Technogym Forma Service Maintenance Manual
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Technogym Forma Service Maintenance Manual

Technogym Forma Service Maintenance Manual

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MAINTENANCE MANUAL
R
. 3.0
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Summary of Contents for Technogym Forma

  • Page 1 & ERVICE MAINTENANCE MANUAL . 3.0...
  • 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 or use of this manual.

  • Page 5: Table Of Contents

    FORMA: Service & Maintenance manual - rev. 3.0 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 CHARACTERISTICS ........................2.1 2.1. M ........................
  • Page 6 FORMA: Service & Maintenance manual - rev. 3.0 6.1. T ........................ 6.2 HE DISPLAY DOES NOT ILLUMINATE 6.2. T “SAFETY SWITCH” ..................... 6.6 HE DISPLAY SHOWS 6.3. T “E 3”..........................6.7 HE DISPLAY SHOWS 6.3.1. The inverter display shows E01, E02, E03, E04 or E05 ..............6.9 6.3.2.
  • Page 7 ......................... 10.1 XTERNAL CLEANING OPERATIONS 10.1.1. Setting up the operation ........................10.1 10.1.2. Cleaning operations ........................10.1 10.1.3. Operazione di lubrificazione del nastro e pianale di corsa per Forma 3 ........10.1 10.2. R ......................10.3 OUTINE MAINTENANCE OPERATIONS 10.2.1. Internal cleaning operations ......................10.3 10.2.2.
  • Page 8 FORMA: Service & Maintenance manual - rev. 3.0 Page intentionally left blank Page iv...

  • Page 9: 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 10: 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 11: Technical Characteristics

    FORMA: Service & Maintenance manual - rev. 3.0 2. TECHNICAL CHARACTERISTICS 2.1. MECHANICAL CHARACTERISTICS Width 73 cm Length 180 cm Height 132 cm Weight 130 Kg 2.2. ELECTRICAL CHARACTERISTICS Mains voltage 220 V Frequency 50 Hz Consumption 1500 VA Fuses 5x20 2xT8AH 2.3.

  • Page 12: Wiring Diagram

    2.5.1. ERSION CURRENTLY IN PRODUCTION This machine version, subsequently identified with the name Forma 3, has been in production starting from SN 01000881. It differs from the preceding version as follows: • Fan for improved cooling of the motor group;...

  • Page 13: Connectors

    FORMA: Service & Maintenance manual - rev. 3.0 2.5.2. ONNECTORS • CPU board name type of connector connection AMP MODU I 4x1 pin f. to driver board (low voltage input) AMP MODU I 2x1 pin f. to LED board (low voltage output) AMP MODU II 9x2 pin f.

  • Page 14: Wiring

    FORMA: Service & Maintenance manual - rev. 3.0 • Portable connectors name type of connector connection CN28 MOLEX mini-fit 7x2 m. portable to CPU board (actuator drive) CN29 MOLEX mini-fit 7x2 f. portable to driver board (actuator drive) CN39 Terminal block...
  • Page 15 FORMA: Service & Maintenance manual - rev. 3.0 FR-5: Transformer high voltage input cable High voltage distribution terminal block – Selector Terminal block Signal Color Selector CN39 Neutral Blue Live Black FR-6: Low voltage power supply cable Power supply – Driver board...
  • Page 16 FORMA: Service & Maintenance manual - rev. 3.0 FR-9: Up-down motor cable Portable connector – Up-down motor cable Portable Signal Color Up-down motor CN46 Motor + White already connected Motor - Blue already connected Up-down motor pulses already connected Pulse Gnd...
  • Page 17 FORMA: Service & Maintenance manual - rev. 3.0 FR-12: CPU cable – lower section Portable connector – Driver board Portable Signal Color Driver board CN29 Up-down motor “down” Green Up-down motor “up” Yellow Up-down motor alarm Blue Up-down motor pulses...
  • Page 18 FORMA: Service & Maintenance manual - rev. 3.0 FR-15: Up-down motor cable extension Portable connector – Driver board Portable Signal Color Driver board CN46 Motor + White Motor - Blue Up-down motor pulses Pulse Gnd Black FR-16: Fan power supply cable Fan interface board –...
  • Page 19 FORMA: Service & Maintenance manual - rev. 3.0 RL-20: TGS cable CPU board – Serial connector CPU board Signal Color Serial connector +12 Vdc Yellow Green White Brown Note that this is a simplified description of the cables, which does not include the ground node connections of the electronics box, the rear roller and the front roller.

  • Page 20: Previous Model

    FORMA: Service & Maintenance manual - rev. 3.0 2.5.4. REVIOUS MODEL This machine version, subsequently identified with the name Forma 2: For the cables, refer to the description in the preceding paragraph with the exception of cables FR- 1/A and FR-7 which are described below: FR-1/A: Filter cable Power inlet socket –...
  • Page 21 FORMA: Service & Maintenance manual - rev. 3.0 FR-7: Inverter cable Driver board – Inverter Driver board Signal Color Inverter CN43 Thermal cutout Green White Thermal cutout Gnd White Start Grey Alarm Alarm Gnd Purple Speed Brown Speed Gnd Black...

