Page 1
SERVICE & MAINTENANCE MANUAL
REV. 1.2
Page 2
Page 3
The information contained in this manual is intended for QUALIFIED TECHNICIANS who have
completed a specific TECHNOGYM training course and are authorized to perform machine start-up
and adjustment procedures as well as extraordinary maintenance or repairs which require a thorough
knowledge of the machine, its operation, its safety devices and working procedures.
CAREFULLY READ THE INFORMATION CONTAINED IN
THIS MANUAL BEFORE PERFORMING ANY MAINTENANCE
PROCEDURES ON THE MACHINE
DANGEROUS VOLTAGES
PRESENT EVEN WHEN THE
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 is protected by copyright. All rights reserved.
No part of this document may be photocopied, reproduced or translated into another language
without the prior written consent of Technogym.
The Technogym® trademark is property of Technogym S.r.l.
The Steprace™ trademark is property of Technogym S.r.l.
MACHINE IS TURNED OFF
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STEPRACE: Service & Maintenance Manual - rev. 1.2
Contents
1. GENERAL NOTICES...........................................................................................................................................1.1
1.1. INTRODUCTION................................................................................................................................................. 1.1
1.2. RECOMMENDATIONS........................................................................................................................................1.1
1.3. GENERAL RULES FOR REPAIR PROCEDURES ......................................................................................................1.2
2. TECHNICAL CHARACTERISTICS..................................................................................................................2.1
2.1. MECHANICAL CHARACTERISTICS......................................................................................................................2.1
2.2. ELECTRICAL CHARACTERISTICS........................................................................................................................2.1
2.3. AMBIENT SPECIFICATIONS ................................................................................................................................2.1
2.4. CONFORMITY TO REGULATIONS........................................................................................................................ 2.1
2.5. WIRING DIAGRAM.............................................................................................................................................2.2
2.5.1. Connectors........................................................................................................................................2.2
2.5.2. Wiring ...............................................................................................................................................2.3
3. PRINCIPLES OF OPERATION.......................................................................................................................... 3.1
3.1. BLOCK DIAGRAM.............................................................................................................................................. 3.1
3.2. ALTERNATOR CONTROL....................................................................................................................................3.4
3.2.1. Mechanics.........................................................................................................................................3.4
3.2.2. Control..............................................................................................................................................3.4
3.2.3. The control signals............................................................................................................................ 3.5
4. ACCESSORIES......................................................................................................................................................4.1
4.1. CONNECTING TO THE TGS................................................................................................................................4.1
4.1.1. TGS adapted machines......................................................................................................................4.1
4.1.2. TGS non-adapted machines..............................................................................................................4.1
4.2. CONNECTING TO THE PRINTER..........................................................................................................................4.2
5. INSTALLATION INSTRUCTIONS....................................................................................................................5.1
5.1. SPECIFICATIONS AND REQUIREMENTS............................................................................................................... 5.1
5.2. INSTALLATION..................................................................................................................................................5.1
5.3. FIRST POWER-ON.............................................................................................................................................. 5.2
6. TROUBLESHOOTING.........................................................................................................................................6.1
6.1. THE DISPLAY DOES NOT ILLUMINATE................................................................................................................6.2
6.2. THERE IS NO RESISTANCE .................................................................................................................................6.5
6.3. THE RESISTANCE IS INCORRECT........................................................................................................................6.6
6.4. THE SPM VALUE IS INCORRECT........................................................................................................................6.9
6.5. THE MACHINE DOES NOT PRINT ...................................................................................................................... 6.11
6.6. THE MACHINE FAILS TO READ THE STEPPING MODE ........................................................................................6.13
6.7. THE MACHINE DOES NOT OPERATE IN MASTER - SLAVE MODE........................................................................ 6.15
6.8. THERE IS NO HEART RATE SIGNAL...................................................................................................................6.17
6.9. THE HEART RATE SIGNAL IS INCORRECT .........................................................................................................6.18
7. DISASSEMBLY OF COMPONENTS................................................................................................................. 7.1
7.1. DISASSEMBLING THE DISPLAY .......................................................................................................................... 7.1
7.2. DISASSEMBLING THE EPROM.......................................................................................................................... 7.3
7.3. DISASSEMBLING THE CPU BOARD....................................................................................................................7.4
7.4. DISASSEMBLING THE KEYBOARD...................................................................................................................... 7.6
7.5. DISASSEMBLING THE CARDIO RECEIVER...........................................................................................................7.8
7.6. DISASSEMBLING THE UPRIGHT GUARD..............................................................................................................7.9
7.7. DISASSEMBLING THE ELECTRONIC CIRCUIT BOARDS....................................................................................... 7.10
7.8. DISASSEMBLING THE SIDE GUARDS................................................................................................................. 7.11
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7.9. DISASSEMBLING THE CHAIN GUARD................................................................................................................7.12
7.10. DISASSEMBLING THE HANDLEBARS ................................................................................................................ 7.13
7.11. DISASSEMBLING THE PEDAL JOINT.................................................................................................................. 7.14
7.12. DISASSEMBLING THE PEDALS AND PEDAL GROUP............................................................................................ 7.15
7.13. DISASSEMBLING THE PEDAL CONNECTING RODS.............................................................................................7.17
7.14. DISASSEMBLING THE LEVERS..........................................................................................................................7.18
7.15. DISASSEMBLING THE PEDAL CHAINS............................................................................................................... 7.19
7.16. DISASSEMBLING THE PRIMARY SHAFT - SECONDARY SHAFT CHAIN.................................................................7.20
7.17. DISASSEMBLING THE PRIMARY SHAFT GROUP.................................................................................................7.21
7.18. DISASSEMBLING THE PRIMARY DRIVE SPROCKETS..........................................................................................7.22
7.19. DISASSEMBLING THE SECONDARY DRIVE SPROCKETS.....................................................................................7.23
7.20. DISASSEMBLING THE SLIDE DRIVE SPROCKET ................................................................................................. 7.24
7.21. DISASSEMBLING THE SECONDARY SHAFT .......................................................................................................7.25
7.22. DISASSEMBLING THE BELT..............................................................................................................................7.27
7.23. DISASSEMBLING THE ALTERNATOR................................................................................................................. 7.29
7.24. DISASSEMBLING THE ALTERNATOR BRUSHES .................................................................................................7.30
7.25. DISASSEMBLING THE SPRINGS......................................................................................................................... 7.31
7.26. DISASSEMBLING THE SPRING PULLEYS............................................................................................................7.33
7.27. DISASSEMBLING THE SLIDE BARS....................................................................................................................7.34
7.28. DISASSEMBLING THE SELECTION KNOB........................................................................................................... 7.35
7.29. DISASSEMBLING THE SELECTION KNOB PIN.....................................................................................................7.36
7.30. DISASSEMBLING THE MICROSWITCH ...............................................................................................................7.38
8. ADJUSTMENTS....................................................................................................................................................8.1
8.1. ALIGNING THE BELT..........................................................................................................................................8.1
8.2. BELT TENSION ..................................................................................................................................................8.2
8.3. ALIGNING THE PRIMARY SHAFT - SECONDARY SHAFT CHAIN.............................................................................8.3
8.4. PRIMARY SHAFT - SECONDARY SHAFT CHAIN TENSION..................................................................................... 8.4
8.5. ADJUSTING THE ALIGNMENT OF THE PRIMARY DRIVE SPROCKET ......................................................................8.5
8.6. WEAR OF ALTERNATOR BRUSHES..................................................................................................................... 8.6
8.7. ALIGNING THE PEDALS......................................................................................................................................8.7
8.8. ADJUSTING THE POSITION OF THE SLIDE AND BARS........................................................................................... 8.8
8.9. ADJUSTING THE MICROSWITCH POSITION..........................................................................................................8.9
8.10. ADJUSTING THE LCD BACKLIGHTING............................................................................................................. 8.10
8.11. ADJUSTING THE BUZZER TONE........................................................................................................................8.11
9. CONFIGURING THE MACHINE ......................................................................................................................9.1
9.1. MACHINE HW CONFIGURATION .......................................................................................................................9.1
9.1.1. Machine No. configuration...............................................................................................................9.1
9.1.2. Alternator configuration...................................................................................................................9.1
9.1.3. Microswitch configuration................................................................................................................ 9.1
10. SCHEDULED MAINTENANCE ....................................................................................................................... 10.1
10.1. EXTERNAL CLEANING OPERATIONS................................................................................................................. 10.1
10.1.1. Setting up the operation ..................................................................................................................10.1
10.1.2. Cleaning operations........................................................................................................................10.1
10.2. ROUTINE MAINTENANCE OPERATIONS ............................................................................................................ 10.2
10.2.1. Setting up the operation ..................................................................................................................10.2
10.2.2. Internal cleaning ............................................................................................................................. 10.2
10.2.3. Lubrication......................................................................................................................................10.2
10.2.4. Checking the state of wear of the pedal chains ............................................................................... 10.2
10.2.5. Checking the amount of play on the ball joints...............................................................................10.2
10.3. SPECIAL MAINTENANCE OPERATIONS..............................................................................................................10.3
10.3.1. Setting up the operation ..................................................................................................................10.3
10.3.2. Checking the working conditions .................................................................................................... 10.3
10.3.3. Performing the routine maintenance procedure..............................................................................10.3
10.3.4. Checking the wiring and connections..............................................................................................10.3
10.3.5. Checking the display........................................................................................................................10.3
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10.3.6. Checking the wear of the rubber handlebar covers.........................................................................10.4
10.3.7. Checking the operation of the stepping mode selection knob and slide..........................................10.4
10.3.8. Checking the alternator belt............................................................................................................ 10.4
10.3.9. Checking the primary shaft chain.................................................................................................... 10.4
10.3.10. Checking the wear of the pulleys.....................................................................................................10.4
10.3.11. Checking the play of the lever and pedal group.............................................................................. 10.4
10.3.12. Checking the operation of the cardio receiver................................................................................10.4
10.3.13. Checking the resistance setting ....................................................................................................... 10.5
10.3.14. Checking the noise of the brushes...................................................................................................10.5
11. APPENDIX...........................................................................................................................................................11.1
11.1. TECHNICAL NOTES ON CARDIO RECEIVERS .....................................................................................................11.1
11.1.1. Type of ASIC....................................................................................................................................11.2
11.1.2. Presence of electromagnetic fields.................................................................................................. 11.2
11.1.3. Reducing receiver sensitivity........................................................................................................... 11.3
11.1.4. Mechanical vibrations..................................................................................................................... 11.4
11.1.5. Position of the receiver.................................................................................................................... 11.4
11.1.6. Routing of cables............................................................................................................................. 11.5
11.2. PERSONAL CODED DEVICE .............................................................................................................................11.6
11.2.1. Operating modes ............................................................................................................................. 11.6
11.2.2. Upgrade of machines already installed...........................................................................................11.7
11.3. SPECIAL FUNCTIONS .......................................................................................................................................11.8
11.3.1. Displaying the selected type of alternator....................................................................................... 11.8
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1. GENERAL NOTICES
1.1. INTRODUCTION
This document is reserved for Technogym Service technicians, and is intended to provide
authorized personnel with the necessary information to correctly carry out repairs and maintenance.
