Technogym Step XT Service Maintenance Manual
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Technogym Step XT Service Maintenance Manual

Technogym Step XT Service Maintenance Manual

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ERVICE
MAINTENANCE MANUAL
PRELIMINARY

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

    STEP XT: Service & Maintenance Manual - rev. 2.0 Contents 1. GENERAL NOTICES............................1.1 1.1. I ............................1.1 NTRODUCTION 1.2. R .............................1.1 ECOMMENDATIONS 1.3. G .....................1.2 ENERAL RULES FOR REPAIR PROCEDURES 2. TECHNICAL CHARACTERISTICS.......................2.1 2.1. M ........................2.1 ECHANICAL CHARACTERISTICS 2.2. E ........................2.1 LECTRICAL CHARACTERISTICS 2.3.
  • Page 6 STEP XT: Service & Maintenance Manual - rev. 2.0 7.19. D .....................7.21 ISASSEMBLING THE SECONDARY SHAFT 7.20. D ........................7.23 ISASSEMBLING THE PULLEYS 7.21. D ..........................7.24 ISASSEMBLING THE BELT 7.22. D ......................7.26 ISASSEMBLING THE ALTERNATOR 7.23. D ....................7.27 ISASSEMBLING THE ALTERNATOR BRUSHES 8.

  • Page 7: 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 8: General Rules For Repair Procedures

    1. Always mark any parts or positions which may be confused with each other at the time of reassembly. 2. Use original Technogym spare parts and lubricants of the recommended brands. 3. Use special tools where specified. 4. Consult the technical circulars, which may contain more up-to-date information on adjustments and maintenance than those contained in this manual.

  • Page 9: Technical Characteristics

    STEP XT: Service & Maintenance Manual - rev. 2.0 2. TECHNICAL CHARACTERISTICS 2.1. MECHANICAL CHARACTERISTICS Width 64 cm Length 130 cm Height 139 cm Weight 103 kg 2.2. ELECTRICAL CHARACTERISTICS Mains voltage 115 - 230 VAC Frequency 50 - 60 Hz Consumption ~ 60 Watt –...

  • Page 10: Wiring Diagram

    STEP XT: Service & Maintenance Manual - rev. 2.0 2.5. WIRING DIAGRAM 2.5.1. C 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 Page 2.2...

  • Page 11: Wiring

    STEP XT: Service & Maintenance Manual - rev. 2.0 • Power supply name type of connector connection PANDUIT 6-pin to mains power supply PANDUIT 8-pin to alternator interface board • 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.
  • Page 12 STEP XT: Service & Maintenance Manual - rev. 2.0 SX-5: Alternator cable Alternator interface board - Alternator – Resistor Alter, interface Signal Color Alternator Resistor board / CN2 Alternator RPM X 6 Violet eyelet 4 Resistor - Blue Yellow Blue...

  • Page 13: Principles Of Operation

    STEP XT: Service & Maintenance Manual - rev. 2.0 3. PRINCIPLES OF OPERATION 3.1. BLOCK DIAGRAM The block diagram of the machine is shown in the figure below: CARDIO TRANSMITTER It is worn by the person using the machine, and transmits to the cardio receiver one pulse for every heart beat that is detected.
  • Page 14 STEP XT: Service & Maintenance Manual - rev. 2.0 CARDIO RECEIVER It is connected to the machine’s CPU board and receives the pulses sent by the transmitter. Its reception area is approximated by a circle with a 50 cm radius. If there is electromagnetic noise (produced by high voltage lines, radio transmitters, monitors, motors, etc.) within its reception...

  • Page 15: Accessories

    4. ACCESSORIES 4.1. CONNECTING TO THE TGS The machine can be connected to the Technogym System by means of the 9-pin D-connector situated on the back of the display, which provides the RS 232 serial port for connecting the TGS reader.
  • Page 16 STEP XT: Service & Maintenance Manual - rev. 2.0 Page intentionally left blank Page 4.2...

