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Technogym SYNCHRO Excite +, Service And Maintenance Manual

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Summary of Contents for SYNCHRO Excite +

Page 1: ...S Sy yn nc ch hr ro o E X C I T E REV 7 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 errors contained in this manual and declines all liability for accidents or damages resulting from the supply characteristics or use of this manual This document contains proprietary information that ...

Page 4: ......

Page 5: ...9 CABLES 2 13 2 9 1 CBQ cables 2 13 2 9 2 Cavi CU2 14 2 9 3 Cavi ELT 2 15 3 PRINCIPLES OF OPERATION 3 1 3 1 BLOCK DIAGRAM 3 1 3 2 LED DISPLAY BOARDS 3 2 3 2 1 ARM Board 500 and 500SP models 3 2 3 2 2 ARM Board 700 and 700SP models 3 3 3 2 3 C Safe board 3 3 3 2 4 Dual TGS reader 3 3 3 3 VISIO DISPLAY BOARD 3 4 3 3 1 CPU Board 700VISIO model 3 4 3 3 1 1 Back Up battery 3 4 3 3 2 LCD inverter 3 5 3 ...

Page 6: ...ccessing configuration of 700 models 6 2 6 1 3 Automatic Test 6 3 6 1 3 1 I2C Devices Test 6 3 6 1 3 2 LED Test 6 4 6 1 3 3 Serial Ports Test 6 4 6 1 4 Manual Test 6 4 6 1 4 1 Man Keyboard Test 6 4 6 2 TROUBLESHOOTING MENU VISIO MODEL 6 5 6 3 THE DISPLAY FAILS TO ILLUMINATE 6 6 6 3 1 LED models 6 6 6 3 2 SP models 6 8 6 3 2 1 The Display does not illuminate 6 8 6 3 2 2 The Display doesn t remain o...

Page 7: ...S 7 24 7 6 DISASSEMBLING THE HAND SENSOR 7 26 7 7 DISASSEMBLING THE GUARDS 7 28 7 7 1 Rear guard 7 28 7 7 2 Brake box cover guard 7 30 7 7 3 Front guards 7 31 7 8 DISASSEMBLING THE LEVERS 7 32 7 9 DISASSEMBLING THE BRAKE BOX 7 34 7 10 DISASSEMBLING THE HAND SENSOR 7 35 7 11 DISASSEMBLY THE PRIMARY SHAFT AND PULLEY 7 36 7 12 DISASSEMBLING THE PLATFORM LEVER 7 41 7 13 DISASSEMBLING THE BRAKE WINDING...

Page 8: ...sing configuration of 700 models 9 13 9 3 3 Low kit parameter 9 15 9 3 3 1 Read from low kit 9 15 9 3 3 2 Write to low kit 9 15 9 3 3 3 Default Setting 9 16 9 3 3 4 Table of configuration parameters 9 16 9 3 4 Operating data 9 17 9 3 4 1 Read from low kit 9 17 9 3 4 2 Write to low kit 9 18 9 3 4 3 Machine usage data 9 18 9 3 5 Errors log 9 19 9 3 5 1 Read from low kit 9 19 9 3 5 2 Reset Errors 9 1...

Page 9: ...TENANCE OPERATIONS 12 3 12 2 1 Checking the working conditions 12 3 12 2 2 Checking the operation of the Cardio Receiver 12 3 12 2 3 Checking the operation of the hand sensor receiver 12 3 12 2 4 Checking the amount of play on the ball joints 12 3 12 2 5 Checking the wear of rubber parts 12 3 12 2 6 Checking the belts 12 3 12 2 7 Checking the play of the lever and pedal group 12 3 12 2 8 Checking ...

Page 10: ...SYNCHRO Excite Service maintenance manual rev 7 1 Page vi Page intentionally left blank ...

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

Page 12: ...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 Th...

Page 13: ...rs Description Key to values 1 2 Line type DA Excite 3 Machine type 5 Synchro 4 Model 2 500 3 700 5 Type of power supply 3 multi voltage 4 self powered M Medical Device CE 6 Type of Display L LED W VisioWEB Y VisoWEB Capacitive TS 7 Integrated accessories N None T Wellness System I iPod USB A iPod USB WS 8 9 Colour of the frame AL Silver AN Anthracite 10 11 Colour of upholstery 00 None AG Grey K0 ...

Page 14: ...eans a change in the product code Specifically the last character of the product code will be characterised based on the options shown in the table below 16th Character Product code Main country of use Plug standard Type of packaging A Australia A S NZS 3112 Overseas B Brazil NBR 14136 Overseas C China CPC S CCC Overseas D South Africa SANS 164 2 Overseas E Europe EC EEC 7 16 European F USA UL 250...

Page 15: ...ranged as follows Characters Description key to values 1 2 3 4 5 6 Product type DA5 Synchro Excite 2 500 3 700 3 multi voltage 4 self powered M Medical Device CE L LED W VisioWEB Y VisoWEB Capacitive TS 7 8 Year of production 10 2010 9 10 11 12 13 14 Progressive 000001 For example a possible product code would be DA533W10000001 2 3 COLOUR OPTIONS ...

Page 16: ... NO HR monitoring Double Hand sensor Telemetry Telemetry Maintenance Maintenance not required software Serial upload Goal oriented display YES Select language at the start of exercise YES NO Plug Play System YES Calorie Coach YES Total number of programs 23 Quick Start Goals Time Distance Calorie CPR Profiles 6 default 9 custom Custom Training Zone Weight Loss 11 Quick Start Goals Time Distance Ca...

Page 17: ...rvice maintenance manual rev 7 1 Page 2 5 2 5 MECHANICAL CHARACTERISTICS MECHANICAL CHARACTERISTICS Width mm in 2042mm 80 Length mm in 752mm 30 Height mm in 1609mm 63 Weight Kg lbs 150Kg 331lbs 2 5 1 OVERALL DIMENSIONS ...

Page 18: ...SYNCHRO Excite Service maintenance manual rev 7 1 Page 2 6 2 5 2 EUROPEAN AND OVERSEAS PACKING DIMENSIONS ...

Page 19: ...ondensing Storage from 20 to 90 non condensing 2 7 CONFORMITY TO REGULATIONS The machine conforms to the following standards EUROPA USA EMI EN 55014 1 2008 EN 55014 2 1998 EN 61000 3 2 2007 EN 61000 3 3 2009 UL 1647 Safety EN 60335 1 2008 EN 957 1 2006 EN 957 9 class SA 2009 Directives 2006 42 CE 2004 108 CE 2006 95 CE Moreover Electrical isolation class Class I Protection rating IP20 ...

Page 20: ...SPLAY ARM BOARD CBQ 13 KEYBOARD C SAFE BOARD CN8 CN1 CN9 CN1 CN2 BRAKE BRAKE BOARD CN4 CN3 CN1 CN2 SPEED SENSOR Patch Conn CN3 Patch Conn Patch Conn DUAL TGS READER CN7 CBQ 32 CU132 CN1 HRCARDIO RECEIVER CN1 ELT 16 POWER ENTRY MODULE VAC CU128 Power Serial ELT 02 ELT 07 ELT 05 Patch Conn 2 Patch Conn 1 ELT 04 ELT 06 ...

Page 21: ...R Patch Conn BATTERY INPUT CHARGE ELT 01 DISPLAY ARM BOARD CBQ 13 KEYBOARD C SAFE BOARD CN8 CN1 CN9 CN1 CN2 BRAKE BRAKE BOARD CN3 CN4 CN1 CN2 Patch Conn CN3 Patch Conn Patch Conn DUAL TGS READER CN7 CBQ 32 CU132 CN1 HRCARDIO RECEIVER CN1 ELT 16 Power Serial ELT 02 ELT 07 ELT 05 Patch Conn 2 Patch Conn 1 ELT 04 ELT 06 ...

Page 22: ...ake POWER ENTRY MODULE VAC BRAKE BOARD CN4 CN3 CN1 CN2 SPEED SENSOR Patch Conn CN4 J3 J2 HAND SENSOR R HAND SENSOR L Patch Conn 4 CN5 CN6 J1 J2 J4 Patch Conn R Patch Conn L J4 J3 Patch Conn 5 ELT 09 ELT 23 CN1 CN7 Patch Conn 2 Patch Conn 1 ELT 02 ELT 19 CU 132 Patch Conn CBQ 32 CU128 ELT 04 ELT 06 ELT 05 ELT 07 Hand Sensor L Fast Track Left Lever Hand Sensor Rx Fast Track Right lever Serial Power ...

