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Technogym FORMA LINE BIKE FORMA DDC5 Series Technical Assistance Manual

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BIKE FORMA
(DDC5xxx...)
Technical Assistance manual
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. 1.1
EV

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Summary of Contents for Technogym FORMA LINE BIKE FORMA DDC5 Series

  • Page 1 BIKE FORMA (DDC5xxx…) Technical Assistance manual . 1.1...
  • Page 3 The information contained in this document may be changed without prior notification. Technogym does not issue guarantees of any kind regarding this material. Technogym will not be held responsible for any errors contained herein or for any accidental damage or damage consequent to the supply, services or use of this material.

  • Page 5: Table Of Contents

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 Contents 1. GENERAL WARNINGS ............................1.1 1.1. I ..............................1.1 NTRODUCTION 1.2. U ..............................1.1 SEFUL ADVICE 1.3. G ..................1.2 ENERAL REGULATIONS REGARDING SERVICE WORK 2. TECHNICAL SPECIFICATIONS ......................... 2.1 2.1.
  • Page 6 Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 6.1.2.1. Man. Keyboard Test ..............................6.4 6.2. T ..........................6.5 HE DISPLAY REMAINS OFF 6.3. T “THE EQUIPMENT IS BLOCKED (COM)” ..........6.7 HE DISPLAY SHOWS THE MESSAGE 6.4. T ....................
  • Page 7 Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 9.2. C ..................9.7 ONFIGURATION OF THE ECHNICAL ASSISTANCE MENU 9.2.1. Low kit parameter ..........................9.9 9.2.1.1. Read from low kit ................................ 9.9 9.2.1.2. Write to low kit ................................9.9 9.2.1.3.

  • Page 8: Forma Line Bike Forma (Ddc5): Technical Assistance Manual - Rev

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 Page blank. Page iv...

  • Page 9: General Warnings

    1. GENERAL WARNINGS 1.1. INTRODUCTION This document has been prepared specifically for Technogym After Sales Service with the aim of providing authorised personnel with the information for carrying out maintenance and repair operations in the correct manner. A thorough understanding of the technical data contained herein is absolutely fundamental for the operator to achieve the highest level in professional training.

  • Page 10: General Regulations Regarding Service Work

    1. Always mark components or positions which might easily be confused with each other during re-assembly. 2. Use original Technogym spare parts and recommended brand lubricants. 3. Use special tools when specified to do so. 4. Consult the Technical Newsletters as they might contain more up-to-date details on regulation and servicing procedures compared to those in this manual.

  • Page 11: Technical Specifications

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 2. TECHNICAL SPECIFICATIONS 2.1. PRODUCT CODE NUMBERS The equipment code numbering takes into account all the possible variants and available options for the products. The equipment code number, which does not contain the Serial Number, is made up of 16 alphanumeric characters as follows: Characters Description Values and meaning...

  • Page 12: Serial Number Structure

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 2.2. SERIAL NUMBER STRUCTURE The Serial Number is made up of 14 alphanumeric characters as follows: Characters Description Values and meaning DD = FORMA LINE C = Bike Forma Type of product, 1,2,3,4,5,6, 5 = 500...

  • Page 13: Product Characteristics

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 2.3. PRODUCT CHARACTERISTICS Bike Forma 100-240Vac Power supply: 50-60Hz Energy consumption: Max 35W (50VA) Consumption in Stand-by: Resistance: 30-500Watt (a 70 rpm) Difficulty Levels: 1 - 25 Max. user weight: 180Kg –...

  • Page 14: Mechanical Characteristics

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 2.6. MECHANICAL CHARACTERISTICS MECHANICAL CHARACTERISTICS 1216mm –48” Length (mm | in) 600mm –24” Width (mm | in) Height (mm | in) 1338mm –53” Total weight (kg | lbs) 61Kg –134.5lbs 2.6.1.

  • Page 15: Packing Dimensions Europe And Overseas

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 2.6.2. ACKING DIMENSIONS UROPE AND VERSEAS Page 2.5...

  • Page 16: Wiring Diagram

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 2.7. WIRING DIAGRAM 2.7.1. (ARM B OWERED ODEL OARD Page 2.6...

