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Technogym Steprace Service Maintenance Manual

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MAINTENANCE MANUAL
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. 1.2
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Summary of Contents for Technogym Steprace

  • Page 1 & ERVICE MAINTENANCE MANUAL . 1.2...
  • 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

    STEPRACE: Service & Maintenance Manual - rev. 1.2 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 STEPRACE: Service & Maintenance Manual - rev. 1.2 7.9. D ........................ 7.12 ISASSEMBLING THE CHAIN GUARD 7.10. D ........................ 7.13 ISASSEMBLING THE HANDLEBARS 7.11. D ........................7.14 ISASSEMBLING THE PEDAL JOINT 7.12. D .................... 7.15 ISASSEMBLING THE PEDALS AND PEDAL GROUP 7.13.
  • Page 7 STEPRACE: Service & Maintenance Manual - rev. 1.2 10.3.6. Checking the wear of the rubber handlebar covers................. 10.4 10.3.7. Checking the operation of the stepping mode selection knob and slide .......... 10.4 10.3.8. Checking the alternator belt ......................10.4 10.3.9. Checking the primary shaft chain....................10.4 10.3.10.
  • Page 8 STEPRACE: Service & Maintenance Manual - rev. 1.2 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 Newsletters, which may contain more up-to-date information on adjustments and maintenance than those contained in this manual.

  • Page 11: Technical Characteristics

    STEPRACE: Service & Maintenance Manual - rev. 1.2 2. TECHNICAL CHARACTERISTICS 2.1. MECHANICAL CHARACTERISTICS Width 66.5 cm Length 142 cm Height 151 cm Weight 154 Kg 2.2. ELECTRICAL CHARACTERISTICS Mains voltage 115 / 230 VAC Frequency 50 - 60 Hz Consumption ~ 60 Watt –...

  • Page 12: Wiring Diagram

    STEPRACE: Service & Maintenance Manual - rev. 1.2 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...

  • Page 13: Wiring

    STEPRACE: Service & Maintenance Manual - rev. 1.2 • 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.
  • Page 14 STEPRACE: Service & Maintenance Manual - rev. 1.2 ST-5: Alternator cable Alternator interface board – Alternator – Resistor Alternator Signal Color Alternator Resistor interface board Alternator RPM X 6 Purple Red eyelet 4 Blue Resistor - Yellow eyelet 4 Blue...
  • Page 15 STEPRACE: Service & Maintenance Manual - rev. 1.2 ST-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...
  • Page 16 STEPRACE: Service & Maintenance Manual - rev. 1.2 Page intentionally left blank Page 2.6...

  • Page 17: Principles Of Operation

    STEPRACE: Service & Maintenance Manual - rev. 1.2 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 18 STEPRACE: Service & Maintenance Manual - rev. 1.2 • 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.
  • Page 19 STEPRACE: Service & Maintenance Manual - rev. 1.2 ALTERNATOR INTERFACE BOARD Receives from the display a square-wave signal whose frequency is proportional to the selected level of difficulty, and sends it to the alternator. Receives the RPM signal from the alternator, which it filters and sends to the display for calculating the speed of exercise (SPM).

  • Page 20: Alternator Control

    STEPRACE: Service & Maintenance Manual - rev. 1.2 3.2. ALTERNATOR CONTROL 3.2.1. ECHANICS The movement of the pedals imparts a rotation to the primary shaft via the chain connected to the 2 pedals. The chain turns on a sprocket which is attached to a slide that can move up and down along 2 guide bars.

  • Page 21: The Control Signals

    STEPRACE: Service & Maintenance Manual - rev. 1.2 alternator speed signal as a feedback signal, the CPU board adjusts the excitation PWM signal so as to maintain a constant speed (closed loop control). • mode B: In this stepping mode, the user can choose between 3 different resistance levels (WEAK, MEDIUM and STRONG), while the difficulty level setting determines the target speed to be maintained.
  • Page 22 STEPRACE: Service & Maintenance Manual - rev. 1.2 • Excitation signal (PWM) This is the signal generated by the CPU board (pin 6-3 of connector CN1) for controlling the resistance. It is a PWM signal, i.e. a fixed frequency square wave signal with variable duty cycle.

  • Page 23: Accessories

    STEPRACE: Service & Maintenance Manual - rev. 1.2 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;...

  • Page 24: Connecting To The Printer

    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.

