Technogym FORMA LINE BIKE FORMA DDC5 Series Technical Assistance Manual Download

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Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1

Page 2.2

2.2.

SERIAL NUMBER STRUCTURE

The

Serial Number

is made up of 14 alphanumeric characters as follows:

Characters

Description

Values and meaning

1,2,3,4,5,6,

Type of product,

= FORMA LINE

= Bike Forma

= 500

= Powered

7,8,

Year of production,

= LED

9,10,11,12,13,14.

Progressive.

= 2011

For example, a possible code number could be the following:

DD C 5 3 L 11 000001

Summary of Contents for FORMA LINE BIKE FORMA DDC5 Series

Page 1: ...F FO OR RM MA A L LI IN NE E BIKE FORMA DDC5xxx Technical Assistance manual REV 1 1 ...

Page 2: ......

Page 3: ...PMENT IS SWITCHED OFF WARNING The information contained in this document may be changed without prior notification Technogym does not issue guarantees of any kind regarding this material Technogym will not be held responsible for any errors contained herein or for any accidental damage or damage consequent to the supply services or use of this material This document contains proprietary informatio...

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Page 5: ...s 2 7 2 8 2 CU Cables 2 7 3 OPERATING PRINCIPLE 3 1 3 1 BLOCK DIAGRAM 3 1 3 2 LED DISPLAY BOARDS 3 2 3 2 1 ARM Board 3 2 3 2 2 C Safe Board 3 2 3 3 CARDIO RECEIVER BOARD 3 3 3 3 1 HR Band 3 3 3 4 BRAKE BOARD 3 4 3 4 1 Brake Board Models 3 5 3 5 ELECTROMAGNETIC BRAKE 3 6 3 6 SPEED SENSOR 3 6 3 7 INPUT MODULE 3 6 3 8 BRAKE COMMAND 3 7 3 8 1 The Mechanics 3 7 3 8 2 Control 3 7 3 8 3 The signals invol...

Page 6: ...al bushing 7 16 7 9 3 Dismantling the seat group 7 17 7 9 3 1 Dismantling the seat upholstery 7 17 7 9 3 2 Dismantling the handle pin 7 18 7 9 3 3 Dismantling the spring and the handle 7 19 7 9 3 4 Dismantling the handle support plate 7 23 7 9 3 5 Dismantling the handle pin 7 24 7 10 DISMANTLING THE BELT AND BELT TENSIONER 7 26 7 11 DISMANTLING THE BRAKE AND THE FLYWHEEL UNIT 7 28 7 12 DISMANTLING...

Page 7: ... 9 2 2 2 Write to low kit 9 12 9 2 2 3 Operating data 9 12 9 2 3 Errors Log 9 13 9 2 3 1 Read from low kit 9 13 9 2 3 2 Reset errors 9 13 9 2 3 3 COM Fault 9 14 9 2 3 4 Display errors 9 14 9 2 4 Standard settings 9 15 9 2 5 Low kit menu 9 15 9 2 5 1 Low kit version 9 16 9 2 5 2 Config registers 9 16 9 2 5 3 Low Kit fault code 9 16 9 2 6 High kit version 9 16 9 2 7 BOOT version 9 17 9 2 8 Key Reade...

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Page 9: ...achine CAREFUL Information about the operation in progress Observation about the operation in progress 1 2 USEFUL ADVICE Technogym advises you to program your technical assistance task in the following way Make a careful assessment of the impressions given by the Customer regarding the equipment s operating faults and formulate some appropriate questions to clarifythe symptoms relating to the defe...

Page 10: ...brand lubricants 3 Use special tools when specified to do so 4 Consult the Technical Newsletters as they might contain more up to date details on regulation and servicing procedures compared to those in this manual 5 Before undertaking any work check that the recommended tools are available and that they are in good condition 6 With regard to the procedures given in this manual only use the tools ...

Page 11: ...aning 1 2 Type of Line DD FORMA LINE 3 Type of equipment C Bike Forma 4 Model 5 500 5 Type of energy supply used 3 Powered 6 Type of Display L LED 7 Built in devices N None 8 9 Frame Colour AN Anthracite 10 11 Upholstery Colour 00 none NA Nero 12 Guard Colour R Renault Grey 13 Type of standard TV 0 none 14 15 Language BR Portuguese DA Danish DE German ES Spanish FR French IT Italian JP Japanese NL...

Page 12: ...mber is made up of 14 alphanumeric characters as follows Characters Description Values and meaning 1 2 3 4 5 6 Type of product DD FORMA LINE C Bike Forma 5 500 3 Powered 7 8 Year of production L LED 9 10 11 12 13 14 Progressive 11 2011 For example a possible code number could be the following DD C 5 3 L 11 000001 ...

Page 13: ...SI Total number of programs 3 Quick start Goal CPR Languages available 13 UK English US English Italian German Spanish French Dutch Portuguese Japanese Chinese Russian Turkish Danish 2 4 ENVIRONMENTAL CHARACTERISTICS Temperature In operation from 5 to 35 C In storage from 10 to 70 C Dampness In operation from 30 to 80 without condensation In storage from 5 to 85 without condensation 2 5 COMPLIANCE...