A thorough knowledge of the technical information contained in this manual is essential for
completing the professional training of the operator.
In order to facilitate consultation, the paragraphs are accompanied by schematic drawings which
illustrate the procedure being described.
This manual contains notices and symbols which have a specific meanings:
WARNING: non observance may result in accident or injury.
ATTENTION: non observance 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 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 diagnose the causes of the problem. This manual provides the fundamental theoretical
basis, which must then be integrated by personal experience and attendance at the training
courses periodically offered by Technogym.
• Rationally plan the repair procedure so as to minimize the downtime necessary for procuring
spare parts, preparing tools, etc.
• Access the component to be repaired, avoiding any unnecessary operations. In this regard it will
be useful to refer to the disassembly sequence described in this manual.
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1.3. GENERAL RULES FOR REPAIR PROCEDURES
1. Always mark any parts or positions which may be confused with each other at the time of
reassembly.
2. Use original Technogym spare parts and lubricants 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 tools.
OBSERVE: The tool sizes quoted in this manual are expressed in mm.
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2. TECHNICAL CHARACTERISTICS
2.1. MECHANICAL CHARACTERISTICS
Width 66.5 cm
Length 142 cm
Height 151 cm
Weight 154 Kg
2.2. ELECTRICAL CHARACTERISTICS
Mains voltage 115 / 230 VAC
Frequency 50 - 60 Hz
Consumption ~ 60 Watt – 0.6 / 0.3 A
Fuses 5x20 3.15 A fast-blow
The mains voltage is set by means of a special jumper on the power supply circuit board.
An 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 output.
2.3. AMBIENT SPECIFICATIONS
Temperature
Humidity
Operating from 5° to 35° C
Storage from -20 to 55° C
Operating from 30% to 80% non-condensing
Storage from 5% to 85% non-condensing
2.4. CONFORMITY TO REGULATIONS
The machine conforms to the following directives:
EMI
Safety
Directive
Europe USA
EN 60601-1-2
EN 60601-1
EN 957-1
73/23/CEE
93/68/CEE
89/336/CEE
UL 2601-1
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2.5. WIRING DIAGRAM
STEPRACE: Service & Maintenance Manual - rev. 1.2
2.5.1. CONNECTORS
• CPU board
name type of connector connection
CN1 AMP MATE-N-LOCK 12-pin F. to alternator interface board
CN3 AMP MODU II 4-pin M. to cardio receiver
• Power supply
name type of connector connection
CN1 PANDUIT 6-pin to mains power supply
CN2 PANDUIT 8-pin to alternator interface board
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• Alternator interface board
name type of connector connection
CN1 AMP MATE-N-LOCK 15-pin F. to CPU board
CN2 AMP MATE-N-LOCK 6-pin F. to alternator
CN3 AMP MODU I 4-pin M. to power supply
CN4 AMP MODU I 8-pin M. to serial ports
2.5.2. WIRING
ST-1: Internal connecting cable
CPU Board – alternator interface board
CPU board
CN1
1 +12 Vdc White 1
2 +5 Vdc Black-Gray 2
3 ground Black 3
4 ground Orange 4
5 Alternator RPM X 6 Pink 5
6 PWM alternator resistance Red 6
7 - - 7
8 Selection knob position Black-Blue 8
9 CTS Blue 9
10 Master – Slave selection Purple 10
11 Y – bus Green 11
12 Z – bus Brown 12
13 -12 Vdc Yellow 13
14 A – bus Orange-gray
15 B – bus Yellow-
On some machines, the signal designated +12 Vdc in the above table is actually 10.5 Vdc.
Signal Color Alternator
interface board
CN1
14
15
green
ST-3: High voltage power supply
Power input socket – Power supply
Power entry Signal Color Power supply
CN1
Yellow Faston Ground Yellow 1
Red Faston Live Blue 4
Red Faston Neutral Black 6
The above description of cable ST-3 is simplified and does not detail the ground node connections.
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ST-5: Alternator cable
Alternator interface board – Alternator – Resistor
Alternator
interface
board
CN2
1 Alternator RPM X 6 Purple Red eyelet 4 2 Blue -
5 ground Black
3 Red Yellow eyelet 4
4 Excitation Orange Red Faston -
Signal Color Alternator Resistor
Resistor -
Resistor +
Blue
Red Yellow eyelet 6
Yellow eyelet 6
ST-5M: Microswitch cable
Microswitch – Alternator interface board – PE
Microswitch Signal Color Alternator
interface board
1 ground Brown 6 2 NC
Yellow-
green
ST-6: Low voltage power supply cable
Power supply – Alternator interface board
Power supply
CN2
2 +5 Vdc Yellow 4
5 +12 Vdc Red 2
6-7-4 ground Black 3
8 -12 Vdc Blue 1
Signal Color Alternator
ST-7: Heart rate meter cable
CPU Board – Cardio receiver
CPU board
CN4
1 +5 Vdc Red 1
2 Pulse per beat Blue 2
3 ground Black 3
Signal Color Receiver
Yellow eyelet 4
-
PE
CN2
- Yellow eyelet 4
interface board
CN3
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ST-8: Serial ports cable
Alternator interface board – Serial ports
Alternator
interface board
CN4
1 Y – bus White 1
2 Z – bus Orange 2
3 A – bus Brown 3
4 B – bus Yellow 4
5 CTS Green 5
6 +5 Vdc Red 6
7 ground Blue 7
8 - - 8
Signal Color Serial ports
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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 receiver one pulse for
every heart beat that is detected. There are 2 types of transmitter:
• Non-coded: this is the standard product;
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• Coded: this is the product which, utilizing Personal Coded Device technology, transmits
the heart rate together with a code that identifies the transmitter in question. In this way,
the coded receiver on the machine can identify the source of the heart rate signal, thereby
avoiding interference problems.
(2) CARDIO RECEIVER
It is connected to the machine’s CPU board and receives the pulses sent by the transmitter.
There are 2 types of receiver:
• Non-coded: this is the standard product. If used in conjunction with a coded transmitter, it
may provide an incorrect heart rate reading;
• Coded: this is the product which, utilizing Personal Coded Device technology, receives
the heart rate together with a code that identifies the transmitter in question. In this way
the machine can identify the source of the heart rate signal, thereby avoiding interference
problems.
Its reception area is approximately a circle of 1 meter of radius. If there is electromagnetic
noise (produced by high voltage lines, radio transmitters, monitors, motors, etc.) within its
reception area, the receiver becomes saturated and stops receiving any signal. If it is noncoded and there are 2 transmitters within its area of reception, it will receive signals from
both, and may produce an error or irregular reading.
(3) DISPLAY
This is the heart of the machine, which controls all the machine functions by executing the
program stored in EPROM. It receives information from the user (age, weight, etc.) during
set-up of the training session, from the cardio receiver (user’s heart rate) and from the
alternator interface board for displaying workload data (Watt and SPM). It controls the
difficulty level selected with the “+” “−” keys or according to the chosen training program.
It consists of 2 circuit boards:
• CPU board: contains the microprocessor, and all the logic circuits for controlling the
machine and the LCD;
• LED board: contains the circuits pertaining to the display and indicators: LEDs and 7-
segment display.
The CPU board contains 2 banks of 4 dip-switches one and 2 dip-switches the other, which
are used for configuring the machine.
On the CPU boards of TGS adapted machines there is a jumper J2 which sets the transmission
mode of the serial port.
• J2 in position 1-2: sets the RS 485 serial port in full duplex mode;
• J2 in position 2-3: sets the RS 485 serial port in half duplex mode.
(4) POWER SUPPLY
Receives the mains voltage at its input and outputs the DC voltages (+5 Vdc, +12 Vdc and
−12 Vdc) which supply the display and the alternator interface board.
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(5) ALTERNATOR INTERFACE BOARD
Receives from the display a square-wave signal whose frequency is proportional to the
selected level of difficulty, and sends it to the alternator. Receives the RPM signal from the
alternator, which it filters and sends to the display for calculating the speed of exercise (SPM).
(6) ALTERNATOR
Is put into rotation by the user, and generates a resistance to the movement proportional to the
excitation voltage received from the alternator interface board. It also generates the RPM
signal (6 pulses per revolution) necessary for counting the number of revolutions and hence
measuring the speed. Its rotation produces energy which is dissipated by the power resistor.
Starting from the model manufactured by MAGNETI MARELLI, the excitation
circuit is equipped with a series-connected thermal cutout, which is normally
closed and opens when the temperature exceeds an established threshold.
(7) POWER RESISTOR
Has the function of dissipating the energy produced by the alternator.
(8) SELECTION KNOB
This knob is used for selecting the stepping mode:
• mode A: independent stepping motion. The user must maintain a “floating” position by
moving the pedals at a rate which depends on the difficulty level of the workout.
• mode B: dependent stepping motion. When one pedal goes up the other comes down and
vice versa. The user must move the pedals at the speed indicated by a pacer, which
determines the difficulty level of the workout.
The selection knob operates a microswitch:
• mode A: the knob is in the “out” position and the microswitch is in its normal released
state. In this condition the electrical contact is closed.
