selecting one of the items in the above table it is possible...

Page 166: ...ludes the 3 sub functions described below 9 4 3 1 Read from low kit To read the errors stored in low kit memory and view them on the display scroll using the keys until the display shows READ FROM LOW KIT press ENTER to read the errors from the low kit and return to the upper menu level by pressing CLEAR for a few seconds 9 4 3 2 Reset Errors To clear the error history in both the low and high kit...

Page 167: ...between error codes and descriptions is given in the table below Error Code Description 1 OVERHEATING this condition occurs when the temperature detected by the sensor on the circuit board exceeds 90 C 2 OVERCURRENT this condition occurs when the Brake board detects an excessive amount of current being sent to the winding 8 OVERVOLTAGE this condition occurs when the 12 Vdc voltage goes above 13 7 ...

Page 168: ...or return to the upper menu level by pressing CLEAR for a few seconds This function does not alter the language and the TV standard setting 9 4 5 LOW KIT MENU This function directly accesses the firmware of the brake board To access this menu when the display shows LOW KIT MENU press ENTER This function is structured as follows LOW KIT MENU Low Kit Version Low Kit fault code 9 4 5 1 Low kit versio...

Page 169: ... VERSION This function displays the SW version of the display To do this when the display shows HIGH KIT VERSION press ENTER the message that identifies the SW version will appear 9 4 7 BOOT VERSION This function displays the BOOT version To do this when the display shows BOOT VERSION press ENTER to display the message which identifies the BOOT version 9 4 8 KEY READER VERSION This function displa...

Page 170: ... can access the different configuration menus using the proper password To access the menu type in the password 2501 and press ENTER key to confirm or BACK key to back forward At this point the machine display will shows the different parameters of the menu collected in different pages which can be scrolled with the FORWARD and BACK keys To exit the configuration press HOME key Pressing HOME in an...

Page 171: ...when the display shows In addition to the 13 configuration parameters this function also includes the 3 sub functions described below 9 5 1 1 Read from low kit To read the parameter values from the low kit memory and view them on the display press READ FROM LOW KIT key 9 5 1 2 Write to low kit To write the values of the currently displayed parameters to the low kit press WRITE TO LOW KIT key 9 5 1...

Page 172: ... load them in the low kit using the Write to low kit function Parameter Description Default values Par 01 Transmission ratio 141 Par 02 Speed ratio integer part 1 Par 03 Minimum braking current standby pos mA 0 Par 04 Maximum continuous power W 200 Par 05 Machine torque correction coefficient constant torque 100 Par 06 User friction torque 60 Par 07 Maximum coil temperature C 125 Par 08 Minimum re...

Page 173: ...lay the parameter values you need to load them from the low kit using the Read from low kit function MESSAGE ON DISPLAY DESCRIPTION Life Brake Minutes x 10 of operation of the brake Life Kit H Minutes x 10 of operation of the upper assembly Life Kit L Minutes x 10 of operation of the lower assembly Tot Km Total km traveled KJ Total KJ during exercise By pressing the RESET key on the side of the va...

Page 174: ...ey on the side of the value To correctly display the parameter values you need to load them from the low kit using the Read from low kit function For every error generated by the machine the error history log records the information in the table below Counter Error code Current when the error occurred Distance in km when the error occurred The correspondence between error codes and descriptions is...

Page 175: ...TV board SW version the iPod docking station SW version Press HOME to confirm and save FORWARD or BACK to scroll the pages 9 5 5 STANDARD SETTINGS This function allows you to reset the usage data of the machine and simultaneously set the default values of the parameters of the inverter To make the restoration of values press the STANDARD SETTINGS button This function does not change the language a...

Page 176: ...ULGARY DVB T SECAM D K NORWAY DVB T PAL B G CANADA ATSC NTSC M OMAN DVB T COLOMBIA ATSC NTSC M PHILIPPINES DVB T NTSC M CYPRUS DVB T PAL B POLAND DVB T PAL D K CZECH REPUBLIC DVB T SECAM PAL D K PORTUGAL DVB T PAL B G DENMARK DVB T PAL B P R CHINA DVB T PAL D K EGYPT DVB T SECAM B QATAR DVB T FAROE ISLANDS DVB T PAL B ROMANIA DVB T PAL G FINLAND DVB T PAL B G RUSSIA DVB T SECAM D K FRANCE DVB T SE...