Page 14: ...5 Technical Assistance manual rev 1 1 Page 2 4 2 6 MECHANICAL CHARACTERISTICS MECHANICAL CHARACTERISTICS Length mm in 1216mm 48 Width mm in 600mm 24 Height mm in 1338mm 53 Total weight kg lbs 61Kg 134 5lbs 2 6 1 BULK DIMENSIONS ...

Page 15: ...Forma Line BIKE FORMA DDC5 Technical Assistance manual rev 1 1 Page 2 5 2 6 2 PACKING DIMENSIONS EUROPE AND OVERSEAS ...

Page 16: ...Forma Line BIKE FORMA DDC5 Technical Assistance manual rev 1 1 Page 2 6 2 7 WIRING DIAGRAM 2 7 1 POWERED MODEL ARM BOARD ...

Page 17: ...y cable for High Kit and Low Kit Brake Board CPU ARM Board Brake Board CN1 Signal Colour ARM Board CN1 CPU Board CN15 1 GND Yellow Green Faston Eyelet 2 GND 12V White 2 3 GND 5V Yellow 3 4 sensing GND 5V Pink 4 5 n c 5 6 12 Vdc Brown 6 7 5 Vdc Green 7 8 sensing 5V Grey 8 CU196 Serial communication cable for High Kit and Low Kit Brake Board CPU ARM Board Brake Board CN3 Signal Colour ARM Board CN9 ...

Page 18: ...309 Cable for 100 220V internal power supply signal Input module Brake Board Input Module Signal Colour Brake Board CN4 N NEUTRAL Light Blue 1 F PHASE Brown 3 T Earth cable Yellow Green 5 CU504 Brake power supply cable Brake Board Brake Speed sensor Brake Board CN2 Signal Colour Brake Speed Sensor magnetic PK 1 Brake power supply Brown Faston 2 Brake power supply White Faston 3 R P M Sens Yellow F...

Page 19: ...Forma Line BIKE FORMA DDC5 Technical Assistance manual rev 1 1 Page 3 1 3 OPERATING PRINCIPLE 3 1 BLOCK DIAGRAM The block diagram for the equipment is represented in the following figure ...

Page 20: ...ard exchange with the Brake Board the piloting commands for the brake on the RS 485 serial line manage the LEDs and the 7 display segments to provide feedback on operating There are some signal LEDs on the board LED Name Colour Description LED1 GREEN if ON the 12Vdc power supply provided by the Brake Board is reaching the board correctly LED2 YELLOW if ON the 5Vdc power supply provided by the Brak...

Page 21: ...Transmitter Heart Rate Band used by the user during training sessions The Receiver Board receives a power supply of 5Vdc from the Display Board The Receiver Board communicates with the Display Board using negative logic procedures When it is in stand by the signal has a 5Vdc value and with every heart beat it picks up it generates an impulse of 0Vdc with an amplitude of 30msec ...

Page 22: ...he memory of errors detected by the board the signals relating to use of the equipment RPM WATT distance etc 3 Section that generates the current for the winding of the Electromagnetic Brake when the current varies the resistance supplied to the Brake itself also varies proportionately The excitation current supplied to the Brake varies according to the user power torque requested by the display a...

Page 23: ...ee as regards appearance that the LASER board compared with the previous 65W board which also was in the form of a black plastic box has a bevel on one of its sides the NEW EFI board as opposed to all the other brake boxes used up to now has a metal heat dissipator on one of its sides In order to identify the board unequivocally you should refer to the kernel revision which can be found on the lab...

Page 24: ...romotive forces are generated which cause the circulation of induced currents These currents have a direction that is opposite to the element that generated them i e the movement of the disk inside the magnetic field itself As a consequence a braking effect is created which slows down the movement of the disk The effect increases in intensity according to the size of the magnetic field of the coil...

Page 25: ...peed value of the exercise in revs per minute RPM On the basis of the commands received from the Display Board the Brake Board sends an excitation current to the winding on the brake which will generate an electromagnetic field WARNING When the Brake Board receives the signal to start the exercise from the Display Board the green LED comes on and current is supplied to the electromagnetic brake pr...

Page 26: ... only needs to maintain a constant RPM value In practice in addition to the control over the CURRENT the Brake Board exercises in this case a CLOSED LOOP control over the RPM since it knows the target value to be achieved It activates the current to achieve it and constantly reads the RPM value on the speed sensor so as to converge the control During movement the speed sensor detects the heads of ...

Page 27: ...ment algorithm Impulses from the speed sensor speed sensor or generator according to the type of equipment This is the signal produced by the speed sensor and it normally appears as in the following illustration Figure 3 8 1 This enters the Brake Board pin 3 4 on CN2 connector and here it is used to determine the speed value RPM which is sent to the Display Board via the RS 485 serial cable This s...