• mode B: the knob is pushed “in” and the microswitch lever is pressed. In this condition
the electrical contact is open.
By reading the state of the microswitch signal, the machine is able to detect the selected
stepping mode and control the resistance accordingly.
The microswitch is installed on machines starting from SN 206.
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3.2. ALTERNATOR CONTROL
3.2.1. MECHANICS
The movement of the pedals imparts a rotation to the primary shaft via the chain connected to the 2
pedals. The chain turns on a sprocket which is attached to a slide that can move up and down along
2 guide bars. The other side of the slide is connected to 2 springs which provide an elastic
connection between the slide and the machine frame.
The primary shaft is coupled to the secondary shaft by means of a chain, and the secondary shaft is
coupled to the alternator by means of a belt. In this way, the movement of the pedals is transmitted
to the alternator.
The stepping mode selection knob determines the type of movement of the slide:
• mode A: the slide is free to move, with the springs acting as dampers. The downward movement
of a pedal causes a downward movement of the slide, which is damped by the action of the
springs. In this way neither pedal is affected by the changes in position of the other pedal.
• mode B: the slide is locked into place and the springs are not in use. The downward movement
of one pedal causes the upward movement of the other due to the fixed length of the chain.
3.2.2. CONTROL
To control the difficulty level of the workout, the machine adjusts the excitation of the alternator
which generates a resistance to the movement that is proportional to the excitation level. To do this,
the CPU board transmits a PWM (Pulse Width Modulation) signal to the alternator interface board
which the alternator interface board passes directly to the alternator itself. The alternator filters the
incoming PWM signal to extract its dc component: in other words, the alternator sees the PWM
signal as an analog voltage. The higher this voltage (corresponding to a duty cycle of the PWM
signal close to 100%), the higher the alternator excitation signal will be and hence the greater the
resistance.
The alternation rotates in the field produced by the excitation signal, generating electrical energy
which is dissipated by the power resistor.
The rotation of the alternator also generates a square wave signal proportional to its speed, with 6
pulses corresponding to one complete rotation of the alternator. This signal enters on the interface
alternator board where it is filtered and sent to the CPU board.
If the CPU board does not receive the speed signal, which means that the alternator is
not rotating, it does not transmit any PWM signal. Therefore the alternator does not
receive the excitation signal and there is no resistance at all.
The alternator control differs depending on the selected stepping mode:
• mode A: In this stepping mode, the user moves at a constant speed (which increases with
increasing difficulty level) in order to maintain a “floating” position on the pedals. By using the
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RPM
Resistor
alternator speed signal as a feedback signal, the CPU board adjusts the excitation PWM signal
so as to maintain a constant speed (closed loop control).
• mode B: In this stepping mode, the user can choose between 3 different resistance levels
(WEAK, MEDIUM and STRONG), while the difficulty level setting determines the target speed
to be maintained. In this case, the CPU board sets one of 3 different values for the PWM
excitation signal as a function of the selected resistance level, independently of the selected
difficulty level (open loop control).
3.2.3. THE CONTROL SIGNALS
The machine controls the difficulty level of the workout by means of the CPU board, the alternator
interface board and the alternator, as illustrated in the figure below:
8-3 6-3 5-3 CN1
micro
8-3 6-3 5-3 CN1
Alternator interface
5-6 4-5
Microswitch
Alternator
The following signals are involved in the control loop:
• Microswitch signal
This is the microswitch contact which detects the position of the selection knob and hence the
chosen stepping mode. The contact is closed if the selection knob is released in the “out”
position, and open if the knob is pushed in.
This signal reaches the alternator interface board (pin 5-6 of connector CN2) and is logic level
high (5 Vdc) if the knob is pushed in, and logic level low (0 Vdc) if the selection knob is
released. The signal is output (pin 8-3 of connector CN1) to the CPU board (pin 8-3 of
connector CN1).
CPU board
PWM
board
PWM
RPM
1-5 CN2
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• Excitation signal (PWM)
This is the signal generated by the CPU board (pin 6-3 of connector CN1) for controlling the
resistance. It is a PWM signal, i.e. a fixed frequency square wave signal with variable duty
cycle. The logic of this control causes the duty cycle to increase with increasing resistance.
Measuring the dc component of this signal with a multimeter shows a value which increases
with increasing resistance, from a minimum of a few hundred mVdc to approximately 5 Vdc.
This signal enters the alternator interface board (pin 6-3 of connector CN1), and is sent to the
alternator (pin 4-5 of connector CN2 on the alternator interface board) to supply its rotor via the
brushes.
• RPM Signal
This is the speed signal output by the alternator. It enters the alternator interface board (pin 1-5
of connector CN2) and is a square wave which varies from –1 Vdc to a maximum value
dependent on the training speed, as illustrated in the figure below:
The signal is cleaned and level-converted before being sent from the alternator interface board
(pins 5-3 of connector CN1) to the CPU board (pins 5-3 of connector CN1) as a square wave
which varies between 0 and 5 Vdc, as illustrated in the figure below:
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4. ACCESSORIES
4.1. CONNECTING TO THE TGS
The machine can be connected to the Technogym System by installing a special upgrade kit, which
involves the following:
• Installation of a special SW;
• Installation of special cables, for providing – through a 9-pin D-connector at the back of the
display – the half duplex RS 485 serial port for connecting to the TGS reader.
The CPU board is connected to the serial connector via the cable described below, which is supplied
together with the upgrade kit.
4.1.1. TGS ADAPTED MACHINES
TGS adapted machines can be connected to the TGS reader using the RS 485 serial port of the CPU
board in half duplex mode. Install the special cable illustrated below to make this serial port
available on a 9-pin D connector at the back of the display.
TGSRN2RACE: Internal cable
Retrofit support flange – CPU board
CPU board
CN2
1 +12 Vdc Yellow 1
3 GND Green 5
7 -Serial Brown 3
8 +Serial White 2
Signal Color DB9 male
4.1.2. TGS NON-ADAPTED MACHINES
TGS non-adapted machines can be connected to the TGS reader using the full-duplex mode RS 485
serial port of the CPU board, available on the serial ports panel. Install the special kit – consisting of
a cable and a full-to-half duplex 485 serial protocol converter – to make available the half duplex
RS 485 port for the TGS reader on a 9-pin D connector at the back of the display.
In both cases, the TGS reader is of type 485.
For further information, including troubleshooting, refer to the manual “Technogym System:
Installation Manual”.
Page 4.1
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4.2. CONNECTING TO THE PRINTER
The machine is pre-set for printing via the full duplex RS 485 port available on the serial ports
panel.
If the machine is equipped with Technogym System SW, the print function is not
available.
The printer is connected using a special cable, which can be ordered using code A419. This cable is
equipped with an RS 485 to RS 232 serial converter. The printer connection diagram is as follows:
WARNING: In order to enable the print function, the 4 dip-switches of the right-hand
group must be set as indicated in paragraph 9.1. .
The printer used must conform to the following specifications:
• equipped with RS 232 serial port;
• 80 characters;
• 8 data bits;
• 1 stop bit;
• 9600 baud;
• no parity;
• ASCII characters.
Page 4.2
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5. INSTALLATION INSTRUCTIONS
5.1. SPECIFICATIONS AND REQUIREMENTS
For correct machine installation, make sure that:
1. The machine is installed on a level surface that is free of vibrations and has sufficient carrying
capacity for the combined weight of the machine and user.
2. The environment is dust or sand free.
3. The environment meets the operating temperature and humidity conditions specified in
paragraph 2.3. .
4. The machine is not positioned close to sources of heat, sources of electromagnetic noise
(television sets, electric motors, antennas, high voltage lines, appliances etc…) or medical
equipment.
5. To eliminate any interference with the cardio receiver, there should not be any transmitters at a
distance of 100 cm from the display.
6. The mains voltage must match the value specified on the machine rating plate.
7. The electrical system must be provided with an efficient ground connection.
8. The wall output 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 the same type in cascade, up to a maximum of 5 machines. In this case, make
sure that the wall output has a power rating of at least 300 Watt.
10. Position the mains lead of the machine where is will not be underfoot. For this purpose, it is
recommended to use the special trackways supplied with the machine.
5.2. INSTALLATION
To correctly install the machine, proceed as follows:
1. Ensure that the specifications and requirements for installation have been met (see paragraph
5.1. ).
2. Remove the machine from its packing materials: one carton fixed to a wooden pallet for
overseas shipment, one nylon bag for Italy. On machines which are shipped in a carton, the
display is disassembled and placed on the machine inside the packing material.
3. 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 the user.
4. For machines shipped in a carton, it is necessary to reassemble the components that were
removed for transport. Carry out the procedure for reassembling described in the “User manual”
supplied with each machine.
5. Connect the mains lead to the input socket on the machine.
6. Place the on/off switch in the “0” position.
7. Plug the mains lead into the electrical output.
Page 5.1
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5.3. FIRST POWER-ON
After completing the installation procedure, the machine is ready to be powered up. To turn on the
machine, simply toggle the on/off switch from the 0 position to the 1 position.
When the machine is turned on it will perform a power-on test which:
• sounds the buzzer;
• lights all 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 SPM value displayed varies accordingly;
• check that the effort level varies when the “+” and “−” keys are pressed, and that the
corresponding difficulty level LEDs come on and off;
• change the position of the selection knob and check that the SW recognizes the selected
stepping mode;
• put on the heart rate transmitter and check that the machine correctly measures the heart rate
value.
Page 5.2
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6. TROUBLESHOOTING
The troubleshooting procedures are shown in the form of flow charts. In order to facilitate
consultation, the following standard box shapes are used.
This type of box is the START point of the troubleshooting procedure. It
typically contains a description of the problem or malfunction.
This type of box represents a decision point in the troubleshooting procedure.
It typically contains a description of the CHECK to be made, with an outcome
that can be either a positive (YES) or negative (NO) response.
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 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 shown on the left) next to a box of the
troubleshooting procedure indicates that detailed instructions for performing
that particular check or action are provided below the flowchart.
A circled letter (such as that shown on the left) is used to highlight a point in
the procedure. Typically, this indicator is used in page changes.
