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Technogym CROSS PERSONAL, Service Maintenance Manual

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CROSS PERSONAL: Service & maintenance manual - rev. 1.1 

 

 

Page 8.1 

8. 

 

ADJUSTMENTS 

8.1. 

 

MECHANICS/CRANK ASSEMBLY SHAPING 

OPERATION 

DESCRIPTION 

Mechanics/Crank 
assembly Shaping 

 

NOTE_1:

 

The procedure described below differs according to 
whether it is performed on the right-hand or the left-
hand assembly. 

 

 

 

Note that the references for the right-hand “R” and left-
hand “L” configuration are stamped on the aluminium 
block (in the red circle in the illustration above). 

 

NOTE_2:

 

Before performing the following procedure, check 
that the crank is fitted. 

 

NOTE_3:

 

If the timing belt of  the mechanics/crank assembly 
has not been removed, timing only requires 
repositioning of the timing lever in the previous 
position (previously marked on the frame) otherwise 
follow the instructions below. 

 

1.

 

Remove the belt from the positive drive pulley. 

 

 
 
 
 
 
 
 
 
 

Continued on the next page… 

Summary of Contents for CROSS PERSONAL

Page 1: ...CROSS PERSONAL REV 1 1...

Page 2: ......

Page 3: ...PRESENT NOTE The information contained in this document is subject to change without notice Technogym does not guarantee this documentation in any way Technogym shall not be held responsible for any e...

Page 4: ......

Page 5: ...3 2 2 LCD inverter 3 3 3 2 3 Digital Analog tuner board 3 3 3 2 4 LAN network board integrated 3 3 3 2 5 Wireless network board without cables 3 4 3 2 6 Audio Video external device connector board 3...

Page 6: ...28 6 14 1 Hand sensor 6 28 6 14 2 Chest belt 6 32 6 15 THE TELEMETRIC HEART RATE SIGNAL IS INCORRECT 6 35 6 15 1 Chest belt 6 35 6 15 2 Hand Sensor 6 39 7 PART DISASSEMBLY 7 1 7 1 DISASSEMBLY OF THE R...

Page 7: ...Service maintenance manual rev 1 1 Page iii 9 2 1 1 Table of configuration parameters 9 4 10 UPDATING THE SW 10 1 11 SCHEDULED MAINTENANCE 11 1 12 APPENDIX 12 1 12 1 MENU PASSWORD TABLE 12 1 12 2 REQU...

Page 8: ...CROSS PERSONAL Service maintenance manual rev 1 1 Page iv Page intentionally left blank...

Page 9: ...ION non observance may cause damage to the machine Information about the operation in progress Observation about the operation in progress 1 2 RECOMMENDATIONS Technogym recommends the following steps...

Page 10: ...of the recommended brands 3 Use special tools where specified 4 Consult the Technical Newsletters which may contain more up to date information on adjusts and maintenance than those contained in this...

Page 11: ...4 Model 7 700 5 Power supply type 3 Powered 6 Display type Y VISIOWEB 7 Accessories F Full 8 9 Colour of the frame 00 None 10 11 Colour of the upholstery 00 None 12 Colour of the guards R Renault Grey...

Page 12: ...Overseas G Great Britain BS1363 European H Argentina IRAM 2073 Overseas I Italy EEC 7 16 Italy J Japan JIS 8303 Overseas K Great Britain BS1363 Overseas S Europe EC EEC 7 16 Overseas U USA UL 110 V N...

Page 13: ...g Hand sensor Telemetria Goal oriented display YES Wellness System YES Total Number of Programs 23 Quick Start Goal Time Distance Calories CPR Profiles 6 predefined 12 customizable Custom Training Zon...

Page 14: ...CROSS PERSONAL Service maintenance manual rev 1 1 Page 2 4 2 5 DIMENSIONS 2 6 PACKING DIMENSIONS EUROPE AND OVERSEAS...