  • Page 17: Cu Cables

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 2.8. CABLES The colour of the cables may change: in particular, refer to the Pin Out. 2.8.1. CBQ C ABLES CBQ-13: C-Safe Board Cable (Only LED) (ARM Board - C-Safe Board) ARM Board C-Safe Board Signal...
  • Page 18 Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 CU208: Cable for HR Cardio Receiver (ARM Board - HR Receiver) HR Receiver: ARM Board: CN3 Signal Colour Power supply + 5Vdc White Impulse (beat to beat) Brown Green CU309: Cable for 100/220V internal power supply signal (Input module - Brake Board) Brake Board...

  • Page 19: Operating Principle

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 3. OPERATING PRINCIPLE 3.1. BLOCK DIAGRAM The block diagram for the equipment is represented in the following figure: Page 3.1...

  • Page 20: Led Display Boards

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 3.2. LED DISPLAY BOARDS 3.2.1. ARM B OARD The Display includes a single board which contains the CPU, an ARM microprocessor, the logic for its operation and the EPROM FLASH containing the equipment's work program, and also acts as a connection centre for all the display components and a connection point with the Brake Board.

  • Page 21: Cardio Receiver Board

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 3.3. CARDIO RECEIVER BOARD 3.3.1. HR (B This is the Board that manages the signal sent by the Telemetric Transmitter (Heart Rate Band), used by the user during training sessions. The Receiver Board receives a power supply of +5Vdc from the Display Board.

  • Page 22: Brake Board

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 3.4. BRAKE BOARD Every Brake Board is divided up into: Power supply section which generates the low voltages used by the equipment: +5Vdc (used only by high kits of the LED type) and +12Vdc (used by all types of high kits). Depending on the equipment version, these voltage levels are originally generated from mains voltage (both 110Vac and 220Vac) or by a battery-generator.

  • Page 23: Brake Board Models

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 3.4.1. RAKE OARD ODELS Two interchangeable models of Brake Board (LASER and NEW EFI) are used, each is characterized by a specific SW. They can be distinguished from each other by different features on the cover, while the SW is identifiable according to the version of the kernel.

  • Page 24: Electromagnetic Brake

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 3.5. ELECTROMAGNETIC BRAKE It is an eddy current Brake, consisting of a flywheel mass and a flat copper disk which turns in the air gap of a winding. When there is a variation in the current to the winding, the field produced by it also varies and there is a consequent variation in the eddy currents induced in the copper disk and the resistance supplied to the movement of the pedals on the equipment.

  • Page 25: Brake Command

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 3.8. BRAKE COMMAND 3.8.1. ECHANICS The movement of the pedals sets the primary shaft into rotation. The primary shaft is attached to the secondary shaft and then to the brake, via a belt. The speed sensor, built into the frame, detects the heads of the screws that fix the disk to the flywheel and generates a signal representing the speed.
  • Page 26 "on" to flashing mode and sends an appropriate error message to the Display Board which visualizes the following message on the display: “THE EQUIPMENT IS BLOCKED. CONTACT THE TECHNOGYM TECHNICAL SERVICE (X)”, where “X” represents the Error Code for the error that has occurred.

  • Page 27: The Signals Involved

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 3.8.3. HE SIGNALS INVOLVED During control, the following signals may occur: • RS-485 Signal It is a digital signal between the Brake Board and Display Board. We have no possibility of monitoring its state.
  • Page 28 Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 Page blank. Page 3.10...

  • Page 29: Accessories

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 4. ACCESSORIES 4.1. CONNECTION TO THE PC FOR PROGRAMMING The equipment is connected to a PC for programming via the RJ45 connector of the C-Safe Board. WARNING: in order to identify the numbering of the pins on the RJ45 connector, you should refer to the following diagram: While programming the equipment, sometimes you need to use an RJ45 plug on the vacant RJ45 port on the back of the display, to avoid interference of any kind during...

  • Page 30: Monitor Plug For C-Safe Port

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 4.2. MONITOR PLUG FOR C-SAFE PORT By inserting the plug - code number 0WC00639AA - into the C-Safe port on the equipment, the LED mounted on it must come on as a signal that the 5Vdc is reaching the port. During the test function for the C-Safe ports, the plug allows the transmission channel to be diverted onto the reception channel, thereby obtaining a positive result for the test if the port is functioning.