  • Page 22: Forma: Service & Maintenance Manual - Rev

    FORMA: Service & Maintenance manual - rev. 3.0 Page intentionally left blank Page 2.12...

  • Page 23: Principles Of Operation

    FORMA: Service & Maintenance manual - rev. 3.0 3. PRINCIPLES OF OPERATION 3.1. BLOCK DIAGRAM The block diagram of the machine is shown in the figure below: 3.1.1. ARDIO 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 24: Display

    LED board: contains the circuits for the LED indicators and the 7 segment display. ATTENTION: The EPROM SW versions used on Forma 2 and Forma 3 are different, due to differences in certain mechanical characteristics between the two machines. In consequence: •...

  • Page 25: Inverter

    When this contact opens, the inverter generates an alarm. The tread-belt motor has a power of 1.1 KW (1.5 Hp). The motor used on Forma 3 is different from the one used on Forma 2. WARNING: The tread-belt motor is isolated from earth. It is fixed using plastic bushings and dowels to ensure its isolation from the machine frame.

  • Page 26: Voltage Selector Switch

    FORMA: Service & Maintenance manual - rev. 3.0 3.1.9. OLTAGE SELECTOR SWITCH This is a selector which, when used together with a transformer having 2 primary 110 VAC circuits, ensures the correct power supply to the transformer when powered at either 110 VAC or 230 VAC.

  • Page 27: Tread-Belt Motor Drive

    FORMA: Service & Maintenance manual - rev. 3.0 3.2. TREAD-BELT MOTOR DRIVE 3.2.1. ECHANICS The tread-belt is actuated by the motor through a linkage consisting of the motor pulley, the driving roller and the belt which connects them. In this way, a given belt motor speed corresponds to a predetermined linear tread-belt speed.

  • Page 28: The Signals Involved

    FORMA: Service & Maintenance manual - rev. 3.0 3.2.3. HE SIGNALS INVOLVED The machine controls the speed of the belt motor by means of the CPU board and the inverter interface board, as shown in the following figure: CPU board...
  • Page 29 FORMA: Service & Maintenance manual - rev. 3.0 • Speed reference signal This is the signal generated by the CPU board (pin 4-12 on connector K4) to control the motor speed. It is a PWM signal, i.e. a fixed-frequency square wave signal with variable duty cycle.

  • Page 30: Up-Down Motor Drive

    FORMA: Service & Maintenance manual - rev. 3.0 3.3. UP-DOWN MOTOR DRIVE 3.3.1. ECHANICS The machine incline is varied by the up-down motor rod, which moves a frame connected to the front wheels. The motor movement is detected by a hall sensor which provides the motor motion control signal: each motor revolution corresponds to a predetermined number of pulses and to a predetermined displacement of the rod, and hence of the machine incline.

  • Page 31: The Signals Involved

    FORMA: Service & Maintenance manual - rev. 3.0 3.3.3. HE SIGNALS INVOLVED The machine controls the incline through the CPU board and the driver board, as illustrated in the figure below: CPU board 5-12 3-12 9-11 7-12 Down Pulses Alarm...
  • Page 32 FORMA: Service & Maintenance manual - rev. 3.0 • Motor voltage signal (Vdc) This is the DC voltage generated by the driver board (pin 1-2 of connector J1) to supply the up- down motor. Its absolute value is 24 Vdc, and the motor will rotate either clockwise or anticlockwise depending on its polarity, causing the rod to become longer or shorter, thereby increasing or decreasing the machine incline.

  • Page 33: Fan Drive

    The fan is independent of the treadmill motor and assembled on its axis, on the other side of the flywheel. It is a larger sized fan than the one used on Forma 2, which resolves the overheating problems of the preceding version, especially during operation at low speeds.

  • Page 34: The Signal Involved

    FORMA: Service & Maintenance manual - rev. 3.0 3.4.3. HE SIGNAL INVOLVED The machine controls the operation of the fan as illustrated in the diagram below: CPU board 6-12 Start CN28 10-12 Start 6-12 Driver board Start 1-P24 Inverter CM2-L...
  • Page 35 FORMA: Service & Maintenance manual - rev. 3.0 • Enable signal This is the signal generated by the inverter (pin CM2-L) for enabling the fan. When the treadmill is halted it is at logic level low (0 Vdc), and immediately switches to logic level high (24.55 Vdc) when the "Start"...
  • Page 36 FORMA: Service & Maintenance manual - rev. 3.0 Page intentionally left blank Page 3.14...