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Page 29: ... WARNING in order to identify the numbering of the pins on the RJ45 connector you should refer to the following diagram While programming the equipment sometimes you need to use an RJ45 plug on the vacant RJ45 port on the back of the display to avoid interference of any kind during the operation The diagram of the RJ45 plug is as follows The RJ45 connection cable and plug are both available by ord...

Page 30: ...er 0WC00639AA into the C Safe port on the equipment the LED mounted on it must come on as a signal that the 5Vdc is reaching the port During the test function for the C Safe ports the plug allows the transmission channel to be diverted onto the reception channel thereby obtaining a positive result for the test if the port is functioning ...

Page 31: ...ansmitter must be within a distance of 90cm from the display in Figure 6 1 and Figure 6 2 6 The mains voltage must be the same as the voltage indicated on the equipment label 7 The electric circuit must have a good earth connection 8 The electricity socket must be used exclusively for the equipment and have a power of at least 100VA 9 Connect a maximum number of pieces of equipment in cascade acco...

Page 32: ...eat care must be taken because the equipment could easily lose stability 1 The equipment is equipped with fixed front wheels In order to move it you need to lift it slightly as shown in the figure and push it forwards or backwards Figure 5 2 1 Figure 5 2 2 Once the equipment is placed in its working position you can regulate the height of one or two of the equipment s feet in order to get it level...

Page 33: ...Check Up between the High Kit and Low Kit At the end the equipment goes into Stand By position while waiting for a command from the keyboard In order to check that the equipment functions correctly Get on the equipment and start an exercise Check that the speed indicator varies Check that the hardness of the exercise and the level of difficulty varies from 1 to 25 when you press the difficulty lev...

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Page 35: ...an ACTION needs to be taken This box usually has a detailed description of the type of ACTION to be taken which should be the one to resolve the problem Therefore after taking this ACTION we advise you to 1 Check that the problem has been solved 2 If the problem persists we would recommend that you continue to follow the procedure from the point where you left it in order to perform the action Not...

Page 36: ...e machine is in stand by to enter The Display will show ENTER PASSWORD In order to access the procedure you need to enter the password 2501 which protects against unauthorised accesses and press the ENTER key in order to confirm At this point two choices are offered 1 Tech Config 2 Troubleshooting Press the numerical key 2 to enter the Troubleshooting menu and the equipment will start to display t...

Page 37: ... tests that the equipment proposes in this section perform checks in a wholly automatic manner After selecting the item for the test you require by using the and difficulty level keys you activate it by pressing the ENTER key and wait for the result Press ENTER again in order to continue and use the CANCEL key to return to the superior level by holding it down for a few seconds The various tests a...

Page 38: ...st was a failure and the term COM1 will be displayed if the communication test related to the C Safe COM test COM2 if relating to communication with the Low Kit and COM3 if relating to communication of the TGS COM test A TGS COM test performed on equipment that does not have a TGS reader will have a negative result as will a C Safe COM test if the equipment is not connected to the monitor plug ind...

Page 39: ...utlet supplythe correct voltage Is the mains lead OK Are the LEDs on the DisplayBoard lit on Plug the machine into a working electrical outlet Replace the mains lead Replace the DisplayBoard THE DISPLAY DOES NOT ILLUMINATE NO YES NO YES NO YES A 1 Are the fuses OK Replace the fuses YES NO Continues on the next page ...

Page 40: ...n the Display Board 2 Insert the tips of the tester onto pins 3 and1 of the CN4 connector on the Brake Board They should register about 220Vac or 110Vac according to the mains voltage 3 Gently lift the fastons on the power supply socket on the equipment Insert the tips of the tester between the phase and neutral on the connector They should register about 220Vac or 110Vac according to the mains vo...

Page 41: ...as not been upgraded proceed 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 follows 1 Check that the Serial Communication Cable CU196 is intact by using the Test Box Excite and if necessary replace it 2 Upgrade the SW on the Brake Board by loading the...

Page 42: ...rtemperature 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 board In this case the board passes into fault status and the error is recorded in the error log Switch off the equipment and switch it back on again If the error persists replace the Brake Board 2 Trip overcurrent brake kit Trip ov...

Page 43: ...s that 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 verifying that the braking current is zero against a braking current control other than zero the control unit goes into fault and saves the event in the error log The control is performed for any kind...

Page 44: ...ROM This 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 Firmware FW on the Brake Board If the same errors occur after upgrading has been successfully completed the problem is NOT the Brake Board ...

Page 45: ... powered 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 problem with the reading of the RPM by the speed sensor if it is mains powered equipment 3 the Brake Board was not programmed correctly with the sequence of Firmware FW Brake Table and Standard Setti...

Page 46: ...utthe The speed signalRPMis incorrect troubleshooting procedure OK There is the tension atthe inputofthe Brake NO Replace the Brake Replace connecting cable NO 3 Is the resistance on the Brake winding more or less 5Ohm Replace the Brake NO 2 Someone is training NO OK proper operation Reinstallthe latestversion of Firmware FW Brake Table and carry outthe Standard Setting Working NO Replace the Brak...