  • Page 31: Installation Instructions

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 5. INSTALLATION INSTRUCTIONS 5.1. INSTALLATION In order to install the equipment correctly, you need to proceed as follows: 1. The equipment is installed on a flat surface, where there are no vibrations and adequate weight capacity also taking into consideration the weight of the user.

  • Page 32: Handling The Equipment

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 5.2. HANDLING THE EQUIPMENT In order to move the equipment from the packing pallet to the floor, you should lift it as indicated in the figure and then slide it to the ground. Considering its weight, we suggest that at least 2 people help with moving the equipment.

  • Page 33: First Start-Up

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 5.3. FIRST START-UP After completing the installation procedure the equipment is ready for use. On POWERED models, all you need to do to start the equipment is turn the start switch from position 0 to position 1.
  • Page 34 Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 Page blank. Page 5.4...

  • Page 35: Troubleshooting

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 6. TROUBLESHOOTING The troubleshooting procedures are shown on flow charts. In order to make reading easier, the following standards have been adopted: This box is the point of departure, where you start your START troubleshooting procedure.

  • Page 36: Troubleshooting Menu

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 6.1. TROUBLESHOOTING MENU This section allows to check the proper functioning of some components (Low Kit, LED Display, keyboard, serial ports). Press the keys at the same time when the machine is in stand by, to enter.

  • Page 37: Automatic Tests

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 TROUBLESHOOTING AUTOMATIC TEST MANUAL TEST MAN.KEYBOARD I2C Dev ices Test TEST LED Test TGS COM Test SERIAL PORTS Low Kit COM Test TEST CSaf e COM Test Use the ENTER key to scroll from one parameter to another saving the data if modified, whereas with the + and –...

  • Page 38: Led Test

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 6.1.1.2. LED Test The LED test checks on the functioning of all the LEDs in the display by turning on all the matrices. The BUZZER is also tested by varying the frequency which causes a variation in the tone of the sound.

  • Page 39: The Display Remains Off

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 6.2. THE DISPLAY REMAINS OFF THE DISPLAY DOES NOT ILLUMINATE Plug the machine into a Does the wall outlet supply the correct voltage? working electrical outlet Replace the mains lead Is the mains lead OK? Replace the fuses Are the fuses OK?
  • Page 40 Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 Is the voltage at the input Is the voltage at the Replace the power of the Brake Board output of the power entry entry module correct? module correct? Replace Chack the cable that Are the voltages at the CU309 cable...

  • Page 41: The Display Shows The Message "The Equipment Is Blocked (Com)

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 6.3. THE DISPLAY SHOWS THE MESSAGE “THE EQUIPMENT IS BLOCKED (COM)” The (COM) error indicates that there is no communication between the two KITs. This may occur essesntially in the following cases: 1.

  • Page 42: The Brake Board Has Detected An Error

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 6.4. THE BRAKE BOARD HAS DETECTED AN ERROR When the Brake Board detects an error, it blocks by interrupting the power supply and memorizes a numeric code in its memory which identifies the detected error. In addition it sends a signal regarding the status of the error to the DISPLAY Board, via the serial line.
  • Page 43 Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 Error Description Meaning Solution Code Upgrade the Firmware (FW) on the Brake Board. If the same errors occur after Not used. upgrading been successfully completed, the problem Brake Board. The error relates to the Powered board...
  • Page 44 Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 Error Description Meaning Solution Code Corrupt EEPROM. This happens when the flag relating to the Re-load the braking EEPROM Fault. CURRENT zone and the flag relating to the table. MIRROR zone (in EEPROM) indicate results that are not consistent.

  • Page 45: There Is No Resistance

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 6.5. THERE IS NO RESISTANCE The equipment does not produce resistance if: 1. the Brake Board does not receive a speed signal: if the equipment is stationary, then this behaviour is correct.
  • Page 46 Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 T HERE IS NO RESIST ANCE Someone is training? proper operation Are the Watt and RPM values Carry out the "The speed shown on the display different signal RPM is incorrect" from zero? troubleshooting procedure Reinstall the latest version of...
  • Page 47 Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 Follow the chart step by step in order to make a correct diagnosis. In particular, pay attention to the checks highlighted in the numbered boxes and listed here below: Measure the voltage leaving the Brake Board on pins 1 and 2 of the CN2 connector by maintaining a constant 60Rpm and increasing the level of difficulty: the Vdc measurement must increase.