  • Page 25: Installation Instructions

    STEPRACE: Service & Maintenance Manual - rev. 1.2 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 26: First Power-On

    STEPRACE: Service & Maintenance Manual - rev. 1.2 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 27: Troubleshooting

    STEPRACE: Service & Maintenance Manual - rev. 1.2 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 28: The Display Does Not Illuminate

    STEPRACE: Service & Maintenance Manual - rev. 1.2 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?
  • Page 29 STEPRACE: Service & Maintenance Manual - rev. 1.2 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 ST-6...
  • Page 30 STEPRACE: Service & Maintenance Manual - rev. 1.2 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.

  • Page 31: There Is No Resistance

    STEPRACE: Service & Maintenance Manual - rev. 1.2 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...

  • Page 32: The Resistance Is Incorrect

    STEPRACE: Service & Maintenance Manual - rev. 1.2 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...
  • Page 33 STEPRACE: Service & Maintenance Manual - rev. 1.2 The operation of this machine is such that the braking resistance is higher for level 1 than for 12. This is because the user does not work to push against the pedals, but rather must "float"...
  • Page 34 STEPRACE: Service & Maintenance Manual - rev. 1.2 As for step (5) but with the oscilloscope between pins 6 and 3 of connector CN1 of the display CPU board. Page 6.8...

  • Page 35: The Spm Value Is Incorrect

    STEPRACE: Service & Maintenance Manual - rev. 1.2 6.4. THE SPM VALUE IS INCORRECT This error occurs when there are problems with the RPM signal output by the alternator. THE SPM VALUE IS INCORRECT Is the SPM wire of cable...
  • Page 36 STEPRACE: Service & Maintenance Manual - rev. 1.2 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.

  • Page 37: The Machine Does Not Print

    STEPRACE: Service & Maintenance Manual - rev. 1.2 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.
  • Page 38 STEPRACE: Service & Maintenance Manual - rev. 1.2 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.

  • Page 39: The Machine Fails To Read The Stepping Mode

    STEPRACE: Service & Maintenance Manual - rev. 1.2 6.6. THE MACHINE FAILS TO READ THE STEPPING MODE This error occurs when there are HW problems with the microswitch or its signal. THE MACHINE DOES NOT READ THE STATE OF THE...
  • Page 40 STEPRACE: Service & Maintenance Manual - rev. 1.2 Place the tester probes on the microswitch terminals and check that, when the selection knob is moved, the microswitch changes state from open to closed and vice versa. The microswitch contact is NC for stepping mode A, and NO for stepping mode B.

  • Page 41: The Machine Does Not Operate In Master - Slave Mode

    STEPRACE: Service & Maintenance Manual - rev. 1.2 6.7. 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...
  • Page 42 STEPRACE: Service & Maintenance Manual - rev. 1.2 Are the signals output by the Replace cable ST-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.

  • Page 43: There Is No Heart Rate Signal

    STEPRACE: Service & Maintenance Manual - rev. 1.2 6.8. 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...

  • Page 44: The Heart Rate Signal Is Incorrect

    STEPRACE: Service & Maintenance Manual - rev. 1.2 6.9. 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.
  • Page 45 STEPRACE: Service & Maintenance Manual - rev. 1.2 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 46 STEPRACE: Service & Maintenance Manual - rev. 1.2 Page intentionally left blank Page 6.20...

  • Page 47: Disassembly Of Components

    STEPRACE: Service & Maintenance Manual - rev. 1.2 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 3 screws a using a 4-mm hex T wrench.
  • Page 48 STEPRACE: Service & Maintenance Manual - rev. 1.2 4. Open the DISPLAY. To remove the DISPLAY: 1. Disconnect connector c. 2. Remove the DISPLAY. To reassemble the DISPLAY, carry out the above steps in reverse order. Figure 7.1-3 Page 7.2...

  • Page 49: Disassembling The Eprom

    STEPRACE: Service & Maintenance Manual - rev. 1.2 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.

  • Page 50: Disassembling The Cpu Board

    STEPRACE: Service & Maintenance Manual - rev. 1.2 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.
  • Page 51 STEPRACE: Service & Maintenance Manual - rev. 1.2 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.

  • Page 52: Disassembling The Keyboard

    STEPRACE: Service & Maintenance Manual - rev. 1.2 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 on the protective cover using a small Philips screwdriver.
  • Page 53 STEPRACE: Service & Maintenance Manual - rev. 1.2 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.

  • Page 54: Disassembling The Cardio Receiver

    STEPRACE: Service & Maintenance Manual - rev. 1.2 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.

