Technogym Rotex XT Service Maintenance Manual
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Technogym Rotex XT Service Maintenance Manual

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S
&
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

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 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 ROTEX XT: Service & Maintenance Manual - rev. 1.0 7.18. D ......................7.19 ISASSEMBLING THE FRONT WHEELS 7.19. D ....................7.20 ISASSEMBLING THE REAR WHEEL GROUP 7.20. D ....................7.21 ISASSEMBLING THE ALTERNATOR BRUSHES 8. ADJUSTMENTS ...............................8.1 8.1. B ............................8.1 ELT ALIGNMENT 8.2. B ..............................8.2...

  • 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

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 2. TECHNICAL CHARACTERISTICS 2.1. MECHANICAL CHARACTERISTICS Width 70 cm Length 190 cm Height 160 cm Weight 105 kg 2.2. ELECTRICAL CHARACTERISTICS Mains voltage 115 - 230 VAC Frequency 50 - 60 Hz Consumption ~ 60 Watt –...

  • Page 10: Wiring Diagram

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 2.5. WIRING DIAGRAM 2.5.1. C ONNECTORS • Free connectors Name type of connector connection CN10 AMP MATE-N-LOCK 6-pin M free to connection on frame CN11 AMP MATE-N-LOCK 6-pin F panel to alternator board...

  • Page 11: Wiring

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 • CPU board Name type of connector connection AMP MATE-N-LOCK 12 -pin F. to connector on frame AMP MODU II 4-pin M. to cardio receiver • Power supply Name type of connector...
  • Page 12 ROTEX XT: Service & Maintenance Manual - rev. 1.0 BK-7: Heart rate meter cable CPU board – Cardio receiver CPU/CN4 Signal Color Receiver +5 V Pulse per beat Blue ground Black BK-6: Low voltage power supply cable Power supply – Alternator interface board...

  • Page 13: Principles Of Operation

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 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 3.1...
  • Page 14 ROTEX XT: Service & Maintenance Manual - rev. 1.0 CARDIO RECEIVER It is connected to the machine’s CPU board and receives the pulses sent by the transmitter. Its reception area is approximately a circle of 1 meter of 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 ROTEX XT: Service & Maintenance Manual - rev. 1.0 Page intentionally left blank Page 4.2...

  • Page 17: Installation Instructions

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 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

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 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

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 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

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 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 ROTEX XT: Service & Maintenance Manual - rev. 1.0 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 ROTEX XT: Service & Maintenance Manual - rev. 1.0 Disconnect connector CN1 from the power supply. Place the tester probes on pins 4 and 6 of the connector. The measured voltage should be approximately 220 VAC or 110 VAC depending on the mains electricity supply.

  • Page 23: The Resistance Is Incorrect

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 6.2. THE RESISTANCE IS INCORRECT THERE IS NO RESISTANCE IS RESISTANCE INCORRECT Is the alternator excitation voltage Are the Watt and SPM values shown Replace the alternator: correct? on the display correct? see paragraph 7.8.
  • Page 24 ROTEX XT: Service & Maintenance Manual - rev. 1.0 Replace cable RT-1B Is the control signal on panel connecting the alternator connector CN11 correct? interface board and panel connector CN11 Replace cable RT-1A Replace the CPU board Is the control signal output by the...
  • Page 25 ROTEX XT: Service & Maintenance Manual - rev. 1.0 Disconnect all the cables from the 2 power resistor terminals. Place the tester probes on the 2 terminals and measure the value of the resistance. WARNING: Because all tester probes have a non zero internal resistance, which varies...

  • Page 26: The Spm Value Is Incorrect

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 6.3. THE SPM VALUE IS INCORRECT THE SPM VALUE IS INCORRECT Is the SPM wire of cable RT-5 Rewire the cable correctly connected to the correctly alternator? Is the SPM signal output...
  • Page 27 ROTEX XT: Service & Maintenance Manual - rev. 1.0 Replace cable RT-1B which connects the alternator interface Is the SPM signal on panel board to panel connector CN11 correct? connector CN11 Replace cable RT-1A Replace the display CPU which connects the CPU Is the SPM signal on board: see paragraph 7.3.
  • Page 28 ROTEX XT: Service & Maintenance Manual - rev. 1.0 while on connectors CN1 of the alternator interface board and on CN1 on the CPU board the following square wave should be obtained: As for step (2) but with the oscilloscope probes between pins 1 (probe) and 5 (ground) of connector CN2 on the alternator interface board.