  • Page 48: The Resistance Is Not Correct

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 6.6. THE RESISTANCE IS NOT CORRECT The equipment produces an incorrect resistance if: 1. the mechanics are not perfect; 2. the speed as measured is not correct; 3. the Brake Board is faulty; 4.
  • Page 49 Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 Follow the chart step by step in order to make a correct diagnosis. In particular, pay attention to the checks highlighted in the numbered boxes and listed here below: Carry out the Standard Settings, as described in the paragraph: 9.2.4.

  • Page 50: The Speed Signal Is Not Correct

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 6.7. THE SPEED SIGNAL IS NOT CORRECT The speed signal is not correct if: 1. The disk of the Electromagnetic Brake is incorrectly mounted on the flywheel; 2. The special speed measurement screws are missing or badly assembled (only for Crossover) 3.
  • Page 51 Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 Follow the chart step by step in order to make a correct diagnosis. In particular, pay attention to the checks highlighted in the numbered boxes and listed here below: Carry out the Standard Settings, as described in the paragraph: “STANDARD SETTINGS”.

  • Page 52: There Is No Heart Frequency Signal

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 6.8. THERE IS NO HEART FREQUENCY SIGNAL 6.8.1. HR R ECEIVER EART THERE IS NO HR SIGNAL (Chest Belt) Check if it works properly using Chest Belt a chest belt you are sure it's ok. defective The problem solved? Check the SW and the groundin...
  • Page 53 Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 Follow the chart step by step in order to make a correct diagnosis. In particular, pay attention to the checks highlighted in the numbered boxes and listed here below: Check on the correct SW version, according to the “EXCITE SW SMART TABLE”...

  • Page 54: Telemetric Signal Of Heart Rate Is Not Correct

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 6.9. TELEMETRIC SIGNAL OF HEART RATE IS NOT CORRECT 6.9.1. EART CORRECT USE OF BAND: Place the heart-rate band on the chest in direct contact with the skin and make sure that it is moist in the contact area. THE TELEMETRIC HR SIGNAL IS INCORRECT (Chest belt)
  • Page 55 Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 Are there sources of Receiver Board defective. electromagnetic noise near the Replace it. receiver? The problem does not depend on the equipment Follow the chart step by step in order to make a correct diagnosis. In particular, pay attention to the checks highlighted in the numbered boxes and listed here below: Check on the correct SW version, according to the “EXCITE SW SMART TABLE”...
  • Page 56 Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 Comply with the distance and positioning of the pieces of equipment with each other, keeping to the following diagram: Figure 6-1 The lateral range (130cm) is greater than the frontal range (90cm) even though it covers a tighter area.
  • Page 57 Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 Check on the correct positioning of the Receiver Board as indicated in paragraph: 7.4. “Dismantling the Cardio Receiver”. In order to check whether there is electromagnetic noise near the equipment, use the Text Box Excite as detailed below.
  • Page 58 Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 Page blank. Page 6.24...

  • Page 59: Dismantling The Parts

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 7. DISMANTLING THE PARTS 7.1. IMPORTANT NOTE ON DISMANTLING Figure 7.1-1 Figure 7.1-2 DANGER: DO NOT under any circumstances unscrew the screws and nuts highlighted in the figure. During the initial assembling during production of the (X) and (Y) components, the highlighted screws and nuts are tightened, buckling the frame on the fusion component, making them integral with each other.

  • Page 60: Dismantling The Control Panel

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 7.2. DISMANTLING THE CONTROL PANEL Switch off the equipment and remove the power supply plug from the wall socket. 1. Unscrew the 4 screws (a) using a medium- sized Phillips screwdriver. Figure 7.2-1 2.
  • Page 61 Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 5. Disconnect the connectors highlighted in the figure at the side and remove the Display assembly (e). Figure 7.2-4 6. Unscrew the 2 screws (f), using a 17mm wrench to remove the rear protection (g) of the display.