Page 23: ...N8 CN1 DUAL TGS READER CN9 CN1 CN3 CN2 ELT 16 Freno BRAKE BOARD CN3 CN4 CN1 CN2 Patch Conn CN4 J3 J2 HAND SENSOR R HAND SENSOR L Patch Conn 4 CN5 CN6 J1 J2 J4 Patch Conn R Patch Conn L J4 J3 Patch Conn 5 ELT 09 ELT 23 CN1 CN7 Patch Conn 2 Patch Conn 1 ELT 02 ELT 19 CU 132 Patch Conn CBQ 32 ELT 04 ELT 06 ELT 05 ELT 07 Hand Sensor L Fast Track Leva Sinistra Hand Sensor Rx Fast Track Leva Destra seri...

Page 24: ...ELT 02 TV DIGITAL BOARD Tuner Interface WIRELESS BOARD CN5 CN4 USB CN15 CN4 L R LAN V C SAFE Ingresso Antenna J12 CU308 Antenna MAIN B Antenna AUX A J1 J2 J9 CN2 CU331 CN3 ELT 32 CN16 WB670 CU381 J14 LAN CU299 ELT 05 FS JP8 CN23 Patch Conn 2 Patch Conn 1 Patch Conn CU298 ELT 06 ELT 04 HR CARDIO RECEIVER ELT 16 HS BOARD J3 J2 CONNECTORS BOARD J1 J2 J4 Patch Conn R Patch Conn L J4 J3 HAND SENSOR R H...

Page 25: ...in Out 2 9 1 CBQ CABLES CBQ 13 C Safe Board cable LED Only Display Board C Safe Board Display Board CN8 Signal Colour C Safe Board CN1 1 Digital 1 Flat cable 1 14 Digital 14 Flat cable 14 CBQ32 TGS cable Patch Conn CPU ARM Board ARM Board CN7 CPU Board CN19 Signal Colour Patch Conn 1 Power 12Vdc Brown 3 2 RX Blue 5 6 TX Black 9 8 GND Red 1 ...

Page 26: ...Conn Dual TGS reader Patch conn Signal Colour Dual TGS Reader CN1 3 12Vdc power Black 1 5 RX Green 2 9 TX Black 3 1 GND Black 8 CU128 100 220V power signal cable Power entry module Brake Board Power entry module Signal Colour Brake board CN4 N NEUTRAL Light Blue 1 F PHASE Brown 3 T GROUND Yellow Green 5 ...

Page 27: ...welded at the internal contact 1 V Battery Red Faston 6 V Battery Black Faston ELT 02 Brake power supply cable Brake Board Brake Speed Sensor Brake Board CN2 Signal Colour Brake Speed Sensor 1 Brake power supply Brown Fast on 2 Brake power supply Brown Fast on 3 SPM Red Faston connected to brown cable 4 SPM Reference Black eyelet 5 n c 6 n c ELT 04 High Kit and Low Kit power supply cable Brake Boa...

Page 28: ...ow Kit Serial cable Brake Board Patch Conn 2 Brake Board CN3 Signal Colour Patch Conn 2 1 Digital Gnd Orange White 1 2 Digital Gnd Orange 2 3 NC Green White 3 4 Download Green 4 5 Reset Blue White 5 6 NC Blue 6 7 485 Tx Rx Brown White 7 8 485 Tx Rx Brown 8 ELT 07 Cavo comunicazione seriale fra Kit Alto e Kit Basso Patch Conn 2 CPU ARM Board Patch Conn 2 Signal Colour ARM Board CN9 CPU Board CN18 1...

Page 29: ...ver button signal Green 2 4 Sensor signal reference Brown Faston 5 Reference Brown 4 6 5Vdc Power supply White 1 ELT 16 HR Cardio Receiver cable CPU ARM Board HR Cardio Receiver CPU Board CN29 ARM Board CN3 Signal Colour HR Cardio Receiver CN1 1 5 Vdc power supply White 2 7 Pulse beat to beat Black 4 8 Gnd Green 1 ELT 19 Hand Sensor Board cable and Fast Track CPU ARM Board Patch Conn 4 Display Boa...

Page 30: ...ensor Board cable Fast Track Patch Conn 4 HS Board CN L CN R Connector Board Patch Conn 4 Signal Colour HS Board J3 Levers Patch Conn Connectors Board CN R CN L J2 J4 1 Reference White 1 2 Out pulse Green 3 7 5Vdc Power supply Brown 2 3 Reference Brown 5 4 Right lever button signal Green 3 5 5Vdc Power supply White 6 8 Reference Brown 5 9 Left lever button signal Green 3 10 5Vdc Power supply Green...

Page 31: ...ow 1 7 GND Blue 30 8 Ztxn1 Black 9 9 Ztxp1 Red 7 10 GND Black 24 11 Ztxn2 Black 15 12 Ztxp2 Grey 13 13 GND Red 17 14 Ztxcn Black 27 15 Ztxcp White 25 CU328 Inverter LCD Fronteck cable VISIO Only CPU Board LCD Inverter LCD Inverter CN1 Signal Colour CPU Board CN5 11 12Vdc Power supply inlet Black 1 1 GND Black 2 4 ON OFF Black 3 3 GND Black 4 12 12Vdc Black 5 2 Save lamp Black 6 5 GND Black 2 10 12...

Page 32: ...3 3 TX RX Black 11 4 RX TX Black 12 5 CTS Black 10 6 5Vdc Black 9 7 GND Black 8 8 GND Black 7 9 Video Gnd Black 6 10 Video siganl Black 5 11 Gnd audio L Black 4 12 L Signal audio Black 3 13 R Signal audio Black 2 14 Gnd audio R Black 1 CU333 Audio headphone Jack cable VISIO only CPU Board headphone Jack CPU Board J5 Signal Colour headphone Jack 2 Out_R Green 4 4 Schield Yellow 5 1 GND Red 2 3 Out_...

Page 33: ...BOARD C SAFE BOARD HS RECEIVER BOARD DUAL TGS READER KEYBOARD HAND SENSOR L TOUCH SENSOR L TOUCH SENSOR R VISIO DISPLAY TOUCH SCREEN HAND SENSOR R WIRELESS BOARD DIGITAL TV BOARD iPod Doking Station Antenna Inlet USB POWERED VERSION POWER ENTRY MODULE BRAKE BOARD VAC SPEED SENSOR BRAKE SELF POWERED VERSION BRAKE BATTERY BRAKE BOARD INPUT BATTERY CHARGE External power supply HR RECEIVER BOARD ...

Page 34: ...ons of the board are Manages and process signals from 1 Keyboard 2 HR receiver 3 C Safe Board Optional 4 Dual TGS reader if present distributes the voltages received from the Brake Board to the display exchanges via the RS 485 serial link to the Brake Board the commands for controlling the brake controls the LEDs and the 7 segment displays which provide feedback about the exercise session The boar...

Page 35: ...ays which provide feedback about the exercise session The board includes the following indicator LEDs LED name Colour Description LED1 GREEN if ON the 12Vdc power supply from the Brake Board correctly reaches the board LED2 YELLOW if ON the 5Vdc power supply from the Brake Board correctly reaches the board 3 2 3 C SAFE BOARD This board makes available a communication port on 1 externally accessibl...

Page 36: ...re Manages and process signals from 1 LCD 2 LCD Inverter 3 Touch Screen 4 Digital Analogue TUNER Board 5 LAN network board integrated 6 Wireless network Board 7 HR Receiver 8 HS Receiver 9 Audio Video external device Connectors Board 10 Headphone Jack 11 C Safe integrated 12 Service USB port integrated Optional 13 Dual TGS Reader 14 User USB port 15 iPod docking station Distributes the voltages re...

Page 37: ...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 reaches the board OFF if the power supply does not reach the board FLASHING if loading starting the SW in the first seconds after it switch on During the firmware upload In case of HW SW malfunctionin...

Page 38: ... 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 intermittent and security vulnerability to attacks by hackers Where possible it is in any case preferable to use the wired network The possibility of using Wi Fi also depends greatly on the type of service application that is to b...

Page 39: ...hine display has one jack for connecting headphones The jack is connected on a stereo output of the CPU Board 3 3 8 C SAFE BOARD INTEGRATED It a function that allows the connection using a appropriate cable for connecting other devices such as external PC suitably programmed to control the machine speed level of difficulty etc 3 3 9 SERVICE USB PORT INTEGRATED It is used to connect USB keys for up...

