Technogym GROUP CYCLE Service And Maintenance Manual
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Technogym GROUP CYCLE Service And Maintenance Manual

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  • Page 1 . 6.4...
  • Page 3 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.

  • Page 5: Table Of Contents

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 Contents 1 GENERAL NOTICES ............................. 1.1 1.1 I ..............................1.1 NTRODUCTION 1.2 R ............................1.1 ECOMMENDATIONS 1.3 G ......................1.2 ENERAL RULES FOR REPAIR PROCEDURES 2 TECHNICAL SPECIFICATIONS ......................... 2.1 2.1 P ..............................
  • Page 6 GROUP CYCLE: Service & Maintenance manual rev. 6.4 7.2 A BELT ......................... 7.4 DJUSTING THE TENSION 7.3 A ) ................7.5 DJUSTING THE FLYWHEEL PARALLELISM ELT VERSION 7.4 S ..........................7.7 ADDLE PLAY ADJUSTMENT 7.5 ADJUSTING ..................7.8 THE SPRING TENSION OF THE BINDING 7.6 A...

  • Page 7: General Notices

    1 GENERAL NOTICES 1.1 INTRODUCTION This document is reserved for Technogym Service technicians, and is intended to provide authorized personnel with the necessary information to correctly carry out repairs and maintenance. A thorough knowledge of the technical information contained in this manual is essential for completing the professional training of the operator.

  • Page 8: General Rules For Repair Procedures

    1. Always mark any parts or positions which may be confused with each other at the time of reassembly. 2. Use original Technogym spare parts and lubricants of the recommended brands. 3. Use special tools where specified. 4. Consult the Technical Newsletters, which may contain more up-to-date information on adjustments and maintenance than those contained in this manual.

  • Page 9: Technical Specifications

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 2 TECHNICAL SPECIFICATIONS 2.1 PRODUCT CODES The machine codes take into account all the possible variants and options available for the products. The machine code, which does not include the Serial Number, consists of 14 alphanumeric...

  • Page 10: Product Characteristics

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 2.2 PRODUCT CHARACTERISTICS Min – max user height 140-240cm / 4,6” – 6,9” Max user weight 160Kg / 320lbs Q factor 180mm / 7” Transmission Chain Frame Aluminium Dual-sided SPD pedals STANDARD...

  • Page 11: Ambient Specifications

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 2.3.2 PACKING D IMENSIONS UROPE AND VERSEAS 2.4 AMBIENT SPECIFICATIONS Operating to 5° a 35° C Temperature Storage to -10 a 70° C Operating to 30% a 80% non-condensing Humidity Storage to 5% a 85% non-condensing 2.5 CONFORMITY TO REGULATIONS...
  • Page 12 GROUP CYCLE: Service & Maintenance manual rev. 6.4 Page intentionally left blank. Page 2.4...

  • Page 13: Accessories

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 3 ACCESSORIES 3.1 FLYWHEEL LOCK SYSTEM Figure 3.1-1 The accessories supplied with the equipment, are indicated in the User Manual with the relative indications of use. Page 3.1...

  • Page 14: Handlebar Protection

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 3.2 HANDLEBAR PROTECTION Figure 3.2-1 This rubber protection is used to preserve the handlebar, in case of the equipment is positioned as in figure below: Figure 3.2-2 Page 3.2...

  • Page 15: Wireless Console

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 3.3 WIRELESS CONSOLE A0000488 Group Cycle Wireless Console CAUTION: It is advisable to use ANT+ type chest belts. An analogue chest belt may be subject to interferences from nearby users. If using analogue chest belts, the equipment must be placed at least 170cm from each other as shown in the picture, in order to avoid interferences.
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  • Page 17: Installation And Handling Instructions

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 4 INSTALLATION AND HANDLING INSTRUCTIONS 4.1 SPECIFICATIONS AND REQUIREMENTS For correct machine installation, make sure that: • The machine is installed on a level surface that is free of vibrations and has sufficient carrying capacity for the combined weight of the machine and user.

  • Page 18: Equipement Moving

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 4.3 EQUIPEMENT MOVING Movement and positioning of the equipment on the ground must be done with great caution, because there may be a loss of stability of it. Figure 4.3-1 1. The equipment is equipped of fixed front wheel. To move should lift slightly and push forward or backward, as shown in Figure.

  • Page 19: Troubleshooting

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 5 TROUBLESHOOTING 5.1 THE CADENCE READING (RPM) IS INCORRECT 1. If the cadence reading (RPM) is incorrect, verify that the display receiver and the transmitter have the same code. 2. If the codes match, replace the transmitter batteries.