  • Page 62: Dismantling The Arm And C-Safe Board

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 7.3. DISMANTLING THE ARM AND C-SAFE BOARD Carry out the operations in the paragraph: 7.2. “Dismantling the control panel” up to step 5. Place the control panel on a workbench: Now it is possible to remove the boards it contains: •...
  • Page 63 Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 After the display reassembling, check that the keyboard correctly works as detailed at paragraph 6.1.2.1 “Man. Keyboard Test”. Page 7.5...

  • Page 64: Dismantling The Cardio Receiver

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 7.4. DISMANTLING THE CARDIO RECEIVER 7.4.1. HR R ECEIVER 1. Unscrew the 3 screws (a) using a medium- sized Phillips screwdriver. 2. Remove the bottom guard (b). Figure 7.4-1 3.
  • Page 65 Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 Re-wrap the receiver in the sponge protection and re-apply a strap to bind it. 1. Connect the cable again to the connector (a) on the receiver. Figure 7.4-3 WARNING: Position the receiver so that the coil (b) is turned upwards and towards the user.

  • Page 66: Dismantling The Handlebars

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 7.5. DISMANTLING THE HANDLEBARS 1. Unscrew the 3 screws (a) using a medium- sized Phillips screwdriver. 2. Remove the bottom guard (b). Figure 7.5-1 3. Unscrew the 4 screws (c) using a 5mm Allen wrench.

  • Page 67: Disassembling The Pedal And The Pedal Lever With Guard

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 7.6. DISASSEMBLING THE PEDAL AND THE PEDAL LEVER WITH GUARD 1. Unscrew the threaded pin (a) using a 15mm wrench and remove the pedal. WARNING: During re-assembly, tighten the screws (a) using a torque wrench set at 32Nm.

  • Page 68: Dismantling The Guard

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 7.7. DISMANTLING THE GUARD 1. Unscrew the screw (a) using a 4mm Allen wrench. 2. Remove the top guard (b) and fix it with a strap, as shown in the figure at the side. Figure 7.7-1 3.
  • Page 69 Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 On the right-hand side: 5. Unscrew the 6 screws (d) using a 4mm Allen wrench. 6. Line up the pedal in line with the saddle support, as indicated by the yellow arrow. 7.
  • Page 70 Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 Figure 7.7-8 Figure 7.7-7 9. With care, lift the guard slightly (Figure 7.7-7) in order to pass it through the pedal (Figure 7.7-8). 10. Unscrew the 2 top screws (e) using a 4mm Allen wrench and loosen the 2 side screws.

  • Page 71: Dismantling The Pulley Unit With Pedal Crank

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 7.8. DISMANTLING THE PULLEY UNIT WITH PEDAL CRANK Carry out the operations in the paragraph: 7.1. “IMPORTANT NOTE ON DISMANTLING” and 7.7. “Dismantling the guard”. 1. Unscrew the cap (a) using snap ring pincers or scissors.
  • Page 72 Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 4. Unscrew the 4 nuts (d) using a 13mm wrench, while blocking the screws on the opposite side, using a wrench of the same size. WARNING:: During re-assembly, position the screws at the top inside of the flange before refitting the shaft onto the frame.

  • Page 73: Dismantling The Seat

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 7.9. DISMANTLING THE SEAT 7.9.1. ISMANTLING THE SEAT SUPPORT 1. Unscrew the 2 screws (a) using a 4mm Allen wrench and slide off the bush. Figure 7.9-1 Figure 7.9-2 2.

  • Page 74: Dismantling The Internal Bushing

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 7.9.2. ISMANTLING THE INTERNAL BUSHING Figure 7.9-4 1. Lightly force the bushing lever (c) downward and rotate as indicated by the yellow arrow to remove it from its housing. To re-fit the seat group, follow the above operations in reverse, considering the following NOTES: 1.

  • Page 75: Dismantling The Seat Group

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 7.9.3. ISMANTLING THE SEAT GROUP 7.9.3.1. Dismantling the seat upholstery Figure 7.9-6 1. Unscrew the 4 screws (a) using a medium-sized Phillips screwdriver. 2. Remove the seat (b). To re-fit the all what removed, follow the above operations in reverse.