Page 40: ...s iPod 5th gen iPod Classic iPod mini iPod Nano iPod Touch iPhone 3 3 10 2 Client USB port This is an additional port which can be installed on the VISIO Display and makes available a USB port for connecting to external devices The user can connect USB devices for playing a vast range of multimedia files including mp3 wma wav wmv MPEG2 MPEG4 DivX XVID jpg 3 3 10 3 Dual TGS reader It s the device w...

Page 41: ...SENSOR This board manages the signals received from the Hand Sensors used by the user when exercising The Board receives the 5Vdc power supply from the Display Board The Receiver Board communicate with the Display Board in a positive logic mode When the Board is in stand by the signal is 5Vdc as soon the Board receives a reliable source of heart rate signal change to 0Vdc and then for each heartbe...

Page 42: ...ric Transmitter Chest Belt used by the user when exercising The Board receives the 5Vdc power supply from the Display Board The Receiver Board communicate with the Display Board in a negative logic mode When the Board is in stand by the signal is 5Vdc and for each heartbeat detected generates a pulse of 0Vdc with a 30msec width signal ...

Page 43: ...uired of the Electromagnetic Brake Electromagnetic Brake error messages commands for modifying the circuit board configuration parameters commands for viewing the errors logged by the circuit board Commands of equipment usage RPM WATT distance etc 3 Section which generates the current for the brake winding varying the current produces a proportional variation in the resistance of the brake The exc...

Page 44: ...ctromotive forces within it that cause induced currents to circulate These currents flow in a direction which opposes the cause that induced them i e the movement of the disk inside the magnetic field Consequently they have a braking 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 ...

Page 45: ...s supply and N 5 equipments with a 110Vac mains supply If other types of machines are connected together the maximum number is determined by their current draw 3 9 ALTERNATOR Only for models SELF POWERED The alternator consists of a stator winding whose rotor is put into rotation by the movement of the pedals generating the voltage necessary for the machine s operation Depending on the rate of ped...

Page 46: ...a to be saved in memory The battery can be recharged in 2 ways during the exercise through the Brake Board in the Stand By condition from an external power supply included with the machine which is able to fully recharge the battery in 8 hours Do not use the machine during recharging with the external power supply 3 11 EXTERNAL POWER SUPPLY INPUT Only for models SELF POWERED This is a socket for p...

Page 47: ...ignal proportional to the speed 3 12 2 CONTROLS The control block diagram is as follows ARM CPU BOARD BRAKE BOARD BRAKE Excitation current RS 485 CN18 CN9 CN2 CN4 Speed Sensor CN2 Green LED Pulses To obtain a given exercise effort level the display board sends the required value of exercise speed in rpm per minute to the Brake board via the RS 485 serial link Based on the commands received the bra...

Page 48: ...librate the resistance value produced but only using the braking table stored in the Brake Board The accuracy of the braking system has a tolerance of 10 During the movement the speed sensor detects the heads of the brake disk fixing screws and produces a speed feedback signal that is sent to the Brake board The brake board will adjust s the excitation current of the brake winding so that the spee...

Page 49: ...produced by the speed sensor and has the waveform shown in the figure below Figure 3 12 1 The signal enters the Brake Board pins 3 4 on connector CN2 where it is used to determine the speed value RPM that is sent to the Display Board via the RS 485 serial link This signal can also be measured qualitatively using a multimeter The voltage measured across the sensor terminals should be 0Vdc when the ...

Page 50: ...SYNCHRO Excite Service maintenance manual rev 7 1 Page 3 18 Page intentionally left blank ...

Page 51: ...ion The machine 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 Signal 5 5Vdc 7 Ground WARNING for the numbering of the pins on RJ45 connector please refer to the diagram below ...

Page 52: ...able to use must be wired as follows WARNING for the numbering of the pins on RJ45 connector please refer to the diagram below When programming the machine sometimes it is necessary to fit plug into the free RJ 45 port on the back of the display to avoid any type of interference during the operation The wiring diagram of the RJ 45 plug is as follows Programming cable and plug can be ordered using ...

Page 53: ...l characteristic They are briefly detailed below 1 On machines with VISIOWEB display it is possible for the user browsing and use internet services during the training session 2 VISIOWEB has been developed on Linux instead of Windows CE used for VISIO This difference can not be noticed by the final user because on both the product versions there is the same user interface and just few steps of the...

Page 54: ...tallation instructions The table below gives the codes of the kits to be chosen according to the TV standard used in the installation country VISIO UPGRADE KIT CODE Synchro DVB T A0000478 D Synchro ATSC A0000478 A Synchro ISDB T A0000478 I Table 4 1 CAUTION At the end of the Upgrade steps of Standard Setting as described in the relevant paragraph of the Service menu 4 5 ACCESSORISE ACCESSORISE COD...

Page 55: ...tromagnetic noise television sets electrical motors antennas high voltage lines household appliances etc or medical equipment 5 To eliminate any interference with the cardio receiver no transmitters should be placed less than 90cm from the display Only for powered models 1 The mains voltage must match the value specified on the machine rating plate 2 The electrical system must be correctly earthed...

Page 56: ...ame and not the levers or the control pannel Take great care when moving the equipment and positioning it on the ground as it may overbalance 1 The equipment has two fixed rear wheels To move the equipment lift it up slightly as shown in the illustration and push it forwards and backwards Figure 5 2 1 After every moving check if the equipment is flat adjusting the left foot as indicated at the par...

Page 57: ...ge 5 3 5 3 RECOMMENDED ANTENNA SIGNAL REQUIREMENTS All the information about the minimum requirements concerning the antenna signal are detailed in the proper manual Electrical and antenna requirements you can find and download into the Technogym Direct ...

Page 58: ...o the wall outlet and make sure all the technical requirements are respected according to the specific paragraph of this manual 5 5 FIRST POWER ON After completing the installation procedure the machine is ready for use On the POWERED models simply turn the on off switch from position 0 to position 1 while on the SELF POWERED models identified with the initials SP it is necessary to get on the mac...

Page 59: ... 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 Note Clarification of the operation in progress or that will be...

Page 60: ...digits At this point there are two options available Tech Config Troubleshooting Press numeric key to access the menu for configuring technical parameters the machine display will begin showing the current configuration structured as in the diagram below 6 1 2 ACCESSING CONFIGURATION OF 700 MODELS It is invoked when the machine is in Stand By mode Simultaneously press the keys 369 for LED models T...

Page 61: ... grouped under this section conduct checks on the machine s operation in a fully automatic manner After selecting the desired test using the and effort level keys press ENTER to initiate the test and then await the result Press ENTER again to continue and use the CLEAR key to return to the higher menu level holding it down for a few seconds The various tests are described below 6 1 3 1 I2C Devices...

Page 62: ...e of the test was negative the message will specify COM1 in the case of the C Safe COM test COM2 in the case of communications with the low kit or COM3 in the case of the TGS COM test The TGS COM test done on machine not provided with the key reader gives a fail outcome The same if the C Safe COM test is done on a machine which C Safe port is not plugged with the monitor plug described at paragrap...

Page 63: ...hentheequipment is inStand By as showninthefigurebelow 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 password 2501 and press the ENTER key to confirm or EXIT to quit By selecting the key which is highlighted in red you will gain access to the TROUBLESHOOTING menu For the following menu please re...

Page 64: ...wall outlet 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 Continued on following page ...

Page 65: ...1 Check the LEDs 1 and 2 green and yellow of Display Board are correctly lit on 2 Place the tester probes across pins 3 and 1 of CN4 connectors on the Brake Board The measured value should be approximately 220Vac or 110Vac depending on the mains voltage 3 Slightly lift up the Faston on the machine power entry module Place the tester probes across the live and neutral pins on the same connector The...

Page 66: ...he LEDs on the Brake Board lit on while pedaling Correct operation after 30 seconds without pedaling the machine switches off Replace the DisplayBoard THE DISPLAY DOES NOT ILLUMINATE NO YES NO YES NO YES 2 1 B Chackthe cable that connect the LowKit with High Kit Are the voltages at the output of the Brake Board correct NO 3 Replace the Brake Board YES 4 Continued on following page ...

Page 67: ...f it isn t about 12Vdc recharge the battery for 8 hour with an external power 2 Check the LEDs 1 and 2 green and yellow of the Display Board are correctly lit on 3 Check if the LEDs 1 and 2 green and yellow of the Brake Board are correctly lighting on as described in paragraph 3 5 Brake Board 4 Using a tester check that all the output voltages on connector CN1 of the Brake board The measured value...