Page 15: ...ng Storage from 20 to 90 non condensing 2 8 CONFORMITY TO REGULATIONS EUROPE USA EMI regulations EN61000 6 1 2007 EN61000 6 3 2007 EN61000 3 2 2007 EN61000 3 3 2009 Electrical safety regulations EN 60...

Page 16: ...CROSS PERSONAL Service maintenance manual rev 1 1 Page 2 6 2 9 WIRING DIAGRAMS...

Page 17: ...Colour Patch conn 1 12 Vdc power supply Red 8 3 Rx Brown 1 5 Tx Blue 2 9 Gnd Black 6 2 10 2 WB CABLES WB657 Flat Tuner Board cable CPU Board TUNER Board CPU Board J9 Signal TUNER Board J13 1 Capaciti...

Page 18: ...lack 8 8 GND Black 7 9 Video Gnd Black 6 10 Video signal Black 5 11 Audio L Gnd Black 4 12 Audio L signal Black 3 13 Audio R signal Black 2 14 Audio R Gnd Black 1 CU308 User USB port cable CPU Board U...

Page 19: ...n 4 9 Gnd Green 3 10 Audio IN L Power OFF White 5 11 Audio IN R Green 2 12 Gnd Yellow 1 CU614 AUX Audio Video Antenna signal cable CPU Board AUX connector Tuner Board Antenna connector CPU Board CN27...

Page 20: ...ack Brown 6 1 Left UP HS White 1 2 Left DOWN HS Brown 5 3 Left HS shield 4 Right UP HS White 1 5 Right DOWN HS Brown 5 6 Right HS shield 1 3 Gnd Right Black 4 2 4 OUT R amplified Red 8 1 2 Gnd Left Bl...

Page 21: ...OFF Yellow 4 Gnd Yellow green 5 Faston CU619 Display Power supply signals cable Patch conn Brake board Power Supply board Patch Conn CN1 Signal Colour Brake Board CN3 Power supply board P3 1 485 sign...

Page 22: ...supply board P2 Signal Colour Brake board CN4 1 Line Brown 3 5 Neutral Blue 1 3 Earth Yellow green 5 CU623 Cavo Freno Scheda Freno Freno Sensore velocit Scheda Freno CN2 Signal Colour Brake Speed sens...

Page 23: ...CROSS PERSONAL Service maintenance manual rev 1 1 Page 3 1 3 PRINCIPLES OF OPERATION 3 1 BLOCK DIAGRAM...

Page 24: ...s and process signals from and to Secondary ON OFF switch LCD LCD Inverter Touch screen control board Capacitive Touch Screen TUNER board C Safe and USB connector board Dual TGS reader User USB port i...

Page 25: ...d radio channels The data is then sent to the CPU Board where it is processed and managed in order to correctly display it on the LCD Display LED name Colour Description D4 RED ON if the power supply...

Page 26: ...work The advantage of Wi Fi is the absence of cables but this is also a limitation in terms of protection against interference disturbance performance the stability of service and bandwidth may be int...

Page 27: ...that manages the Touch Screen through 2 flat cables and connect it to the CPU board The board includes the following 2 LEDs indicator LED name Colour Description LED 1 GREEN It light up when switch ON...

Page 28: ...ER BOARD This Board allows the audio signal from the Display to be amplified so that it is played through the loud speakers on the machine 3 2 14 HAND SENSOR BOARD This is the Board that manages the s...

Page 29: ...ontrol iPod devices In the table below you can see all the compatible iPod APPLE models Recharging battery All iPod iPhone models exception iPod shuffle and first generations Play Control Audio All iP...

Page 30: ...700 and 700SP version and 12Vdc all version Depending on the machine version these voltages will be generated either from the 110VAC or 220VAC mains supply or from the alternator battery 2 Section for...

Page 31: ...g effect that slows down the movement of the disk The braking effect is intensified as the magnetic field strength of the coils increases and therefore with increasing speed of the disk This operating...

Page 32: ...signal proportional to the speed 3 3 2 CONTROLS The control block diagram is as follows CPU BOARD BRAKE BOARD BRAKE Excitation current RS 485 CN18 CN9 CN2 CN4 Speed Sensor CN2 Green LED Pulses To obta...