Page 47: ... 2 of the 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 equipment stationary 3 Same as point 1 but reconnecting what was disconnected and on the winding of the Electromagnetic Brake If the Brake Board is replaced check that the correct SW version is in...

Page 48: ...the sequence of a Firmware FW b Brake Table c Standard Settings 5 the Electromagnetic Brake is faulty Are the mechanics of the machine in good condition Does the Brake Board output the correct current to the brake winding Replace the Brake Board NO Replace the Brake winding HE RESISTANCE IS INCORRECT 2 Repair the f aulty mechanical parts NO Carry out the Speed signal is Incorrect troubleshooting p...

Page 49: ...h 9 2 4 Standard settings 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 Board provides at the winding In the Rapid Start up mode set the level of difficulty and check that the value is different from 0 If the Brake Board is replaced check that the correct SW version is...

Page 50: ...y assembled 4 the Brake Board was not programmed correctly with the sequence of a Firmware FW b Brake Table c Standard Settings 5 The Brake Board is faulty YES YES YES Does the speed sensor send the correct signal to the Brake Board 3 Reassembly in the right way NO Replace the Brake Board THE SPEED SIGNAL IS INCORRECT 1 Update the Low Kit SW Is the speed signal correct Instal the latest version of...

Page 51: ... Figure 3 8 1 at about 80rpm user The speed signal can also be measured in a qualitative manner using a multimeter When the equipment is stationary you should register a value of 0Vdc which will tend to grow as the speed increases With mains powered equipment the Speed Sensor detects the heads of the screws that fix the copper disk to the flywheel this is valid for all pieces of equipment except C...

Page 52: ...eck if the 5Vdc are at the output of the ARM CPU Board Are them present 4 NO Receiver Board defective Replace Check the SW and the groundin of Receiver Board Problem persists Place correclty 1 YES NO Check the proper functioning of the Receiver Board Is proper placed OK 2 NO NO YES YES Check if it works properly using a chest belt you are sure it s ok The problem solved Chest Belt defective SIRepl...

Page 53: ...XCITE SW SMART TABLE table found in the TG Direct 2 Check on the correct positioning of the Receiver Board as indicated in paragraph 7 4 Dismantling the Cardio Receiver HR Receiver Band 3 Insert the tips of the tester onto pins 1 and 2 on the CN1 connector on the receiver They must register 5Vdc 4 Do the same as in point 3 but between pins 1 and 8 on the CN3 connector of the CU208 If the Display B...

Page 54: ...LEMETRIC HR SIGNAL IS INCORRECT Chest belt Are the machines correctly spaced bythe required minimum distance Checkthe Receiver Board has been correctlymounted on the machine Reposition the machines so theyare adequately spaced Mount the Receiver Board in the right way NO YES NO Checkthe DisplaySW versione and the grounding of the receiver 1 2 Chest belt defective NO NO YES A Checkif it works prope...

Page 55: ...1 Check on the correct SW version according to the EXCITE SW SMART TABLE table found in the TG Direct Carry out the earth check on the HR Receiver by measuring the resistance value between the following points with a tester a The faston on the HR Bboard and the earth pole on the Power Supply Box b The earth pole on the Power Supply Box and the wall socket The value must be less than 1Ω Ohm Lastly ...

Page 56: ...tance and positioning of the pieces of equipment with each other keeping to the following diagram Figure 6 1 The lateral range 130cm is greater than the frontal range 90cm even though it covers a tighter area Position the pieces of equipment therefore as shown in the following diagram Figure 6 2 ...

Page 57: ...ailed below You can use one of the following cables as the connection cable between the receiver and the Test Box ELT 16 0WC00518AB CBQ 28 0WC00390AC or TRM 28 0WC00336AC TEST BOX EXCITE RECEIVER LED Connecting cable The circuit switches on the LED for each heart beat and or disturbance received In this way it is possible to assess whether there is any disturbance and what produces it Do not move ...

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Page 59: ... DANGER DO NOT under any circumstances unscrew the screws and nuts highlighted in the figure During the initial assembling during production of the X and Y components the highlighted screws and nuts are tightened buckling the frame on the fusion component making them integral with each other These will together constitute a single frame for the equipment ...

Page 60: ...the power supply plug from the wall socket 1 Unscrew the 4 screws a using a medium sized Phillips screwdriver Figure 7 2 2 2 Remove the keyboard b as indicated by the yellow arrows Figure 7 2 3 3 Disconnect the flat cable highlighted in the figure 4 Unscrew the 4 screws c using a medium Phillips screwdriver remove the Display d Continues on the next page ...

Page 61: ...lighted in the figure at the side and remove the Display assembly e Figure 7 2 5 6 Unscrew the 2 screws f using a 17mm wrench to remove the rear protection g of the display WARNING During re assembly tighten the pedal lever using a torque wrench set at 40Nm To re fit the display follow the above operations in reverse ...

