Technogym spin trainer Maintenance Manual
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Technogym spin trainer Maintenance Manual

Technogym spin trainer Maintenance Manual

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S
& M
M
ERVICE
AINTENANCE
ANUAL
R
. 2.0
EV

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Summary of Contents for Technogym spin trainer

  • Page 1 & M ERVICE AINTENANCE ANUAL . 2.0...
  • 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 and use of this manual.

  • Page 5: Table Of Contents

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 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. M ........................2.1 ECHANICAL CHARACTERISTICS 2.2. E ........................2.1...
  • Page 6 SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 7.15. D ........................7.15 ISASSEMBLING THE BUSHINGS 7.16. D RUNNER BARS .......................7.16 ISASSEMBLING THE 7.17. D ..................7.17 ISASSEMBLING THE FRONT HUB SHOCK ABSORBERS 7.18. D ....................7.19 ISASSEMBLING THE ALTERNATOR BRUSHES 8. ADJUSTMENTS ...............................8.1 8.1.

  • Page 7: 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 circulars, which may contain more up-to-date information on adjustments and maintenance than those contained in this manual.

  • Page 9: Technical Specifications

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 2. TECHNICAL SPECIFICATIONS 2.1. MECHANICAL CHARACTERISTICS Width 47.5 cm Length 165 cm Height 121 cm Weight 60 Kg 2.2. ELECTRICAL CHARACTERISTICS Mains voltage 115 - 230 VAC Frequency 50 - 60 Hz Consumption ~ 60 Watt - 0.3 A...

  • Page 10: Conformity To Regulations

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 The recommended tire pressure is 8 Atm for street bikes and 6 Atm for mountain bikes, in order to avoid puncturing or deforming the tire. It is recommended to disassemble the rear brake shoes.

  • Page 11: Wiring Diagram

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 2.6. WIRING DIAGRAM 2.6.1. C ONNECTORS • CPU board name type of connector connection AMP MATE-N-LOCK 12-pin F. to alternator interface board AMP MODU II 6-pin M. to serial connector AMP MODU II 4-pin M.

  • Page 12: Wiring

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 • Fan control board name type of connector connection AMP MODU II 4-pin M. to CPU board (logic) AMP MODU II 2-pin M. to fan AMP MODU II 2-pin M. to CPU board and alternator (power) •...
  • Page 13 SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 SP-1: Internal connecting cable – fan control Fan control board – CPU Fan control Signal Color CPU/CN1 board / K1 ground Black Fan enable Brown +12 V SP-8: Serial connector cable CPU –...
  • Page 14 SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 SP-5: Alternator cable Alternator interface board – Alternator – Resistor Alter. interface Signal Color Alternator Resistor board / CN2 Alternator RPM X 6 Violet Red eyelet 4 Resistor - Blue Yellow...

  • Page 15: Principles Of Operation

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 3. PRINCIPLES OF OPERATION 3.1. BLOCK DIAGRAM The block diagram of the machine is shown in the figure below: CARDIO TRANSMITTER It is worn by the person using the machine, and transmits to the cardio receiver one pulse for every heart beat that is detected.
  • Page 16 SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 CARDIO RECEIVER It is connected to the machine’s CPU board and receives the pulses sent by the transmitter. Its reception area is approximately a circle of 1 meter of radius. If there is electromagnetic noise (produced by high voltage lines, radio transmitters, monitors, motors, etc.) within its reception...

  • Page 17: Accessories

    4.1. CONNECTING TO THE TGS The machine can be connected to the Technogym System by means of the 9-pin D-type connector situated on the back of the display, which provides the RS 232 serial port for connecting the TGS reader.
  • Page 18 SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 Page intentionally left blank Page 4.2...

  • Page 19: Installation Instructions

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 5. INSTALLATION INSTRUCTIONS 5.1. SPECIFICATIONS AND REQUIREMENTS For correct machine installation, make sure that: 1. The machine is installed on a level surface that is free of vibrations and has sufficient carrying capacity for the combined weight of the machine and user.

  • Page 20: First Power On

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 5.3. FIRST POWER-ON After completing the installation procedure, the machine is ready to be powered up. To turn on the machine, simply toggle the on/off switch from the 0 position to the 1 position.

  • Page 21: Troubleshooting

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 6. TROUBLESHOOTING The troubleshooting procedures are shown in the form of flow charts. In order to facilitate consultation, the following standard box shapes are used. This type of box is the START point of the troubleshooting procedure. It typically contains a description of the problem or malfunction.