Page 33: ...effective user torque is Open Loop The system Brake Board brake provides no adjustment to calibrate the resistance value produced but only using the braking table stored in the Brake Board The accura...

Page 34: ...roduced by the speed sensor and has the waveform shown in the figure below Figure 3 3 1 The signal enters the Brake Board pins 3 4 on connector CN2 where it is used to determine the speed value RPM th...

Page 35: ...pper central part of the frame in the area where the Total levers are connected normally used for connecting headphones One non amplified audio output jack socket at the base of the equipment in the p...

Page 36: ...the frame a signal is sent to switch off the amplifier so that no sound is put out by the speakers POWER OFF signal interrupted If no device is connected to the 2 jack sockets the audio will be playe...

Page 37: ...ne can be connected to the Cardio Theater by means of the RJ45 connector on the C Safe board The Cardio Theater unit must be provided with a power cable having the following pin out RJ45 Connector Sig...

Page 38: ...into any one of the C Safe ports on the machine the corresponding LED should illuminate to indicate the presence of the 5 Vdc supply on the port During the C Safe port test function the plug connects...

Page 39: ...e and user 2 The place of installation is free of dust and sand 3 The place of installation meets the operating temperature and humidity conditions specified in paragraph 2 7 Ambient specifications 4...

Page 40: ...it AVVERTENZA Lift the equipment by holding onto the frame and not the levers or the control panel Take great care when moving the equipment and positioning it on the ground as it may overbalance If...

Page 41: ...bed in the instruction sheets supplied with the machines 4 Connect the mains lead to the power inlet socket on the machine 5 Place the on off switch in the 0 position 6 Plug the mains lead into the wa...

Page 42: ...CROSS PERSONAL Service maintenance manual rev 1 1 Page 5 4 Page intentionally left blank...

Page 43: ...ox 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 speci...

Page 44: ...uipment is inStand By as showninthe figure below A new display will appear from which you can gain access to the various configuration menus by entering the password on the number keyboard Enter the p...

Page 45: ...CROSS PERSONAL Service maintenance manual rev 1 1 Page 6 3 6 2 THE DISPLAY STAYS OFF Continued on following page...

Page 46: ...CROSS PERSONAL Service maintenance manual rev 1 1 Page 6 4 Continued on following page...

Page 47: ...CROSS PERSONAL Service maintenance manual rev 1 1 Page 6 5 Continued on following page...

Page 48: ...are with the checks highlighted by circled numbers which are described in detail below 1 Check that LED 1 green is lit on the Display Board 2 Check the voltages between the pins on the CN1 connector a...

Page 49: ...the Brake Board between PINS 2 and 6 7 Check the 12 Vdc voltage on the CN17 connector of the Brake Board on PINS 1 and 7 8 Check the 12 Vdc voltage on the P3 connector of the Power Board on PINS 1 and...

Page 50: ...SS PERSONAL Service maintenance manual rev 1 1 Page 6 8 6 3 NO AUDIO SOUND This error is due to the incorrect configuration of the equipment or problems with the audio circuit Continued on following p...

Page 51: ...CROSS PERSONAL Service maintenance manual rev 1 1 Page 6 9 Continued on following page...

Page 52: ...CROSS PERSONAL Service maintenance manual rev 1 1 Page 6 10 Continued on following page...

Page 53: ...e earth node on the Display and the 4 PINS on the connector by disconnecting it DANGER Take this measurement with the equipment switched off PIN 1 earth node 1 K Ohm PIN 2 earth node 1 Ohm PIN 3 earth...

Page 54: ...please refer to the relevant chapter in the VISIO manual 6 5 THE TOUCH SCREEN DOES NOT WORK IT S NOT CALIBRATED For the following menu please refer to the relevant chapter in the VISIO manual 6 6 THE...

Page 55: ...CROSS PERSONAL Service maintenance manual rev 1 1 Page 6 13 6 7 THE IPOD DOES NOT WORK Continued on following page...