  • Page 37: Accessories

    4. ACCESSORIES 4.1. CONNECTING TO THE TGS The machine can be connected to the Technogym System by installing a special upgrade kit. The CPU board is connected to the serial connector via the cable described below, which is supplied together with the upgrade kit.
  • Page 38 FORMA: Service & Maintenance manual - rev. 3.0 Page intentionally left blank Page 4.2...

  • Page 39: Installation Instructions

    FORMA: Service & Maintenance manual - rev. 3.0 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 40 FORMA: Service & Maintenance manual - rev. 3.0 When the machine is turned on it will perform a power-on test which: • sounds the buzzer; • lights all the LEDs; • resets the elevation. After completing this power-on test the machine enters standby mode, awaiting a keyboard command.

  • Page 41: Troubleshooting

    FORMA: Service & Maintenance manual - rev. 3.0 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 42: The Display Does Not Illuminate

    FORMA: Service & Maintenance manual - rev. 3.0 6.1. THE DISPLAY DOES NOT ILLUMINATE This problem occurs when the supply voltage fails to reach the display. THE DISPLAY DOES NOT ILLUMINATE Are the fuses OK? Replace the blown fuses Is mains lead OK?
  • Page 43 FORMA: Service & Maintenance manual - rev. 3.0 Replace the power Are DC voltages output by the supply power supply correct? Do all DC voltages reach the Replace the display CPU board display? Do all DC voltages reach the Replace cable FR-6...
  • Page 44 FORMA: Service & Maintenance manual - rev. 3.0 Is the mains voltage present at Replace the mains plug the output of the mains plug? of the machine Replace the cable Is the mains voltage present at FR-1/A the input to the filter?
  • Page 45 FORMA: Service & Maintenance manual - rev. 3.0 As for step (2), but on connector K1 on the CPU board of the display. As for step (2), but on connector J3 of the driver board. As for step (2), but on connector J4 of the driver board.

  • Page 46: The Display Shows "Safety Switch

    FORMA: Service & Maintenance manual - rev. 3.0 6.2. THE DISPLAY SHOWS “SAFETY SWITCH” The machine displays this message if: • The “Safety switch” is tripped during a training session. • The emergency system is damaged. THE DISPLAY SHOWS “SAFETY TRIPPED”...

  • Page 47: He Display Shows "E 3

    FORMA: Service & Maintenance manual - rev. 3.0 6.3. THE DISPLAY SHOWS “E 3” The machine displays this message if: • it has detected a failure to actuate movement of the belt motor at the start of the training session;...
  • Page 48 FORMA: Service & Maintenance manual - rev. 3.0 THE DISPLAY SHOWS "E 3" Check the error message displayed and/or memorized by the inverter None The following paragraphs describe the troubleshooting procedures associated with the individual errors. Page 6.8...
  • Page 49 FORMA: Service & Maintenance manual - rev. 3.0 6.3.1. E01, E02, E03, E04 HE INVERTER DISPLAY SHOWS These inverter error messages are related to output short-circuit problems. Is the inverter output Replace the inverter short-circuited? Replace the belt motor Is there a short-circuit on the...
  • Page 50 FORMA: Service & Maintenance manual - rev. 3.0 Place the tester probes between the blue – black, blue – brown and black – brown conductors of the motor cable. The measured resistance should be 4.4 Ohm. Disconnect the motor cable from the motor and place a tester between its terminals U-V, U-W and V-W.

  • Page 51: The Inverter Display Shows E06 Or E07

    FORMA: Service & Maintenance manual - rev. 3.0 6.3.2. HE INVERTER DISPLAY SHOWS These inverter error messages are related to problems with the inverter braking group or the braking resistor. Is the braking resistor correctly connected to the Reinstate the connection...

  • Page 52: The Inverter Display Shows E08, E10, E11 Or E22

    FORMA: Service & Maintenance manual - rev. 3.0 6.3.3. E08, E10, E11 HE INVERTER DISPLAY SHOWS These inverter error messages are related to HW and SW problems with the inverter. Does the error occur Replace the inverter frequently? Does the machine resume Probable interference.

  • Page 53: The Inverter Display Shows E09

    FORMA: Service & Maintenance manual - rev. 3.0 6.3.4. HE INVERTER DISPLAY SHOWS This inverter error message is related to low line voltage problems on the inverter power supply. Does the machine resume Probable low line voltage. correct operation after being...
  • Page 54 FORMA: Service & Maintenance manual - rev. 3.0 Disconnect the filter supply cables and place the tester probes across them. The measured voltage should be 220 VAC. Disconnect the filter output cables and place the tester probes across the filter terminals. The measured voltage should be 220 VAC.

