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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.
BIKERACE: Service & Maintenance Manual - rev. 1.1 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 CHARACTERISTICS ........................2.1 2.1. M ........................
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BIKERACE: Service & Maintenance Manual - rev. 1.1 7.8. D ......................... 7.10 ISASSEMBLING THE ALTERNATOR 7.9. D ..........................7.11 ISASSEMBLING THE BELT 7.10. D ..........................7.13 ISASSEMBLING THE CHAIN 7.11. D .......................... 7.14 ISASSEMBLING THE PULLEY 7.12. D ....................7.15 ISASSEMBLING THE PEDAL CRANK GROUP 7.13.
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.
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.
BIKERACE: Service & Maintenance Manual - rev. 1.1 2.5. WIRING DIAGRAM 2.5.1. ONNECTORS • CPU board name type of connector connection AMP MATE-N-LOCK 12-pin F. to alternator interface board AMP MODU II 4-pin M. to cardio receiver • Power supply...
BIKERACE: Service & Maintenance Manual - rev. 1.1 • Alternator interface board name type of connector connection AMP MATE-N-LOCK 15-pin F. to CPU board AMP MATE-N-LOCK 6-pin F. to alternator AMP MODU I 4-pin M. to power supply AMP MODU I 8-pin M.
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BIKERACE: Service & Maintenance Manual - rev. 1.1 BK-3B: High voltage power supply ON-OFF Switch – Power supply ON-OFF Switch Signal Color Power supply Red Faston Live Blue Red Faston Neutral Black The above description of cable BK-3 is simplified and does not detail the ground node connections.
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BIKERACE: Service & Maintenance Manual - rev. 1.1 BK-8: Serial ports cable Alternator interface board – Serial ports Alternator Signal Color Serial ports interface board Y – bus White Z – bus Orange A – bus Brown B – bus...
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BIKERACE: Service & Maintenance Manual - rev. 1.1 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.
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BIKERACE: Service & Maintenance Manual - rev. 1.1 • Non-coded: this is the standard product; • Coded: this is the product which, utilizing Personal Coded Device technology, transmits the heart rate together with a code that identifies the transmitter in question. In this way, the coded receiver on the machine can identify the source of the heart rate signal, thereby avoiding interference problems.
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BIKERACE: Service & Maintenance Manual - rev. 1.1 POWER SUPPLY Receives the mains voltage at its input and outputs the DC voltages (+5 Vdc, +12 Vdc and −12 Vdc) which supply the display and the alternator interface board. ALTERNATOR INTERFACE BOARD Receives from the display a square wave signal (PWM) whose frequency is proportional to the difficulty level setting, and converts it into an analogue excitation signal for the alternator.
BIKERACE: Service & Maintenance Manual - rev. 1.1 3.2. ALTERNATOR CONTROL 3.2.1. ECHANICS The movement of the pedals turns the pedal crank which by means of a chain transmits the motion to a pulley, which in turn transmits the motion to the alternator by means of a belt.
BIKERACE: Service & Maintenance Manual - rev. 1.1 3.2.3. HE CONTROL SIGNALS The machine controls the difficulty level of the workout by means of the CPU board, the alternator interface board and the alternator, as illustrated in the figure below:...
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BIKERACE: Service & Maintenance Manual - rev. 1.1 • RPM Signal This is the speed signal output by the alternator. It enters the alternator interface board (pin 1-5 of connector CN2) and is a square wave which varies from –1 Vdc to a maximum value...
BIKERACE: Service & Maintenance Manual - rev. 1.1 4. ACCESSORIES 4.1. CONNECTING TO THE TGS The machine can be connected to the Technogym System by installing a special upgrade kit, which involves the following: • Installation of a special SW;...
The machine is pre-set for printing via the full duplex RS 485 port available on the serial ports panel. If the machine is equipped with Technogym System SW, the print function is not available. The printer is connected using a special cable, which can be ordered using code A419. This cable is equipped with an RS 485 to RS 232 serial converter.