Page 56: ...ento non stata trovata Errore L origine riferimento non stata trovata 4 To update the iPod SW you just need to connect to iTunes and it automatically upgrades to the last version 5 Enable the iPod con...

Page 57: ...eed with upgrading The error is displayed with a message on the display and recorded in the Errors Log section In order to re instate communication between the High Kit and the Brake Board proceed as...

Page 58: ...Electrical Overtemperature Overtemperature error internal NTC This error occurs when the temperature measured by the internal NTC probe exceeds 90 C OLD EFI board 110 C NEW EFI board or 105 C Laser b...

Page 59: ...its opening has taken place If the brake does not include a Klixon e g a 2 A brake this means in general that a hardware error has occurred that does not allow the brake to be controlled After verifyi...

Page 60: ...s happens when the flag relating to the CURRENT zone and the flag relating to the MIRROR zone in EEPROM indicate results that are not consistent Re load the braking table 128 Not used Upgrade the Firm...

Page 61: ...d equipment 2 the Brake Board does not generate any current if the equipment is stationary then this behaviour is correct If on the other hand the equipment is in movement then there might be a proble...

Page 62: ...CROSS PERSONAL Service maintenance manual rev 1 1 Page 6 20...

Page 63: ...he CN2 connector by maintaining a constant 60Rpm and increasing the level of difficulty the Vdc measurement must increase 2 Measure the resistance on the two fastons on input to the Brake with the equ...

Page 64: ...equipment produces an incorrect resistance if 1 the mechanics are not perfect 2 the speed as measured is not correct 3 the Brake Board is faulty 4 the Brake Board was not programmed correctly with the...

Page 65: ...of the Service menu 2 Check that the mechanical system consisting of pedals belt and Brake is fluid and does not provide resistance and friction above the norm 3 Measure the voltage that the Brake Bo...

Page 66: ...he Electromagnetic Brake is incorrectly mounted on the flywheel 2 The special speed measurement screws are missing or badly assembled only for Crossover 3 The Speed Sensor is defective or badly assemb...

Page 67: ...ter on the ends of the speed sensor If you have an oscilloscope the signal that should be measured is like the one indicated in Errore L origine riferimento non stata trovata at about 80rpm user The s...

Page 68: ...RSONAL Service maintenance manual rev 1 1 Page 6 26 6 13 THE MACHINE DOES NOT READ THE TGS KEY The error is due to the fact the TGS reader is not working properly or if it is not supplied by the Displ...

Page 69: ...d in detail below 1 Place the tester probes across pins 1 and 3 of connector CN1 of the TGS reader The measured value should be 12Vdc 2 As for step 1 but across pins 1 and 9 of connector CN19 of the D...

Page 70: ...ty of the contact between the human skin and the HS plates as hands only just washed or particularly dry acidity of the skin and or a particular body fat mass index For these people it s suggested to...

Page 71: ...CROSS PERSONAL Service maintenance manual rev 1 1 Page 6 29 Continued on following page...

Page 72: ...n 1 and 5 on CN24 connector of the Display Board 3 Check the correct display SW version according to the EXCITE SW SMART TABLE you can find in TG Direct NEWS section Check the grounding of the Receive...

Page 73: ...The faston of the cable are well connected to the Hand Sensor plates b The signal continuity of the CU616 cable which connect the HS plates to the HD3 2 connectors on the receiver using a tester and r...

Page 74: ...aintenance manual rev 1 1 Page 6 32 6 14 2 CHEST BELT CORRECT USE OF THE CHEST BELT Wear the chest belt taking care the area of contact with the body is humid in order to guarantee it proper works Con...

Page 75: ...CROSS PERSONAL Service maintenance manual rev 1 1 Page 6 33 Continued on following page...

Page 76: ...RT TABLE you can find in TG Direct section Check the grounding of the HR Receiver Board measuring the resistance value between a The Faston on Receiver Board and the ground node on the equipment b The...