  • Page 55: The Inverter Display Shows E12

    FORMA: Service & Maintenance manual - rev. 3.0 6.3.5. HE INVERTER DISPLAY SHOWS This inverter error message is related to the opening of the motor thermal cutouts. Does the machine resume Probable overheating of correct operation after being the motor. The machine is...
  • Page 56 FORMA: Service & Maintenance manual - rev. 3.0 Disconnect the motor thermal cutout cable from both the motor and the inverter, and place the tester probes across the ends of each wire. The measured resistance should be 0 Ohm. Disconnect the motor thermal cutout from the inverter: pin P24 and 3.

  • Page 57: The Inverter Display Shows E14

    FORMA: Service & Maintenance manual - rev. 3.0 6.3.6. HE INVERTER DISPLAY SHOWS This inverter error message is related to poor isolation between the motor phases and ground. Are the motor phases isolated from ground at the Replace the inverter...

  • Page 58: The Inverter Display Shows E15

    FORMA: Service & Maintenance manual - rev. 3.0 6.3.7. HE INVERTER DISPLAY SHOWS This inverter error message is caused by high voltage problems on the inverter power supply line. Does the machine resume Probable high line voltage. correct operation after being The machine is OK.
  • Page 59 FORMA: Service & Maintenance manual - rev. 3.0 Disconnect the supply cables from the filter and place the tester probes across them. The measured voltage should be 220 VAC. Disconnect the filter output cables and place the tester probes across the filter terminals. The measured voltage should be 220 VAC.

  • Page 60: The Inverter Display Shows E21

    FORMA: Service & Maintenance manual - rev. 3.0 6.3.8. HE INVERTER DISPLAY SHOWS This inverter error message is associated with problems of high inverter temperature. Probable overheating of Does the machine resume Replace the inverter the inverter. The machine correct operation after being is OK.

  • Page 61: The Inverter Display Does Not Show Any Error

    FORMA: Service & Maintenance manual - rev. 3.0 6.3.9. HE INVERTER DISPLAY DOES NOT SHOW ANY ERROR This is an anomalous error condition in which the machine display reports an error but the inverter has not generated an error. No error displayed...
  • Page 62 FORMA: Service & Maintenance manual - rev. 3.0 Place the tester probes between terminals AL1 and AL0 of the inverter. The measured voltage should be 5 Vdc in the alarm condition, and 0 Vdc in normal conditions. As for step (1), but between pins 3 (signal) and 4 (ground) of connector J5 on the driver board.

  • Page 63: The Belt Motor Is Jerking

    FORMA: Service & Maintenance manual - rev. 3.0 6.4. THE BELT MOTOR IS JERKING The probable cause of this error is a disconnected phase on the motor or inverter output. THE BELT MOTOR IS JERKING Are the belt motor windings...

  • Page 64: The Belt Motor Starts With Delay

    Table 6.6-1 or Table 6.6-2 depending on whether the machine is a Forma 2 or a Forma 3. To check the Start signal, place a tester between pin 2 (signal) and 1 (ground) of connector J5 on the driver board.

  • Page 65: The Displayed Speed Is Incorrect

    FORMA: Service & Maintenance manual - rev. 3.0 6.6. THE DISPLAYED SPEED IS INCORRECT The machine displays this error if: • the calibration is incorrect; • there are HW problems with the CPU board – driver board – inverter and motor group.
  • Page 66 When the machine is in operation, check that the speed shown on the display and the inverter operating frequency are approximately those shown in the tables below, depending on whether the machine is a Forma 2 or a Forma 3. • Forma 2:...
  • Page 67 FORMA: Service & Maintenance manual - rev. 3.0 Place the tester probes between the 0 (signal) and L (ground) terminals of the inverter. Check that during machine operation the speed shown on the display and the voltage measured on the inverter correspond the values shown in Table 6.6-1 or in Table 6.6-2.

  • Page 68: The Display Shows "E5

    FORMA: Service & Maintenance manual - rev. 3.0 6.7. THE DISPLAY SHOWS “E 5” The machine displays this error if:. • it receives an up-down motor alarm signal from the driver board; • it fails to receive an encoder feedback signal after having actuated the motor.
  • Page 69 FORMA: Service & Maintenance manual - rev. 3.0 Does the driver board send the Replace the driver board drive voltage to up-down motor? Is there an alarm signal asserted at the output of the driver board? Does the encoder signal reach...
  • Page 70 FORMA: Service & Maintenance manual - rev. 3.0 Does the encoder signal reach the output of the driver board? Replace the driver board Does the encoder signal reach trailing connector CN28 Replace cable FR-12 Does the encoder signal reach Replace the CPU board...
  • Page 71 FORMA: Service & Maintenance manual - rev. 3.0 Check for the click of the relay. Place the tester probes between pins 1 and 2 of connector J1 on the driver board. Press the “↑” or “↓” key: the absolute measured value should be approximately 20 Vdc.