  • Page 20: E6 Error On The Wireless Console

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 5.2 E6 ERROR ON THE WIRELESS CONSOLE The error E6 is displayed in case of the communication is missing between the receiver in the display and the transmitter on the flywheel. If the error appear, follow the below procedure to fix it.

  • Page 21: Disassembly Of Components

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 6 DISASSEMBLY OF COMPONENTS 6.1 DISASSEMBLING HANDLEBAR 1. Lift up the lever (a) as indicated by arrow. 2. Remove the upright (b) upward. 3. Back off the screws (c) on both sides, using a 5mm hexagonal wrench, to remove the handlebar from the upright.

  • Page 22: Disassembling Saddle

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 6.2 DISASSEMBLING SADDLE 1. Lift up the pin (a), sliding the saddle following the arrows. 2. Remove the saddle group. To reassemble the saddle, carry out the above steps in reverse order.

  • Page 23: Disassembling Bushes Adjustment Lever Of Seddle And Handlebar

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 6.3 DISASSEMBLING BUSHES ADJUSTMENT LEVER OF SEDDLE AND HANDLEBAR For both bushings: 1. Remove the saddle group and/or the handlebar group. 2. Force towards the inside of the frame the plastic tab with the pin (a), using a flat Phillips screwdriver.

  • Page 24: Disassembling The Guards

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 6.4 DISASSEMBLING THE GUARDS Lateral casings 1. Back off the screw (a) using a 3mm hexagonal wrench and remove the spacer (b). Figure 6.4-1 2. Back off the 5 screws (c), (d), (e) and (f), using a 3mm hexagonal wrench.
  • Page 25 GROUP CYCLE: Service & Maintenance manual rev. 6.4 1. Press on the guard (f) as indicated by the arrows, since it can be possible to remove it from the frame. Figure 6.4-4 Rear guard: 2. Back off the 4 screws (g) using a 3mm hexagonal wrench.

  • Page 26: Disassembling Pedal Pedal Cage And Pedal Cranks

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 6.5 DISASSEMBLING PEDAL, PEDAL CAGE AND PEDAL CRANKS 6.5.1 D ISASSEMBLING THE PEDAL 1. Back off the grub screw (a) from the internal side of the pedal crank, as shown in the figure at side.

  • Page 27: Assembling The Pedal

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 6.5.2 A SSEMBLING THE PEDAL The loosening of the pedals from the pedal cranks, is possible due the presence of paint in the area of contact between the two components, follow the below procedure: 1.
  • Page 28 GROUP CYCLE: Service & Maintenance manual rev. 6.4 6. Apply some Loctite 243 to grub screws (b). Holding the pedal in position with a spanner, tighten the grub screw. CAUTION: lock down the grub screws using a torque wrench set for 40Nm.

  • Page 29: Disassembling The Pedal Cage

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 6.5.3 D ISASSEMBLING THE PEDAL CAGE 1. Back off the 2 screws (a) using a medium Phillips screwdriver. 2. Remove the pedal cage (b). Figure 6.5-4 During reassembly follow sequence indicated side,...

  • Page 30: Disassembling The Pedal Crank

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 6.5.4 D ISASSEMBLING THE PEDAL CRANK 6.5.4.1 CHAIN transmission version Disassemble the lateral casings as described in paragraph: 6.4Disassembling the Guards”. 1. Remove the pedal crank cap (a) using a flat screwdriver.
  • Page 31 GROUP CYCLE: Service & Maintenance manual rev. 6.4 Reassembly notes on the chain side: 4. To reassemble the chain is not necessary to act on its tension, it just need to place it on the crown wheel and slightly force rotating the pedal crank as shown in the figure at side.
  • Page 32 GROUP CYCLE: Service & Maintenance manual rev. 6.4 6.5.4.2 BELT transmission version Remove the lateral guard, as indicated at the paragraph: 6.4Disassembling the Guards”. Loosen the belt tension to facilitate the operations that follow. 1. Remove the pedal crank cap (a) using a flat screwdriver.
  • Page 33 GROUP CYCLE: Service & Maintenance manual rev. 6.4 3. Remove the pedal crank (c) using a pedal crank extractor (d). If the pedal crank extractor pin is not long enough, use an additional pin checking the diameter is 10mm ≤ D ≤15mm.