  • Page 55: Disassembling The Upright Guard

    STEPRACE: Service & Maintenance Manual - rev. 1.2 7.6. DISASSEMBLING THE UPRIGHT GUARD 1. Turn off the machine and unplug the mains lead from the wall outlet. 2. Back off the 4 fixing screws a on the UPRIGHT GUARD, using a large Philips screwdriver.

  • Page 56: Disassembling The Electronic Circuit Boards

    STEPRACE: Service & Maintenance Manual - rev. 1.2 7.7. DISASSEMBLING THE ELECTRONIC CIRCUIT BOARDS Carry out the procedures described in paragraph 7.6. “Disassembling the upright guard”. 1. Back off the 4 screws a using a medium Philips screwdriver. 2. Remove the protective grill from the circuit boards.

  • Page 57: Disassembling The Side Guards

    STEPRACE: Service & Maintenance Manual - rev. 1.2 7.8. DISASSEMBLING THE SIDE GUARDS 1. Turn off the machine and unplug the mains lead from the wall outlet. 2. Select stepping mode B (dependent stepping motion). On either side of the machine: 3.

  • Page 58: Disassembling The Chain Guard

    STEPRACE: Service & Maintenance Manual - rev. 1.2 7.9. DISASSEMBLING THE CHAIN GUARD Carry out the procedures described in paragraph 7.8. “Disassembling the side guards”. 1. Working on the right pedal, back off the screw a which fixes the pedal to the ball joint using a 17-mm socket wrench.

  • Page 59: Disassembling The Handlebars

    STEPRACE: Service & Maintenance Manual - rev. 1.2 7.10. DISASSEMBLING THE HANDLEBARS Carry out the procedure described in paragraph 7.6. “Disassembling the upright guard”. For each SIDE HANDLEBAR: 1. Back off the 2 screws a using a 17-mm wrench. 2. Remove the HANDLEBAR.

  • Page 60: Disassembling The Pedal Joint

    STEPRACE: Service & Maintenance Manual - rev. 1.2 7.11. DISASSEMBLING THE PEDAL JOINT Turn off the machine and unplug the mains lead from the wall outlet. 1. Select stepping mode B (dependent stepping motion). Working from both sides: 2. Align the pedals.

  • Page 61: Disassembling The Pedals And Pedal Group

    STEPRACE: Service & Maintenance Manual - rev. 1.2 7.12. DISASSEMBLING THE PEDALS AND PEDAL GROUP Turn off the machine and unplug the mains lead from the wall outlet. 1. Select stepping mode B (dependent stepping motion). Working from both sides: 2.
  • Page 62 STEPRACE: Service & Maintenance Manual - rev. 1.2 8. Using a T wrench and a rubber mallet, remove the PEDAL GROUP pivot from the lever. 9. Remove the PEDAL GROUP. To reassemble the PEDAL GROUPS, carry out the above steps in reverse order.

  • Page 63: Disassembling The Pedal Connecting Rods

    STEPRACE: Service & Maintenance Manual - rev. 1.2 7.13. DISASSEMBLING THE PEDAL CONNECTING RODS Carry out the procedures described in paragraph 7.8. “Disassembling the side guards”. Working from both sides: 1. Remove the protective cap a. 2. Back off the screw underneath the cap using a 17-mm wrench.

  • Page 64: Disassembling The Levers

    STEPRACE: Service & Maintenance Manual - rev. 1.2 7.14. DISASSEMBLING THE LEVERS Carry out the procedures described in paragraphs 7.8. “Disassembling the side guards”, 7.11. “Disassembling the pedal joint” up until step 3., 7.12. “Disassembling the pedals and pedal group” and 7.13. “Disassembling the pedal connecting rods”.

  • Page 65: Disassembling The Pedal Chains

    STEPRACE: Service & Maintenance Manual - rev. 1.2 7.15. DISASSEMBLING THE PEDAL CHAINS Carry out the procedures described in paragraphs 7.6. “Disassembling the upright guard”, 7.8. “Disassembling the side guards” and 7.9. “Disassembling the chain guard”. 1. Select stepping mode B (dependent stepping motion).

  • Page 66: Disassembling The Primary Shaft - Secondary Shaft Chain

    STEPRACE: Service & Maintenance Manual - rev. 1.2 7.16. DISASSEMBLING THE PRIMARY SHAFT - SECONDARY SHAFT CHAIN Carry out the procedures described in paragraphs 7.8. “Disassembling the side guards” and 7.9. “Disassembling the chain guard”. 1. Turn the CHAIN until the connecting link a is on the sprocket wheel of primary shaft b.