  • Page 22: The Display Does Not Illuminate

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 6.1. THE DISPLAY DOES NOT ILLUMINATE THE DISPLAY DOES NOT ILLUMINATE Are the fuses OK? Replace blown fuses Is the mains lead OK? Replace mains lead Connect machine to a suitable...
  • Page 23 SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 Replace the power Are DC output voltages of the supply: see paragraph power supply correct? 7.10. Replace the CPU Do all DC voltages reach the board: see paragraph display? 7.4. Replace cable BK-6...
  • Page 24 SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 As for step (1) but with the tester between terminals L1 and N1 of the inlet socket / on-off switch block. Slightly lift connector CN2 on the power supply to access the pins with the tester probes.

  • Page 25: The Resistance Is Not Correct

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 6.2. THE RESISTANCE IS NOT CORRECT THERE IS NO RESISTANCE IS RESISTANCE NOT CORRECT Check whether the Is the Watt values shown on machine is calibrated: the display correct? see paragraph 8.2.
  • Page 26 SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 Replace cable SP-1 Replace the display CPU connecting the CPU Is the control signal output by board: see paragraph 7.4. board to the alternator the CPU board correct? interface board Follow the procedure step by step to correctly diagnose the problem. Take particular care with the checks highlighted by circled numbers, which are described in detail below: Perform the troubleshooting procedure described in paragraph 6.3.
  • Page 27 SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 The correct value for the power resistor is approximately 0.5 Ω. As for point (2) but with an oscilloscope (if available) between pins 6 (probe) and 3 (ground) of connector CN1 on the alternator interface board.

  • Page 28: The Speed Value Is Incorrect

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 6.3. THE SPEED VALUE IS INCORRECT THE KM/H VALUE IS INCORRECT Is the RPM wire of cable Rewire the cable SP-5 correctly connected to correctly the alternator? Is the RPM signal output...
  • Page 29 SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 Check whether the black and violet wires, which connect the alternator to pins 1 and 5 of CN2 on the alternator interface board, are correctly connected. Place the probes of an oscilloscope between the violet wire and the alternator ground. When...
  • Page 30 SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 As for step (2) but with the oscilloscope probes between pins 5 (probe) and 3 (ground) of connector CN1 on the display CPU board. Page 6.10...

  • Page 31: There Is No Heart Rate Signal

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 6.4. THERE IS NO HEART RATE SIGNAL THERE IS NO CARDIO SIGNAL Is the supply voltage on the Replace the receiver: see receiver connector correct? paragraph 7.6. Is the supply voltage on...

  • Page 32: The Heart Rate Signal Is Incorrect

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 6.5. THE HEART RATE SIGNAL IS INCORRECT In some case the machine may show “Err” on the heart rate display. THE HEART RATE SIGNAL IS INCORRECT Move the machines to Is the minimum distance...
  • Page 33 SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 Is the transmitter in good Use a transmitter that is working order? working Is the transmitter always Keep the transmitter within a distance of 80 cm within the minimum from the receiver? reception distance Change the receiver.

  • Page 34: The Fan Does Not Work

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 6.6. THE FAN DOES NOT WORK THE FAN DOES NOT WORK When the Fan “ON” key is pressed, does the correct voltage Replace the fan: see appear at the terminals of chapter 7.7.
  • Page 35 SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 Follow the procedure step by step to correctly diagnose the problem. Take particular care with the checks highlighted by the circled numbers, which are described in detail below: WARNING: Carry out all these operations with the alternator in rotation.

  • Page 36: The Machine Does Not Print

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 6.7. THE MACHINE DOES NOT PRINT THE MACHINE DOES NOT PRINT Is the machine correctly configured for Correctly configure the printing? machine: see paragraph 9.1. There is a problem with the...
  • Page 37 SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 RS-232 MINI TESTER Connect the tester on the output connector printer cable A441, while the other end is connected to the machine. Select any training program: as soon as the last input is confirmed and training starts, the machine will transmit the data through the serial port.
  • Page 38 SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 Page intentionally left blank Page 6.18...

  • Page 39: Disassembly Of Components

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 7. DISASSEMBLY OF COMPONENTS 7.1. DISASSEMBLING THE DISPLAY 1. Turn off the machine and unplug the mains lead from the wall outlet. 2. Unscrew the 7 self-tapping screws a which fix the DISPLAY, using a large Phillips screwdriver.