  • Page 76: Dismantling The Handle Pin

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 7.9.3.2. Dismantling the handle pin Figure 7.9-7 1. On both the sides, unscrew the screw (a) using a 3mm wrench. 2. Remove the spacers (b) and (c) and the pin (d). To re-fit the all what removed, follow the above operations in reverse.

  • Page 77: Dismantling The Spring And The Handle

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 7.9.3.3. Dismantling the spring and the handle Figure 7.9-8 Carry out the operations in the paragraph: 7.9.3.1 “Dismantling the seat upholstery”. 1. Use a small-sized flat screwdriver to remove the circlip (a), as indicated by the orange arrow. Continues on the next page...
  • Page 78 Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 Figure 7.9-9 2. Remove the pin (b) in the direction of the yellow arrows. 3. Remove the pin (c) as indicated at paragraph: 7.9.3.2 “Dismantling the handle pin”. Continues on the next page... Page 7.20...
  • Page 79 Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 To remove the handle: Figure 7.9-10 4. Remove the handle (d) in the direction of the yellow arrow. With the seat group on a work bench: 1. Overturn the group. 2.
  • Page 80 Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 3. Remove the selector group (f) in the direction of the yellow arrow. 4. Remove the spring (g). Figure 7.9-12 WARNING: check the spring is correctly mounted to avoid it can easily slip off, as shown in the figure at side.

  • Page 81: Dismantling The Handle Support Plate

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 7.9.3.4. Dismantling the handle support plate Figura 7.9-14 Carry out the operations in the paragraph:7.9.3.3“Dismantling the spring and the handle”. 1. Unscrew the 4 screws (a) using a 7mm socket wrench. 2.

  • Page 82: Dismantling The Handle Pin

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 7.9.3.5. Dismantling the handle pin Carry operations paragraph:7.9.3.3“Dismantling the spring and the handle”. 1. Rotate the lever (a) of 180°, in the direction of the yellow arrow. 2. Slide the lever in the direction of the orange arrow.
  • Page 83 Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 5. Rotate the lever counter-clock wise and free from the support plate. 6. Remove the lever (a). To re-fit the all what removed, follow the above operations in reverse. Figure 7.9-18 Page 7.25...

  • Page 84: Dismantling The Belt And Belt-Tensioner

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 7.10. DISMANTLING THE BELT AND BELT-TENSIONER Carry out the operations in the paragraph: 7.1. “IMPORTANT NOTE ON DISMANTLING” and 7.7. “Dismantling the guard”. 1. Make a mark on the initial position. 2.
  • Page 85 Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 Figure 7.10-4 As regards the passage of the belt, refer to the figure at the side. WARNING: At the end of the operation, adjust the tension of the belt as described in the paragraph: 8.1.

  • Page 86: Dismantling The Brake And The Flywheel Unit

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 7.11. DISMANTLING THE BRAKE AND THE FLYWHEEL UNIT Carry out the operations in the paragraph: 7.1. “IMPORTANT NOTE ON DISMANTLING” and 7.7. “Dismantling the guard”. 1. Disconnect the two fastons on the brake winding, as highlighted in the figure at the side.
  • Page 87 Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 In order to remove the copper disk: 1. Unscrew the 6 screws (d) using a 4mm Allen wrench. 2. Remove the copper disk (e). WARNING: During re-assembly, tighten the screws (d) using a torque wrench set at 6Nm.

  • Page 88: Dismantling The Speed Sensor

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 7.12. DISMANTLING THE SPEED SENSOR Carry out the operations in the paragraph: 7.1. “IMPORTANT NOTE ON DISMANTLING” and 7.7. “Dismantling the guard”. 1. Unscrew the 2 screws (a) using a medium- sized Phillips screwdriver.

  • Page 89: Dismantling The Brake Board

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 7.13. DISMANTLING THE BRAKE BOARD Carry out the operations in the paragraph: 7.1. “IMPORTANT NOTE ON DISMANTLING” and 7.7. “Dismantling the guard”. 1. Remove Brake Board from equipment, gripping it with your hands as indicated by the orange arrows and pull in the direction of the yellow arrows.

  • Page 90: Dismantling The Platforms

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 7.14. DISMANTLING THE PLATFORMS Front Platform: 1. Unscrew the 4 screws (a) using a medium- sized Phillips screwdriver. 2. Remove the front platform (b). Figure 7.14-1 Rear Platform: 3. Unscrew the 6 screws (c) using a medium- sized Phillips screwdriver.