  • Page 29: There Is No Heart Rate Signal

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 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 30: The Heart Rate Signal Is Incorrect

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 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 31 ROTEX XT: Service & Maintenance Manual - rev. 1.0 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 32 ROTEX XT: Service & Maintenance Manual - rev. 1.0 Page intentionally left blank Page 6.14...

  • Page 33: Disassembly Of Components

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 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 34: Disassembling The Eprom

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 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 35: Disassembling The Cpu Board

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 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 36: Disassembling The Keyboard

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 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 37: Disassembling The Cardio Receiver

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 7.5. DISASSEMBLING THE CARDIO RECEIVER Carry out the procedure described in paragraph 7.1. “Disassembling the display”. With the display on a work bench: 1. Unscrew the 2 screws a on RECEIVER housing box b using a small Phillips screwdriver.

  • Page 38: Disassembling The Upright Guard

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 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 39: Disassembling The Frame Guards

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 7.7. DISASSEMBLING THE FRAME GUARDS 1. Turn off the machine and disconnect the mains lead from the wall output. To remove the RIGHT GUARD: 2. Unscrew the 5 screws a and the screw b which fix the RIGHT GUARD, using a large Phillips screwdriver.

  • Page 40: Disassembling The Handlebars

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 7.8. 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 Electronic Circuit Boards

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 7.9. DISASSEMBLING THE ELECTRONIC CIRCUIT BOARDS Carry out the procedure described in paragraph 7.7. “Disassembling the frame guards”. 1. On each side, back off the 2 screws a fixing ELECTRONIC CIRCUIT BOARD group to the machine frame.

  • Page 42: Disassembling The Alternator

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 7.10. DISASSEMBLING THE ALTERNATOR Carry out the procedure described in paragraph 7.7. “Disassembling the frame guards”. 1. Disconnect the ALTERNATOR cables. 2. Unscrew the nut a using a 17-mm wrench. 3. Back off dowel b using a 4-mm hex T wrench.

  • Page 43: Disassembling The Rear Cover

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 7.11. DISASSEMBLING THE REAR COVER 1. Turn off the machine and unplug the mains lead from the wall output. 2. Align the pedals as shown in the figure. 3. Pull up on the REAR COVER, which snaps onto the frame.

  • Page 44: Disassembling The Belt

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 7.12. DISASSEMBLING THE BELT Carry out the procedure described in paragraph 7.7. “Disassembling the frame guards”. 1. Back off the nut a with a 17-mm wrench. 2. Back off the dowel b with a 4-mm hex T wrench.

  • Page 45: Disassembling The Pedal Wheel Track

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 7.13. DISASSEMBLING THE PEDAL WHEEL TRACK Carry out the procedure described in paragraph 7.11. “Disassembling the rear cover”. 1. Unscrew the 4 screws a fixing the PEDAL WHEEL TRACK to the frame using a 13- mm wrench.

  • Page 46: Disassembling The Pedal Lever Group

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 7.14. DISASSEMBLING THE PEDAL LEVER GROUP Version A: TNS - locked pedals. Carry out the procedures described in paragraphs 7.7. “Disassembling the frame guards” and 7.11. “Disassembling the rear cover”. On each side: 1.
  • Page 47 ROTEX XT: Service & Maintenance Manual - rev. 1.0 Version B: TNSS - floating pedals. Carry out the procedures described in paragraphs 7.7. “Disassembling the frame guards” and 7.11. “Disassembling the rear cover”. On each side: 1. Unscrew the screw a fixing the PEDAL LEVER GROUP to the flywheel, using a 6- mm T wrench.

  • Page 48: Disassembling The Pedals

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 7.15. DISASSEMBLING THE PEDALS 1. Turn off the machine and unplug the mains lead from the wall output. For each PEDAL: 2. Unscrew the 4 screws a fixing the PEDAL to the pedal lever using a 5-mm T wrench.

  • Page 49: Disassembling The Pedal Wheels

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 7.16. DISASSEMBLING THE PEDAL WHEELS Carry out the procedure described in paragraph 7.11. “Disassembling the rear cover”. For each PEDAL WHEEL: 1. Move the pedal so as to access the ring nut a fixing the PEDAL WHEEL.