  • Page 34: Disassembling The Pedals Shaft

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 6.6 DISASSEMBLING THE PEDALS SHAFT Carry out the procedure described in paragraph: 6.5.4“Disassembling the pedal crank” and remove both the pedal cranks. 1. Back off the ring nut (a) using a 29mm wrench, docking down the pin on the opposite side using a 17mm wrench.
  • Page 35 GROUP CYCLE: Service & Maintenance manual rev. 6.4 3. If damaged, remove the 2 bearings (c) and replace them. During the reassembly insert again the spacer (d) between the bearings (c). This will act as stops and reference for the bearings position.

  • Page 36: Disassembling Brake

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 6.7 DISASSEMBLING BRAKE 6.7.1 D ISASSEMBLING BRAKE KNOB 1. Back off the knob (a) and remove the rubber bellow (b) from the bottom. 2. Remove the protection guard (c), as detailed at Figure 6.4-1.

  • Page 37: Disassembling Brake Pad

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 6.7.2 D ISASSEMBLING BRAKE PAD 1. Back completely off the brake knob (a). 2. Remove the rubber bellow (b). 3. Remove the protection guard (c), as describe at Figure 6.4-1. Figure 6.7-4 4.

  • Page 38: Disassembling And Replacing The Chain

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 6.8 DISASSEMBLING AND REPLACING THE CHAIN Carry out the procedure described in paragraph: 6.4“Disassembling the Guards”. Mark the position of the block, using a pen, on both right (R -Dx) and left side (L - Sx) as shown in the figure Figure 6.8-1...
  • Page 39 GROUP CYCLE: Service & Maintenance manual rev. 6.4 Continued on following page... Page 6.19...
  • Page 40 GROUP CYCLE: Service & Maintenance manual rev. 6.4 1. Reassembly the flywheel if previously disassembled. 2. Open the connecting link of the new chain and pass it on the front pinion (d). 3. Pass the chain on the rear toothed wheel (e) and then close the connecting link.

  • Page 41: Disassembling The Flywheel And The Pinion

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 6.9 DISASSEMBLING THE FLYWHEEL AND THE PINION Carry out the procedure of disassembly described in paragraph: 6.8“Disassembling and replacing the chain”. On both side of the equipment: 1. Back off the 2 screws (a) using a 4mm hexagonal wrench.

  • Page 42: Disassembling The Belt And Flywheel Group

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 6.10 DISASSEMBLING THE BELT AND FLYWHEEL GROUP Carry out the procedure of disassembly described in paragraph: 6.4“Disassembling the Guards”. On the right side: 1. Loosen the 2 screws (a), using a 5mm hexagonal wrench.
  • Page 43 GROUP CYCLE: Service & Maintenance manual rev. 6.4 Figure 6.10-4 During the reassembly take care of the parts order, as detailed above; pay particular attention to the parts (2) and (4). Before reassembly the flywheel group, replace the belt on the secondary pulley.

  • Page 44: Disassemblin The Secondary Pulley

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 6.11 DISASSEMBLIN THE SECONDARY PULLEY Carry out the procedure of disassembly described in paragraph: 6.10“Disassembling the belt and flywheel group” up to point (8). On a work bench: 1. Back off the ring nut (a) using a socket wrench for ring nut.

  • Page 45: Disassembling The Feet

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 6.12 DISASSEMBLING THE FEET Carefully urn the machine on one side Figure 6.12-1 FRONT foot: 1. Back completely off the lower foot (a). 2. Back off the screw (b) using a medium Phillip screwdriver.
  • Page 46 GROUP CYCLE: Service & Maintenance manual rev. 6.4 3. Loosen the counter-nut (c), using a 19mm wrench. 4. Remove the split pin (d). 5. Back completely off the foot (e) to remove it. To reassemble the rear foot, carry out the above steps in reverse order.

  • Page 47: Disassembling The Wireless Console

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 6.13 DISASSEMBLING THE WIRELESS CONSOLE CAUTION: If replacing the Console or the RPMs Transmitter, it is necessary to carry out the procedure of re-Pairing, as detailed in the User Manual. 6.13.1 D...

  • Page 48: Disassembling The Sensor

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 6.13.2 D ISASSEMBLING THE SENSOR Carry out the procedure described in paragraph: 6.4“Disassembling ”, up to step (3). 1. Back off the screw (a) using a medium Phillip screwdriver. Figure 6.13-3 2. Back off the 2 screws (b) using a 4mm hexagonal wrench.