  • Page 72: The Up-Down Moves In Only One Direction

    FORMA: Service & Maintenance manual - rev. 3.0 6.8. THE UP-DOWN MOVES IN ONLY ONE DIRECTION The machine displays this error if: • a relay on the driver board is defective; • the CPU board fails to send the enable signal;...
  • Page 73 FORMA: Service & Maintenance manual - rev. 3.0 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 pins 5 (signal) and 12 (ground) of connector K4 on the CPU board.

  • Page 74: The Displayed Elevation Is Incorrect

    FORMA: Service & Maintenance manual - rev. 3.0 6.9. THE DISPLAYED ELEVATION IS INCORRECT The machine displays this error if: • the reset procedure detects an incorrect reference; • the encoder signal is incorrect due to a bad reading or noise.
  • Page 75 FORMA: Service & Maintenance manual - rev. 3.0 Is there something obstructing Remove the obstruction the movement of the machine? Adjust the current limiter Replace the up-down on the driver board and/or Does the motor draw the correct motor replace the driver board current? Follow the procedure step by step to correctly diagnose the problem.

  • Page 76: The Fan Is Not Working

    FORMA: Service & Maintenance manual - rev. 3.0 6.10. THE FAN IS NOT WORKING This problem occurs when the supply voltage fails to reach the fan. THE FAN DOES NOT WORK Does the correct supply v oltage Replace cable FR-1/A...
  • Page 77 FORMA: Service & Maintenance manual - rev. 3.0 Is the supply v oltage correct at Replace the f an the output of the f an interf ace interf ace board board? Is the supply v oltage correct at Check/replace cable FR...
  • Page 78 FORMA: Service & Maintenance manual - rev. 3.0 As for point (1) but across the OUT pins of connector CN2. Check the supply voltage across the Faston terminals at the input to the fan: the measured value should be 220 VAC.

  • Page 79: There Is No Heart Rate Signal

    FORMA: Service & Maintenance manual - rev. 3.0 6.11. THERE IS NO HEART RATE SIGNAL The machine displays this error if the receiver is not working or if it is not supplied by the CPU board. THERE IS NO CARDIO SIGNAL...

  • Page 80: The Heart Rate Signal Is Incorrect

    FORMA: Service & Maintenance manual - rev. 3.0 6.12. THE HEART RATE SIGNAL IS INCORRECT The machine displays this error if the receiver is disturbed by electromagnetic noise. THE HEART RATE SIGNAL IS INCORRECT Move the machines to Is the minimum distance...
  • Page 81 FORMA: Service & Maintenance manual - rev. 3.0 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.
  • Page 82 FORMA: Service & Maintenance manual - rev. 3.0 Page intentionally left blank Page 6.42...

  • Page 83: Disassembly Of Components

    FORMA: Service & Maintenance manual - rev. 3.0 7. DISASSEMBLY OF COMPONENTS 7.1. DISASSEMBLING THE DISPLAY 1. Turn off the machine and unplug the mains lead from the wall outlet. 2. Back off the 4 screws a using a phillips screwdriver.

  • Page 84: Disassembling The Eprom

    ATTENTION: The EPROM SW versions used on Forma 2 and Forma 3 are different, due to differences in certain mechanical characteristics between the two machines. In consequence: •...

  • Page 85: Disassembling The Display Boards

    FORMA: Service & Maintenance manual - rev. 3.0 7.3. DISASSEMBLING THE DISPLAY BOARDS Carry out the procedure described in paragraph 7.1. “Disassembling the display”. With the display placed on a work bench: 1. Unplug connectors a. 2. Remove the 4 fasteners b.

  • Page 86: Disassembling The Keyboard

    FORMA: Service & Maintenance manual - rev. 3.0 7.4. DISASSEMBLING THE KEYBOARD Carry out the procedure described in paragraph 7.1. “Disassembling the display”. With the display placed on a work bench: 1. Unplug the KEYBOARD connector a. Figure 7.4-1 2. Using a pointed tool, lift up and detach a corner of the KEYBOARD.

  • Page 87: Disassembling The Cardio Receiver

    FORMA: Service & Maintenance manual - rev. 3.0 7.5. DISASSEMBLING THE CARDIO RECEIVER Carry out the procedure described in paragraph 7.1. “Disassembling the display”. With the display placed on a work bench: 1. Unplug connector a of cable RL-14 from the CPU board.

  • Page 88: Disassembling The Safety Switch

    FORMA: Service & Maintenance manual - rev. 3.0 7.6. DISASSEMBLING THE SAFETY SWITCH Carry out the procedure described in paragraph 7.1. “Disassembling the display”. With the display placed on a work bench: 1. Lift up the sticker a situated underneath the “Safety switch”;...

  • Page 89: Disassembling The Motor Guard

    FORMA: Service & Maintenance manual - rev. 3.0 7.7. DISASSEMBLING THE MOTOR GUARD 1. Raise the machine to its maximum incline position. 2. Turn off the machine and unplug the mains lead from the wall outlet. 3. Take off the fuse holder a.