Page 77: ...Page 6 35 6 15 THE TELEMETRIC HEART RATE SIGNAL IS INCORRECT 6 15 1 CHEST BELT CORRECT USE OF THE CHEST BELT Wear the chest belt taking care the area of contact with the body is humid in order to guar...

Page 78: ...iver Board measuring the resistance value between a The ground faston of receiver board and the ground node on the Power supply box of the machine b The ground node on the Power supply box of the mach...

Page 79: ...Service maintenance manual rev 1 1 Page 6 37 Figure 6 1 The active area of the transmitter is wider on the lateral side 130 cm instead of the front or the back side 90cm Take care of the following dia...

Page 80: ...use Test Box Excite as detailed here below You can use one of the following cables ELT 16 0WC00518AB CBQ 28 0WC00390AC or TRM 28 0WC00336AC as connection cable TEST BOX EXCITE RECEIVER LED connecting...

Page 81: ...icular body fat mass index For these people it s suggested to wear the chest belt transmitter HS CORRECT USE Grasp both the upper and lower plate avoiding to clench them too hardly Avoid to wash the h...

Page 82: ...of the main wall socket measuring that the following voltages are present P N phase neutral 220Vac 110 Vac P G phase ground 220Vac 110 Vac N G neutral ground 0 Vac 2 Check that a The faston of the ca...

Page 83: ...Disassembly of the rear display cover 1 Switch off the equipment and disconnect the power supply plug from the wall socket 2 Remove the CSafe and USB connectors from the rear of the display 3 Remove t...

Page 84: ...ere before 5 Loosen the 3 screws anchoring the client TGS USB support plate using a Phillips screwdriver 6 Remove the iPod docking station panel 7 Unscrew the 4 screws anchoring the display board supp...

Page 85: ...the power supply plug from the wall socket 2 Remover the Rear display cover 3 Disconnect and remove the Touch Screen interface card flat cable USB cable 2 screws using a Phillips screwdriver 4 Unscre...

Page 86: ...lug from the wall socket 2 Remover the Rear display cover 3 Disconnect the following cables from the CPU iPod docking station and AUX inputs 4 Remove the plastic grille protecting the display boards 8...

Page 87: ...vers support cover 4 Remove the front plastic angle pieces under the polished aluminium display frame 5 Remove the rear plastic angle pieces under the polished aluminium display frame 2 screws using a...

Page 88: ...f the equipment and disconnect the power supply plug from the wall socket 2 Remove the front column guard assembly with Fast Milano fastener 3 Remove the headphone connector support on the central fra...

Page 89: ...AKERS OPERATION DESCRIPTION Dismantling the Amplifier speakers 1 Remove the Front guards 2 Remove the guards covering the speakers on the column 2 screws using a 3 mm hex key 3 Remove the speakers 2 s...

Page 90: ...er 5 Remove the headphone jack socket on the central frame 6 Slide out the lever cable connector from the slot in the frame of the central headphone jack socket housing see photo below 7 Loosen the 2...

Page 91: ...E TOTAL LEVER OPERATION DESCRIPTION Dismantling the tweeter from the Total Lever 1 Remove the top end cap from the Total lever and the tweeter cover Unscrew the screws using a 2 5 mm hex key 2 Unscrew...

Page 92: ...ng a 23Nm 17lbf ft torque spanner 4 Disconnect the lever from the crank 5 Disconnect the platform lever from the Total lever see procedure for dismantling the Total Lever 6 Remove the lower lever guar...

Page 93: ...rews using a 5 mm hex key 5 If necessary use an extractor to remove the crank 6 Unscrew the 5 screws on the coupling using a 5 mm hex key Use 3 of the 5 screws as an extractor by screwing them into th...

Page 94: ...T OPERATION DESCRIPTION Dismantling the Crank assembly belt 1 Dismantle the Mechanics crank assembly 2 Slacken the belt tension by turning the belt stretcher eccentric anchor screw using a 5 mm hex ke...

Page 95: ...screw using a 4 mm hex key Fast Milano fastener 6 Remove the central rear guard covering the mechanics assembly with Fast Milano fastener On the right hand side of the equipment 7 Unscrew the screw a...