  • Page 17: Installation Instructions

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

  • Page 18: First Power On

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

  • Page 19: Troubleshooting

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

  • Page 20: The Display Does Not Illuminate

    STEP XT: Service & Maintenance Manual - rev. 2.0 6.1. THE DISPLAY DOES NOT ILLUMINATE THE DISPLAY DOES NOT ILLUMINATE Are the fuses OK? Replace the blown fuses Is the mains lead OK? Replace the mains lead Connect machine to a...
  • Page 21 STEP XT: Service & Maintenance Manual - rev. 2.0 Replace the power Are DC voltages output by the supply: see paragraph power supply correct? 7.7. Replace the display Do all DC voltages reach the CPU board: see display? paragraph 7.3.
  • Page 22 STEP XT: Service & Maintenance Manual - rev. 2.0 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 23: The Resistance Is Incorrect

    STEP XT: Service & Maintenance Manual - rev. 2.0 6.2. THE RESISTANCE IS INCORRECT THERE IS NO RESISTANCE IS RESISTANCE INCORRECT Is the alternator excitation Replace the alternator: Are the Watt and SPM voltage correct? see paragraph 7.22. values shown on the display...
  • Page 24 STEP XT: Service & Maintenance Manual - rev. 2.0 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 25 STEP XT: Service & Maintenance Manual - rev. 2.0 As for step (2) but with a tester between pins 6 (probe) and 3 (ground) of connector CN1 on the alternator interface board. As for step (5) but with a tester between pins 6 (probe) and 3 (ground) of connector CN1 of the display CPU board.

  • Page 26: The Spm Value Is Incorrect

    STEP XT: Service & Maintenance Manual - rev. 2.0 6.3. THE SPM VALUE IS INCORRECT THE SPM VALUE IS INCORRECT Is the SPM wire of cable Rewire the cable SX-5 correctly connected to correctly the alternator? Is the SPM signal output...
  • Page 27 STEP XT: Service & Maintenance Manual - rev. 2.0 Check whether the black and violet wires, which connect the alternator to pins 1 and 5 of CN2 on the alternator interface board, are correctly connected. Place the probes of an oscilloscope between the violet wire and the alternator ground. When...

  • Page 28: There Is No Heart Rate Signal

    STEP XT: Service & Maintenance Manual - rev. 2.0 6.4. THERE IS NO HEART RATE SIGNAL THERE IS NO CARDIO SIGNAL Is the supply voltage on the Replace the receiver: see receiver connector correct? paragraph 7.5. Is the supply voltage on...

  • Page 29: The Heart Rate Signal Is Incorrect

    STEP XT: Service & Maintenance Manual - rev. 2.0 6.5. THE HEART RATE SIGNAL IS INCORRECT In some case the machine may show “Err” on the heart rate display. THE HEART RATE SIGNAL IS INCORRECT Move the machines to Is the minimum distance...
  • Page 30 STEP XT: Service & Maintenance Manual - rev. 2.0 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.

  • Page 31: Disassembly Of Components

    STEP XT: Service & Maintenance Manual - rev. 2.0 7. DISASSEMBLY OF COMPONENTS 7.1. DISASSEMBLING THE DISPLAY 1. Turn off the machine and unplug the mains lead from the wall output. 2. Unscrew the 6 self-tapping screws a which fix the DISPLAY, using a large Phillips screwdriver.

  • Page 32: Disassembling The Eprom

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

  • Page 33: Disassembling The Cpu Board

    STEP XT: Service & Maintenance Manual - rev. 2.0 7.3. DISASSEMBLING THE CPU BOARD Carry out the procedures described in paragraph 7.1. “Disassembling the display”. With the display placed on a work bench: 1. Disconnect keyboard connector a. 2. Remove the 5 screws b, using a small Phillips screwdriver.

  • Page 34: Disassembling The Keyboard

    STEP XT: Service & Maintenance Manual - rev. 2.0 7.4. DISASSEMBLING THE KEYBOARD Carry out the procedure described in paragraph 7.1. “Disassembling the display”. 1. Disconnect KEYBOARD connector a. Figure 7.4-1 With the display placed on a work bench: 1. Use a sharp tool to lift up a corner of the KEYBOARD and detach it.

  • Page 35: Disassembling The Cardio Receiver

    STEP XT: Service & Maintenance Manual - rev. 2.0 7.5. DISASSEMBLING THE CARDIO RECEIVER Version A: receiver positioned under the display. 1. Turn off the machine and unplug the mains lead from the wall output. 2. Remove the label from the CARDIO RECEIVER box using the blade of a screwdriver.
  • Page 36 STEP XT: Service & Maintenance Manual - rev. 2.0 Version C: receiver housed in a box inside the display. Carry out the procedure described in paragraph 7.1. “Disassembling the display”. With the display on a work bench: 1. Unscrew the 2 screws g on RECEIVER housing box i using a small Phillips screwdriver.