BIKERACE: Service & Maintenance Manual - rev. 1.1 4.3. CONNECTING TO AN EXTERNAL DEVICE (ECG AND/OR METABOLIC MONITOR) The medical version of the machine (HC800) can be connected to an external device (ECG and/or metabolic monitor) in order to perform exertion tests. The external device must provide an analogue output which is interfaced –...
BIKERACE: Service & Maintenance Manual - rev. 1.1 Because the machine is able to operate at power levels ranging from a minimum of 30 to a maximum of 500 Watts, it can therefore handle external analog signals ranging from 0.3 to 5 Vdc.
BIKERACE: Service & Maintenance Manual - rev. 1.1 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.
BIKERACE: Service & Maintenance Manual - rev. 1.1 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.
BIKERACE: Service & Maintenance Manual - rev. 1.1 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.
BIKERACE: Service & Maintenance Manual - rev. 1.1 6.1. THE DISPLAY DOES NOT ILLUMINATE This error occurs when the supply voltage fails to reach the display. THE DISPLAY DOES NOT ILLUMINATE Are the fuses OK? Replace the blown fuses Is the mains lead OK?
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BIKERACE: Service & Maintenance Manual - rev. 1.1 Replace the power Are DC voltages output by the supply power supply correct? Do all DC voltages reach the Replace the CPU board display? Do all DC voltages reach the Replace cable BK-6...
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BIKERACE: Service & Maintenance Manual - rev. 1.1 As for step (1) but with the tester between terminals L1 and N1 of the input socket / on-off switch block. Slightly lift connector CN2 on the power supply to access the pins with the tester probes.
BIKERACE: Service & Maintenance Manual - rev. 1.1 6.2. THERE IS NO RESISTANCE This error can be caused by absence of the speed signal, problems with the excitation circuit, overheating of the alternator or defective alternator brushes. THERE IS NO...
BIKERACE: Service & Maintenance Manual - rev. 1.1 6.3. THE RESISTANCE IS INCORRECT The resistance is incorrect if the alternator does not receive the correct excitation signal or if the power resistor is defective. RESISTANCE IS INCORRECT Is the alternator excitation...
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BIKERACE: Service & Maintenance Manual - rev. 1.1 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: Place the tester probes between the orange (positive) and black (negative) cables on the alternator.
BIKERACE: Service & Maintenance Manual - rev. 1.1 6.4. THE RPM VALUE IS INCORRECT This error occurs when there are problems with the RPM signal output by the alternator. THE RPM VALUE IS INCORRECT Is the RPM wire of cable...
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BIKERACE: Service & Maintenance Manual - rev. 1.1 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: 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.
BIKERACE: Service & Maintenance Manual - rev. 1.1 6.5. THE MACHINE DOES NOT PRINT This error occurs when there are HW problems, or if the machine has not been configured correctly. Always check that the printer itself is working correctly first.
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BIKERACE: Service & Maintenance Manual - rev. 1.1 Connect the tester to the output connector of printer cable A419, and connect the other end to the machine. Choose any workout program: as soon as the last value entered has been confirmed, the workout starts and the machine immediately transmits the data via the serial port.
BIKERACE: Service & Maintenance Manual - rev. 1.1 6.6. THE MACHINE DOES NOT OPERATE IN MASTER - SLAVE MODE This error is due to problems on the Master - Slave control signal. THE MACHINE DOES NOT OPERATE IN MASTER - SLAVE MODE...
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BIKERACE: Service & Maintenance Manual - rev. 1.1 Are the signals output by the Replace cable BK-1 Replace the CPU board serial port on the CPU board correct? Follow the step by step procedure to correctly diagnose the problem. Take particular care with the checks highlighted by circled numbers, which are described in detail below: Disconnect any race cables linking the machines before performing these checks.
BIKERACE: Service & Maintenance Manual - rev. 1.1 6.7. THERE IS NO HEART RATE SIGNAL This error occurs when the receiver is not working or when it does not receive the power supply from the CPU board. THERE IS NO...
BIKERACE: Service & Maintenance Manual - rev. 1.1 6.8. THE HEART RATE SIGNAL IS INCORRECT The machine displays this message when the receiver is disturbed by electromagnetic noise in the surrounding environment. In some cases, the machine may show the message “Err” on the heart rate display.