Page 62: ...RM board a The C Safe board b Figure 7 3 2 Dismantling the ARM board a 1 Unscrew the 4 screws highlighted in the figure at side using a medium sized Phillips screwdriver Figure 7 3 3 Dismantling the C Safe board b 2 Disconnect the flat cable highlighted in the figure at side 3 Remove the C Safe board as indicated by the yellow arrows During the reassembly use some hot glue to fix the C Safe board ...

Page 63: ...Forma Line BIKE FORMA DDC5 Technical Assistance manual rev 1 1 Page 7 5 After the display reassembling check that the keyboard correctly works as detailed at paragraph 6 1 2 1 Man Keyboard Test ...

Page 64: ...1 Unscrew the 3 screws a using a medium sized Phillips screwdriver 2 Remove the bottom guard b Figure 7 4 2 3 Remove the receiver c 4 Cut the strap and remove the sponge protection d 5 Disconnect the receiver from the cables To re fit the receiver follow the above operations in reverse considering the following NOTES Continues on the next page ...

Page 65: ...1 Page 7 7 Figure 7 4 3 Re wrap the receiver in the sponge protection and re apply a strap to bind it 1 Connect the cable again to the connector a on the receiver Figure 7 4 4 WARNING Position the receiver so that the coil b is turned upwards and towards the user ...

Page 66: ...screw the 3 screws a using a medium sized Phillips screwdriver 2 Remove the bottom guard b Figure 7 5 2 3 Unscrew the 4 screws c using a 5mm Allen wrench DANGER Support the handlebars before unscrewing the last screw 4 Remove the handlebars WARNING During re assembly tighten the screws c using a torque wrench set at 16Nm ...

Page 67: ...h set at 32Nm Figure 7 6 2 In order to dismantle the pedal lever 2 Unscrew the cap b using snap ring pincers or with scissors 3 Unscrew the bolt c which you gain access to using a 13mm socket wrench 4 Remove the spacer d Figure 7 6 3 5 Dismantle the pedal lever e using a common bicycle pedal remover as shown in the figure WARNING During re assembly tighten the pedal lever using a torque wrench set...

Page 68: ...g a 4mm Allen wrench 2 Remove the top guard b and fix it with a strap as shown in the figure at the side Figure 7 7 2 3 Unscrew the 2 screws c using a 4mm Allen wrench Figure 7 7 3 4 Gently press downwards on the top part of the right hand guard in order to unhook it from the left hand one as shown in the figure Continues on the next page ...

Page 69: ... saddle support as indicated by the yellow arrow 7 Remove the right hand guard Figure 7 7 5 On the left hand side After removing the right hand guard all you need do for the left hand side is unscrew the corresponding screws as highlighted in the figure at the side Figure 7 7 6 8 Protect the pedal as far as its base using a cloth as indicated in the figure at the side Continues on the next page ...

Page 70: ...9 With care lift the guard slightly Figure 7 7 7 in order to pass it through the pedal Figure 7 7 8 Figure 7 7 9 10 Unscrew the 2 top screws e using a 4mm Allen wrench and loosen the 2 side screws 11 Remove the central support f In order to re fit the guards carry out the above operations in reverse ...

Page 71: ...RTANT NOTE ON DISMANTLING and 7 7 Dismantling the guard 1 Unscrew the cap a using snap ring pincers or scissors Figure 7 8 2 2 Unscrew the bolt c using a 13mm socket wrench Figure 7 8 3 3 Dismantle the pedal lever c using a common bicycle pedal remover as shown in the figure WARNING During re assembly tighten the pedal lever using a torque wrench set at 40Nm Continues on the next page ...

Page 72: ...refitting the shaft onto the frame WARNING During re assembly tighten the screws d using a torque wrench set at 22Nm Figure 7 8 5 5 On the left hand side of the equipment remove the snap ring 3 the spacer 2 and the elastic spring 1 WARNING During re fitting take care to re insert the components according to the sequence shown in the figure Figure 7 8 6 6 Remove the pulley shaft f from the right ha...

Page 73: ...and slide off the bush Figure 7 9 2 2 Give a gentle knock to the bush of the end of run b raising the seat above its maximum height so as to facilitate its removal from the frame 3 Lift the bush b by exerting leverage under the housing of the screws if necessary Figure 7 9 3 4 Continue to press on the seat adjustment system under the saddle and slide off the Seat Unit Continues on the next page ...

Page 74: ...ate as indicated by the yellow arrow to remove it from its housing To re fit the seat group follow the above operations in reverse considering the following NOTES Figure 7 9 5 1 When insert the seat tub keep pressed the seat adjusting system 2 Place the seat group just above the teethed guide as indicated by the yellow arrow 3 Insert the seat group and carefully slide it down ...