Page 68: ...exercise Measure the battery There are the 12Volt Check if the fuse on the ELT 01 cable Is it whole Carge and or repalce the battery THE DISPLAY DOESN T REMAIN ON WHEN STOPPING THE EXECUTION OF THE EXERCISE NO NO YES Clean the contacts of fuse holder and or repalce the ELT 01 cable 2 Replace the fuse YES 1 Continued on following page ...

Page 69: ...01 cable is whole If necessary replace the F5A fuse A indicated in the figure follows 2 Clean the contacts of fuse holder inside of the fuse housing highlight in the figure follows Figure 6 3 1 At the end to check if the contacts inside of the fuse housing are intact and functioning check the continuity of red cable V battery Carry out the measure on the CN3 connector of Brake Board and on the fas...

Page 70: ...ll outlet supplythe correct voltage Is the power supplycable OK Are the LED on the CPU Board lit on Plug the machine into a working electrical outlet Replace thecable THE DISPLAY DOES NOT ILLUMINATE NO YES NO YES YES NO B 1 Are the fuses OK Replace the fuses YES NO Continued on following page ...

Page 71: ...ntenance manual rev 7 1 Page 6 13 Replace the LCD Inverter Does the problempersist NO Defective LCD Inverter YES Replace the LCD Does the problem persists YES Replace the CPU Board A NO Defective LCD Continued on following page ...

Page 72: ...able NO Replace the power entrymodule YES Checkif there are the voltages at the output of the Brake Board YES Replace the Brake Board 4 B Checkif there are the voltages at the input of the CPU Board Replace CPU Board NO YES 5 3 Is the voltage at the output of the power entry module correct Replace the connecting between High Kit and LowKit NO ...

Page 73: ...power entry module Place the tester probes across the live and neutral pins on the same connector The measured value should be approximately 220VAC or 110VAC depending on the mains voltage 4 Using a tester check that all the output voltages on connector CN1 of the Brake board The measured value should be 12Vdc between pins 6 2 5Vdc between pins 7 3 5 Place the tester probes across pins 1 and 2 of ...

Page 74: ...ter in the VISIO manual 6 5 NO AUDIO SOUND Only for VISIO models For the following menu please refer to the relevant chapter in the VISIO manual 6 6 NO TV PICTURE Only for VISIO models For the following menu please refer to the relevant chapter in the VISIO manual 6 7 THE RADIO DOES NOT PLAY Only for VISIO models For the following menu please refer to the relevant chapter in the VISIO manual ...

Page 75: ...e files uploaded on the iPod Check the audio connection system NO Replace the Docking station board 2 3 YES Check the iPod cable connection Is the iPod detected by the machine OK YES Is the voltage at the input of the docking station correct Replace the docking station board YES 5 NO 6 NO A Update the iPod SW version Has been the device enabled from the proper function in the user menu Enable the ...

Page 76: ... the VISIO interface 3 Carry out the troubleshooting procedure 6 5 No audio sound 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 control as detailed in the relevant paragraph of the User menu 6 The CU331 cable has identical connectors on either end then it can sometimes be connected the wrong way round 7 Place the test...

Page 77: ...upgrade The error is displayed by a massage and stored in the Errors Log section To reinstate communications between the lower and upper assemblies 1 Check that cables ELT 06 and ELT 07 is correct using the Test Box Excite and replace if necessary 2 Try replacing the Brake Board and the CPU ARM Board in turn and check whether the communication works If you replace Brake Board check that its SW ver...

Page 78: ...e Does the Brake Board supply tension at the brake THERE IS NO RESISTANCE Are the Watt and SPM values shown on the displaydifferent fromzero NO YES 1 Carryout the The speed signal is incorrect troubleshooting procedure Replace the Brake Board YES Is there the tension to the input of the brake NO Replace the Brake YES Replace connecting cable NO 3 YES Is the resistance on the Brake winding more or ...

Page 79: ...w 1 Place the tester probes across pins 1 and 2 of the connector CN2 on the Brake Board and exercise at a speed of 60RPM You should measure a Vdc which increases according to the exercise level 2 Measure the resistance on the 2 fast on of the Brake 3 As for step 1 but with everything reconnected and across the Electromagnetic Brake If you replace Brake Board check that its SW version is updated ot...

Page 80: ... is incorrect the Brake Board is defective the brake is defective Are the mechanics of the machine in good condition Does the Brake Board output the correct current to the brake winding Replace the Brake Board NO Replace the Brake winding YES THE RESISTANCE IS INCORRECT 2 Repair the faulty mechanical parts NO Carryout the Speed signal is Incorrect troubleshooting procedure 3 Carryout the Standard ...

Page 81: ...s procedure as detailed in the relevant paragraph of the Service menu 2 Check that the mechanical system consisting of the pedals belt and brake moves smoothly and without higher than normal friction or resistance 3 Measure the voltage supplied by the Brake Board to the winding In Quick Start mode select the effort level and check that the value is different from 0 If you replace Brake Board check...

Page 82: ...the flywheel The speed sensor is defective The Brake Board is defective Does the speed sensor send the correct signal to the Brake Board 3 Replace the speed sensor generator on SP models NO Replace the Brake Board YES THE SPEED SIGNAL IS INCORRECT 1 YES YES Update the Brake Board SW Is the speed signal correct Defective SW NO Carryout the Standard Setting procedure 2 ...

Page 83: ... 12 1 In addition when pedalling at 80RPM the frequency of the signal should be 136Hz 3 Self Powered models Check the signal at paragraph 2 9 Cables The measured signal should be that indicated in Figure 3 12 1 In addition when pedalling at 80RPM the frequency of the signal should be 136Hz The speed signal can also be observed qualitatively using a multimeter The value should be 0Vdc when the mach...

Page 84: ... the voltage at the input to the TGS reader correct Is the voltage at the output to the DisplayBoard correct Replace cable CBQ 32 and or CU132 1 2 YES NO YES Replace the DisplayBoard NO A Is the serial communication link between the DisplayBoard and the TGS reader OK Replace the TGS reader Is the communication linkbetween the DisplayBoard and the TGS reader OK TGS reader defective 3 3 YES NO YES R...

Page 85: ...detail below 1 In 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 8 of connector CN19 CPU Board or on the CN7 connector ARM Board 3 Use the serial communications test described at paragraph 6 1 3 3 Serial Ports Test If you replace ARM CPU Board check that its SW version is updated otherwise inst...

Page 86: ...e the quality 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 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 hands using soaps that can dry the skin too much The...

Page 87: ... ARM CPU board Are present HS Board def ective Replace it 2 YES NO YES Check the display SW version and the grounding of the HS Board The problem persists 3 Check and or replace the CU365 and CU366 cables YES Check the Hand Senson are correctly connectedat to the Connector Board NO ok Restore the connections NO 4 Check the connection between Hand Sensor Board and Connector Board is ok YES Restore ...

Page 88: ...ue should be 5Vdc 3 As at step 2 but on pin 1 and 6 on CN4 connector ARM Board and on CN23 connector CPU Board 4 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 Hand Sensor Board HS measuring the resistance value between a The Faston on the HS Board and the ground node on the equipment b The ground node o...

Page 89: ...ee it proper works THE HR SIGNAL IS INCORRECT Chest belt Check the Receiver Board SW and the Grounding The problem persists Check the Receiver Board has been correctly mounted on the machine Proper placement OK Mount the Receiver Board in the right way NO YES NO 1 Chest belt def ective YES YES YES A Check if it works properly using a chest belt you are sure it s ok Problem solved 2 NO Continued on...

Page 90: ...if the 5Vdc are at the input of the Receiver Board Are present ARM CPU Board defective Replace it 3 NO YES Check if the 5Vdc are at the output of the ARM CPU Board Are present 4 NO Replace the cable A Receiver Board defective Replace it YES Continued on following page ...

Page 91: ...e equipment and the main wall socket t The measured value should be approximately lower than 1Ω Ohm Check finally the grounding 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 if the receiver has been correctly mounted on the machine as detail at paragraph 7 4 Disassembling t...

Page 92: ...IGNAL IS INCORRECT Chest belt Are the machines correctly spaced by the required minimum distance Check the Receiver Board has been correctly mounted on the machine Reposition the machines so they are adequately spaced Mount the Receiver Board in the right way NO YES NO Check the Display SW versione and the grounding of the receiver 1 2 Chest belt def ective NO NO YES A Check if it works properly u...

Page 93: ...ART TABLE you can find in TG Direct section Check the grounding of the HR Receiver Board measuring the resistance value between The ground faston of Receiver Board and the ground node on the Power supply box of the machine The ground node on the Power supply box of the machine and the main wall socket The measured value should be approximately lower than 1Ω Ohm Check finally the grounding of the m...