  • Page 90: Disassembling The Rear Roller

    FORMA: Service & Maintenance manual - rev. 3.0 7.8. DISASSEMBLING THE REAR ROLLER Carry out the procedure described in paragraph 7.7. “Disassembling the motor guard”. On each side of the machine: 1. Back off the 2 screws a using a 2.5-mm hex T wrench.
  • Page 91 FORMA: Service & Maintenance manual - rev. 3.0 5. Return the machine to the upright position. 6. Back off the 2 screws c using a 2.5-mm hex T wrench. 7. Remove the rear plug d. Figure 7.8-3 To facilitate the subsequent tightening...

  • Page 92: Disassembling The Motor Roller And Drive- Belt

    FORMA: Service & Maintenance manual - rev. 3.0 7.9. DISASSEMBLING THE MOTOR ROLLER AND DRIVE- BELT Carry out the procedure described in paragraph 7.7. “Disassembling the motor guard”. 1. Slacken the drive-belt tension by turning the rear roller fixing screws.
  • Page 93 FORMA: Service & Maintenance manual - rev. 3.0 5. Using a felt-tip pen, mark the top part of both flywheels as shown in the figure. 6. Disassemble the outer flywheel by backing off the two screws b using a 4-mm Allen wrench.

  • Page 94: Disassembling The Tread Belt And Running Track

    FORMA: Service & Maintenance manual - rev. 3.0 7.10. DISASSEMBLING THE TREAD-BELT AND RUNNING TRACK Carry out the procedures described in paragraphs 7.7. “Disassembling the motor guard”, 7.8. “Disassembling the rear roller” and 7.9. “Disassembling the motor roller and drive-belt”.
  • Page 95 FORMA: Service & Maintenance manual - rev. 3.0 To reassemble the TREAD-BELT and the RUNNING TRACK, carry out the above steps in reverse order. When reassembling the TREAD-BELT, make sure that: • it is assembled in the direction indicated by the direction arrow on the inner side, if one is present;...

  • Page 96: Disassembling The Shock Absorbers

    FORMA: Service & Maintenance manual - rev. 3.0 7.11. DISASSEMBLING THE SHOCK ABSORBERS Carry out the procedures described in paragraph 7.10. “Disassembling the tread-belt and running track”. 1. On each side of the machine, remove the SHOCK ABSORBERS from top, detaching them from the adhesive film.

  • Page 97: Disassembling The Footrest Guide

    FORMA: Service & Maintenance manual - rev. 3.0 7.12. DISASSEMBLING THE FOOTREST GUIDE Carry out the procedure described in paragraph 7.7. “Disassembling the motor guard”. On each side of the machine: 1. Back off the 2 screws a using a 2.5-mm hex T wrench.

  • Page 98: Disassembling The Side Guards

    FORMA: Service & Maintenance manual - rev. 3.0 7.13. DISASSEMBLING THE SIDE GUARDS Carry out the procedures described in paragraphs 7.7. “Disassembling the motor guard”, 7.8. “Disassembling rear roller”, 7.9. “Disassembling the motor roller and drive-belt” and 7.10. “Disassembling the tread-belt and running track”.

  • Page 99: Disassembling The Motor Guard Grille

    FORMA: Service & Maintenance manual - rev. 3.0 7.14. DISASSEMBLING THE MOTOR GUARD GRILLE 1. Raise the machine to an incline of approximately 5%. 2. Turn off the machine and unplug the mains lead from the wall outlet. 3. Overturn the machine on one side.

  • Page 100: Disassembling The Tread-Belt Motor

    FORMA: Service & Maintenance manual - rev. 3.0 7.15. DISASSEMBLING THE TREAD-BELT MOTOR Carry out the procedures described in paragraphs 7.7. “Disassembling the motor guard”, 7.14. “Disassembling the motor guard grille”. 1. Remove the dowel a using a 5-mm hex T wrench.

  • Page 101: Disassembling The Electronic Circuit Boards

    FORMA: Service & Maintenance manual - rev. 3.0 7.16. DISASSEMBLING THE ELECTRONIC CIRCUIT BOARDS Carry out the procedures described in paragraph 7.7. “Disassembling the motor guard”. 1. Back off the 2 screws a using a 5-mm hex T wrench. Figure 7.16-1 2.
  • Page 102 FORMA: Service & Maintenance manual - rev. 3.0 1. Back off the 4 cover fixing screws using a medium phillips screwdriver. 2. Remove the cover, taking care not to damage the connected wires. To disassemble the FILTER e: 1. Unplug the connected cables.

  • Page 103: Smontaggio Scheda Interfaccia Ventola

    FORMA: Service & Maintenance manual - rev. 3.0 7.17. SMONTAGGIO SCHEDA INTERFACCIA VENTOLA 1. Carry out the procedure described in paragraph 7.7. “Disassembling the motor guard” 2. Back off the two screws a using a 5-mm Allen wrench. 3. Disconnect all four cables which reach connector CN2 and connector CN1.