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BIKERACE: Service & Maintenance Manual - rev. 1.1 Is the transmitter in good Use a known good working order? transmitter Is the transmitter always Keep the transmitter within a distance of 80 cm within the minimum from the receiver? reception distance Change the receiver Follow the procedure step by step to correctly diagnose the problem.
BIKERACE: Service & Maintenance Manual - rev. 1.1 7. DISASSEMBLY OF COMPONENTS 7.1. DISASSEMBLING THE DISPLAY 1. Turn off the machine and unplug the mains lead from the wall outlet. 2. Back off the 5 screws a using a 4-mm hex T wrench.
BIKERACE: Service & Maintenance Manual - rev. 1.1 7.2. DISASSEMBLING THE EPROM 1. Turn off the machine and unplug the mains lead from the wall outlet. 2. Back off the 4 fixing screws a of the protective cover using a small Philips screwdriver.
BIKERACE: Service & Maintenance Manual - rev. 1.1 7.3. DISASSEMBLING THE CPU BOARD 1. Turn off the machine and unplug the mains lead from the wall outlet. 2. Back off the 4 fixing screws a of the protective cover using a small Philips screwdriver.
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BIKERACE: Service & Maintenance Manual - rev. 1.1 Rest the keyboard – electronic circuit boards group on a work bench: 7. Disconnect connectors e. 8. Back off the 6 studs f using a 7-mm wrench. Figure 7.3-4 9. Separate the CPU board g from the LED board h by flipping it over toward the left, being careful not to damage cable strip i.
BIKERACE: Service & Maintenance Manual - rev. 1.1 7.4. DISASSEMBLING THE KEYBOARD 1. Turn off the machine and unplug the mains lead from the wall outlet. 2. Back off the 4 fixing screws a of the protective cover using a small Philips screwdriver.
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BIKERACE: Service & Maintenance Manual - rev. 1.1 Rest the keyboard – electronic circuit boards group on a work bench: 7. Unplug the keyboard connector. 8. Use a sharp tool to lift up a corner of the KEYBOARD and detach it.
BIKERACE: Service & Maintenance Manual - rev. 1.1 7.5. DISASSEMBLING THE CARDIO RECEIVER 1. Turn off the machine and unplug the mains lead from the wall outlet. If the receiver is positioned under the display: 2. Use a flat blade screwdriver to open the box a which contains the RECEIVER.
BIKERACE: Service & Maintenance Manual - rev. 1.1 7.6. DISASSEMBLING THE RIGHT AND LEFT SIDE GUARDS 1. Turn off the machine and unplug the mains lead from the wall outlet. 2. Unscrew the 12 self-tapping screws a which fix the LEFT SIDE GUARD using a large Phillips screwdriver.
BIKERACE: Service & Maintenance Manual - rev. 1.1 7.7. DISASSEMBLING THE ELECTRONIC CIRCUIT BOARDS Carry out the procedure described in paragraph 7.6. “Disassembling the right and left ”, removing only the right side guard. 1. Cut the straps securing the cables to the protective grille.
BIKERACE: Service & Maintenance Manual - rev. 1.1 7.8. DISASSEMBLING THE ALTERNATOR Carry out the procedure described in paragraph 7.6. “Disassembling the right and left side guards”. 1. Disconnect cables from ALTERNATOR. 2. Loosen nut a of belt tension rod b using a 17- mm wrench.
BIKERACE: Service & Maintenance Manual - rev. 1.1 7.9. DISASSEMBLING THE BELT Carry out the procedure described in paragraph 7.6. “Disassembling the right and left side guards”. 1. Loosen nut a of belt tension rod b using a 17- mm wrench.
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BIKERACE: Service & Maintenance Manual - rev. 1.1 From the left-hand side of the machine: 8. Remove BELT g from the guide of pulley h. 9. Remove snap ring i using the special pliers. 10. In the case of a non-threaded pin: use a...
BIKERACE: Service & Maintenance Manual - rev. 1.1 7.10. DISASSEMBLING THE CHAIN Carry out the procedures described in paragraphs 7.6. “Disassembling the right and left side guards”. 1. Turn the CHAIN until the connecting link a is on the sprocket wheel b.