Page 94: ...vice maintenance manual rev 7 1 Page 6 36 Figure 6 15 1 The active area of the transmitter is wider on the lateral side 130 cm instead of the front or the back side 90 cm Take care of the following diagram Figure 6 15 2 ...

Page 95: ...xcite 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 cable The circuit lights the LED for each heart beat and or disturbance received in this way it is possible to determine whether there is any interference and identify its sources Do not keep the Test Box Excite to...

Page 96: ... just washed or particularly dry acidity of the skin and or a particular 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 hands using soaps that can dry the skin too much THE TELEMETRIC HR SIGNAL IS INCORRECT Hand Sensor Check the state of wear of cable The...

Page 97: ...ound node on the equipment and the main wall socket The measured value should be approximately lower than 1Ω Ohm Check finally the grounding 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 he fastons of the cable are well connected to the HS plates b The continuity of ...

Page 98: ...SYNCHRO Excite Service maintenance manual rev 7 1 Page 6 40 Page intentionally left blank ...

Page 99: ...nd unplug the mains lead from the wall outlet 1 Back off the 4 screws a using a medium Phillips screwdriver Figure 7 1 2 2 Unplug the connector highlighted in the figure at the side 3 Remove the Display Figure 7 1 3 4 Back off the 2 screws b using a 8mm hexagonal wrench for remove the rear support of the Display To reassemble the Display carry out the above steps in reverse order ...

Page 100: ...he wall outlet 1 Back off the 4 screws a using a medium Phillips screwdriver Figure 7 1 5 2 Unplug the connector highlighted in the figure at the side 3 Remove the Display Figure 7 1 6 4 Back off the 2 screws b using a 8mm hexagonal wrench for remove the rear support of the Display To reassemble the LED Display carry out the above steps in reverse order ...

Page 101: ...dium Phillips Screwdriver 2 Lower the guard b Figure 7 1 8 3 Back off the 2 screws c using a 3mm hexagonal wrench on both side Figure 7 1 9 4 Unplug the connectors highlighted in the figure at the side 5 Remove the Display CAUTION Connect the network cables on the left in the photo correctly because they may not be inverted To reassemble the VISIO Display carry out the above steps in reverse order...

Page 102: ...SSEMBLING BOARDS AND COMPONENTS 7 2 1 LED DISPLAY ARM BOARD Figure 7 2 1 Carry out the procedure described in paragraph 7 1 Disassembling the display Place the Display on a work bench It is now possible to remove the following boards The ARM board A The C Safe board B ...

Page 103: ... Page 7 5 7 2 1 1 ARM board A Figure 7 2 2 1 Unplug the connectors highlighted in the figure 2 Back off the 5 screws c using a medium Phillips Screwdriver 1 Remove the ARM board A To reassemble the ARM board carry out the above steps in reverse order ...

Page 104: ...nnect from the ARM board the connector highlighted in the figure 2 Remove the hot glue that fix the board on the casing and remove the C Safe board B sliding it upward During the reassembly use the hot glue to fix the C Safe board To reassemble the C Safe board carry out the above steps in reverse order ...

Page 105: ...bed in paragraph 7 1 Disassembling the display Place the display on a work bench It is now possible to remove the following components Wireless Board A TUNER Board B LCD Inverter C CPU board D LCD Touch Screen E Headphone Jack F Dual TGS reader USB port G iPod Docking Station H Front plugs TGS USB and cover Continued on following page ...

Page 106: ...e routing as shown in Figure 7 2 8 Figure 7 2 6 2 Push simultaneously the 2 side tabs outward in the direction of the purple arrows 1 The Wireless Board will automatically lift up Figure 7 2 7 3 Remove the Wireless Board A in the direction of the orange arrow 2 as shown in the figure at the side CAUTION During the reassembly mount the antennas of Figure 7 2 5 on Wireless Board and after the Board ...

Page 107: ...SYNCHRO Excite Service maintenance manual rev 7 1 Page 7 9 To reassemble the antenna cables X and Y follow the routing shown below The Dissipator Z is only on the ATSC and ISDB T version Figure 7 2 8 ...

Page 108: ...Back off the 3 screws a using a medium Phillips Screwdriver 2 Remove the protection guard of Tuner board b Figure 7 2 10 3 Back off the 3 spacers c 4 Lift up the black tab and disconnect the flat cable d 5 Remove the Tuner Board B To reassemble the Tuner Board follows the above steps in the reverse order ...

Page 109: ... Carry out the procedure described in paragraph 7 2 2 2 Tuner DVB T board B at step 4 1 Remove the Tuner board ver ATSC B1 or ver ISDB T B2 Figure 7 2 12 2 Back off the 2 screws a using a medium Phillips Screwdriver 3 Remove the dissipater b To reassemble the Tuner Boards follows the above steps in the reverse order ...

Page 110: ...the connectors highlighted in the Figure 2 Back off the 4 screws a using a medium Phillips Screwdriver 3 Remove the LCD inverter cover b Figure 7 2 14 4 Unplug the 4 connectors highlighted in figure 5 Remove the LCD Inverter board C To reassemble the Tuner Boards follows the above steps in the reverse order ...

Page 111: ... the procedure described in paragraph 7 2 2 1 Wireless board A and 7 2 2 2 Tuner DVB T board B 1 Unplug the connectors highlighted in the figure 2 Back off the 8 screws a using a medium Phillips Screwdriver 3 Remove the CPU board D To reassemble the CPU Board follows the above steps in the reverse order ...

Page 112: ... a medium Phillips Screwdriver 2 Remove the LCD Inverter as described in the paragraph 7 2 2 4 LCD Inverter C 3 Remove the LCD group completely Figure 7 2 17 4 Carefully overturn the LCD group 5 Back off the 2 screws c on the both side using a medium Phillips Screwdriver 6 Remove the LCD E from the support plate To reassemble the LCD and the Touch Screen follows the above steps in the reverse orde...

Page 113: ...15 7 2 2 7 Headphone Jack F Figure 7 2 18 1 Unplug the connector highlighted in the figure 2 Back off the 2 screws a using a small Phillips screwdriver 3 Remove the Headphone Jack F To reassemble the Headphone Jack follows the above steps in the reverse order ...

Page 114: ...igure 7 2 19 1 Unplug the cables highlighted in the figure 2 Back off the 3 screws a using a medium Phillips Screwdriver 3 Remove the TGS group and the USB port G as indicated in the figure at the side To reassemble the Dual TGS reader and the USB port follows the above steps in the reverse order ...

Page 115: ...ure 7 2 20 1 Lift the Docking Station covering cap up and back off the screw a using a medium Phillips screwdriver Figure 7 2 21 2 Unplug the cable highlighted in the figure and remove the iPod Docking Station H To reassemble the iPod Docking Station follows the above steps in the reverse order ...

Page 116: ...7 18 7 2 2 10 Frontal plugs TGS USB and cover Figure 7 2 22 1 Back off the 4 screws a using a medium Phillips screwdriver 2 Remove the frontal plug from the front side To reassemble the Frontal plugs and USB port follows the above steps in the reverse order ...

Page 117: ...aph 7 1 Disassembling the display to the point 3 Place the display assembly on a work bench 1 Unplug the connector a After the reassembling of the board remember to fix the keyboard connector using a drop of hot glue 500 model Figure 7 3 2 700 model Figure 7 3 3 2 Use a sharp tool to lift up and detach a corner of the keyboard then remove the keyboard Continued on following page ...

Page 118: ... part starting from the left and working toward the right without bending the keyboard 4 Remove the protective film The keyboard assembly procedure can only be carried out once because disassembly damages the tracks and keys When reassembling the keyboard make sure that none of the keys are bent or remain pushed in After the reassembly of the Display check the proper functioning of new keyboard as...

Page 119: ...Excite Service maintenance manual rev 7 1 Page 7 21 7 3 2 VISIO VERSION For the Touch Screen disassembly refer to the Display Board disassembling procedure described at the paragraph 7 2 2 6 LCD E Touch Screen ...

Page 120: ...g the mains lead from the wall outlet 1 Back off the 6 screws a using a medium Phillips screwdriver Figure 7 4 2 2 Back of the 4 screws a with a medium Phillip screwdriver 3 Lift up and remove the display from the machine Figure 7 4 3 4 Loosen the 2 screws c using an 8mm hexagonal wrench 5 Remove the upper cover d Continued in following page ...