  • Page 104: Disassembling The Inverter

    FORMA: Service & Maintenance manual - rev. 3.0 7.18. DISASSEMBLING THE INVERTER 1. Carry out the procedures described in paragraph 7.7. “Disassembling the motor guard”. 2. Open the INVERTER covers, backing off screw a with a small phillips screwdriver. 3. Disconnect the electrical cables b using a...

  • Page 105: Disassembling The Column And Rubber Guard

    FORMA: Service & Maintenance manual - rev. 3.0 7.19. DISASSEMBLING THE COLUMN AND RUBBER GUARD 1. Carry out the procedure described in paragraph 7.7. “Disassembling the motor guard”. 2. Raise the machine to its maximum incline position. 3. Unplug connector a.

  • Page 106: Disassembling The Up-Down Motor

    FORMA: Service & Maintenance manual - rev. 3.0 7.20. DISASSEMBLING THE UP-DOWN MOTOR 1. Carry out the procedure described in paragraph 7.19. “Disassembling the column and rubber guard”. 2. Disconnect the motor supply cable a from the electrical box. 3. Detach its locking strip.

  • Page 107: Disassembling The Up-Down Frame

    FORMA: Service & Maintenance manual - rev. 3.0 7.21. DISASSEMBLING THE UP-DOWN FRAME 1. Raise the machine to its maximum incline position. 2. Overturn the machine on its right side. 3. Back off the 2 screws a using two 4-mm hex T wrenches.

  • Page 108: Disassembling The Handlebars

    FORMA: Service & Maintenance manual - rev. 3.0 7.22. DISASSEMBLING THE HANDLEBARS 1. Turn off the machine and unplug the mains lead from the wall outlet. For each handlebar, and on both the parts secured to the machine column: 2. Shift the rubber bushings a.

  • Page 109: Adjustments

    FORMA: Service & Maintenance manual - rev. 3.0 8. ADJUSTMENTS 8.1. TENSIONING A NEW TREAD-BELT 1. After assembling the new tread-belt, turn it until the seam is underneath, and tighten the tread-belt until it is just slightly taut. 2. Place a tape measure along the right edge of...

  • Page 110: Tensioning A Used Tread-Belt

    FORMA: Service & Maintenance manual - rev. 3.0 8.2. TENSIONING A USED TREAD-BELT 1. Before disassembling the used tread-belt, place a tape measure along the right-hand edge of the tread-belt and, using a pen, make two reference marks spaced exactly 1 meter apart.

  • Page 111: Centering The Tread Belt

    FORMA: Service & Maintenance manual - rev. 3.0 8.3. CENTERING THE TREAD-BELT 1. Start the machine at a speed of 10 Km/h. 2. Observe the movement of the tread-belt, correcting any tendency to shift to the right or left exclusively by adjusting the left tensioning screw a.

  • Page 112: Aligning The Tread Belt Motor Drive Belt

    FORMA: Service & Maintenance manual - rev. 3.0 8.4. ALIGNING THE TREAD-BELT MOTOR DRIVE-BELT 1. Using a felt-tip pen, mark the top part of both flywheels as shown in the figure. 2. Back off the 2 bolts a fixing the flywheel b to the pulley, using a 4-mm Allen T-wrench.

  • Page 113: Tensioning The Tread-Belt Motor Drive Belt

    FORMA: Service & Maintenance manual - rev. 3.0 8.5. TENSIONING THE TREAD-BELT MOTOR DRIVE BELT 1. Carry out the procedure described in paragraph 7.7. “Disassembling the motor guard”. 2. Use a belt tension gauge. 3. Back off the dowel a using a 5-mm hex T wrench.

  • Page 114: Calibrating The Tread-Belt Speed

    FORMA: Service & Maintenance manual - rev. 3.0 8.6. CALIBRATING THE TREAD-BELT SPEED 1. Carry out the procedure described in paragraph 7.7. “Disassembling the motor guard”. The operations described below must be carried out with the machine powered they should...

  • Page 115: Adjusting The Up-Down Motor Current Limiter

    FORMA: Service & Maintenance manual - rev. 3.0 8.7. ADJUSTING THE UP-DOWN MOTOR CURRENT LIMITER 1. Carry out the procedures described in paragraph 7.16. “Disassembling electronic circuit boards”. The operations described below must be carried out with the machine powered...
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  • Page 117: Machine Configuration

    FORMA: Service & Maintenance manual - rev. 3.0 9. MACHINE CONFIGURATION 9.1. LANGUAGE CONFIGURATION To call up the language configuration procedure, simultaneously press the “1”, “3” and “4” keys with the machine in stand by mode. The machine display shows: P A S S W O R D To access the procedure, type in the password which protects against unauthorized access.