BIKERACE: Service & Maintenance Manual - rev. 1.1 7.11. DISASSEMBLING THE PULLEY Carry out the procedures described in paragraphs 7.6. “Disassembling the right and left side guards”, 7.9. “Disassembling the belt ” and 7.10. “Disassembling the chain”. Regardless of the type of pin: 1.
BIKERACE: Service & Maintenance Manual - rev. 1.1 7.12. DISASSEMBLING THE PEDAL CRANK GROUP Carry out the procedures described in paragraphs 7.6. “Disassembling the right and left side guards” and 7.10. “Disassembling the chain”. 1. Unscrew the left pedal a using a 15-mm wrench.
BIKERACE: Service & Maintenance Manual - rev. 1.1 7.13. DISASSEMBLING THE ALTERNATOR BRUSHES Carry out the procedures described in paragraph 7.6. “Disassembling the right and left side guards”, removing only the left side guard. 1. Disconnect cable a from the alternator.
BIKERACE: Service & Maintenance Manual - rev. 1.1 8. ADJUSTMENTS 8.1. ALIGNING THE BELT Carry out the procedures described in paragraphs 7.6. “Disassembling the right and left side guards”. 1. Back off the lock nut a on alternator pivot b using a 19-mm wrench.
BIKERACE: Service & Maintenance Manual - rev. 1.1 8.2. BELT TENSION Carry out the procedures described in paragraph 7.6. “Disassembling the right and left side guards”. 1. Back off lock nut of alternator pivot a using a 19-mm wrench. 2. Back off dowel b of alternator pivot a.
BIKERACE: Service & Maintenance Manual - rev. 1.1 8.3. CHAIN ALIGNMENT Machine version with non threaded pin: Carry out the procedures described in paragraph 7.6. “Disassembling the right and left side guards”. 1. From both sides of the machine, use a marker pen to fix a reference point between cam a and the frame.
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BIKERACE: Service & Maintenance Manual - rev. 1.1 Machine version with threaded pin: Carry out the procedures described in paragraph 7.6. “Disassembling the right and left side guards”. Working from the right-hand side: 1. Unscrew the screw e using a 4-mm hex T wrench.
BIKERACE: Service & Maintenance Manual - rev. 1.1 8.4. CHAIN TENSION Carry out the procedures described in paragraph 7.6. “Disassembling the right and left side guards”. From both sides of the frame: 1. Back off the 2 screws a which fix cam b onto the frame using a 4-mm hex T wrench.
BIKERACE: Service & Maintenance Manual - rev. 1.1 8.5. PLAY OF SADDLE STEM 1. Turn off the machine and unplug the mains lead from the wall outlet. 2. Raise the rubber protection a. On each of the 4 fixing points: 3.
BIKERACE: Service & Maintenance Manual - rev. 1.1 8.6. WEAR OF ALTERNATOR BRUSHES Carry out the procedures described in paragraph 7.13. “Disassembling the alternator brushes”. Inspect the 2 brushes for wear, referring to the figures at left and to the descriptions below: •...
BIKERACE: Service & Maintenance Manual - rev. 1.1 8.7. PLAY OF THE PEDAL GROUP Carry out the procedures described in paragraph 7.12. “Disassembling the pedal crank group” up until step 4 . 1. Adjust the 2 ring nuts a using 36-mm wrenches until the pedal group is securely fixed.
BIKERACE: Service & Maintenance Manual - rev. 1.1 8.8. ADJUSTING THE LCD BACKLIGHTING After the machine has been switched on for at least 1 hour, without switching it off: 1. Adjust trimmer P1 on the back of the display to obtain the desired level of LCD luminosity.
BIKERACE: Service & Maintenance Manual - rev. 1.1 8.9. ADJUSTING THE BUZZER TONE Turn on the machine and, when the buzzer is sounded during the start-up procedure: 1. Adjust trimmer P2 on the back of the display to obtain the desired buzzer tone.