Page 121: ...t the cardio receiver as shown in the figure f and disconnect the connector as shown in the figure g 7 Remove the receiver and replace if it is necessary Figure 7 4 6 3 Rewind the receiver in the sponge and rewind all in a cable tie for look all ATTENTION Position the receiver so that the coil is oriented upward and towards the user as shown in the figure at the side To reassemble the cardio recei...

Page 122: ...e and unplug the mains lead from the wall outlet 1 Back off the 6 screws a with a medium Phillip screwdriver Figure 7 5 2 2 Back off the 4 screws a with a medium Phillips screwdriver 3 Lift up the display Figure 7 5 3 4 Loosen the 2 screws c with a 8mm hexagonal wrench 5 Remove the upper tray bracket d Continued in following page ...

Page 123: ...Back off the 6 screws f with a 6mm hexagonal wrench back off the 3 at the right side or at the left side depending on the handlebar you want to remove 3 Remove the handgrips In case of a 700 machine before disassembly the levers disconnect the Hand Sensor cables leaving from upright down when to come out To reassemble the handgrips carry out the above steps in reverse order ...

Page 124: ...0VISIO Figure 7 6 1 Turn off the machine and unplug the mains lead from the wall outlet For each handle sensor 1 Back off the 2 screws a using a small Phillips screwdriver Figure 7 6 2 2 Lift up the top sensor 3 Remove the lower sensor 4 To disconnect the sensors unplug the two Faston indicated in the figure Continued in following page ...

Page 125: ...k off the 4 screws b using a small Phillips screwdriver Figure 7 6 4 2 Lift up the top sensor 3 Remove the lower sensor 4 To disconnect the sensors unplug the two faston and the connector c of the touch sensor indicated in the figure To reassemble the sensors carry out the above steps in reverse order ...

Page 126: ...e mains lead from the wall outlet 1 Back off the screws a on both sides of the machine using a 4mm hexagonal wrench 2 Remove the top cover b Figure 7 7 2 3 Back off the 4 screws c using an 8mm hexagonal wrench Figure 7 7 3 4 Back off the screw d on both sides of the machine using a 4mm hexagonal wrench 5 Remove the rear guard Continued in following page ...

Page 127: ...e 7 29 Figure 7 7 4 6 Back off the 2 screws e with a medium Phillips screwdriver Figure 7 7 5 7 Back off the 3 screws f on both side of the machine using a medium Phillip screwdriver 8 Back off the 2 screws g with a 4mm hexagonal wrench 9 Remove the guard ...

Page 128: ...ne using a medium Phillips screwdriver 2 Lift up the top cover along the display column and secure it with a strap Figure 7 7 7 3 Back off the 4 screws b with a 4mm hexagonal wrench 4 Back off the 2 screws c with a medium Phillips screwdriver 5 Remove the front casing d Figure 7 7 8 6 Back off the 2 screw i with 4mm hexagonal wrench 7 Remove the casing ...

Page 129: ... Remove the guard a unhook the tabs in the direction indicated by the arrows 2 Pull it out from the top Figure 7 7 10 3 Back off the screws b on either side of the machine using a 4mm hexagonal wrench Figure 7 7 11 4 Back off the 4 screws c using a 4mm hexagonal wrench m 5 Remove the two lateral guards To reassemble the guards carry out the above steps in reverse order ...

Page 130: ...2 Disconnect the connector c 3 Back off the 4 screws d with a 6mm hexagonal wrench 4 Remove the lever from the machine frame ATTENTION During reassembly apply a drop of Loctite and lock down the screws d using a torque wrench setting of 37Nm Figure 7 8 3 Carry out the operations described in paragraphs 7 7 2 Brake box cover guard 5 Back off the screw inside the housing e with a 3mm hexagonal wrenc...

Page 131: ...rench ATTENTION During reassembly lock down the ring using a torque wrench setting of 44Nm Figure 7 8 5 The bearings are press assembled and lock with a Seeger To reassemble the lever carry out the above steps in reverse order Figure 7 8 6 CAUTION In case is necessary to remove the pin h during the reassembly take care that the X measure between the fulcrum of h and i is the same on the both side ...

Page 132: ... out the operations described in paragraph 7 7 2 Brake box cover guard 1 Back off the 2 screws a with a 4mm hexagonal wrench Figure 7 9 2 2 Disconnect the 4 connectors highlighted in the figure at the side 3 Replace the brake board if needed To reassemble the brake box carry out the above steps in reverse order ...

Page 133: ... described in paragraph 7 7 2 Brake box cover guard 1 Back off the 2 screws a that fixes the Brake Box at the frame with a 3mm hexagonal wrench 2 Remove the brake box Figure 7 10 2 3 Remove the board 1 and 2 through the plastic clip sand b and or remove the glue or the adhesive replace if it s necessary To reassemble the hand sensor board carry out the above steps in reverse order ...

Page 134: ...oth levers 1 Back off the screw a with a 10mm hexagonal wrench looking it on the opposite side ATTENTION During reassembly lock down the screws a using a torque wrench setting of 9Nm Figure 7 11 2 2 If necessary replace the bearing b removing the internal snap ring c Figure 7 11 3 3 Back off the screw d that looks the bars e with a small extractor as shown in the figure at the side Continued in fo...

Page 135: ... with a 17mm wrench to loosen the tension on the belt Figure 7 11 6 5 Mark the position of the pillow blocks using a pen 6 Unscrew the nut h using a 17mm wrench locking the bolt on the opposite side as shown in the figure at the side AVVERTENZA If working on plastic support pay attention to lock down the screws using a torque wrench setting of 20Nm and no more Continued in following page ...

Page 136: ...ort i as shown in the figure at the side Figure 7 11 8 8 Back off the 4 screws l with a 13mm wrench looking the nut on the opposite side If necessary replace the primary shaft or the pulley To reassemble the group carry out the above steps in reverse order taking care of the following notes Continued in following page ...

Page 137: ... block on the machine frame so that the shaft is horizontal 6 Rotate the pulley as indicated by the arrows to align the right grub screws c and d with the left ones 7 Tighten the right grub screws ATTENTION Screw the grub screws indicated in the picture by the arrows which are fixing the bearings keeping them aligned on both the sides of the shaft 8 Place the belt on the pulley leaving one race fr...

Page 138: ...he pinion races 11 Once stabilized the position of the belt check that it works completely on the tighten device wheel f during the rotation CAUTION In case of the belt during THE rotation DOES NOT work completely on the tighten device wheel repeat the above operations shifting the belt of one race To reassemble the same belt tighten again referring to the marks previously done see at the Figure 7...

Page 139: ...n paragraph 7 7 Disassembling the guards 1 Back off the screw a with a 10mm hexagonal wrench locking it on the opposite side Figure 7 12 2 During the reassembly insert first the bolt 1 and on the opposite side the washer 2 and the nut 3 Figure 7 12 3 2 If necessary replace the bearing b removing the internal snap ring c Continued in following page ...

Page 140: ...5 Carry out the operations described in paragraph 7 7 3 Front guard 4 Remove the plug f using a small flat Phillip screwdriver on both the sides Figure 7 12 6 5 Back off the nut g using a 17mm wrench locking the bolt on the opposite side with the same wrench as shown in the figure ATTENTION During reassembly lock down the nut using a torque wrench setting of 40Nm Continued in following page ...

Page 141: ...board Figure 7 12 8 8 Back off the 4 screws i with a 4mm hexagonal wrench ATTENTION During reassembly lock down the screws using a torque wrench setting of 15Nm not overly so as not to damage the plastic Figure 7 12 9 9 At this point it s possible to release the footboard lever from the front connection mechanism Continued in following page ...

Page 142: ... ring nut on the opposite side with a 20mm ring nut spanner as highlight in figure B ATTENTION During reassembly lock down the ring nut using a torque wrench setting of 62Nm Figure 7 12 11 11 Release the front lever m During the reassembly place the 3 washer on the lever side and 1 washer on the internal side as shown in the detail Continued in following page ...

Page 143: ...uring reassembly lock down the ring nut using a torque wrench setting of 50Nm Figure 7 12 13 During the reassembly respect the sequence at the side of spacers and washers when remount again the two levers o1 and o2 Place some grease on the levers shaft before reassembly Figure 7 12 14 14 Release the lever p from the pin highlight in figure using a 6mm hexagonal wrench and locking it the opposite r...

Page 144: ...nect the 2 Faston highlighted in the figure Figure 7 13 2 2 Back off the screw a with a 4mm hexagonal wrench on both sides 3 Remove the brake winding from the bottom and replace if necessary To reassemble the brake winding carry out the above steps in reverse order After completing the reassembly carry out the adjustment procedure described in paragraph 8 3 Brake winding positioning ...