  • Page 91: Dismantling The Input Module

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 7.15. DISMANTLING THE INPUT MODULE 1. To gain access to the connectors, turn the equipment on its side. 2. Unscrew the 2 screws (a) using a medium- sized Phillips screwdriver and remove the input module on the front platform.
  • Page 92 Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 Blank page Page 7.34...

  • Page 93: Adjustments

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 8. ADJUSTMENTS 8.1. BELT TENSION Figure 8.1-1 1. To adjust the belt tension, all you need to do is to choose between the various available positions for the spring (a). WARNING: The right tension must be between 50 - 60Hz.

  • Page 94: Aligning The Belt

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 8.2. ALIGNING THE BELT Figure 8.2-1 To align the belt: 1. Position it correctly in the races of the small pulley of the flywheel (a) and in the races of the pulley of the pedal cranks (b).

  • Page 95: Adjustment Of The Play On The Seat Column

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 8.3. ADJUSTMENT OF THE PLAY ON THE SEAT COLUMN 1. Raise the seat on the equipment so as to gain access to the adjustment bush. 2. Turn the 2 screws (a) on the bush and adjust the play of the seat column, using a 3mm Allen wrench.

  • Page 96: Adjusting The Position Of The Speed Sensor

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 8.4. ADJUSTING THE POSITION OF THE SPEED SENSOR 1. Loosen the 2 screws (a) using a 3mm Allen wrench. 2. Move the speed sensor support sideways in the direction of the yellow arrows, moving it closer to or further away from the copper disk up to a distance from the screws of 0.7mm.

  • Page 97: Adjusting The Position Of The Brake Unit

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 8.5. ADJUSTING THE POSITION OF THE BRAKE UNIT 1. Disconnect the 2 fastons highlighted in the figure. Figure 8.5-1 2. Loosen the 2 screws (a) using a 4mm Allen wrench.

  • Page 98: The Equipment Is Not Level

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 8.6. THE EQUIPMENT IS NOT LEVEL This problem may be due to the positioning of the equipment on an unflat surface. In order to resolve the problem, you need to regulate the adjustment foot. Figure 8.6-1 In order to make the equipment level, adjust the two front and rear feet.

  • Page 99: Equipment Configuration

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 9. EQUIPMENT CONFIGURATION 9.1. CONFIGURATION OF THE USER MENU The configuration procedure of the equipment is activated when the equipment is in Stand-By, by pressing the buttons at the same time. The following will appear on the display: ENTER PASSWORD: 2406...
  • Page 100 Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 At this point, the equipment starts to show on the display the current configuration, structured like the following diagram: Use the ENTER key to scroll from one parameter to another saving the data if modified, whereas with the + and –...

  • Page 101: Language: Xxx

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 9.1.1. ANGUAGE When a language has been chosen from the list of available languages, all the messages on the equipment's display are shown in the selected language. In order to change the setting, when the display shows the current setting: LANGUAGE: xxx Press the +/- GOAL keys to choose the desired language from among the available options.

  • Page 102: Cooldown Time: Xxx

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 9.1.5. OOLDOWN TIME It is possible to set the Time of the Cooldown at the end of every exercise in seconds, with values ranging from 5 to 180. In order to change the setting, when the display shows: COOLDOWN TIME: xxx To change the parameter you need to press the ENTER key: the current value of the parameter will be displayed in flashing mode and it is necessary to press CANCEL to cancel the current value and...

  • Page 103: Activating The Keyboard

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 9.1.7. CTIVATING THE EYBOARD It is possible to disable the use of the function keys so as to allow the equipment to be used only with the TGS. In order to change the setting, when the display shows the current setting: KEYS : xxx press the +/- GOAL keys to choose the desired setting from among the options shown in the following table:...

  • Page 104: Setting The Parameters To Default Values

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 9.1.10. S ETTING THE PARAMETERS TO DEFAULT VALUES It is possible to set the default values of the user menu. In order to select the function, when the display shows: DEFAULT CONFIG.