  • Page 40: Disassembling The Eprom

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 7.2. DISASSEMBLING THE EPROM Carry out the procedure described in paragraph 7.1. “Disassembling the display”. With the display on a work bench: 1. Remove EPROM a from its socket using an integrated-circuit extractor tool.

  • Page 41: Disassembling The Fan Control Board

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 7.3. DISASSEMBLING THE FAN CONTROL BOARD Carry out the procedure described in paragraph 7.1. “Disassembling the display”. With the display on a work bench: 1. Remove the two fixing screws a of the fan control board using a 5.5-mm socket wrench.

  • Page 42: Disassembling The Cpu Board

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 7.4. DISASSEMBLING THE CPU BOARD Carry out the procedures described in paragraph 7.1. “Disassembling the display” and 7.3. “Disassembling the fan control board”. With the display placed on a work bench: 1.

  • Page 43: Disassembling The Keyboard

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 7.5. DISASSEMBLING THE KEYBOARD Carry out the procedure described in paragraph 7.1. “Disassembling the display”. 1. Disconnect KEYBOARD connector a. Figure 7.5-1 With the display on a work bench: 1. Use a sharp tool to lift up a corner of the KEYBOARD and detach it.

  • Page 44: Disassembling The Cardio Receiver

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 7.6. DISASSEMBLING THE CARDIO RECEIVER 1. Turn off the machine and unplug the mains lead from the wall outlet. 2. Remove the CARDIO RECEIVER housing from its support on the machine.

  • Page 45: Disassembling The Fan Assembly

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 7.7. DISASSEMBLING THE FAN ASSEMBLY Carry out the procedure described in paragraph 7.1. “Disassembling the display”. 1. Disconnect connector K3 from the fan control board. 2. Unscrew the 2 self-tapping screws a using a large Phillips screwdriver.

  • Page 46: Disassembling The Guard

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 7.8. DISASSEMBLING THE GUARD 1. Turn off the machine and unplug the mains lead from the wall outlet. 2. Unscrew the 3 self-tapping screws a fixing the GUARD with a large Phillips screwdriver.

  • Page 47: Disassembling The Footboard

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 7.9. DISASSEMBLING THE FOOTBOARD 1. Turn off the machine and unplug the mains lead from the wall outlet. 2. Unscrew the 3 screws a which hold the FOOTBOARD in place using a 6-mm Allen wrench.

  • Page 48: Disassembling The Electronic Circuit Boards

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 7.10. DISASSEMBLING THE ELECTRONIC CIRCUIT BOARDS Carry out the procedures described in paragraph 7.9. “Disassembling the footboard”. To disassemble the POWER SUPPLY a: 1. Disconnect the 2 connectors CN1 and CN2.

  • Page 49: Disassembling The Rear Assembly

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 7.11. DISASSEMBLING THE REAR ASSEMBLY Carry out the procedure described in paragraph 7.8. “Disassembling the guard”. 1. Disconnect alternator cables a. Figure 7.11-1 2. Unscrew the 4 screws b which fix the REAR GROUP to the machine frame using a 6-mm hex T-wrench.

  • Page 50: Disassembling The Second Roller

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 7.12. DISASSEMBLING THE SECOND ROLLER Carry out the procedure described in paragraph 7.8. “Disassembling the guard”. 1. Remove the 2 screws a using a 6-mm hex T- wrench. 2. Remove the SECOND ROLLER.

  • Page 51: Disassembling The Flywheel And Alternator Group

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 7.13. DISASSEMBLING THE FLYWHEEL AND ALTERNATOR GROUP Carry out the procedure described in 7.11. “Disassembling the rear assembly”. 1. Unscrew the nut on the flywheel side using a 24-mm socket wrench.

  • Page 52: Disassembling The Rear Hub Supporting Frame

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 7.14. DISASSEMBLING THE REAR HUB SUPPORTING FRAME Carry out the procedure described in paragraph 7.8. "Disassembling the guard". 1. Unscrew the two screws a fixing the limit stop bracket to the machine frame using 4- mm hex T-wrench.

  • Page 53: Disassembling The Bushings

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 7.15. DISASSEMBLING THE BUSHINGS Carry out the procedure described in paragraph 7.14. “Disassembling the rear hub supporting frame ”. With the rear hub frame placed on a bench, and working from both sides: 1.