Page 145: ... Figure 7 14 1 Carry out the operations described in paragraph 7 7 1 Rear guard 1 Loosen the transmission belt with a 17mm wrench as highlighted in the figure Figure 7 14 2 2 Mark the position of pillow blocks as shown in the figure 3 Back off the 4 screws a that supports the flywheel with an 8mm hexagonal wrench locking the nut on the opposite side Continued in following page ...

Page 146: ...rench setting of 10Nm and using the LOCTITE 243 Figure 7 14 4 6 Unthread the pillow blocks belt tension system b 7 Replace the tension system belt d if necessary Figure 7 14 5 8 Back off the 6 screws e with a 4mm hexagonal wrench 9 Replace the copper disk f if necessary CAUTION During reassembly lock down the screws e using a torque wrench setting of 6Nm To reassemble the flywheel group carry out ...

Page 147: ...to bring the flywheel group on a workbench carry out the operations described in paragraph 7 14 1 Powered models disconnecting the 3 Faston highlight in the figure Bring the flywheel group on a work bench as for the powered version Figure 7 14 7 1 Back off the 2 screws a with a 4mm hexagonal wrench 2 Remove the covering plate b Continued in following page ...

Page 148: ... the screws c using a torque wrench setting of 10Nm and using the LOCTITE 243 Figure 7 14 9 3 Back off the 3 screws f with a 4mm hexagonal wrench and the relative flat spring g 4 Remove and or replace the stator h if necessary CAUTION The screws f should be tightened using a torque wrench setting of 22 Nm To reassemble the stator carry out the above steps in reverse order WARNING Remember to place...

Page 149: ...out the operations described in paragraph 7 7 1 Rear guard 1 Back off the 2 screws a with a medium Phillips screwdriver 2 Remove and or replace the speed sensor b To reassemble the speed sensor carry out the above steps in reverse order CAUTION After completing the reassembly carry out the adjustment procedure described in paragraph 8 2 Speed sensor positioning ...

Page 150: ...ly for powered version 500SP and 700SP Figure 7 16 1 Carry out the operations described in paragraphs 7 7 2 Brake box cover guard and 7 7 3 Front guards 1 Disconnect the 2 Faston highlighted in the figure 2 Remove the battery To reassemble the battery carry out the above steps in reverse order ...

Page 151: ... in paragraph 7 7 3 Front guards 1 Turn the machine on one side 2 Back off the 6 screws a on the front footboard with a medium Phillips screwdriver Figure 7 17 2 Rear Footboard Carry out the operations described in paragraph 7 7 1 Rear guard 3 Back off the 3 screws b on the rear footboard with a medium Phillips screwdriver and the 2 screws c with a 17mm wrench Continued in following page ...

Page 152: ... small Phillips screwdriver for remove the cover 3 Remove the power entry module VISIO models 4 Back off the antenna cable c from the footboards Figure 7 17 4 Wheels disassembly 1 Remove the snap ring a on both the sides 2 Remove the central pin b 3 Remove the wheel and replace if necessary To reassemble the footboards the power entry module and the wheels carry out the above steps in reverse orde...

Page 153: ...e 8 1 1 1 Back off the nut a with a 17mm wrench 2 Adjust the tension acting on the screw b with a 17mm wrench as indicated by arrows in figure 3 Tighten the nut a again Figure 8 1 2 CAUTION The right tension of belt must be 230Hz 10Hz If the belt is new the measure X should be approximately 51mm ...

Page 154: ...IONING Only for powered version 500 700 e 700WTV Figure 8 2 1 1 Loosen the 2 screws a and move the speed sensor support b laterally as indicated by arrows Figure 8 2 2 2 Adjust the speed sensor so that it is 0 7 mm from the screws heads c on copper dick 3 Tighten the screws a again ...

Page 155: ... the brake winding plate support b horizontally as indicated by arrows so that the copper disk is centred on the brake winding using a 1mm thickness gauge 3 Tighten again the screws ATTENTION To correctly adjust the brake position test the machine at high levels and check that the flywheel it is not touching on it WARNING Use a flatness comparator to check the copper disk flatness the permissible ...

Page 156: ...ositioning of the machine on a not flat surface To solve this problem it is necessary to act on foot adjustment Figure 8 4 1 The equipment is levelled by adjusting the two front feet and the two rear feet 1 Screw the foot a in or out until the frame is in a stable position 2 Adjustment made to tighten the counter nut b ...

Page 157: ...the procedure type in the password 2406 and press ENTER to confirm To enter the password increase or decrease the displayed value using the and keys or use the GOAL keys to scroll through and modify the individual digits At this point the machine display begins showing the current configuration structured as in the diagram below USER MENU 500LED Language MAX time Cooldown time Distance Pause time ...

Page 158: ...REMENT It is possible to choose between EUROPEAN units kilograms kg and ceilometers km or IMPERIAL units Pounds lb and Miles mi To change the selection when the display shows the current setting UNITS xxx Press the GOAL keys to select the desired unit of measurement from the options listed in the table below UNITS KG default POUNDS 9 1 3 MAXIMUM EXERCISE TIME It is possible to set a maximum durati...

Page 159: ...y shows the currently selected maximum time COOLDOWN TIME xxx Press the ENTER key to change the value The current parameter value starts to blink on the display use the and keys to increase or decrease the value or use the GOAL keys to scroll through and modify the individual digits The default value of this parameter is 60 If you are exercising with a TGS key the cooldown will be stopped if you e...

Page 160: ... 1 to 999 minutes To change the setting when the display shows the current duration DEFAULT DURATION MIN xxx Press the ENTER key to change the parameter The current parameter value starts to blink on the display use the and keys to increase or decrease the value or use the GOAL keys to scroll through and modify the individual digits The default value of this parameter is 15 minutes 9 1 9 DEFAULT C...

Page 161: ...ough and modify the individual digits The default value of this parameter is 10 9 1 11 ENABLE TGS It is possible to enable or disable the use of the TGS reader To change the selection when the display shows the current setting TGS xxx Press the GOAL keys to select the desired option out of those listed in the table below TGS ENABLED default DISABLED 9 1 12 ENABLE KEYBOARD It is possible to disable...

Page 162: ...message is displayed when the machine is in the standby state To change the selection when the display shows the current setting CUSTOM MESS xxx Press the GOAL number keys to select the desired option out of those listed in the table below CUSTOM MESS YES default NO 9 1 15 RESETTING PARAMETERS TO DEFAULT VALUES It is possible to reset the user menu parameters to their default values To select the ...

Page 163: ...ion To select the function when the display shows FORMAT P P Press ENTER to confirm At the end of the formatting procedure hold down the CLEAR key for a few seconds to exit The CLEAR key can be pressed at any time to interrupt the procedure and revert to standby mode 9 1 17 SN This parameter shows the serial number of the machine SN xxxxx ...

Page 164: ...TER to confirm At this point the machine display begins showing the current configuration structured as in the diagram below USER MENU 700LED Language Pause time MAX time Distance TGS Keys HR Edit Messages Default config Format P P Change Mess Lang Languages SN Custom Mess Cooldown time To scroll through the list of available functions press the or speed keys to display the next or the preceding i...

Page 165: ...MUM EXCERCISE TIME It is possible to set a maximum duration for the exercise in minutes with a value ranging from 1 to 9999 To change the setting when the display shows the current maximum exercise time MAX TIME xxx Press the ENTER key to modify the value when the current parameter value starts to blink press the CLEAR key to erase the current value and then use the number keys to enter the desire...

Page 166: ...ult value of this parameter is 60 If you are exercising with a TGS key the cooldown will be stopped if you extract the key 9 2 6 ENABLE TGS It is possible to enable or disable the use of the TGS reader To change the selection when the display shows the current setting TGS xxx Press the GOAL keys to select the desired option out of those listed in the table below TGS ENABLED default DISABLED 9 2 7 ...

Page 167: ...w CUSTOM MESS YES default NO 9 2 10 EDIT CUSTOM MESSAGES It is possible to modify the custom messages press ENTER to invoke a submenu which displays the first custom message then use the effort level keys to move to the other messages Press the ENTER key again to begin editing a message or hold down the CLEAR key for a few seconds to return to the upper menu level While editing a message move the ...

Page 168: ...y shows DEFAULT CONFIG Press ENTER to confirm the operation use the or effort level keys to move to the next or preceding parameter If the ENTER key is pressed the LED matrix will show CONFIRM Press ENTER to confirm or cancel by pressing the CLEAR key for a few seconds 9 2 14 FORMAT P P This function formats a TGS key for Plug Play mode operation To select the function when the display shows FORMA...