  • Page 67: Disassembling The Primary Shaft Group

    STEPRACE: Service & Maintenance Manual - rev. 1.2 7.17. DISASSEMBLING THE PRIMARY SHAFT GROUP Carry out the procedures described in paragraphs 7.11. “Disassembling the pedal joint” up until disconnecting the chains from the levers and 7.16. “Disassembling the primary shaft - secondary shaft chain ”.

  • Page 68: Disassembling The Primary Drive Sprockets

    STEPRACE: Service & Maintenance Manual - rev. 1.2 7.18. DISASSEMBLING THE PRIMARY DRIVE SPROCKETS Carry out the procedures described in paragraphs 7.8. “Disassembling the side guards” and 7.9. “Disassembling the chain guard”. On each side of the machine: 1. Back off the lock nut a using a 32-mm wrench.

  • Page 69: Disassembling The Secondary Drive Sprockets

    STEPRACE: Service & Maintenance Manual - rev. 1.2 7.19. DISASSEMBLING THE SECONDARY DRIVE SPROCKETS Carry out procedures described in paragraph 7.6. “Disassembling the upright guard”. On each side of the machine: 1. Select stepping mode B (dependent stepping motion). 2. Back off dowel a using a 3-mm hex T wrench.

  • Page 70: Disassembling The Slide Drive Sprocket

    STEPRACE: Service & Maintenance Manual - rev. 1.2 7.20. DISASSEMBLING THE SLIDE DRIVE SPROCKET Carry out the procedure described in paragraph 7.6. “Disassembling the upright guard”. 1. Select stepping mode B (dependent stepping motion). 2. Back off screw a using a 22-mm wrench.

  • Page 71: Disassembling The Secondary Shaft

    STEPRACE: Service & Maintenance Manual - rev. 1.2 7.21. DISASSEMBLING THE SECONDARY SHAFT Carry out the procedures described in paragraph 7.16. “Disassembling the primary shaft - secondary shaft chain ”. 1. Select stepping mode B (dependent stepping motion). 2. Align the pedals.
  • Page 72 STEPRACE: Service & Maintenance Manual - rev. 1.2 After completing the procedure, adjust the alignment and tension of the belt and of the primary shaft - secondary shaft chain as described in the paragraphs 8.1. , 8.2. , 8.3. and 8.4. .

  • Page 73: Disassembling The Belt

    STEPRACE: Service & Maintenance Manual - rev. 1.2 7.22. DISASSEMBLING THE BELT Carry out the operations described in paragraph 7.8. “Disassembling the side guards”. 1. Back off the nut a of the belt tension rod using a 17-mm wrench. Figure 7.22-1 2.
  • Page 74 STEPRACE: Service & Maintenance Manual - rev. 1.2 If the gap is not large enough for the BELT to pass through, disassemble the primary shaft - secondary shaft chain. After completing the procedure, adjust the alignment and tension of the belt as described in paragraphs 8.1.

  • Page 75: Disassembling The Alternator

    STEPRACE: Service & Maintenance Manual - rev. 1.2 7.23. DISASSEMBLING THE ALTERNATOR Carry out the procedure described in paragraph 7.8. “Disassembling the side guards”. 1. Disconnect the ALTERNATOR cables. 2. Back off the nut a of the belt tension rod b using a 17-mm wrench.

  • Page 76: Disassembling The Alternator Brushes

    STEPRACE: Service & Maintenance Manual - rev. 1.2 7.24. DISASSEMBLING THE ALTERNATOR BRUSHES Carry out the procedures described in paragraph 7.8. “Disassembling the side guards”. 1. Disconnect cable a from the alternator. 2. Back off the clamping screw b of the...

  • Page 77: Disassembling The Springs

    STEPRACE: Service & Maintenance Manual - rev. 1.2 7.25. DISASSEMBLING THE SPRINGS Carry out the procedure described in paragraph 7.6. “Disassembling the upright guard”. 1. Select stepping mode (independent stepping motion). For each SPRING: 2. Using a hooked tool, extend the SPRING and secure it to the frame.
  • Page 78 STEPRACE: Service & Maintenance Manual - rev. 1.2 5. Remove the SPRING from the upper pulley 6. Using a pipe wrench, unscrew the SPRING from the slide c. 7. Remove the SPRING. To reassemble the SPRINGS, carry out the above steps in reverse order.