Page 6.1
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6.1. THE DISPLAY DOES NOT ILLUMINATE
This error occurs when the supply voltage fails to reach the display.
THE DISPLAY
DOES NOT
ILLUMINATE
Are the fuses OK?
YES
Is the mains lead OK?
YES
Does the wall output supply the
correct voltage?
YES
NO
NO
NO
1
Replace the blown
fuses
Replace the mains lead
Connect machine to a
suitable
electrical output
NO
2
Replace the input
socket / on-off
switch block of the
machine
Is the mains voltage present at
the power supply input?
NO
Is the mains voltage present
at the output of the power
input socket?
YES
Replace cable ST-3
A
YES
Continued on the following page.
Page 6.2
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A
3
Are DC voltages output by the
power supply correct?
YES
Do all DC voltages reach the
display?
NO
Do all DC voltages reach the
alternator interface board?
NO
Replace the power
supply
4
YES
Replace the CPU board
5
NO
Replace cable ST-6
YES
6
Are all DC voltages present at
the output of the alternator
interface board?
NO
Replace the alternator
interface board
YES
Replace cable ST-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) Disconnect connector CN1 from the power supply. Place the tester probes on pins 4 and 6 of
the connector. The measured voltage should be approximately 220 VAC or 110 VAC
depending on the mains electricity supply.
Page 6.3
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(2) As for step (1) but with the tester between terminals L1 and N1 of the input socket / on-off
switch block.
(3) Slightly lift connector 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 2.5.2.
“Wiring”.
(4) As for step (3) but on connector CN1 of the display CPU board.
(5) As for step (3) but on connector CN3 of the alternator interface board.
(6) As for step (3) but on connector CN1 of the alternator interface board.
Page 6.4
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6.2. THERE IS NO RESISTANCE
This error can be caused by absence of the speed signal, problems with the excitation circuit,
overheating of the alternator or defective alternator brushes.
THERE IS NO
RESISTANCE
Are the Watt and RPM
values shown on the display
different from zero?
NO
Execute the procedure
"The RPM signal is
incorrect"
YES
1
Is the alternator excitation
YES
circuit ok?
Execute the procedure
"The resistance is
incorrect"
NO
Allow it to cool down and
then try again. The
thermal cutout is probably
tripped.
Replace the brushes
NO
Is the alternator
overheated?
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:
(1) Disconnect the orange cable (excitation) from the alternator. Place the tester probes between
the point where it was connected and the black cable. The measured resistance should be
approximately 4 Ohm.
Page 6.5
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6.3. THE RESISTANCE IS INCORRECT
The resistance is incorrect if the alternator does not receive the correct excitation signal or if the
power resistor is defective.
THE
RESISTANCE IS
INCORRECT
1
Is the alternator excitation
voltage correct?
NO
Is the excitation voltage
output by the alternator
interface board correct?
NO
Is the power resistor value
correct?
YES
YES
Replace the alternator
2
YES
Check and/or replace
cable BX-5
3
NO
Replace the power
resistor
4
Does the alternator interface
board receive the correct
control signal?
YES
Replace the alternator
interface board
NO
5
Replace the cable
between the CPU board
and the panel connector
YES
Does the CPU board send
the correct control signal to
the alternator interface
board?
NO
Replace the alternator
interface board
Page 6.6
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The operation of this machine is such that the braking resistance is higher for level 1
than for 12. This is because the user does not work to push against the pedals, but rather
must "float" by shifting his or her weight from one pedal to the other as each pedal
starts to descend. Consequently, the braking resistance is higher at level 1 in order to
produce a slower rate of descent and hence a lower stepping speed with respect to level
12 where, with the braking resistance virtually zero, the user must step at high speed in
order to continue floating on the pedals.
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) Place the tester probes between the orange (positive) and black (negative) cables on the
alternator. Select the “Manual Training” function on the display and start exercising on the
machine. When the level of difficulty is varied, maintaining the speed indicated in Table
6.3-1, the excitation voltage should vary as shown in the same table:
LEVEL OF
RESISTANCE
EXCITATION VOLTAGE
(Vdc)
Alternator
Alternator interface board
4-5/CN2 6-3/CN1
PWM SIGNAL
(Vdc)
CPU board
6-3/CN1
WEAK 0.4 0.4 4.75 4.75
MEDIUM 1.55 1.55 4.10 4.10
STRONG 3.2 3.2 3.40 3.40
Table 6.3-1
The voltages quoted above are nominal values.
(2) As for step (2) but with the tester between pins 4 and 5 of connector CN2 on the alternator
interface board.
(3) Disconnect all the cables from the 2 power resistor terminals. Place the tester probes on the 2
terminals and measure the value of the resistance. The correct value for the power resistor is
approximately 0.5 Ω.
BE AWARE: Because all tester probes have a non zero internal resistance, which varies
depending on the model and may be in the same order of magnitude as the quantity
being measured, the following procedure is recommended:
1. Measure the internal resistance of the probes by short-circuiting them with each
other;
2. Measure the resistance of the power resistor.
3. The true resistance value is obtained by subtracting the short-circuit resistance
of the probes from the measured value.
(4) As for step (2) but with an oscilloscope between pins 6 and 3 of connector CN1 on the
alternator interface board.
Page 6.7
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(5) As for step (5) but with the oscilloscope between pins 6 and 3 of connector CN1 of the display
CPU board.
Page 6.8
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6.4. THE SPM VALUE IS INCORRECT
This error occurs when there are problems with the RPM signal output by the alternator.
THE SPM VALUE IS
INCORRECT
1
Is the SPM wire of cable
ST-5 correctly connected to
the alternator?
YES
Is the SPM signal output
correctly by the alternator?
YES
Is the SPM signal on connector
CN2 of the alternator interface
board correct?
NO
Rewire the cable
correctly
2
NO
Replace the alternator
3
NO
Replace/rewire cable
ST-5
YES
4
Is the SPM signal on
connector CN1 of the
alternator interface board
correct?
NO
Replace the alternator
interface board
YES
5
Replace the CPU board
YES
Is the SPM signal on
connector CN1 of the CPU
board correct?
NO
Replace cable ST-1
Page 6.9
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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 whether the black and violet wires, which connect the alternator to pins 1 and 5 of CN2
on the alternator interface board, are correctly connected.
(2) Place the probes of an oscilloscope between the violet wire and the alternator ground. When
the speed is varied, the waveform frequency should vary as shown in the table below:
SPM FREQUENCY
(Hz)
60 187
70 218
80 249
(3) As for step (2) but with the oscilloscope probes between pins 1 (probe) and 5 (ground) of
connector CN2 on the alternator interface board.
(4) As for step (2) but with the oscilloscope probes between pins 5 (probe) and 3 (ground) of
connector CN1 on the alternator interface board.
(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 6.10
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6.5. THE MACHINE DOES NOT PRINT
This error occurs when there are HW problems, or if the machine has not been configured correctly.
Always check that the printer itself is working correctly first.
THE MACHINE
DOES NOT
PRINT
1
Replace or rewire the printer
cable
NO
Is the machine correctly configured for
printing?
YES
Does the signal reach the output of
the printer cable correctly?
NO
Is the printer cable OK?
NO
2
YES
3
YES
Correctly configure the
machine
There is a problem with the
printer or the PC serial port
or their respective
configurations
Replace the CPU board
Follow the step by step procedure to correctly diagnose the problem. Take particular care with the
checks highlighted by circled numbers, which are described in detail below:
(1) Open the display and configure the 4 dip-switches as indicated in the paragraph 9.1. “Machine
HW configuration”.
(2) This check is carried out using the RS-232 tester.
Page 6.11
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Connect the tester to the output connector of printer cable A419, and connect the other end to
the machine. Choose any workout program: as soon as the last value entered has been
confirmed, the workout starts and the machine immediately transmits the data via the serial
port. The RD LED should blink red.
(3) Using a tester, check the continuity of printer cable A419. See paragraph 4.2. “Connecting to
the printer”.
Page 6.12
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6.6. THE MACHINE FAILS TO READ THE STEPPING MODE
This error occurs when there are HW problems with the microswitch or its signal.
THE MACHINE DOES NOT
READ THE STATE OF THE
MICROSWITCH
1
Does the selection knob press
the microswitch lever?
YES
Is the microswitch working
properly?
YES
Does the microswitch signal
reach the input on the
alternator interface board?
YES
NO
Adjust the position of
the selection knob and
microswitch
2
NO
Replace the
microswitch
3
NO
Replace cable ST-5M
4
Does the microswitch signal
reach the output of the
alternator interface board?
NO
Replace the alternator
interface board
YES
5
Replace the CPU board
YES
Does the microswitch signal
reach the input on the CPU
board?
NO
Replace cable SP-1
Follow the step by step procedure to correctly diagnose the problem. Take particular care with the
checks highlighted by circled numbers, which are described in detail below:
(1) Move the stepping mode selection knob and check whether the microswitch changes state.
Page 6.13
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(2) Place the tester probes on the microswitch terminals and check that, when the selection knob
is moved, the microswitch changes state from open to closed and vice versa.
The microswitch contact is NC for stepping mode A, and NO for stepping mode B.
(3) Place the tester probes between pin 6 of connector CN2 on the alternator interface board and
the ground node, and check that moving the selection knob toggles the signal between 0 and 5
Vdc.
(4) Place the tester probes between pins 8 and 3 of connector CN1 on the alternator interface
board, and check that moving the selection knob toggles the signal between 0 and 5 Vdc.
(5) Place the tester probes between pins 8 and 3 of connector CN1 on the CPU board, and check
that moving the selection knob toggles the signal between 0 and 5 Vdc.
Page 6.14
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6.7. THE MACHINE DOES NOT OPERATE IN MASTER - SLAVE
MODE
This error is due to problems on the Master - Slave control signal.
THE MACHINE DOES
NOT OPERATE IN
MASTER - SLAVE MODE
1
Is the Master-Slave signal at the
output of the CPU board
correct?
YES
Is the Master-Slave signal at the
input to the alternator interface
board correct?
YES
Does the relay on the
alternator interface board
switch when the
Master-Slave signal changes
state?