Page 169: ...is point there are two options available Tech Config Troubleshooting Press numeric key to access the menu for configuring technical parameters the machine display will begin showing the current configuration structured as in the diagram below 9 3 2 ACCESSING CONFIGURATION OF 700 MODELS The setup procedure of the equipment is activated when the machine is in Stand by Simultaneously press the keys 3...

Page 170: ...ess the or effort level keys to display the next or the preceding item To modify a parameter value it is necessary to press the ENTER key when the current parameter value starts to blink press the CLEAR key to erase the current value and then use the number keys to enter the desired new value Save the changes made by pressing the ENTER key To cancel the operation press the CLEAR key for a few seco...

Page 171: ...nction also includes the 3 sub functions described below 9 3 3 1 Read from low kit To read the parameter values from the low kit memory and view them on the display scroll using the keys until the display shows READ FROM LOW KIT Press ENTER to read the errors from the low kit and return to the upper menu level by pressing CLEAR for a few seconds 9 3 3 2 Write to low kit To write the values of the ...

Page 172: ...meters Id Par Units Name Description LED powered Self powered 1 decimal Rt Transmission Ratio 166 166 2 Rvel Speed ratio 1 1 3 mA Im Minimum braking 0 0 4 W Pmc Constant maximum power 200 200 5 in cent Km Power factor correction constant torque 100 100 6 0 1N Ca User friction torque 23 23 7 C Tea Maximum temperature on the coil 125 125 8 User Rpm RPMmin Minimum user SPM start cut braking ramp 35 3...

Page 173: ...RATING DATA Life Kit H Life Brake WRITE TO LOW KIT READ FROM LOW KIT Life Kit L Tot Km KJ In addition to the machine usage data this function also includes the 2 sub functions described below 9 3 4 1 Read from low kit To read the parameter values from the low kit memory and view them on the display scroll using the keys until the display shows READ FROM LOW KIT Press ENTER to read the errors from ...

Page 174: ...sage on Display Description Life Brake Minutes x 10 of operation of the Brake Detected by the Low Kit Life Kit High Minutes x 10 of operation of the High Kit Detected by the High Kit Life Kit Low Minutes x 10 of operation of the Low Kit Detected by the Low Kit KJ Total KJ For all the exercises performed Detected by the High Kit Tot Km Total km travelled For all the exercises performed Detected by ...

Page 175: ...he 3 sub functions described below 9 3 5 1 Read from low kit To read the errors stored in low kit memory and view them on the display scroll using the keys until the display shows READ FROM LOW KIT Press ENTER to read the errors from the low kit and return to the upper menu level by pressing CLEAR for a few seconds 9 3 5 2 Reset Errors To clear the error history in both the low and high kit memory...

Page 176: ... View Errors For every error generated by the machine the error history log records the information in the table below Counter Error code Current when the error occurred Distance in km when the error occurred The correspondence between error codes and descriptions is given in the table below Error Code Description 1 OVERHEATING this condition occurs when the temperature detected by the sensor on t...

Page 177: ...nu level by pressing CLEAR for a few seconds This function does not alter the language and the TV standard setting 9 3 7 LOW KIT MENU This function directly accesses the firmware of the brake board To access this menu when the display shows LOW KIT MENU Press ENTER This function is structured as follows LOW KIT MENU Low Kit Version Low Kit fault code 9 3 7 1 Low kit version This function displays ...

Page 178: ...ssage that identifies the SW version will appear 9 3 9 BOOT VERSION This function displays the BOOT version To do this when the display shows BOOT VERSION Press ENTER to display the message which identifies the BOOT version The Boot Version parameter displays the boot SW version of display HW The boot is the part of the SW which allows uploading on the display the TG program This parameter is just...

Page 179: ...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 keyboard Enter the password 2406 and press the ENTER key to confirm or EXIT to quit A menu will then appear which will provide access to the following sub menus For the following menu please refer to the rel...

Page 180: ...creen 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 keyboard Enter the password 2501 and press the ENTER key to confirm or EXIT to quit A menu will then appear which will provide access to the following sub menus For the following menu please refer to the r...

Page 181: ...ered 1 decimal Rt Transmission Ratio 141 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 torque 60 7 C Tea Maximum temperature on the coil 125 8 User rpm RPMmin Minimum user SPM start cut braking ramp 35 9 Type sec RpmF1 Flywheel target RPM speed in standby and power on speed for sel...

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Page 183: ...en 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 the number keyboard In order to access the menu enter the password 2502 and press the ENTER key in order to confirm ESCI in order to quit For the following menu please refer to the relevant chapter...

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Page 185: ...ion of the device in compliance with medical regulations 60601 1 and 60601 1 2 Electrical testing of each device manufactured according to the provisions of the aforementioned standards Training of technical staff who perform technical service Use of checked and tested original Technogym spare parts for all service operations CE Declaration of Conformity 11 1 ELECTRICAL SAFETY TEST Based on the ri...

Page 186: ...SYNCHRO Excite Service maintenance manual rev 7 1 Pagina 11 2 First of all check the resistance on the tester probes is approximately 0Ω ...

Page 187: ...ING THE ASSEMBLY OF THE GUARDS Check the assembly of the machine guards making sure that 1 They are all in place and correctly secured so that no parts of the machine are left exposed that may cause injury to the user 11 3 START UP CHECK Following installation and after every technical intervention on the machine plug it into a power outlet set the power switch to ON On power up the machine perfor...

Page 188: ...own in the table below Code Component R0006668XX Brake Board 0WR00503XX Solenoid assembly R0003767XX Display Board 700 R0003778XX Display Board 500 0WQ00060XX C Safe Board 0WR00633XX Cardio Receiver HR HS N0000034XX Cardio Receiver HR W0005566XX Schuster socket 0WR00598XX N 2 ferrites RKCF 10 A5 RICHCO Display program SW version Brake board program SW version Note XX Baan Revision YY Languages If ...

Page 189: ... maintenance operation The ORDINARY maintenance operations can be performed by the club manager They do not require any kind of technical knowledge they only consist of simple external cleaning for the purposes of general hygiene EXTRAORDINARY maintenance operation The EXTRAORDINARY maintenance operations have to be performed by a TG qualified technician specially trained by Technogym They consist...

Page 190: ...on 0 OFF 2 Unplug the mains lead from the wall outlet 3 Open the motor guard 4 Use a vacuum cleaner to clean the interior paying particular attention to the tread belt motor and the electronic circuit boards WARNING when carrying out these operations be careful not to damage the cables 5 Move the machine and clean the floor underneath using a vacuum cleaner 12 1 4 COMPLETE OPERATION SIX MENTHLY 1 ...

Page 191: ...chine and the separate monitor both measure the same heart rate and that when the sensors are released the machine does not receive any signal 12 2 4 CHECKING THE AMOUNT OF PLAY ON THE BALL JOINTS 1 Check the amount of play on the ball joints If any anomalies are found call in the authorized Technogym Technical Service 12 2 5 CHECKING THE WEAR OF RUBBER PARTS 1 Check the state of wear of the rubbe...

Page 192: ... and the buzzer 3 Check VISIO Touch Screen calibration 12 2 9 CHECKING THE WIRING AND CONNECTIONS 1 Check the condition of all the cables External conditions Possible rusting of the connectors Electrical continuity of the individual wires Isolation of the individual wires toward ground 2 Repair and or replace any non conforming wires Check the condition of the fuses using a tester ...

Page 193: ...te User 2406 VisioWEB 2404 Configurazione IP TV IP TV configuration VISIO 2405 Configurazione IP Radio IP Radio configuration VISIO 2406 Configurazione Utente letture Serial Number User Configuration Serial number reading LED VISIO 2407 Sintonizzazione canali Analogici e Digitalli TV Analog and Digital TV channels tuning VISIO 2408 Sintonizzazione canali Analogici e Digitalli Radio Analog and Digi...

Page 194: ...llips screwdriver Big Phillips screwdriver 17mm wrench 3mm hexagonal wrench 4mm hexagonal wrench 5mm hexagonal wrench 6mm hexagonal wrench 8mm hexagonal wrench 10mm hexagonal wrench 25mm Racket wrench 27mm Racket wrench 10mm socket wrench Snap ring pliers Bicycle pedal extractor You can order a complete set of hexagonal wrenches consisting of 7 pieces 2 2 5 3 4 5 6 and 8mm The code to be used is R...

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Page 196: ...0SM00587AA 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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