  • Page 79: Disassembling The Spring Pulleys

    STEPRACE: Service & Maintenance Manual - rev. 1.2 7.26. DISASSEMBLING THE SPRING PULLEYS Carry out the procedures described in paragraph 7.25. “Disassembling the springs” leaving them connected to the slide. For each PULLEY: 1. Back off the self-locking nut a using a 17- mm wrench, while holding its screw b in place with a 17-mm wrench.

  • Page 80: Disassembling The Slide Bars

    STEPRACE: Service & Maintenance Manual - rev. 1.2 7.27. DISASSEMBLING THE SLIDE BARS Carry out the procedures described in paragraph 7.15. “Disassembling the pedal chains” for the chains on the short stretch only, and 7.25. “Disassembling the springs”. 1. Select stepping mode B (dependent stepping motion).

  • Page 81: Disassembling The Selection Knob

    STEPRACE: Service & Maintenance Manual - rev. 1.2 7.28. DISASSEMBLING THE SELECTION KNOB 1. Turn off the machine and unplug the mains lead from the wall outlet. 2. Back off the 2 dowels a using a 3-mm hex T wrench.

  • Page 82: Disassembling The Selection Knob Pin

    STEPRACE: Service & Maintenance Manual - rev. 1.2 7.29. DISASSEMBLING THE SELECTION KNOB PIN Carry out the procedures described in paragraphs 7.6. “Disassembling the upright guard”, 7.25. “Disassembling springs”, 7.27. “Disassembling the slide bars” and 7.28. “Disassembling the selection knob”.
  • Page 83 STEPRACE: Service & Maintenance Manual - rev. 1.2 5. Pushing the PIN out from the upright, remove the pointed tool. 6. Gradually reduce the pressure on the PIN until it can be removed from the front together with its spring.

  • Page 84: Disassembling The Microswitch

    STEPRACE: Service & Maintenance Manual - rev. 1.2 7.30. DISASSEMBLING THE MICROSWITCH 1. Turn off the machine and unplug the mains lead from the wall outlet. 2. Select stepping mode (independent stepping motion). 3. Back off the 2 screws a using a medium Philips screwdriver.

  • Page 85: Adjustments

    STEPRACE: Service & Maintenance Manual - rev. 1.2 8. ADJUSTMENTS 8.1. ALIGNING THE BELT Carry out the procedures described in paragraphs 7.8. “Disassembling the side guards” and 7.9. “Disassembling the chain guard”. 1. Back off the lock nut a on alternator pivot b using a 19-mm wrench.

  • Page 86: Belt Tension

    STEPRACE: Service & Maintenance Manual - rev. 1.2 8.2. BELT TENSION Carry out the procedures described in paragraphs 7.8. “Disassembling the side guards” and 7.9. “Disassembling the chain guard”. 1. Back off the lock nut of alternator pivot a using a 19-mm wrench.

  • Page 87: Aligning The Primary Shaft Secondary Shaft Chain

    STEPRACE: Service & Maintenance Manual - rev. 1.2 8.3. ALIGNING THE PRIMARY SHAFT - SECONDARY SHAFT CHAIN Carry out the procedures described in paragraphs 7.8. “Disassembling the side guards” and 7.9. “Disassembling the chain guard”. 1. Back off the screw a on sprocket b of the secondary shaft.

  • Page 88: Primary Shaft - Secondary Shaft Chain Tension

    STEPRACE: Service & Maintenance Manual - rev. 1.2 8.4. PRIMARY SHAFT - SECONDARY SHAFT CHAIN TENSION Carry out the procedures described in paragraphs 7.8. “Disassembling the side guards” and 7.9. “Disassembling the chain guard”. 1. Back off the 4 screws a which fix the secondary shaft to the frame.

  • Page 89: Adjusting The Alignment Of The Primary Drive Sprocket

    STEPRACE: Service & Maintenance Manual - rev. 1.2 8.5. ADJUSTING THE ALIGNMENT OF THE PRIMARY DRIVE SPROCKET Carry out the procedures described in paragraphs 7.8. “Disassembling the side guards” and 7.9. “Disassembling the chain guard”. 1. Back off lock nut a using a 32-mm wrench.