YES
NO
Replace the CPU
board
2
NO
Replace cable ST-1
3
Replace the alternator
NO
interface board
4
Are the signals output by the
serial port on the alternator
interface board correct?
NO
A
YES
5
Replace the serial ports
YES
Is cable ST-8 connected
correctly?
NO
Replace cable ST-8
Page 6.15
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A
6
Replace cable ST-1
YES
Are the signals output by the
serial port on the CPU board
correct?
NO
Replace the CPU board
Follow the step by step procedure to correctly diagnose the problem. Take particular care with the
checks highlighted by circled numbers, which are described in detail below:
Disconnect any race cables linking the machines before performing these checks.
The machine is configured as MASTER if it is assigned No. 1, and as SLAVE if it is
assigned any other number.
(1) Place the tester probes between pins 10 and 3 of connector CN1 on the CPU board, and check
that the reading is 5 Vdc when the machine is configured as MASTER, and 0 Vdc when the
machine is configured as SLAVE.
(2) Place the tester probes between pins 10 and 3 of connector CN1 on the alternator interface
board and check that the reading is 5 Vdc when the machine is configured as master, and 0
Vdc when the machine is configured as SLAVE.
(3) After changing the state of the Master – Slave signal, when the machine is turned back on
check that the relay switches by listening for its typical “clicking” sound.
(4) Place the tester probes between the pins of connector CN4 on the alternator interface board
and check that the measured voltages are those given in the table below:
Signal CN1
CPU board
Alternator interface
board
Voltage
(Vdc)
CN1 CN4 Master Slave
A – bus 14-3 14-3 3-7 3.7 3.7
B – bus 15-3 15-3 4-7 0.8 0.8
Y – bus 11-3 11-3 1-7 3.7 3.7
Z – bus 12-3 12-3 2-7 0.8 0.8
Table 6.7-1
(5) Check the cable by following the diagram in paragraph 2.5. “Wiring diagram”.
(6) Place the tester probes between the pins of connector CN1 on the CPU board and check that
the measured voltages are the same as those given in Table 6.7-1.
Page 6.16
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6.8. THERE IS NO HEART RATE SIGNAL
This error occurs when the receiver is not working or when it does not receive the power supply
from the CPU board.
THERE IS NO
CARDIO SIGNAL
1
Is the supply voltage on the
receiver connector correct?
NO
Is the supply voltage on
connector CN3 of the CPU board
correct.
NO
Replace the display CPU
board
YES
Replace the receiver
2
YES
Replace or repair cable
ST-7
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) Place the tester probes between pins 1 (signal) and 3 (ground) (corresponding to the red and
black wires) of the 4-pin cardio receiver connector: the voltage should be +5 Vdc.
(2) Place the tester probes between pins 1 (signal) and 3 (ground) (corresponding to the red and
black wires) of connector CN3 on the display CPU board: the voltage should be +5 Vdc.
Page 6.17
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6.9. THE HEART RATE SIGNAL IS INCORRECT
The machine displays this message when the receiver is disturbed by electromagnetic noise in the
surrounding environment. In some cases, the machine may show the message “Err” on the heart rate
display.
THE HEART RATE
SIGNAL IS
INCORRECT
Is the minimum distance
between machines OK?
YES
Is the receiver positioned
correctly, and are the
connecting cables correctly
routed?
YES
If the TGS is present, is the
TGSRN2RACE cable correctly
routed?
NO
Move the machines to
the minimum distance:
see paragraph 5.1.
NO
Position the receiver and
the cable correctly: see
paragraph 11.1
NO
Correctly route the cable:
see paragraph 11.1.
YES
1
Are there sources of
electromagnetic noise near
the receiver?
Move the machine away
YES
from the electromagnetic
source or attenuate the
power of the noise: see
paragraph 11.1.
NO
A
Continued on the following page.
Page 6.18
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A
2
Is the transmitter in good
working order?
YES
Is the transmitter always
within a distance of 80 cm
from the receiver?
YES
Change the receiver
NO
NO
Use a known good
transmitter
Keep the transmitter
within the minimum
reception distance
Follow the procedure step by step to correctly diagnose the problem. Take particular care with the
checks highlighted 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 lights the LED for every heart beat and/or disturbance that is received: in this way
it possible to determine whether there is any interference, and identify its sources.
(2) Check the battery power level, using a tester if possible. Otherwise use a receiver or another
“reference” machine to check operation up to a distance of about 80 cm from the receiver.
Consult paragraph 11.1. “Technical notes on cardio receivers” in the Appendix.
Page 6.19
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Page intentionally left blank
Page 6.20
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7. DISASSEMBLY OF COMPONENTS
7.1. DISASSEMBLING THE DISPLAY
1. Turn off the machine and unplug the mains
lead from the wall outlet.
2. Back off the 3 screws a using a 4-mm hex T
wrench.
Figure 7.1-1
3. Back off the 2 screws b using a medium
Philips screwdriver.
Support the DISPLAY before removing
the last screw.
Figure 7.1-2
Continued on the following page →
Page 7.1
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4. Open the DISPLAY.
To remove the DISPLAY:
1. Disconnect connector c.
2. Remove the DISPLAY.
To reassemble the DISPLAY, carry out the
above steps in reverse order.
Figure 7.1-3
Page 7.2
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7.2. DISASSEMBLING THE EPROM
1. Turn off the machine and unplug the mains
lead from the wall outlet.
2. Back off the 4 fixing screws a of the
protective cover using a small Philips
screwdriver.
3. Remove the protective cover.
The older model of protective cover is
Figure 7.2-1
fixed to the display with only 2 screws.
Figure 7.2-2
Figure 7.2-3
4. Remove the EPROM b from its socket using
an IC extractor tool.
To reassemble the EPROM:
1. Make sure that reference index c on the
EPROM coincides with reference notch d on
the socket.
2. Be careful to center the EPROM pins above
the corresponding holes in the socket.
3. Push the pins into the socket.
The EPROM can be irreversibly
damaged if the reference index on the
EPROM is not correctly aligned with the
notch on the socket, or if its pins are
bent.
Page 7.3
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7.3. DISASSEMBLING THE CPU BOARD
1. Turn off the machine and unplug the mains
lead from the wall outlet.
2. Back off the 4 fixing screws a of the
protective cover using a small Philips
screwdriver.
3. Remove the protective cover.
Figure 7.3-1
Figure 7.3-2
Carry out the procedures described in paragraph
7.1. “Disassembling the display”.
With the display placed on a work bench:
4. Back off the 13 screws b, using a small
Philips screwdriver.
5. Pushing against the screw studs with a
pointed tool, use a flat-blade screwdriver to
separate outer housing c from the keyboard –
electronic circuit boards group d.
6. Disconnect the cardio receiver cable from the
connector.
Figure 7.3-3
Continued on the following page →
Page 7.4
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Figure 7.3-4
Figure 7.3-5
Rest the keyboard – electronic circuit boards
group on a work bench:
7. Disconnect connectors e.
8. Back off the 6 studs f using a 7-mm wrench.
9. Separate the CPU board g from the LED
board h by flipping it over toward the left,
being careful not to damage cable strip i.
10. Manually disconnect the cable strip i from
the CPU board.
11. Remove the circuit boards.
12. To disconnect the LCD from the CPU board,
back off the 4 screws l using a small Philips
screwdriver, or release the 4 spring fasteners.
13. Disconnect or unsolder the cables on the
CPU board side.
14. Remove the LCD.
To reassemble the circuit boards, carry out the
above steps in reverse order.
Page 7.5
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7.4. DISASSEMBLING THE KEYBOARD
1. Turn off the machine and unplug the mains
lead from the wall outlet.
2. Back off the 4 fixing screws a on the
protective cover using a small Philips
screwdriver.
3. Remove the protective cover.
Figure 7.4-1
Figure 7.4-2
Carry out the procedures described in paragraph
7.1. “Disassembling the display”.
With the display placed on a work bench:
4. Back off the 13 screws b, using a small
Philips screwdriver.
5. Pushing against the screw studs with a
pointed tool, use a flat-blade screwdriver to
separate the outer housing c from the
keyboard– electronic circuit boards group d.
6. Disconnect the cardio receiver cable from the
connector.
Figure 7.4-3
Continued on the following page →
Page 7.6
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STEPRACE: Service & Maintenance Manual - rev. 1.2
Figure 7.4-4
Rest the keyboard – electronic circuit boards
group on a work bench:
7. Unplug the keyboard connector.
8. Use a sharp tool to lift up a corner of the
KEYBOARD and detach it.
To reassemble the new KEYBOARD, with the
display placed on a work bench:
1. Remove the backing film which protects the
adhesive.
2. Apply the adhesive part, starting from the left
and working toward the right, being careful
not to bend the KEYBOARD.
3. Insert the connector on the CPU board.
4. Remove the protective film.
5. Reassemble the display.
When reassembling the KEYBOARD,
be careful to ensure that none of the
keys are bent or remain pushed in.
The KEYBOARD assembly procedure
can only be carried out once, because
disassembly damages the tracks and the
keys.
Page 7.7
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7.5. DISASSEMBLING THE CARDIO RECEIVER
1. Turn off the machine and unplug the mains
lead from the wall outlet.
If the receiver is positioned under the display:
2. Use a flat blade screwdriver to open the box
a which contains the RECEIVER.
Figure 7.5-1
Figure 7.5-2
If the receiver is positioned inside the display:
3. Use a flat blade screwdriver to detach the box
b which contains the RECEIVER.
4. Open the box.
5. Disconnect connector c on cable ST-7 from
the RECEIVER.
6. Remove the RECEIVER.
To reassemble the RECEIVER, carry out the
above steps in reverse order, positioning it
between the 2 foam pads.
Figure 7.5-3
Page 7.8
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7.6. DISASSEMBLING THE UPRIGHT GUARD
1. Turn off the machine and unplug the mains
lead from the wall outlet.
2. Back off the 4 fixing screws a on the
UPRIGHT GUARD, using a large Philips
screwdriver.
Figure 7.6-1
3. Remove the UPRIGHT GUARD.
To reassemble the UPRIGHT GUARD, carry out
the above steps in reverse order.