  • Page 54: Disassembling The Runner Bars

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 7.16. DISASSEMBLING THE RUNNER BARS Carry out the procedure described in paragraph 7.14. “Disassembling the rear hub supporting frame ”. For both RUNNER BARS: 1. Remove the screws which clamp the RUNNER BARS to the machine frame using an 8-mm T-wrench.

  • Page 55: Disassembling The Front Hub Shock Absorbers

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 7.17. DISASSEMBLING THE FRONT HUB SHOCK ABSORBERS VersionA: 1. Turn off the machine and unplug the mains lead from the wall outlet. 2. Disassemble bicycle fork clamp a. 3. Remove snap ring b using the special pliers.
  • Page 56 SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 Version B: 1. Turn off the machine and unplug the mains lead from the wall outlet. 2. Disassemble the bicycle fork clamp f. 3. Remove circlip g using the circlip pliers.

  • Page 57: Disassembling The Alternator Brushes

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 7.18. DISASSEMBLING THE ALTERNATOR BRUSHES Carry out the procedure described in paragraph 7.8. “Disassembling the guard ”. 1. Disconnect alternator cable a. 2. Unscrew BRUSH group fixing screw b. 3. Remove the BRUSHES.
  • Page 58 SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 Page intentionally left blank Page 7.20...

  • Page 59: Adjustments

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 8. ADJUSTMENTS 8.1. WEAR OF BRUSHES Carry out the procedure described in paragraph 7.18. Disassembling the alternator brushes”. • The brush shown in (A) is correctly worn. • The brush shown in (B) is irregularly worn and may result in noise and wear of the alternator collector.

  • Page 60: Calibration

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 8.2. CALIBRATION The machine incorporates a power CALIBRATION function to ensure that the value shown on the display corresponds to the actual power produced by the machine. The various methods for carrying out the CALIBRATION procedure are described in the “Operating and service instructions”...

  • Page 61: Configuring The Machine

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 9. CONFIGURING THE MACHINE Carry out the procedure described in paragraph 7.1. “Disassembling the display” to access the dip- switches on the CPU board. Dip-switch configuration 1 enables the printout function.

  • Page 62: Messages On Led Matrix

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 9.3. MESSAGES ON LED MATRIX Starting from release 2.2 TGS it is possible to select how some messages will be shown on the LED matrix: IP or PI stands for Performance index and PSI or ATM is a reminder to check the pressure of the rear tire.

  • Page 63: Scheduled Maintenance

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 10. SCHEDULED MAINTENANCE To keep the machine in perfect working order, carry out the scheduled maintenance operations specified in the table below: CLEANING LUBRICATION weekly MACHINE EXTERIOR monthly MACHINE INTERIOR yearly...
  • Page 64 SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 Page intentionally left blank Page 10.2...

  • Page 65: Appendix

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 11. APPENDIX 11.1. TECHNICAL NOTES ON CARDIO RECEIVERS The receiver shown in the figure below is equipped with: Figure 11.1-1 • an antenna a, designated the “coil”, which receives the signal from the transmitter strap worn by the user.

  • Page 66: Presence Of Electromagnetic Fields

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 11.1.2. P RESENCE OF ELECTROMAGNETIC FIELDS The receiver is sensitive to electromagnetic fields produced by the switching of LEDs, motor brushes, the commutation of power devices, monitors, neon lights, stereo equipment, etc., which can impair its operation.

  • Page 67: Mechanical Vibrations

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 • presence of electromagnetic fields which interfere with reception or saturate the receiver; • problems due to interaction between the receiver on one machine and the signal transmitted by a user training on another machine that is too close and cannot be moved farther away.

  • Page 68: Position Of The Receiver

    SPIN TRAINER: Service & Maintenance Manual - rev. 2.0 11.1.5. P OSITION OF THE RECEIVER Carefully position the receiver according to the specifications below: • the coil must be directed toward the user; • the coil must be positioned well away (even a few centimeters) from the LEDs;...
  • Page 72 TECHNOGYM INDUSTRIE S.r.l. Via G. Perticari, 20 47035 Gambettola (Forlì ) ITALIA Tel.: +39 - 547 56047 Fax: +39 - 547 650 150 e-mail: service@technogym.com 0SMM0026-ING...

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