  • Page 90: Wear Of Alternator Brushes

    STEPRACE: Service & Maintenance Manual - rev. 1.2 8.6. WEAR OF ALTERNATOR BRUSHES Carry out the procedures described in paragraph 7.8. “Disassembling the side guards”. Inspect the 2 brushes for wear, referring to the figures at left and to the descriptions below: •...

  • Page 91: Aligning The Pedals

    STEPRACE: Service & Maintenance Manual - rev. 1.2 8.7. ALIGNING THE PEDALS Carry out the procedures described in paragraph 7.8. “Disassembling the side guards”. 1. Select stepping mode (independent stepping motion). 2. Back off lock nut a using a 17-mm wrench.

  • Page 92: Adjusting The Position Of The Slide And Bars

    STEPRACE: Service & Maintenance Manual - rev. 1.2 8.8. ADJUSTING THE POSITION OF THE SLIDE AND BARS Carry out the procedures described in paragraph 7.6. “Disassembling the upright guard”. To adjust the machine when no components have been replaced: 1. Back off the 4 fixing screws a of the BARS.

  • Page 93: Adjusting The Microswitch Position

    STEPRACE: Service & Maintenance Manual - rev. 1.2 8.9. ADJUSTING THE MICROSWITCH POSITION Carry out the procedure described in paragraph 7.29. “Disassembling the selection knob pin” for the guard only. 1. Back off the MICROSWITCH fixing screws a and adjust its position so that: •...

  • Page 94: Adjusting The Lcd Backlighting

    STEPRACE: Service & Maintenance Manual - rev. 1.2 8.10. 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.

  • Page 95: Adjusting The Buzzer Tone

    STEPRACE: Service & Maintenance Manual - rev. 1.2 8.11. 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.
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  • Page 97: Configuring The Machine

    STEPRACE: Service & Maintenance Manual - rev. 1.2 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.
  • Page 98 STEPRACE: Service & Maintenance Manual - rev. 1.2 • automatically if the microswitch is present; • by asking the user if the microswitch is not present. Left hand bank Dip-switch Microswitch Absent Present In the case of TGS type SW, the presence of the microswitch is configured by setting the position of dip-switch No.

  • Page 99: Scheduled Maintenance

    STEPRACE: Service & Maintenance Manual - rev. 1.2 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: •...

  • Page 100: Routine Maintenance Operations

    HECKING THE AMOUNT OF PLAY ON THE BALL JOINTS 1. Check the amount of play on the ball joints, taking a pedal in one hand and moving it. If any anomalies are found, call in the authorized Technogym Technical Service or adjust the amount of play.

  • Page 101: 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 102: Checking The Wear Of The Rubber Handlebar Covers

    STEPRACE: Service & Maintenance Manual - rev. 1.2 10.3.6. C HECKING THE WEAR OF THE RUBBER HANDLEBAR COVERS 1. Check the state of wear of the rubber covering on the 2 side handlebars and on the center handlebar. Replace if they show evident signs of wear.

  • Page 103: Checking The Resistance Setting

    STEPRACE: Service & Maintenance Manual - rev. 1.2 frequency simulator, check that the machine does not detect its presence and doesn’t alter the previously measured heart rate. 10.3.13. C HECKING THE RESISTANCE SETTING 1. Working in stepping mode A, select the manual training program and check that, when the difficulty level is changed, the resistance of the machine varies accordingly.
  • Page 104 STEPRACE: Service & Maintenance Manual - rev. 1.2 Page intentionally left blank Page 10.6...

  • Page 105: 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 106: Type Of Asic

    STEPRACE: Service & Maintenance Manual - rev. 1.2 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 107: Reducing Receiver Sensitivity

    STEPRACE: Service & Maintenance Manual - rev. 1.2 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 108: Mechanical Vibrations

    STEPRACE: Service & Maintenance Manual - rev. 1.2 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 109: Routing Of Cables

    STEPRACE: Service & Maintenance Manual - rev. 1.2 • 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 110: Personal Coded Device

    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.

  • Page 111: Upgrade Of Machines Already Installed

    STEPRACE: Service & Maintenance Manual - rev. 1.2 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.

  • Page 112: Special Functions

    STEPRACE: Service & Maintenance Manual - rev. 1.2 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: •...
  • Page 114 TECHNOGYM INDUSTRIE S.r.l. Via G. Perticari, 20 47035 Gambettola (FC) ITALIA Tel.: +39-0547-56047 Fax: +39-0547-650150 e-mail: service@technogym.com 0SMM0020-ING...

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