Page 177: ...shows a window from where you can access the different configuration menus using the proper password To access the menu type in the password 2407 and press ENTER key to confirm or BACK key to back forward At this point the partial screen TV is displayed on the machine display as shown in the picture below To permanently save the changes which are going to be made in this page press SAVE IN EEPROM ...

Page 178: ... is possible to search TV channels on the digital or on the analogue band by pressing on the proper buttons or The default TV standard is the one set at paragraph 9 5 6 TV Standard of the service menu It is anyway possible to store channels transmitted with different TV standard changing this parameter using keys and in the proper menu ...

Page 179: ...rs in column 2 to scroll through the pages with the numbers and names associated to the channels 4 Once you have found a channel to memorise select it in column 1 then press the number that you want to associate it with in column 2 If a channel has already been memorised under that number the old channel will be overwritten with the new one 5 Repeat the procedure above for each channel you want to...

Page 180: ...sualized in column 1 it will be displayed then press the number that you want to associate it with in column 2 5 An alphanumeric keypad is displayed to associate a name to the memorised channel 6 Press the ENTER key the keypad will disappear and the name will be displayed next to the number If a channel has already been memorised under that number the old channel will be overwritten with the new o...

Page 181: ...S The keys in the figure at left can perform certain adjustments on the Wellness TV In particular it is possible to Increase or reduce the brightness of the LCD Increase or reduce the contrast of the LCD Then 1 Press the SAVE IN EEPROM key to permanently save the configuration 2 Exit with the HOME key ...

Page 182: ...ill shows a window from where you can access the different configuration menus using the proper password To access the menu type in the password 2408 and press ENTER key to confirm or BACK key to back forward At this point the partial screen TV is displayed on the machine display as shown in the picture below To permanently save the changes which are going to be made in this page press SAVE IN EEP...

Page 183: ...SYNCHRO EXCITE Class Trend Service maintenance manual rev 2 0 Page 9 43 Press YES to save the changes permanently or NO to continue ...

Page 184: ...hannels in column 1 to scroll through the pages with the channels found during the search while use the keys under the list of numbers in column 2 to scroll through the pages with the numbers and names associated to the channels 4 Once you have found a channel to memorise select it in column 1 then press the number that you want to associate it with in column 2 If a channel has already been memori...

Page 185: ...to be transferred 2 Insert the TGS key into the reader on the machine 3 Press the SAVE IN TGS button this will cause all the channel configuration data to be saved to the key Up to 45 channels can be memorised in the TGS key if there are more channels to be memorised a message indicates the number of TGS keys required The TGS keys must be inserted one at the time as requested by the messages until...

Page 186: ...oper cable described at paragraph 4 3 Cable for exchanging TV channel tuning data between two machines 2 On both machines enter the configuration menu of the channels that need to be tuned 3 Press the READ FROM TGS on the machine to be tuned the channels appears on the machine the written WAITING move on the machine from which you want to transfer channels and press the SAVE IN TGS button on the a...

Page 187: ...n standby mode by pressing the top right hand the bottom left hand and the bottom right hand corner in sequence as shown in the picture below The machine display will shows a window from where you can access the different configuration menus using the proper password To access the menu type in the password 2409 and press ENTER key to confirm or BACK key to back forward ...

Page 188: ...SYNCHRO EXCITE Class Trend Service maintenance manual rev 2 0 Pagina 9 48 At this point the following screenshot appears on the display ...

Page 189: ...s correctly carried out or Calibration incomplete if the procedure was not completed properly after which the machine reverts to standby mode During the machine power up sequence while the message showing the installed software version is scrolling pressing any point on the touch screen for more than 6 seconds will automatically invoke the calibration procedure as soon as the software version disp...