  • Page 37: Disassembling The Upright Guard

    STEP XT: Service & Maintenance Manual - rev. 2.0 7.6. DISASSEMBLING THE UPRIGHT GUARD 1. Turn off the machine and unplug the mains lead from the wall output. 2. Unscrew the 6 screws a which secure the UPRIGHT GUARD, using a large Phillips screwdriver.

  • Page 38: Disassembling The Electronic Circuit Boards

    STEP XT: Service & Maintenance Manual - rev. 2.0 7.7. DISASSEMBLING THE ELECTRONIC CIRCUIT BOARDS Carry out the procedure described in paragraph 7.6. “Disassembling the upright guard”. To disassemble the POWER SUPPLY a: 1. Disconnect the 2 connectors CN1 and CN2.

  • Page 39: Disassembling The Frame Guard

    STEP XT: Service & Maintenance Manual - rev. 2.0 7.8. DISASSEMBLING THE FRAME GUARD 1. Turn off the machine and disconnect the mains lead from the wall output. 2. Step on the pedals to push them both to the ground, and secure them in the all-down position.

  • Page 40: Disassembling The Handlebars

    STEP XT: Service & Maintenance Manual - rev. 2.0 7.9. DISASSEMBLING THE HANDLEBARS 1. Turn off the machine and unplug the mains lead from the wall output. 2. Unscrew the 2 screws a fixing the CENTER HANDLEBAR using an 8-mm hex T wrench.

  • Page 41: Disassembling The Base Supports

    STEP XT: Service & Maintenance Manual - rev. 2.0 7.10. DISASSEMBLING THE BASE SUPPORTS 1. Turn off the machine and unplug the mains lead from the wall output. 2. Overturn the machine on its right side, being careful not to damage the right-hand side handlebar.

  • Page 42: Disassembling The Pedal Spring - Chain

    STEP XT: Service & Maintenance Manual - rev. 2.0 7.11. DISASSEMBLING THE PEDAL SPRING - CHAIN Carry out the procedures described in paragraphs 7.6. “Disassembling the upright guard” and 7.8. “Disassembling the frame guard”. 1. Disengage the PEDAL CHAINS from the lower pulleys a.

  • Page 43: Disassembling The Pedal Joint

    STEP XT: Service & Maintenance Manual - rev. 2.0 7.12. DISASSEMBLING THE PEDAL JOINT Turn off the machine and unplug the mains lead from the wall output. Working from both sides: 1. Lower the pedal to the midway point of its range of travel.

  • Page 44: Disassembling The Pedals And The Pedal Group

    STEP XT: Service & Maintenance Manual - rev. 2.0 7.13. DISASSEMBLING THE PEDALS AND THE PEDAL GROUP Turn off the machine and unplug the mains lead from the wall output. Working from both sides: 1. Grip the chain with the gripper pliers.
  • Page 45 STEP XT: Service & Maintenance Manual - rev. 2.0 To disassemble the PEDAL from the PEDAL GROUP: 9. Unscrew the 4 screws d connecting the PEDAL to its support using a 17-mm wrench. 10. Remove the PEDAL. To reassemble the PEDALS, carry out the above steps in reverse order.

  • Page 46: Disassembling The Pedal Connecting Rods

    STEP XT: Service & Maintenance Manual - rev. 2.0 7.14. DISASSEMBLING THE PEDAL CONNECTING RODS Turn off the machine and unplug the mains lead from the wall output. Working from both sides: 1. Grip the chain with the gripper pliers.

  • Page 47: Disassembling The Levers

    STEP XT: Service & Maintenance Manual - rev. 2.0 7.15. DISASSEMBLING THE LEVERS Carry out the procedure described in paragraphs 7.11. “Disassembling the pedal spring” up to the step releasing the chain from the levers (step 3) and 7.13. “Disassembling the pedals and the pedal group”.

  • Page 48: Disassembling The Lever Frame

    STEP XT: Service & Maintenance Manual - rev. 2.0 7.16. DISASSEMBLING THE LEVER FRAME Carry out the procedure described in paragraph 7.11. “Disassembling the pedal spring” up to the step releasing the chain from the levers (step 3) . 1. Unscrew the 4 screws a fixing the LEVER FRAME to the machine frame, using a 17- mm wrench.