Figure 7.6-2
Page 7.9
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7.7. DISASSEMBLING THE ELECTRONIC CIRCUIT BOARDS
Carry out the procedures described in paragraph
7.6. “Disassembling the upright guard”.
1. Back off the 4 screws a using a medium
Philips screwdriver.
2. Remove the protective grill from the circuit
boards.
Figure 7.7-1
Figure 7.7-2
To disassemble the POWER SUPPLY b:
3. Disconnect the 2 connectors CN1 and CN2.
4. Back off the 4 screws which fix the board to
the plate support, using a 7-mm socket
wrench.
5. Remove the circuit board.
To disassemble the ALTERNATOR
INTERFACE BOARD c:
1. Disconnect the 4 connectors CN1, CN2, CN3
and CN4.
2. Back off the 4 screws which fix the board to
the plate support using a 7-mm socket
wrench.
3. Remove the circuit board.
To disassemble the POWER RESISTOR
positioned on the rear side of the plate support:
1. Back off the 2 nuts securing cable ST-5 using
a 7-mm wrench.
2. Back off the 2 nuts securing the resistor using
a 10-mm wrench.
3. Remove the resistor.
To reassemble the ELECTRONIC CIRCUIT
BOARDS, carry out the above steps in reverse
order.
Page 7.10
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of the SIDE
7.8. DISASSEMBLING THE SIDE GUARDS
1. Turn off the machine and unplug the mains
lead from the wall outlet.
2. Select stepping mode B (dependent stepping
motion).
On either side of the machine:
3. Back off the 5 fixing screws a
GUARD, using a large Philips screwdriver.
4. Pull the SIDE GUARD upward to remove it.
The SIDE GUARDS are attached to the
machine frame with a strip of adhesive
tape.
To reassemble the SIDE GUARD, carry out the
above steps in reverse order.
Figure 7.8-1
Page 7.11
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7.9. DISASSEMBLING THE CHAIN GUARD
Carry out the procedures described in paragraph
7.8. “Disassembling the side guards”.
1. Working on the right pedal, back off the
screw a which fixes the pedal to the ball joint
using a 17-mm socket wrench.
2. Lower the pedal to the ground.
3. Repeat the same procedure on the left pedal.
Figure 7.9-1
4. On each side of the machine, back off the 2
screws b using a 5-mm hex wrench.
5. Pull the CHAIN GUARD upward to remove
it.
On old machines, the CHAIN GUARD
was fixed to the base with a screw that
can be accessed by turning the machine
over on one side.
To reassemble the CHAIN GUARD, carry out
the above steps in reverse order.
Figure 7.9-2
Page 7.12
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7.10. DISASSEMBLING THE HANDLEBARS
Carry out the procedure described in paragraph
7.6. “Disassembling the upright guard”.
For each SIDE HANDLEBAR:
1. Back off the 2 screws a using a 17-mm
wrench.
2. Remove the HANDLEBAR.
The SIDE HANDLEBARS can be
inverted.
For the CENTER HANDLEBAR:
Figure 7.10-1
1. Disassemble the 2 SIDE HANDLEBARS.
2. Remove cable ST-1 from the CENTER
HANDLEBAR.
3. Remove the CENTER HANDLEBAR.
To reassemble the HANDLEBARS, carry out the
above steps in reverse order.
Page 7.13
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7.11. DISASSEMBLING THE PEDAL JOINT
Turn off the machine and unplug the mains lead
from the wall outlet.
1. Select stepping mode B (dependent stepping
motion).
Working from both sides:
2. Align the pedals.
3. Raise one pedal and back off the screw a
which fixes the PEDAL JOINT to the chain
of the other pedal, using a 17-mm socket
wrench.
4. Manually unscrew the PEDAL JOINT.
To reassemble the PEDAL JOINT, carry out the
above steps in reverse order.
Figure 7.11-1
Page 7.14
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7.12. DISASSEMBLING THE PEDALS AND PEDAL GROUP
Turn off the machine and unplug the mains lead
from the wall outlet.
1. Select stepping mode B (dependent stepping
motion).
Working from both sides:
2. Remove the protective cap a.
3. Back off the screw underneath the cap using
Figure 7.12-1
17-mm wrench.
Figure 7.12-2
To disassemble the bracket:
4. Back off the 4 nuts b which fix the bracket c
to the PEDAL, using a 13-mm wrench.
5. Remove the bracket c.
To disassemble only the PEDAL:
6. Rotate the PEDAL.
7. Back off the screw d which fixes the PEDAL
GROUP pivot to the lever, using a 6-mm hex
T wrench.
Figure 7.12-3
Continued on the following page →
Page 7.15
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STEPRACE: Service & Maintenance Manual - rev. 1.2
8. Using a T wrench and a rubber mallet,
remove the PEDAL GROUP pivot from the
lever.
9. Remove the PEDAL GROUP.
To reassemble the PEDAL GROUPS, carry out
the above steps in reverse order.
Align the fixing hole of the PEDAL
GROUP pivot with the corresponding
hole on the PEDAL GROUP.
Figure 7.12-4
To reassemble the PEDALS, carry out the above
steps in reverse order.
Page 7.16
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7.13. DISASSEMBLING THE PEDAL CONNECTING RODS
Carry out the procedures described in paragraph
7.8. “Disassembling the side guards”.
Working from both sides:
1. Remove the protective cap a.
2. Back off the screw underneath the cap using
a 17-mm wrench.
3. Back off screw b using a 17-mm wrench.
4. Remove the CONNECTING ROD.
To reassemble the PEDAL CONNECTING
RODS, carry out the above steps in reverse
order.
Figure 7.13-1
Before reassembling the CONNECTING
RODS, lubricate the bushings with a
thin layer of chain grease.
Page 7.17
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7.14. DISASSEMBLING THE LEVERS
Carry out the procedures described in paragraphs
7.8. “Disassembling the side guards”, 7.11.
“Disassembling the pedal joint” up until step 3.,
7.12. “Disassembling the pedals and pedal
group” and 7.13. “Disassembling the pedal
connecting rods”.
1. Select training mode B (dependent stepping
motion).
On both sides of the machine:
2. Back off the screw a using a 17-mm wrench.
3. Remove the LEVER and its bearings using
Figure 7.14-1
the appropriate extractor tool.
To reassemble the LEVERS, carry out the above
steps in reverse order.
Page 7.18
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7.15. DISASSEMBLING THE PEDAL CHAINS
Carry out the procedures described in paragraphs
7.6. “Disassembling the upright guard”, 7.8.
“Disassembling the side guards” and 7.9.
“Disassembling the chain guard”.
1. Select stepping mode B (dependent stepping
motion).
To disassemble the PEDAL CHAINS, on both
ends of the CHAIN:
2. Release clip a from the link using the special
pliers.
3. Remove the connecting plate b.
4. Remove the connecting link c.
5. Remove the CHAINS:
• Those on the long stretch (CHAINS
connected to the levers) must be removed
from the front of the machine, whilst
Figure 7.15-1
To reassemble the CHAINS, carry out the above
steps in reverse order.
manually accompanying the trailing end.
• Those on the short stretch (SLIDE
CHAIN) must be removed from the
sprocket.
Page 7.19
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7.16. DISASSEMBLING THE PRIMARY SHAFT - SECONDARY
SHAFT CHAIN
Carry out the procedures described in paragraphs
7.8. “Disassembling the side guards” and 7.9.
“Disassembling the chain guard”.
1. Turn the CHAIN until the connecting link a
is on the sprocket wheel of primary shaft b.
2. Release clip c from the link using the special
pliers.
3. Remove the connecting plate d.
4. Remove the connecting link a.
5. Remove the CHAIN.
To reassemble the CHAIN, carry out the above
steps in reverse order.
After completing this procedure, adjust
Figure 7.16-1
the alignment and tension of the
PRIMARY SHAFT - SECONDARY
SHAFT CHAIN as described in
paragraphs 8.3. and 8.4. .
Page 7.20
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7.17. DISASSEMBLING THE PRIMARY SHAFT GROUP
Carry out the procedures described in paragraphs
7.11. “Disassembling the pedal joint” up until
disconnecting the chains from the levers and
7.16. “Disassembling the primary shaft -
secondary shaft chain ”.
1. Rest the pedal chains on the upper part of the
frame.
2. Back off the 4 screws a which fix the
PRIMARY SHAFT to the frame using a 17mm wrench.
3. Remove the PRIMARY SHAFT.
Figure 7.17-1
To disassemble the components of the
PRIMARY SHAFT, rest the group on a work
bench:
1. Back off the 2 dowels b which fix the
bearings to the primary shaft, using a 3-mm
hex T wrench.
2. Remove the components from the shaft.
To reassemble the PRIMARY SHAFT and its
components, carry out the above steps in reverse
order.
During reassembly, be careful to
maintain the correct direction of
rotation of the free wheels.
Figure 7.17-2
After completing the procedure, adjust
the alignment and the tension of the
PRIMARY SHAFT - SECONDARY
SHAFT CHAIN as described in
paragraphs 8.3. and 8.4. .
Page 7.21
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7.18. DISASSEMBLING THE PRIMARY DRIVE SPROCKETS
Carry out the procedures described in paragraphs
7.8. “Disassembling the side guards” and 7.9.
“Disassembling the chain guard”.
On each side of the machine:
1. Back off the lock nut a using a 32-mm
wrench.
2. Lock down shaft b using an 8-mm hex T
wrench.
3. Remove shaft b, pulling out the DRIVE
SPROCKET.
To reassemble the DRIVE SPROCKET, carry
out the above steps in reverse order.
Figure 7.18-1
After completing the procedure, adjust
the alignment of the DRIVE
SPROCKET as described in paragraph
8.5. .
Page 7.22
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7.19. DISASSEMBLING THE SECONDARY DRIVE SPROCKETS
Carry out procedures described in paragraph 7.6.
“Disassembling the upright guard”.
On each side of the machine:
1. Select stepping mode B (dependent stepping
motion).
2. Back off dowel a using a 3-mm hex T
wrench.
Figure 7.19-1
3. Using a pointed tool and a rubber mallet,
push the pin on the left side until it comes out
on the right, gradually pulling out the
SPROCKETS and the spring.