Page 75: ...v 1 1 Page 7 17 7 9 3 DISMANTLING THE SEAT GROUP 7 9 3 1 Dismantling the seat upholstery Figure 7 9 6 1 Unscrew the 4 screws a using a medium sized Phillips screwdriver 2 Remove the seat b To re fit the all what removed follow the above operations in reverse ...

Page 76: ...ce manual rev 1 1 Page 7 18 7 9 3 2 Dismantling the handle pin Figure 7 9 7 1 On both the sides unscrew the screw a using a 3mm wrench 2 Remove the spacers b and c and the pin d To re fit the all what removed follow the above operations in reverse ...

Page 77: ...e 7 19 7 9 3 3 Dismantling the spring and the handle Figure 7 9 8 Carry out the operations in the paragraph 7 9 3 1 Dismantling the seat upholstery 1 Use a small sized flat screwdriver to remove the circlip a as indicated by the orange arrow Continues on the next page ...

Page 78: ...C5 Technical Assistance manual rev 1 1 Page 7 20 Figure 7 9 9 2 Remove the pin b in the direction of the yellow arrows 3 Remove the pin c as indicated at paragraph 7 9 3 2 Dismantling the handle pin Continues on the next page ...

Page 79: ...v 1 1 Page 7 21 To remove the handle Figure 7 9 10 4 Remove the handle d in the direction of the yellow arrow Figure 7 9 11 With the seat group on a work bench 1 Overturn the group 2 Unscrew the 4 screws e using a 7mm socket wrench Continues on the next page ...

Page 80: ... 12 3 Remove the selector group f in the direction of the yellow arrow 4 Remove the spring g Figure 7 9 13 WARNING check the spring is correctly mounted to avoid it can easily slip off as shown in the figure at side To re fit the all what removed follow the above operations in reverse ...

Page 81: ...port plate Figura 7 9 14 Carry out the operations in the paragraph 7 9 3 3 Dismantling the spring and the handle 1 Unscrew the 4 screws a using a 7mm socket wrench 2 Unscrew the screw b using a 13mm socket wrench 3 Remove the support plate To re fit the all what removed follow the above operations in reverse ...

Page 82: ... paragraph 7 9 3 3 Dismantling the spring and the handle 1 Rotate the lever a of 180 in the direction of the yellow arrow 2 Slide the lever in the direction of the orange arrow Figure 7 9 16 3 Rotate the lever again of 180 in the direction of the yellow arrow Figure 7 9 17 4 Slide the lever in the direction of the orange arrow Continues on the next page ...

Page 83: ...DC5 Technical Assistance manual rev 1 1 Page 7 25 Figure 7 9 18 5 Rotate the lever counter clock wise and free from the support plate 6 Remove the lever a To re fit the all what removed follow the above operations in reverse ...

Page 84: ...the belt Figure 7 10 2 4 Remove the snap ring a the underlying washer 5 Remove the belt tensioner b Figure 7 10 3 6 Remove the pin c using a 6mm Allen wrench WARNING During re assembly tighten the pin a using a torque wrench set at 10Nm During re fitting place some LOCTITE 270 on the threaded side of the pin c and grease the part in contact with the belt tensioner using MOLYCOTE W2 grease To re as...

Page 85: ...cal Assistance manual rev 1 1 Page 7 27 Figure 7 10 4 As regards the passage of the belt refer to the figure at the side WARNING At the end of the operation adjust the tension of the belt as described in the paragraph 8 1 Belt tension ...

Page 86: ...NGER Pay particular attention to the copper disk as it could easily buckle WARNING During re assembly tighten the screws a using a torque wrench set at 5Nm Figure 7 11 2 4 Unscrew the flywheel unit a from the central shaft using a 6mm Allen wrench while blocking it on the opposite side using a 10mm Allen wrench 5 With care remove the flywheel unit from the side opposite the speed sensor WARNING Af...

Page 87: ...screws d using a torque wrench set at 6Nm Figure 7 11 4 To remove the central shaft 6 In sequence remove the snap ring 1 the spacer 2 and the elastic washer 3 7 Remove the central shaft f To re assemble the fitting follow the above operations in reverse and pay attention to the following note WARNING At the end of the operation adjust the position of the flywheel as described in the paragraph 8 5 ...

Page 88: ... NOTE ON DISMANTLING and 7 7 Dismantling the guard 1 Unscrew the 2 screws a using a medium sized Phillips screwdriver 2 Remove the speed sensor b To re fit the speed sensor follow the above operations in reverse WARNING If you also remove the sensor s plastic support adjust the position of the sensor as described in the paragraph 8 4 Adjusting the position of the speed sensor ...

Page 89: ...dicated by the orange arrows and pull in the direction of the yellow arrows 2 Remove the Brake Board from its housing Figure 7 13 2 3 Disconnect the 3 connectors highlighted in the figure 4 Unscrew the blocking screw a from the mains power supply connector b and disconnect it 5 Remove the Brake Board c To re fit the Brake Board follow the above operations in reverse Figure 7 13 3 WARNING If you re...