  • Page 105: Configuration Of The Technical Assistance Menu

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 9.2. CONFIGURATION OF THE TECHNICAL ASSISTANCE MENU The configuration procedure for the equipment is activated when the equipment is in Stand-By. Press the keys at the same time. the Display will show: ENTER PASSWORD: 2501 In order to access the procedure you need to enter the password...
  • Page 106 Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 TECHNICAL LOW KIT CONFIGURATION PARAM. OPERATING DATA ERRORS LOG STANDARD SETTINGS LOW KIT MENU HIGH KIT VERSION BOOT VERSION KEY READER VERS. Use the “+” and “–” speed control keys to scroll the list of parameters. To change a parameter you need to press the ENTER key: the current value of the parameter will be displayed in flashing mode and it is necessary to press CANCEL to cancel the current value and use the numerical keys to enter the desired value.

  • Page 107: Low Kit Parameter

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 9.2.1. OW KIT PARAMETER This function allows you to access the parameters with which it is possible to change certain settings on the low kit. In order to access this menu, when the display shows: LOW KIT PARAM.

  • Page 108: Default Setting

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 9.2.1.3. Default Setting To load the default values of the parameters, move using the +/- keys of the difficulty level until the display shows: DEFAULT SETTING ? press ENTER. The following will appear on the display: CONFIRM? press ENTER to recall the low kit default parameters.

  • Page 109: Operating Data

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 9.2.2. PERATING DATA This function allows you to access the operating data of the equipment memorized on the low kit. In order to access this menu, when the display shows: OPERATING DATA press ENTER.

  • Page 110: Write To Low Kit

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 9.2.2.2. Write to low kit To memorize on the low kit the values of the parameters currently on display, move using the +/- keys of the difficulty level until the display shows: WRITE TO LOW KIT ? press ENTER to transfer the new data to the low kit.

  • Page 111: Errors Log

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 9.2.3. RRORS This function allows you to access the log of errors generated by the equipment. In order to access this menu, when the display shows: ERRORS LOG press ENTER. This function is structured in the following way: READ FROM ERRORS LOG LOW KIT ?

  • Page 112: Com.fault X

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 9.2.3.3. COM.Fault This is a counter which displays the number of serial communication errors between the high kit and the low kit. It increases every time a communication error is detected. Move using the +/- keys of the difficulty level until the display shows: COM.FAULT X To reset the counter, press ENTER and the display will show:...

  • Page 113: Standard Settings

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 9.2.4. TANDARD SETTINGS This function allows you to reset the equipment operating data and at the same time to set the default values of the Brake Board parameters. In order to access this menu, when the display shows: STANDARD SETTINGS ? if you press ENTER, the following message will be displayed: CONFIRM ?

  • Page 114: Low Kit Version

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 9.2.5.1. Low kit version This function allows you to display the version of the Firmware (FW) of the Brake Board. In order to access this menu, when the display shows: LOW KIT VERSION press ENTER and the SW numerical sequence will be displayed: X.Y.Z...

  • Page 115: Boot Version

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 9.2.7. BOOT VERSION This function allows you to display the BOOT version. In order to display it, when the display shows: BOOT VERSION press ENTER and a message will be displayed which identifies the BOOT version. The Boot Version parameter refers to the “boot”...
  • Page 116 Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 Page blank. Page 9.18...

  • Page 117: Scheduled Maintenance

    SPECIAL MAINTENANCE SPECIAL maintenance operations may only be carried out by a Qualified Technician specifically trained by Technogym and authorized to perform machine adjustment and start-up operations, repairs and maintenance, and checks on the functioning and wear of mechanical components, in order to ensure correct and safe operation of the machine.

  • Page 119: Appendix

    Forma Line BIKE FORMA (DDC5): Technical Assistance manual - rev. 1.1 11. APPENDIX 11.1. TOOLS TO BE USED The following tools are required to carry out all the fitting, adjustment and maintenance tasks on the equipment: • Small Phillips screwdriver; •...
  • Page 122 TECHNOGYM S.p.A. Via G. Perticari, 20 - 47035 Gambettola (FC) – (Sede legale) Via Calcinaro, 2861 – 47522 Cesena (FC) – (Sede operativa) ITALIA Tel.: +39-0547-650638 Fax: +39-0547-650150 e-mail: service@technogym.com 0SM00729AA-UK...

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