BIKERACE: Service & Maintenance Manual - rev. 1.1 9. CONFIGURING THE MACHINE 9.1. MACHINE HW CONFIGURATION The HW configuration of the machine is set using the 2 banks of dip-switches on the back of the CPU board, according to the tables below: 9.1.1.
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BIKERACE: Service & Maintenance Manual - rev. 1.1 10. SCHEDULED MAINTENANCE To keep the machine in perfect working order and prevent the risk of malfunction, it is necessary to perform the scheduled maintenance operations set out in the table below. There are 3 basic types of maintenance operations: •...
BIKERACE: Service & Maintenance Manual - rev. 1.1 10.2. INTERNAL CLEANING OPERATIONS These operations can be carried out by the owner of the machine and do not require any special skills. The internal cleaning procedures are simple cleaning operations aimed at keeping the interior of the machine clean.
10.3. SPECIAL MAINTENANCE OPERATIONS These operations can only be carried out by a qualified technician specifically trained by Technogym and authorized to carry out machine installation and adjustments, as well as special maintenance operations or repairs which require special knowledge of the machine, its operation, safety systems and working procedures.
BIKERACE: Service & Maintenance Manual - rev. 1.1 10.3.6. C HECKING THE STATE OF WEAR OF THE CHAIN 1. Check the state wear of the chain, inspecting its entire length. Replace if links are jammed and/or have excessive play. 2. Check the tension and the alignment of the chain. Adjust them if necessary.
11. APPENDIX 11.1. TECHNICAL NOTES ON CARDIO RECEIVERS Technogym utilizes Polar technology for measuring the heart rate frequency of the person training on the machine. The Polar system consists of: • a transmitter, worn by the person training on the machine, which uses 2 electrodes to detect the electrical activity of the heart and transmits the measured heart rate by sending an electromagnetic signal at a frequency of 5 kHz.
BIKERACE: Service & Maintenance Manual - rev. 1.1 There are 3 types of problems which can typically occur on the heart rate signal: • interference caused by disturbances from sources of electromagnetic noise. These problems cause the heart rate signal to deviate from the rear value, typically making it higher;...
BIKERACE: Service & Maintenance Manual - rev. 1.1 of the receiver (detected by the coil) whereas they have no effect on digital components such as the CPU receiver connecting cable. Electromagnetic interference can take different forms: on the one hand, the receiver may detect and hence generate spurious transients or periodic noise pulse, or on the other hand the receiver may become saturated.
BIKERACE: Service & Maintenance Manual - rev. 1.1 Sensitivity is reduced by soldering a resistor in parallel with the coil. Normally, the receiver already has a 15 KOhm resistor mounted in parallel with the coil, however it is advisable to check for its presence.
BIKERACE: Service & Maintenance Manual - rev. 1.1 • the receiver must be directed in such a way that its axis of reception is parallel to that of the transmitter, as shown in the figure below: Figure 11.1-2 Please note that even small departures from the above specifications may considerably impair the accuracy of reception.
11.2. PERSONAL CODED DEVICE Starting from April 1999, the machine can be equipped with a new heart rate receiver based on the PERSONAL CODED DEVICE technology developed exclusively by Technogym in conjunction with POLAR. Thanks to a special receiver installed on the machine, and using a new “coded” chest strap, the machine receives only the heart rate signal from its own user.
BIKERACE: Service & Maintenance Manual - rev. 1.1 Code T (msec) At the start of the training session, the coded receiver first of all seeks to detect a coded signal for a maximum of 10 seconds. This is done in reduced sensitivity mode to avoid receiving a signal from users on adjacent machines.
BIKERACE: Service & Maintenance Manual - rev. 1.1 11.3. SPECIAL FUNCTIONS Below is a list of the special functions and passwords available on the machine: 11.3.1. D ISPLAYING THE SELECTED TYPE OF ALTERNATOR Simultaneously press the 1-4-7 keys, the LCD will show: •...
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TECHNOGYM S.p.A. Via G. Perticari, 20 47035 Gambettola (FC) ITALIA Tel.: +39-0547-650438 Fax: +39-0547-650150 e-mail: service@technogym.com 0SMM0019-ING...