  • Page 49: Battery Replacing

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 6.13.3 B ATTERY REPLACING 6.13.3.1 For Console Figure 6.13-6 Carry out the procedure described in paragraph: 6.13.1"Disassembling the Console". 1. Back off the 2 screws (a) using a 3mm hexagonal wrench. 2. Remove the support (b) and replace the batteries if is necessary.
  • Page 50 GROUP CYCLE: Service & Maintenance manual rev. 6.4 6.13.3.2 For sensor group Figure 6.13-7 Carry out the procedure described in paragraph: 6.4“Disassembling ”, fino al punto (3). 1. Back off the 2 screws (a) using a 3mm hexagonal wrench. 2. Remove the cover (b) and replace the batteries if is necessary.
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  • Page 53: Adjustment

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 7 ADJUSTMENT 7.1 ADJUSTING THE CHAIN TENSION AND FLYWHEEL PARALLELISM On both side of the machine: 1. Back off the screw (a), using a 3mm hexagonal wrench. 2. Remove the guard (b).
  • Page 54 GROUP CYCLE: Service & Maintenance manual rev. 6.4 Block flywheel completely rotating to STOP. Figure 7.1-3 On chain side: 5. Make a mark on flywheel at the height of the resting chain (0mm). Figure 7.1-4 6. Press the chain with a wooden tape measure where previously marked and measure the gap in mm.
  • Page 55 GROUP CYCLE: Service & Maintenance manual rev. 6.4 CAUTION: To adjust the chain tension is important to equally act on both sides of flywheel. The flywheel must be centred into the fork. The flywheel must be centred in the fork; the "X" dimensions must be the same in all four positions.

  • Page 56: Adjusting The Belt Tension

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 7.2 ADJUSTING THE BELT TENSION 1. Loosen the 2 screw (a) using a 5mm hexagonal wrench. 2. Loosen the counter nut (b) using a 17mm wrench. 3. Adjust the belt tension, acting on the bolt (c) screw for increase the tension and/or baking off it for decrease.

  • Page 57: Adjusting The Flywheel Parallelism (Belt Version)

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 7.3 ADJUSTING THE FLYWHEEL PARALLELISM (BELT VERSION) 1. Loosen the nut (a), using a 19mm wrench. 2. Loosen the counter-nut (b) using a 10mm wrench. 3. Adjust the parallelism of the flywheel...
  • Page 58 GROUP CYCLE: Service & Maintenance manual rev. 6.4 The flywheel must be centred in the fork; the "X" dimension must be the same in all four positions. Figure 7.3-3 Page 7.6...

  • Page 59: Saddle Play Adjustment

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 7.4 SADDLE PLAY ADJUSTMENT 1. Check the tightening of the screws. 2. Check the play of clamping devices (a) and (b). Figure 7.4-1 3. Check the state of wear of the plastic guides (c) and (d) placed under the saddle and replace them if necessary.

  • Page 60: Adjusting The Spring Tension Of The Binding

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 7.5 ADJUSTING THE SPRING TENSION OF THE BINDING 1. The spring force is adjusted by means of adjustment grub screw, which is located behind the binding. Equalize the tension by screwing or unscrewing the grub screw (a)

  • Page 61: Adjusting The Braking Resistance

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 7.6 ADJUSTING THE BRAKING RESISTANCE Carry out the operation at point (4) of Figure 6.7-2, at paragraph: 6.7.1“Disassembling brake knob”. 1. Loosen the counter nut (a) and back off the close nut (b) of 1 or 2 turns counter- clockwise, taking care to keep it engaged of minimum 4 or 5 turns on the pin.

  • Page 62: The Machines Is Not Flat

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 7.7 THE MACHINES IS NOT FLAT This problem may be due to the positioning of the machine on a not flat surface. To resolve this problem is necessary to act on foot adjustment.

  • Page 63: Scheduled Maintenance

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 8 SCHEDULED MAINTENANCE To keep the machine in perfect working order and forestall possible problems, it is necessary to carry out the planned maintenance operations described below. These operations are essentially grouped according to the type of action and the technical skills needed perform them:...
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  • Page 65: Required Tools

    GROUP CYCLE: Service & Maintenance manual rev. 6.4 9 REQUIRED TOOLS The following tools are required for carrying out the various disassembly, adjustment and maintenance action on the machine: • Small Phillips screwdriver; • Medium Phillips screwdriver; • 10mm wrench;...
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  • Page 68 TECHNOGYM S.p.A. Via G. Perticari, 20 47035 Gambettola (FC) ITALIA Tel.: +39-0547-650638 Fax: +39-0547-650150 e-mail: service@technogym.com 0SM00624AA-UK...

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