  • Page 49: Disassembling The Primary Shaft - Secondary Shaft Chain

    STEP XT: Service & Maintenance Manual - rev. 2.0 7.17. DISASSEMBLING THE PRIMARY SHAFT - SECONDARY SHAFT CHAIN Carry out the procedure described in paragraph 7.8. “Disassembling the frame guard”. 1. Turn the CHAIN until the connecting link a is positioned on the sprocket wheel of the primary shaft b.

  • Page 50: Disassembling The Primary Shaft

    STEP XT: Service & Maintenance Manual - rev. 2.0 7.18. DISASSEMBLING THE PRIMARY SHAFT Carry out the procedures described in 7.11. “Disassembling the pedal spring” up to the release of the chain from the levers (step 3) and 7.17. “Disassembling the primary shaft - secondary shaft chain”.

  • Page 51: Disassembling The Secondary Shaft

    STEP XT: Service & Maintenance Manual - rev. 2.0 7.19. DISASSEMBLING THE SECONDARY SHAFT Carry out the procedure described in paragraph 7.17. “Disassembling the primary shaft - secondary shaft chain”. 1. Back off nut a of the belt tension rod using a 17-mm wrench.
  • Page 52 STEP XT: Service & Maintenance Manual - rev. 2.0 4. Working from both sides of the machine, back off the counternut d and lock down the adjusting screw e of the SECONDARY SHAFT using a 13-mm wrench. 5. Unscrew screws...

  • Page 53: Disassembling The Pulleys

    STEP XT: Service & Maintenance Manual - rev. 2.0 7.20. DISASSEMBLING THE PULLEYS Carry out the procedure described in paragraph 7.6. “Disassembling the upright guard”. For each of the LOWER PULLEYS: 1. Disengage the pedal spring - chain a from the LOWER PULLEYS b.

  • Page 54: Disassembling The Belt

    STEP XT: Service & Maintenance Manual - rev. 2.0 7.21. DISASSEMBLING THE BELT Carry out the procedure described in paragraph 7.8. “Disassembling the frame guard”. 1. Back off the nut a of the belt tension rod using a 17-mm wrench.
  • Page 55 STEP XT: Service & Maintenance Manual - rev. 2.0 4. Remove the BELT d from the pulley on the side opposite the chain. 5. Back off nut e and the adjusting screw f of the secondary shaft using a 13-mm wrench.

  • Page 56: Disassembling The Alternator

    STEP XT: Service & Maintenance Manual - rev. 2.0 7.22. DISASSEMBLING THE ALTERNATOR Carry out the procedure described in paragraph 7.8. “Disassembling the frame guard”. 1. Disconnect the ALTERNATOR cables. 2. Back off the nut a of the belt tension rod b using a 17-mm wrench.

  • Page 57: Disassembling The Alternator Brushes

    STEP XT: Service & Maintenance Manual - rev. 2.0 7.23. DISASSEMBLING THE ALTERNATOR BRUSHES Carry out the procedure described in paragraph 7.8. “Disassembling the frame guard”. 1. Disconnect cable a from the alternator. 2. Back off the BRUSH group clamping screw b using a medium Phillips screwdriver.
  • Page 58 STEP XT: Service & Maintenance Manual - rev. 2.0 Page intentionally left blank Page 7.28...

  • Page 59: Adjustments

    STEP XT: Service & Maintenance Manual - rev. 2.0 8. ADJUSTMENTS 8.1. BELT ALIGNMENT Carry out the procedures described in paragraphs 7.8. “Disassembling the frame guard” 1. Back off the lock nut a on the alternator pivot b using a 19-mm wrench.

  • Page 60: Belt Tension

    STEP XT: Service & Maintenance Manual - rev. 2.0 8.2. BELT TENSION Carry out the procedure described in paragraph 7.8. “Disassembling the frame guard”. 1. Back off the lock nut a of alternator pivot b using a 19-mm wrench. 2. Back off the dowel c of the alternator pivot.