Page 90: ...14 1 Front Platform 1 Unscrew the 4 screws a using a medium sized Phillips screwdriver 2 Remove the front platform b Figure 7 14 2 Rear Platform 3 Unscrew the 6 screws c using a medium sized Phillips screwdriver 4 Remove the rear platform d In order to re fit the Platforms carry out the above operations in reverse ...

Page 91: ...n access to the connectors turn the equipment on its side 2 Unscrew the 2 screws a using a medium sized Phillips screwdriver and remove the input module on the front platform 3 Disconnect the connector of the cable which goes up to the Brake Board from its support b To re fit the connectors follow the above operations in reverse ...

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Page 93: ...stance manual rev 1 1 Page 8 1 8 ADJUSTMENTS 8 1 BELT TENSION Figure 8 1 1 1 To adjust the belt tension all you need to do is to choose between the various available positions for the spring a WARNING The right tension must be between 50 60Hz ...

Page 94: ...2 8 2 ALIGNING THE BELT Figure 8 2 1 To align the belt 1 Position it correctly in the races of the small pulley of the flywheel a and in the races of the pulley of the pedal cranks b Pedal a few times going forward and in reverse until the belt is positioned in the centre ...

Page 95: ...al rev 1 1 Page 8 3 8 3 ADJUSTMENT OF THE PLAY ON THE SEAT COLUMN Figure 8 3 1 1 Raise the seat on the equipment so as to gain access to the adjustment bush 2 Turn the 2 screws a on the bush and adjust the play of the seat column using a 3mm Allen wrench ...

Page 96: ...OSITION OF THE SPEED SENSOR Figure 8 4 1 1 Loosen the 2 screws a using a 3mm Allen wrench 2 Move the speed sensor support sideways in the direction of the yellow arrows moving it closer to or further away from the copper disk up to a distance from the screws of 0 7mm 3 Re tighten the screws a ...

Page 97: ... the 2 screws a using a 4mm Allen wrench 3 Move the Brake Unit sideways in the direction of the yellow arrows up to a distance from the disk of 0 6mm 4 Re tighten the screws a WARNING In order to adjust the brake correctly do some pedalling at high speed to check that there is no contact with the flywheel DANGER Using a comparator measure the planarity of the copper disk It must have a margin of 0...

Page 98: ...der to resolve the problem you need to regulate the adjustment foot Figure 8 6 1 In order to make the equipment level adjust the two front and rear feet 1 Loosen the locknut B then tighten or unscrew the foot A until the frame is stable 2 When you have finished the adjustment tighten the locknut B WARNING During re assembly tighten the nuts b using a torque wrench set at a maximum of 35Nm ...

Page 99: ... THE USER MENU The configuration procedure of the equipment is activated when the equipment is in Stand By by pressing the 369 buttons at the same time The following will appear on the display ENTER PASSWORD In order to access the procedure you need to enter the password 2406 and press the ENTER key in order to confirm ...

Page 100: ...he display the current configuration structured like the following diagram Use the ENTER key to scroll from one parameter to another saving the data if modified whereas with the and speed keys you can scroll from one parameter to another without saving data to cancel the operation press the CANCEL key for a few seconds ...

Page 101: ...ssible to set the maximum time of every exercise in minutes with values ranging from 1 to 9999 In order to change the setting when the display shows the current maximum time MAX TIME xxx To change the parameter you need to press the ENTER key the current value of the parameter will be displayed in flashing mode and it is necessary to press CANCEL to cancel the current value and use the numerical k...

Page 102: ...he current value and use the numerical keys to enter the desired value The default value of this parameter is 60 When training with the TGS key the cool down is interrupted when you pull out the key 9 1 6 ENABLING THE TGS If the TGS key is not present the configuration of the following parameter does not affect at all the machine It is possible to disable the use of the function keys so as to allo...

Page 103: ...d at paragraph 9 1 10 Setting the parameters to default values 9 1 8 MODIFIABILITY OF TARGET HEART RATE It is possible to allow the target heart rate to be modified or otherwise during the running of a constant heart rate exercise In order to change the setting when the display shows the current setting HR xxx press the numerical GOAL keys to choose the required setting from among the options in t...

Page 104: ...ancel by pressing CANCEL for a few seconds 9 1 11 FORMATTING THE P P KEY This function allows the formatting of a TGS key for the Plug Play mode In order to select the function when the display shows FORMATTING P P confirm with ENTER or cancel by pressing CANCEL for a few seconds At the end of the configuration procedure press the CANCEL key for a few seconds to quit The CANCEL key can be pressed ...

Page 105: ...e time the Display will show ENTER PASSWORD In order to access the procedure you need to enter the password 2501 which protects against unauthorised accesses and press the ENTER key in order to confirm At this point two choices are offered 1 Tech Config 2 Troubleshooting Press the numerical key 1 to enter the technical parameter configuration menu and the equipment will start to display the curren...