Page 190: ...SYNCHRO EXCITE Class Trend Service maintenance manual rev 2 0 Pagina 9 50 Page intentionally left blank ...

Page 191: ...ons 60601 1 and 60601 1 2 electrical testing of each device manufactured according to the provisions of the aforementioned standards training of technical staff who perform technical service use of checked and tested original Technogym spare parts for all service operations 10 1 ELECTRICAL SAFETY TEST Based on the risk analysis carried out by the After Sale department regarding installation and te...

Page 192: ...SYNCHRO EXCITE Class Trend Service maintenance manual rev 2 0 Pagina 10 2 First of all check the resistance on the tester probes is approximately 0Ω ...

Page 193: ...That the pedaling action is always smooth and silent even at high effort level 10 2 2 CHECKING THE ASSEMBLY OF THE GUARDS Check the assembly of the machine guards making sure that They are all in place and correctly secured so that no parts of the machine are left exposed that may cause injury to the user 10 3 START UP CHECK Following installation and after every technical intervention on the mach...

Page 194: ...s traceable The list of these critical components is shown in the table below CODE COMPONENT R0004475AB Brake board 0WR00496AA Solenoid assembly W0003778AA Display board 500 W0003767AA Display board 700 0WQ00060AA C Safe board 0WR00678AA Hand sensor board 0WR00285 HFU receiver 0WT005AA Schurter socket Display program SW version Brake board program SW version If a critical component listed in this ...

Page 195: ...es 11 1 DAILY MAINTENANCE OPERATIONS ATTENTION These operations can be carried out by the machine owner and do not require any special skills The daily machine maintenance consists of simple external cleaning for the purposes of general hygiene For the daily maintenance of the machine proceed as follows 11 1 1 SETTING UP THE OPERATION Only for 500 700 and 700WTV models 1 Turn off the machine by pl...

Page 196: ...OTESTER RECEIVER 1 Using a separate heart rate monitor put on the transmitter band and check that the machine and the separate monitor both measure the same heart rate and that when the band is disconnected the machine does not receive any signal 2 Using a heart rate frequency simulator check that the machine detects variations in the heart rate 11 2 2 CHECKING THE OPERATION OF THE HAND SENSOR REC...

Page 197: ...escribed in paragraph 11 2 Monthly maintenance operations 11 3 2 SETTING UP THE OPERATION Only for 500 700 and 700WTV models 1 Turn off the machine by placing the switch in position 0 OFF 2 Unplug the mains lead from the wall outlet 11 3 3 CLEANING OPERATIONS 1 Use a vacuum cleaner to clean the interior paying particular attention to the brake ATTENTION when carrying out these operations be carefu...

Page 198: ...the LEDs and the buzzer 11 3 8 CHECKING THE WIRING AND CONNECTIONS 1 Check the condition of all the cables External conditions Possible rusting of the connectors Electrical continuity of the individual wires Isolation of the individual wires toward ground Repair and or replace any non conforming wires Only for 500 700 and 700WTV models 2 Check the condition of the fuses using a tester ...

Page 199: ...t of the display panel The PC can only update the FLASH EPROM during machine power up before the self test sequence begins After the Display SW update it is necessary to restore all the parameters to the default values following the detailed instructions provided in paragraph 9 2 13 Resetting parameters to default values After the lower electronic SW update it is necessary to restore all the param...

Page 200: ...wrench 17mm wrench 3mm hexagonal wrench 4mm hexagonal wrench 5mm hexagonal wrench 6mm hexagonal wrench 8mm hexagonal wrench 13mm socket wrench Snap ring pliers Bicycle pedal extractor Torque wrench Flatness comparator You can order a complete set of hexagonal wrenches consisting of 7 pieces 2 2 5 3 4 5 6 and 8 mm The code to be used is R0003677AA PC equipped with Service Excite Loader Serial commu...

Page 201: ......

Page 202: ...0SM00583AA UK TECHNOGYM S p A Via G Perticari 20 47035 Gambettola FC ITALIA Tel 39 0547 650638 Fax 39 0547 650150 e mail service technogym com ...