To reassemble the DRIVE SPROCKETS, carry
out the above steps in reverse order.
Figure 7.19-2
Page 7.23
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7.20. DISASSEMBLING THE SLIDE DRIVE SPROCKET
Carry out the procedure described in paragraph
7.6. “Disassembling the upright guard”.
1. Select stepping mode B (dependent stepping
motion).
2. Back off screw a using a 22-mm wrench.
3. Remove the SLIDE DRIVE SPROCKET and
its spacers.
To reassemble the DRIVE SPROCKET, carry
Figure 7.20-1
out the above steps in reverse order.
Page 7.24
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7.21. DISASSEMBLING THE SECONDARY SHAFT
Carry out the procedures described in paragraph
7.16. “Disassembling the primary shaft -
secondary shaft chain ”.
1. Select stepping mode B (dependent stepping
motion).
2. Align the pedals.
3. Back off the nut a of the belt tension rod
using a 17-mm wrench.
Figure 7.21-1
Figure 7.21-2
Figure 7.21-3
4. Back off the dowel b using a 4-mm hex T
wrench.
5. Shift the alternator toward the pulley in order
to slacken belt c.
6. From both sides of the machine, back off the
lock nut d and lock down the SECONDARY
SHAFT adjusting screw e using a 13-mm
wrench.
7. Back off the 4 screws f which fix the
SECONDARY SHAFT to the frame, using a
17-mm wrench.
8. Remove the SECONDARY SHAFT, pulling
out belt g.
To reassemble the SECONDARY SHAFT, carry
out the above steps in reverse order.
Continued on the following page →
Page 7.25
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After completing the procedure, adjust
the alignment and tension of the belt and
of the primary shaft - secondary shaft
chain as described in the paragraphs
8.1. , 8.2. , 8.3. and 8.4. .
Page 7.26
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7.22. DISASSEMBLING THE BELT
Carry out the operations described in paragraph
7.8. “Disassembling the side guards”.
1. Back off the nut a of the belt tension rod
Figure 7.22-1
using a 17-mm wrench.
Figure 7.22-2
Figure 7.22-3
2. Back off the dowel b using a 4-mm hex T
wrench.
3. Shift the alternator toward the pulley in order
to remove the BELT c from the alternator
flywheel.
4. Remove the BELT d from the pulley on the
side opposite the chain.
5. Back off nut e and the secondary shaft
adjusting screw f using a 13-mm wrench.
6. Back off the 2 screws g which fix the
secondary shaft to the frame, using a 17-mm
wrench.
7. Back off the 2 screws h fixing the secondary
shaft to the frame using a 17-mm wrench.
8. Attempt to remove the BELT from the gap
created between the disassembled secondary
shaft support and the frame.
To reassemble the BELT, carry out the above
steps in reverse order.
Continued on the following page →
Page 7.27
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If the gap is not large enough for the
BELT to pass through, disassemble the
primary shaft - secondary shaft chain.
After completing the procedure, adjust
the alignment and tension of the belt as
described in paragraphs 8.1. and 8.2. .
Page 7.28
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7.23. DISASSEMBLING THE ALTERNATOR
Carry out the procedure described in paragraph
7.8. “Disassembling the side guards”.
1. Disconnect the ALTERNATOR cables.
2. Back off the nut a of the belt tension rod b
using a 17-mm wrench.
3. Back off the nut c fixing the belt tension rod
b to the machine frame using a 17-mm
wrench.
4. Back off the dowel d using a 4-mm hex T
wrench.
5. Shift the ALTERNATOR until belt e can be
Figure 7.23-1
removed.
6. Back off the lock nut of the alternator pin f
using a 19-mm wrench.
7. Back off the alternator pin f using an 8-mm
hex wrench. At the same time, back off and
fully remove the lock nut.
8. Remove the ALTERNATOR.
To reassemble the ALTERNATOR, carry out the
above steps in reverse order.
After completing the procedure, adjust
the alignment and tension of the belt as
Figure 7.23-2
described in paragraphs 8.1. and 8.2. .
Page 7.29
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7.24. DISASSEMBLING THE ALTERNATOR BRUSHES
Carry out the procedures described in paragraph
7.8. “Disassembling the side guards”.
1. Disconnect cable a from the alternator.
2. Back off the clamping screw b of the
BRUSH group using a large Philips
screwdriver.
3. Remove the BRUSHES.
To reassemble the BRUSHES, carry out the
above steps in reverse order.
Figure 7.24-1
Page 7.30
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7.25. DISASSEMBLING THE SPRINGS
Figure 7.25-1
Carry out the procedure described in paragraph
7.6. “Disassembling the upright guard”.
1. Select stepping mode A (independent
stepping motion).
For each SPRING:
2. Using a hooked tool, extend the SPRING and
secure it to the frame.
3. Back off self-locking nut a using a 17-mm
wrench, while holding bar b in place with a
5-mm hex T wrench.
4. Using the hooked tool, slowly return the
SPRING to its rest position.
Figure 7.25-2
Continued on the following page →
Page 7.31
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5. Remove the SPRING from the upper pulley
b.
6. Using a pipe wrench, unscrew the SPRING
from the slide c.
7. Remove the SPRING.
To reassemble the SPRINGS, carry out the above
steps in reverse order.
Figure 7.25-3
Page 7.32
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7.26. DISASSEMBLING THE SPRING PULLEYS
Carry out the procedures described in paragraph
7.25. “Disassembling the springs” leaving them
connected to the slide.
For each PULLEY:
1. Back off the self-locking nut a using a 17mm wrench, while holding its screw b in
place with a 17-mm wrench.
2. Remove the PULLEY and its spacers.
To reassemble the SPRING PULLEYS carry out
the above steps in reverse order.
Figure 7.26-1
Page 7.33
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7.27. DISASSEMBLING THE SLIDE BARS
Carry out the procedures described in paragraph
7.15. “Disassembling the pedal chains” for the
chains on the short stretch only, and 7.25.
“Disassembling the springs”.
1. Select stepping mode B (dependent stepping
motion).
2. Back off the 4 screws a which fix the BARS
to the frame using a 17-mm wrench.
3. Remove the BARS and SLIDE.
Figure 7.27-1
To disassemble the runner from the SLIDE:
1. Back off the 4 screws b using a 5-mm hex T
wrench.
2. Remove the runner.
To reassemble the SLIDE and the guide BARS,
carry out the above steps in reverse order.
When reassembling the slide, be careful
to position it correctly: the dead hole
must be aligned with the fixing screw of
the slide sprocket.
Figure 7.27-2
After completing the procedure, adjust
the alignment of the BARS as described
in paragraph 8.8. .
Page 7.34
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7.28. DISASSEMBLING THE SELECTION KNOB
1. Turn off the machine and unplug the mains
lead from the wall outlet.
2. Back off the 2 dowels a using a 3-mm hex T
wrench.
3. Back off screw a using a 4-mm hex T
wrench.
4. Pull firmly to remove the KNOB from its
pin.
To reassemble the KNOB, carry out the above
steps in reverse order.
Figure 7.28-1
To correctly assemble the KNOB, when
the pin is inserted it should be in
position B, and when the pin is released
it should be in position A.
Page 7.35
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7.29. DISASSEMBLING THE SELECTION KNOB PIN
Carry out the procedures described in paragraphs
7.6. “Disassembling the upright guard”, 7.25.
“Disassembling the springs”, 7.27.
“Disassembling the slide bars” and 7.28.
“Disassembling the selection knob”.
1. Select stepping mode A (independent
stepping motion).
2. Back off the 2 screws a using a medium
Philips screwdriver
3. Remove the guard b by rotating it through
90° and pulling it out toward the right.
Figure 7.29-1
4. Using a pointed tool, remove clip c, and
insert the pointed tool in its place.
Figure 7.29-2
Continued on the following page →
Page 7.36
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5. Pushing the PIN out from the upright,
remove the pointed tool.
6. Gradually reduce the pressure on the PIN
until it can be removed from the front
together with its spring.
To reassemble the SELECTION KNOB PIN,
carry out the above steps in reverse order.
To correctly reassemble the
SELECTION KNOB PIN, the slotted
end must be on the side of the knob.
Figure 7.29-3
Page 7.37
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7.30. DISASSEMBLING THE MICROSWITCH
1. Turn off the machine and unplug the mains
lead from the wall outlet.
2. Select stepping mode A (independent
stepping motion).
3. Back off the 2 screws a using a medium
Philips screwdriver.
4. Remove guard b by turning it through 90°
and pulling it out toward the right.
Figure 7.30-1
5. Disconnect the 2 Fastons of the
MICROSWITCH connecting cable.
6. Back off the 2 screws c using a 3-mm hex T
wrench while holding their nuts d in place
with a 7-mm wrench.
7. Remove the MICROSWITCH.
To reassemble the MICROSWITCH, carry out
the above steps in reverse order.
When reassembling the
MICROSWITCH, be careful to
correctly connect the cable to the NC
contact.
Figure 7.30-2
Page 7.38
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8. ADJUSTMENTS
8.1. ALIGNING THE BELT
Carry out the procedures described in paragraphs
7.8. “Disassembling the side guards” and 7.9.
“Disassembling the chain guard”.
1. Back off the lock nut a on alternator pivot b
using a 19-mm wrench.
2. Back off the locking dowel c of 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 alternator pivot b: turn clockwise or
anticlockwise to move the alternator forward
or backward along the pivot axis.
5. After completing the adjustment, lock down
dowel c on alternator pivot b and tighten lock
nut a.
After completing this procedure, check
the belt tension as described in
paragraph 8.2. .
Figure 8.1-1
Page 8.1
Page 86
8.2. BELT TENSION
Figure 8.2-1
STEPRACE: Service & Maintenance Manual - rev. 1.2
Carry out the procedures described in paragraphs
7.8. “Disassembling the side guards” and 7.9.
“Disassembling the chain guard”.
1. Back off the lock nut of alternator pivot a
using a 19-mm wrench.
2. Back off the dowel b of the alternator pivot.
3. Back off the nut c of the belt tension rod d
using a 17-mm wrench.