Page 96: ...mirror finish guard to the frame using a 4 mm hex key 4 Using a tape measure take the reference measurement for the position of the screw of the belt tensioner and then use it to readjust the belt te...

Page 97: ...e 7 15 7 15 DISMANTLING THE BRAKE BELT PULLEY OPERATION DESCRIPTION Dismantling the Brake Belt Pulley 1 Remove the right hand Mechanics crank assembly 2 Remove spline from the shaft 3 Remove the space...

Page 98: ...r from the crank see Platform Lever dismantling procedure 2 Remove the crank guard cover 3 Unscrew the 2 screws anchoring the round mirror finish guard to the frame using a 4 mm hex key 4 Remove the s...

Page 99: ...for the right hand R and left hand L configuration are stamped on the aluminium block in the red circle in the illustration above NOTE_2 Before performing the following procedure check that the crank...

Page 100: ...n blue in the illustration below 3 Position the timing lever at the centre of the R or L reference on the aluminium block depending on the side on which the mechanics crank assembly is to be installed...

Page 101: ...ng lever either to the right or to the left as indicated by the blue arrow until the crank rests against a key positioned as illustrated 7 Tighten the shrink disk screws NOTE tighten the screws to 16...

Page 102: ...fore slackening the belt tension as show in the illustration 2 Unscrew the nut a using an 17 mm spanner 3 Adjust the tension by turning the screw b using a 5 mm hex key When adjusting tension of a new...

Page 103: ...oor If they do not level the equipment 2 Adjust the two back feet first Loosen the lock nut B Screw or unscrew the foot A until the frame is stable After adjusting tighten the lock nut B 3 Once the ba...

Page 104: ...CROSS PERSONAL Service maintenance manual rev 1 1 Page 8 6 Page intentionally left blank...

Page 105: ...corner and the bottom right hand corner of the screen in that sequence in Stand By as shown in the figure below A new display will appear from which you can gain access to the various configuration m...

Page 106: ...CROSS PERSONAL Service maintenance manual rev 1 1 Page 9 2 For the following menu please refer to the relevant chapter in the VISIO manual...

Page 107: ...een in that sequence in Stand By as shown in the figure below A new display will appear from which you can gain access to the various configuration menus by entering the password on the number keyboar...

Page 108: ...decimal Rt Transmission Ratio 134 2 Rvel Speed ratio 1 3 mA Im Minimum braking 0 4 W Pmc Constant maximum power 200 5 in cents Km Power factor correction constant torque 100 6 0 1N Ca User friction t...

Page 109: ...CROSS PERSONAL Service maintenance manual rev 1 1 Page 9 5 Page intentionally left blank...

Page 110: ......

Page 111: ...in that sequence when the equipment is in Stand By as shown in the figure below A new display will appear from which you can gain access to the various configuration menus by entering the password on...

Page 112: ...CROSS PERSONAL Service maintenance manual rev 1 1 Page 10 2 Page intentionally left blank...

Page 113: ...ey consist in simple external cleaning for the purposes of general hygiene Refer to the USER manual SPECIAL maintenance operations may only be carried out by a Qualified Technician specifically traine...

Page 114: ...CROSS PERSONAL Service maintenance manual rev 1 1 Page 11 2 Page intentionally left blank...

Page 115: ...ion VISIO Configurazione IP Radio IP Radio configuration VISIO Configurazione Utente letture Serial Number User Configuration Serial number reading LED VISIO Sintonizzazione canali Analogici e Digital...

Page 116: ...llips screwdriver Small flat Phillips screwdriver Medium flat Phillips screwdriver 13mm wrench 17mm wrench 17mm socket wrench Socket wrench for M20 ringnut 2 5mm Allen T wrench 3mm Allen T wrench 4mm...

Page 117: ......

Page 118: ...0SM00637AA UK TECHNOGYM S p A Via Calcinaro 2861 47521 Cesena FC ITALIA Tel 39 0547 56047 Fax 39 0547 650150 e mail service technogym com...

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