Page 106: ...l keys to scroll the list of parameters To change a parameter you need to press the ENTER key the current value of the parameter will be displayed in flashing mode and it is necessary to press CANCEL to cancel the current value and use the numerical keys to enter the desired value Save the change by pressing ENTER To cancel the operation press on the CANCEL key for a few seconds Here following are...

Page 107: ... described below we also find the following 3 sub functions 9 2 1 1 Read from low kit To recall the parameters memorized by the low kit and to be able to visualize them on the display move using the keys of the difficulty level until the display shows READ FROM LOW KIT press ENTER to load the parameters found in the low kit Return to the upper level by pressing CANCEL for a few seconds 9 2 1 2 Wri...

Page 108: ...on 9 2 1 4 Table of Configuration parameters Id Par Unità misura Nome Descrizione Alim 1 decimali Rt Rapporto di trasmissione 135 2 Rvel Rapporto di velocità parte intera 9 3 mA Im Frenatura minima 500 4 W Pmc Potenza massima in continua 200 5 in centesimi Km Coefficiente correttivo della potenza 100 6 0 1N Ca Coppia di attrito utente 13 7 C Tea Temperatura massima sulla bobina 125 8 Rpm utente RP...

Page 109: ...NG DATA Life Kit H Life Brake WRITE TO LOW KIT READ FROM LOW KIT Life Kit L Tot Km KJ Inside this function in addition to the equipment operating data we also find 2 sub functions as described below 9 2 2 1 Read from low kit To recall the parameters memorized by the low kit and to be able to visualize them on the display move using the keys of the difficulty level until the display shows READ FROM...

Page 110: ...y is lost Display Message Description Life Brake Minutes x 10 of Brake operation measured by the Low Kit Life Kit High Minutes x 10 of High Kit operation measured by the High Kit Life Low Kit Minutes x 10 of Low Kit operation measured by the Low Kit KJ total KJ spent relating to all the exercises performed measured by the High Kit Tot Km total Km travelled relating to all the exercises performed m...

Page 111: ...nt we also find 3 sub functions as described below 9 2 3 1 Read from low kit To recall the errors memorized by the low kit and to be able to visualize them on the display move using the keys of the difficulty level until the display shows READ FROM LOW KIT press ENTER to load the parameters found in the low kit Return to the upper level by pressing CANCEL for a few seconds 9 2 3 2 Reset errors To ...

Page 112: ...rrors The errors log provides a series of information as listed in the following table for every error generated by the equipment Error Code Type of error Current at the time of the error Distance in Km at the time of the error During movement the Brake Board is capable of detecting possible faults The possible detected errors are Error Code Description 1 OVERTEMPERATURE this condition occurs when...

Page 113: ...s this menu when the display shows STANDARD SETTINGS if you press ENTER the following message will be displayed CONFIRM By pressing ENTER again all the default values will be re instated To return to the upper level press CANCEL for a few seconds 9 2 5 LOW KIT MENU This function allows you to directly access Firmware FW of the Brake Board In order to access this menu when the display shows LOW KIT...

Page 114: ...fig registers This function allows to set on register at the time NOT used on FORLA LINE 9 2 5 3 Low Kit fault code This function allows you to display any fault code which is blocking the low kit In order to access this menu when the display shows LOW KIT FAULT CODE if you press ENTER the following message will be displayed FAULT XX If FAULT 00 is displayed the Board is not at fault 9 2 6 HIGH KI...

Page 115: ...play hardware The boot is a part of the software which allows you to load the TG application onto the display board The parameter is used solely as info It is NOT possible to change the version or update it 9 2 8 KEY READER VERSION If the TGS key is not present the configuration of the following parameter does not affect at all the machine This function allows you to display the Key Reader Version...

Page 116: ...Forma Line BIKE FORMA DDC5 Technical Assistance manual rev 1 1 Page 9 18 Page blank ...

Page 117: ...e owner and do not require any special technical skills they consist in simple external cleaning for the purposes of general hygiene WARNING Refer to the USER manual ROUTINE MAINTENANCE No special training 10 2 SPECIAL MAINTENANCE SPECIAL maintenance operations may only be carried out by a Qualified Technician specifically trained by Technogym and authorized to perform machine adjustment and start...

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Page 119: ...sks on the equipment Small Phillips screwdriver Medium sized Phillips screwdriver Large Phillips screwdriver 7mm wrench 10mm wrench 13mm wrench 17mm wrench 19mm wrench 3mm Allen wrench 4mm Allen wrench 5mm Allen wrench 6mm Allen wrench 8mm Allen wrench Torque wrench Snap ring pincers Using the code R0003677AA you can order a full set of Allen wrenches with the following sizes 2 2 5 3 4 5 6 and 8mm...

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Page 122: ...SM00729AA UK TECHNOGYM S p A Via G Perticari 20 47035 Gambettola FC Sede legale Via Calcinaro 2861 47522 Cesena FC Sede operativa ITALIA Tel 39 0547 650638 Fax 39 0547 650150 e mail service technogym com ...

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Technogym FORMA LINE BIKE FORMA DDC5 Series, Technical Assistance Manual

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