  • Page 118: Viewing The Working Parameters

    FORMA: Service & Maintenance manual - rev. 3.0 9.2. VIEWING THE WORKING PARAMETERS In order to check the state of wear of the machine and correctly carry out routine machine maintenance, a special procedure is provided for viewing the values of the working parameters. It is called up by simultaneously pressing the “1”, “3”...

  • Page 119: Modifying The Working Parameters

    FORMA: Service & Maintenance manual - rev. 3.0 9.3. MODIFYING THE WORKING PARAMETERS The procedure for setting the values of the machine’s working parameters (for example, after having replaced the CPU board) is called up by simultaneously pressing the “1”, “3” and “4” keys with the machine in standby mode.

  • Page 120: Up-Down Test

    FORMA: Service & Maintenance manual - rev. 3.0 9.4. UP-DOWN TEST The procedure for testing the machine’s up-down motor is invoked by simultaneously pressing the “1”, “3” and “4” keys when the machine is in standby mode. The machine display shows:...

  • Page 121: Programming The Hitachi Sj100 Inverter

    FORMA: Service & Maintenance manual - rev. 3.0 9.5. PROGRAMMING THE HITACHI SJ100 INVERTER The inverter can be programmed using the special keypad installed on board the machine. It is necessary to correctly configure the values of the main functions labeled with an F, and those of the extended functions labeled with A, b, C and H.

  • Page 122: Monitor Function Parameters

    FORMA: Service & Maintenance manual - rev. 3.0 9.5.1. ONITOR FUNCTION PARAMETERS Parameter Description Motor output frequency Motor current draw Direction of movement Status monitor of intelligent terminal input signals Status monitor of intelligent terminal output signals “Converted” motor output frequency...
  • Page 123 FORMA: Service & Maintenance manual - rev. 3.0 Page 9.7...

  • Page 125: Scheduled Maintenance

    FORMA: Service & Maintenance manual - rev. 3.0 10. SCHEDULED MAINTENANCE To keep the machine in perfect working order, it is necessary to carry out certain scheduled maintenance actions in order to forestall possible problems. There are essentially 3 types of maintenance operations: •...
  • Page 126 FORMA: Service & Maintenance manual - rev. 3.0 2. Start walking on the machine at a speed of approximately 3 km/h, being careful to tread on the full width of the belt so as to distribute the oil evenly over its entire surface.

  • Page 127: Routine Maintenance Operations

    HECKING THE STATE OF WEAR 1. With the machine stopped, check the state of wear of the entire surface of the tread-belt, turning it by hand. If any problems are observed, call in the authorized Technogym Technical Service. 10.2.3. C...

  • Page 128: Special Maintenance Operations

    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.

  • Page 129: Checking The Wear Of The Motor Roller

    FORMA: Service & Maintenance manual - rev. 3.0 4. Next, lubricate the full length of the running track and tread-belt with Silube spray oil (code 0V022). 5. After reassembling the machine, start the tread-belt at approximately 3 Km/h and walk on it, taking care to tread on the entire width of the belt, so as to facilitate the uniform distribution of the oil on its surface.
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  • Page 131: Appendix

    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.

  • Page 132: Type Of Asic

    FORMA: Service & Maintenance manual - rev. 3.0 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;...

  • Page 133: Reducing Receiver Sensitivity

    FORMA: Service & Maintenance manual - rev. 3.0 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.

  • Page 134: Mechanical Vibrations

    FORMA: Service & Maintenance manual - rev. 3.0 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.

  • Page 135: Routing Of Cables

    FORMA: Service & Maintenance manual - rev. 3.0 • 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.

  • Page 136: Hitachi Sj100 Inverter Error Codes

    In this condition, the dissipator reading is 80 °C. PTC error Problem with the PTC sensor (not used on Forma). To display the inverter error codes, follow the instructions below or refer to pages 8-2 of the inverter manual:...
  • Page 137 FORMA: Service & Maintenance manual - rev. 3.0 1. Remove the motor guard. 2. Turn on the machine. 3. Repeatedly press the “1” or “2” key on the inverter keypad until the display shows “d08”. 4. Press the “FUNC” key to display the last error which occurred. The following will sequentially appear: •...

  • Page 138: Procedure For Clearing The Error Memory On Hitachi Sj100 Inverter

    FORMA: Service & Maintenance manual - rev. 3.0 11.3. PROCEDURE FOR CLEARING THE ERROR MEMORY ON HITACHI SJ100 INVERTER For all Hitachi SJ100 inverters, it is available an easy procedure for clearing the error memory. To do this: 1. Turn on the machine;...
  • Page 140 TECHNOGYM S.r.l. Via G. Perticari, 20 47035 Gambettola (FC) ITALIA Tel.: +39-0547-650438 Fax: +39-0547-650150 e-mail: service@technogym.com 0SM00007-ING...

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