4. Rotate the alternator on its pivot in such a
way that, at point A, the belt e has a vertical
play of approximately 1 cm.
5. After completing the adjustment, lock down
what previously backed off.
After completing this procedure, check
the belt tension again.
Figure 8.2-2
Page 8.2
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8.3. ALIGNING THE PRIMARY SHAFT - SECONDARY SHAFT
CHAIN
Carry out the procedures described in paragraphs
7.8. “Disassembling the side guards” and 7.9.
“Disassembling the chain guard”.
1. Back off the screw a on sprocket b of the
secondary shaft.
2. Place a reference rod against the sprocket
wheel of the primary shaft.
3. Align the sprocket b of the secondary shaft
with the reference rod.
4. After completing the alignment, lock down
the previously backed off screw a.
To verify the correct alignment of the
chain, move it back and forth and check
that it doesn’t make any noise.
Figure 8.3-1
After completing this procedure, check
the chain tension as described in
paragraph 8.4. .
Page 8.3
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8.4. PRIMARY SHAFT - SECONDARY SHAFT CHAIN TENSION
Carry out the procedures described in paragraphs
7.8. “Disassembling the side guards” and 7.9.
“Disassembling the chain guard”.
1. Back off the 4 screws a which fix the
secondary shaft to the frame.
2. Adjust nut b and screw c until the vertical
play of the chain at the point midway
between the 2 shafts is approximately1 cm.
3. Check the amount of vertical play at the
midway point with the pedals in various
different positions.
Check that the above adjustments
maintain the alignment between the
primary and secondary shaft axes.
4. After completing the adjustment, lock down
what previously backed off.
Figure 8.4-1
To ensure that the chain tension is
correct, move it back and forth over the
entire circumference of the primary
shaft sprocket wheel.
After completing the procedure, check
the alignment of the chain as described
in paragraph 8.3. .
Page 8.4
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8.5. ADJUSTING THE ALIGNMENT OF THE PRIMARY DRIVE
SPROCKET
Carry out the procedures described in paragraphs
7.8. “Disassembling the side guards” and 7.9.
“Disassembling the chain guard”.
1. Back off lock nut a using a 32-mm wrench.
2. Adjust the position of shaft b using an 8-mm
hex T wrench, in such a way that its sprocket
is aligned with the one on the primary shaft.
3. After completing the adjustment, lock down
nut a.
Figure 8.5-1
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8.6. WEAR OF ALTERNATOR BRUSHES
Carry out the procedures described in paragraph
7.8. “Disassembling the side guards”.
Inspect the 2 brushes for wear, referring to the
figures at left and to the descriptions below:
• The brush shown in (A) has a correct wear
pattern.
• The brush shown in (B) has an irregular wear
pattern which may result in noise and wear of
the alternator collector.
Using abrasive paper, smooth down the jagged
edges so that the brush appears as in figure (C).
Figure 8.6-1
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8.7. ALIGNING THE PEDALS
Figure 8.7-1
Carry out the procedures described in paragraph
7.8. “Disassembling the side guards”.
1. Select stepping mode A (independent
stepping motion).
2. Back off lock nut a using a 17-mm wrench.
3. Adjust the position of the limit stop pad b for
each PEDAL, locking it down or backing it
off so that:
• The PEDALS are at the same height.
• The PEDALS do not touch the machine
guards.
4. Select stepping mode B (dependent stepping
action) and check that the selection knob pin
engages the slide.
If the pin fails to engage the slide, turn
both limit stop pads in a clockwise
direction until the pin of the selection
knob correctly engages the slide.
5. Tighten lock nut a using a 17-mm wrench.
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8.8. ADJUSTING THE POSITION OF THE SLIDE AND BARS
Carry out the procedures described in paragraph
7.6. “Disassembling the upright guard”.
To adjust the machine when no components have
been replaced:
1. Back off the 4 fixing screws a of the BARS.
2. Select stepping mode B (dependent stepping
motion).
3. Engage the pin of the selection knob in the
SLIDE.
4. Lightly lock down the 4 fixing screws a of
the BARS.
5. Select stepping mode A (independent
stepping motion).
6. Move the SLIDE up and down along the
BARS.
7. Check that the slide is able to move freely,
otherwise adjust the position of the BARS.
8. Repeat starting from point 2 until the SLIDE
is correctly engaged and moves smoothly
along the BARS.
9. After completing the adjustment, lock down
what previously backed off.
If this procedure is performed after
replacing a component of the SLIDEBAR group, it is advisable to carry out
the adjustment described above before
assembling the pedal chains and springs.
Figure 8.8-1
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8.9. ADJUSTING THE MICROSWITCH POSITION
Carry out the procedure described in paragraph
7.29. “Disassembling the selection knob pin” for
the guard only.
1. Back off the MICROSWITCH fixing screws
a and adjust its position so that:
• in stepping mode A (independent
stepping motion) its wheel does not touch
the selection knob;
• in stepping mode B (dependent stepping
motion) its lever is pressed by the
selection knob, causing the contact to
change state.
Figure 8.9-1
2. After completing the adjustment, lock down
the fixing screws a.
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8.10. ADJUSTING THE LCD BACKLIGHTING
After the machine has been switched on for at
least 1 hour, without switching it off:
1. Adjust trimmer P1 on the back of the display
to obtain the desired level of LCD
luminosity.
This adjustment must be made when the
LCD is warmed up: the machine must
have been switched on for at least 1
hour.
Figure 8.10-1
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8.11. ADJUSTING THE BUZZER TONE
Turn on the machine and, when the buzzer is
sounded during the start-up procedure:
1. Adjust trimmer P2 on the back of the display
to obtain the desired buzzer tone.
Figure 8.11-1
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9. CONFIGURING THE MACHINE
9.1. MACHINE HW CONFIGURATION
The HW configuration of the machine is set using the 2 banks of dip-switches on the back of the
CPU board, according to the tables below:
9.1.1. MACHINE NO. CONFIGURATION
Using the bank of 4 dip-switches on the back of the CPU board, it is possible to set the machine
number as illustrated below:
Right hand bank
Dip-switch
1 2 3 4
ON OFF OFF ON 1 – MASTER
OFF ON OFF OFF 2
ON ON OFF OFF 3
OFF OFF ON OFF 4
ON OFF ON OFF 5
Number
To be enabled for printing, the machine must be configured with all dip-switches in ON
position.
9.1.2. ALTERNATOR CONFIGURATION
This procedure is applicable starting from SW version 7.0.X .
Using dip-switch No. 1 of the 2-switch bank on the back of the CPU board, it is possible to set the
type of alternator that is fitted on the machine, as indicated below:
Left-hand bank
Dip-switch
1
ON
OFF PESTOLITE
Alternator
EFEL
REAL
MAGNETI MARELLI
9.1.3. MICROSWITCH CONFIGURATION
This procedure is applicable starting from SW version 7.0.X .
Using dip-switch No. 2 of the 2-switch bank on the back of the CPU board, it is possible to
configure the method of setting the stepping mode:
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• automatically if the microswitch is present;
• by asking the user if the microswitch is not present.
Left hand bank
Dip-switch
Microswitch
2
ON Absent
OFF Present
In the case of TGS type SW, the presence of the microswitch is configured by setting the
position of dip-switch No. 1 in the group of 4:
Right hand bank
Dip-switch
Microswitch
1
ON Absent
OFF Present
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10. SCHEDULED MAINTENANCE
To keep the machine in perfect working order and prevent the risk of malfunction, it is necessary to
perform the scheduled maintenance operations set out in the table below. There are 3 basic types of
maintenance operations:
• External cleaning operations;
• Routine maintenance operations;
• Special maintenance operations.
The prescribed frequency differs for each type of operation, as does the required level of operator
qualification. The following paragraphs detail the recommended procedures.
10.1. EXTERNAL CLEANING OPERATIONS
These operations can be carried out by the owner of the machine and do not require any
special skills.
The external cleaning operations are involve simple cleaning for the purposes of general hygiene.
These should be performed at least once a week.
For external cleaning, proceeds as follows:
10.1.1. SETTING UP THE OPERATION
1. Turn off the machine by placing the switch in the 0 position (OFF).
2. Unplug the mains lead from the wall outlet.
10.1.2. CLEANING OPERATIONS
1. Using a cloth moistened with a neutral detergent (non acidic), clean the entire machine, taking
care not to rub too vigorously, especially on the keys of the display.
Never spray the cleaning product directly on the machine.
WARNING: do not use alcohol, petrol or chemical products in general.
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10.2. ROUTINE MAINTENANCE OPERATIONS
These operations can be carried out by the owner of the machine and do not require any
special skills.
The routine maintenance operations involve simple cleaning, lubrication and checking the state of
wear, in order to ensure the correct and safe operation of the machine. It is recommended to perform
these operations at least once a month.
For the routine maintenance of the machine, proceed as follows:
10.2.1. SETTING UP THE OPERATION
1. Turn off the machine by placing the switch in the 0 position (OFF).
2. Unplug the mains lead from the wall outlet.
3. Open the machine guards.
10.2.2. INTERNAL CLEANING
1. Use a vacuum cleaner to clean the interior, paying particular attention to the alternator and the
electronic circuit boards.
WARNING: when carrying out these operations, be careful not to damage the cables.
2. Move the machine and clean the floor underneath using a vacuum cleaner.
10.2.3. LUBRICATION
1. Lubricate the pedal chains with chain spray grease that comes with the service box.
2. Lubricate ball joints of the pedals with chain spray grease that comes with the service box.
3. After lubricating them, move the pedals up and down a few times.
10.2.4. CHECKING THE STATE OF WEAR OF THE PEDAL CHAINS
1. Check the state wear of the pedal chains, inspecting their entire length and in particular the
coupling with the primary shaft sprocket wheels. If any anomalies are found (links that are
jammed and/or have excessive play), call in the authorized Technogym Technical Service.
10.2.5. CHECKING THE AMOUNT OF PLAY ON THE BALL JOINTS
1. Check the amount of play on the ball joints, taking a pedal in one hand and moving it. If any
anomalies are found, call in the authorized Technogym Technical Service or adjust the amount
of play.
Page 10.2
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