  • Page 61: Alignment Of Primary Shaft Secondary Shaft Chain

    STEP XT: Service & Maintenance Manual - rev. 2.0 8.3. ALIGNMENT OF PRIMARY SHAFT - SECONDARY SHAFT CHAIN Carry out the procedure described in paragraph 7.8. “Disassembling the frame guard”. 1. Back off the screw a on sprocket b of the secondary shaft.

  • Page 62: Tension Of Primary Shaft - Secondary Shaft Chain

    STEP XT: Service & Maintenance Manual - rev. 2.0 8.4. TENSION OF PRIMARY SHAFT - SECONDARY SHAFT CHAIN Carry out the procedure described in paragraph 7.8. “Disassembling the frame guard”. 1. Back off the 4 screws a fixing the secondary shaft to the frame.

  • Page 63: Wear Of Alternator Brushes

    STEP XT: Service & Maintenance Manual - rev. 2.0 8.5. WEAR OF ALTERNATOR BRUSHES Carry out the procedure described in paragraph 7.8. “Disassembling the frame guard”. Inspect the 2 brushes for wear, referring to the figures at left and the descriptions below: •...
  • Page 64 STEP XT: Service & Maintenance Manual - rev. 2.0 Page intentionally left blank Page 8.6...

  • Page 65: Configuring The Machine

    STEP XT: Service & Maintenance Manual - rev. 2.0 9. CONFIGURING THE MACHINE Starting from the release 3.0 of the SW, it is possible to set some configuration parameters of the machine. Not all CPU boards are compatible with SW release 3.0. Therefore, if after replacing the EPROM with the new one, the machine doesn’t start up, it means that in order to...

  • Page 66: Maximum Time

    STEP XT: Service & Maintenance Manual - rev. 2.0 and press ENTER to confirm your choice. 9.1.3. M AXIMUM TIME You can set the maximum time that can be programmed for each exercise. To change the current setting, when the maximum time is actually in use will scroll on the LED matrix, input the desired time using the numeric keys and press ENTER to confirm.

  • Page 67: Maintenance Information

    STEP XT: Service & Maintenance Manual - rev. 2.0 9.2. MAINTENANCE INFORMATION In order to perform regular maintenance correctly, the actual number of hours the equipment has been operated and turned on can be visualized by entering a special access code. With the equipment in the standby mode, press numeric keys 314 at the same time.
  • Page 68 STEP XT: Service & Maintenance Manual - rev. 2.0 Page intentionally left blank Page 9.4...

  • Page 69: Scheduled Maintenance

    STEP XT: Service & Maintenance Manual - rev. 2.0 10. SCHEDULED MAINTENANCE To keep the machine in perfect working order, carry out the scheduled maintenance operations specified in the table below: CLEANIN TENSION WEAR PLAY LUBRI- CHECK CHECK CHECK CATION...
  • Page 70 STEP XT: Service & Maintenance Manual - rev. 2.0 (D) BELT WEAR CHECK Carry out once a year. Open the frame guard (see paragraph 7.8. and inspect the belt surface over its entire length, paying particular attention to the edges and the inner part. If it appears worn out or frayed, replace the belt (see paragraph 7.21.

  • Page 71: Appendix

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

  • Page 72: Presence Of Electromagnetic Fields

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

  • Page 73: Mechanical Vibrations

    STEP XT: Service & Maintenance Manual - rev. 2.0 • presence of electromagnetic fields which interfere with reception or saturate the receiver; • problems due to interaction between the receiver on one machine and the signal transmitted by a user training on another machine that is too close and cannot be moved farther away.
  • Page 74 STEP XT: Service & Maintenance Manual - rev. 2.0 • the coil must be positioned well away (even a few centimeters) from the LEDs; • the cable must be folded immediately after the connection on the receiver, so that it does not pass near the coil;...

  • Page 75: Routing Of Cables

    STEP XT: Service & Maintenance Manual - rev. 2.0 • Version with receiver inside the display: Figure 11.1-4 11.1.6. R OUTING OF CABLES Particular care must be taken in the routing of cables to prevent interference with the receiver coil.
  • Page 76 STEP XT: Service & Maintenance Manual - rev. 2.0 Page intentionally left blank Page 11.6...
  • Page 78 TECHNOGYM INDUSTRIE S.r.l. Via G. Perticari, 20 47035 Gambettola (Forlì ) ITALIA Tel.: +39 - 547 56047 Fax: +39 - 547 650 150 e-mail: service@technogym.com 0SMM0010-ING...

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