  • Page 50: Disassembling The Flywheels

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 7.17. DISASSEMBLING THE FLYWHEELS Carry out the procedures described in paragraphs 7.7. “Disassembling the frame guards” and 7.14. “Disassembling the pedal lever group”. To disassemble the RIGHT FLYWHEEL: 1. Unscrew the fixing screw a of the RIGHT FLYWHEEL using a 17-mm wrench.

  • Page 51: Disassembling The Front Wheels

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 7.18. DISASSEMBLING THE FRONT WHEELS 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 left side handlebar.

  • Page 52: Disassembling The Rear Wheel Group

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 7.19. DISASSEMBLING THE REAR WHEEL GROUP Carry out the procedures described in paragraphs 7.11. “Disassembling the rear cover” and 7.13. “Disassembling the pedal wheel track”. 1. Using the special pliers, remove the snap ring 2.

  • Page 53: Disassembling The Alternator Brushes

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 7.20. DISASSEMBLING THE ALTERNATOR BRUSHES Carry out the procedure described in paragraph 7.7. “Disassembling the frame guards”. 1. Disassemble the alternator cable a. 2. Unscrew the BRUSH group clamping screw b using a large Phillips screwdriver.
  • Page 54 ROTEX XT: Service & Maintenance Manual - rev. 1.0 Page intentionally left blank Page 7.22...

  • Page 55: Adjustments

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 8. ADJUSTMENTS 8.1. BELT ALIGNMENT Carry out the procedure described in paragraph 7.7. “Disassembling the frame guards”. 1. Back off the lock nut a on the alternator pivot b using a 19-mm wrench.

  • Page 56: Belt Tension

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 8.2. BELT TENSION Carry out the procedure described in paragraph 7.7. “Disassembling the frame guards”. 1. Back off the nut a using a 17-mm wrench. 2. Back off the dowel b of alternator pivot c.

  • Page 57: Wear Of Alternator Brushes

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 8.3. WEAR OF ALTERNATOR BRUSHES Carry out the procedure described in paragraph 7.20. “Disassembling the alternator brushes”. Inspect the 2 brushes for wear, referring to the figures at left and the descriptions below: •...
  • Page 58 ROTEX XT: Service & Maintenance Manual - rev. 1.0 Page intentionally left blank Page 8.4...

  • Page 59: Configuring The Machine

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 9. CONFIGURING THE MACHINE 9.1. CHANGING THE SETTINGS ON THE DISPLAY PANEL To change the settings of the machine, when the equipment is in the standby mode, press numeric keys 314 at the same time. The following will appear on the LED matrix: PASSWORD = 0 Now, use the numeric keys to enter 2406 (the password) and press ENTER to confirm.

  • Page 60: Type Of Lever System

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 “− − ” 9.1.4. A “+” CTIVATING THE KEYS The user can enable the “+” and “−” keys to modify the target heart rate during exercise sessions in CPR mode. To change the current setting, when the setting is actually in use will scroll on the LED...

  • Page 61: Maintenance Information

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 and press ENTER to confirm your choice. The system will now go back to the standby mode. The “CLEAR” key can be pressed at any time to interrupt the setup procedure and return the equipment to the standby mode.
  • Page 62 ROTEX XT: Service & Maintenance Manual - rev. 1.0 The system will now go back to the standby mode. The “CLEAR” key can be pressed at any time to interrupt the setup procedure and return the equipment to the standby mode.

  • Page 63: Scheduled Maintenance

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 10. SCHEDULED MAINTENANCE To keep the machine in perfect working order, carry out the scheduled maintenance operations specified in the table below: CLEANING TENSION WEAR LUBRI- CHECK CHECK CATION MACHINE weekly...
  • Page 64 ROTEX XT: Service & Maintenance Manual - rev. 1.0 LUBRICATION OF THE LEVER GROUP Carry out every 6 months. Open the frame guard (see paragraph 7.7. ) and lubricate the bearings of the pedal lever group using spray grease (cod. 0V021).

  • Page 65: Appendix

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 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 66: Presence Of Electromagnetic Fields

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 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 67: Mechanical Vibrations

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 • 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 68: Routing Of Cables

    ROTEX XT: Service & Maintenance Manual - rev. 1.0 • 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 69 ROTEX XT: Service & Maintenance Manual - rev. 1.0 The figure below illustrates the optimal routing described above. Figure 11.1-4 Page 11.5...
  • Page 70 ROTEX XT: Service & Maintenance Manual - rev. 1.0 Page intentionally left blank Page 11.6...
  • Page 72 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 0SMM0037-ING...

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