Technogym Bikerace User manual

SERVICE & MAINTENANCE MANUAL
REV. 1.1

The information contained in this manual is intended for QUALIFIED TECHNICIANS who have
completed a specific TECHNOGYM training course and are authorized to perform machine start-up
and adjustment procedures as well as extraordinary maintenance or repairs which require a thorough
knowledge of the machine, its operation, its safety devices and working procedures.
CAREFULLY READ THE INFORMATION CONTAINED IN
THIS MANUAL BEFORE PERFORMING ANY MAINTENANCE
PROCEDURES ON THE MACHINE
DANGEROUS VOLTAGES
PRESENT EVEN WHEN THE
MACHINE IS TURNED OFF
NOTE
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.
This document contains proprietary information that is protected by copyright. All rights reserved.
No part of this document may be photocopied, reproduced or translated into another language
without the prior written consent of Technogym.
The Technogym®trademark is property of Technogym S.p.A.
The Bikerace™trademark is property of Technogym S.p.A.

BIKERACE: Service & Maintenance Manual -rev. 1.1
Page i
Contents
1. GENERAL NOTICES...........................................................................................................................................1.1
1.1. INTRODUCTION.................................................................................................................................................1.1
1.2. RECOMMENDATIONS ........................................................................................................................................1.1
1.3. GENERAL RULES FOR REPAIR PROCEDURES ......................................................................................................1.2
2. TECHNICAL CHARACTERISTICS..................................................................................................................2.1
2.1. MECHANICAL CHARACTERISTICS......................................................................................................................2.1
2.2. ELECTRICAL CHARACTERISTICS........................................................................................................................2.1
2.3. AMBIENT SPECIFICATIONS................................................................................................................................2.1
2.4. CONFORMITY TO REGULATIONS........................................................................................................................2.1
2.5. WIRING DIAGRAM.............................................................................................................................................2.2
2.5.1. Connectors........................................................................................................................................2.2
2.5.2. Wiring ...............................................................................................................................................2.3
3. PRINCIPLES OF OPERATION..........................................................................................................................3.1
3.1. BLOCK DIAGRAM..............................................................................................................................................3.1
3.2. ALTERNATOR CONTROL....................................................................................................................................3.4
3.2.1. Mechanics.........................................................................................................................................3.4
3.2.2. Control..............................................................................................................................................3.4
3.2.3. The control signals............................................................................................................................3.5
4. ACCESSORIES......................................................................................................................................................4.1
4.1. CONNECTING TO THE TGS................................................................................................................................4.1
4.1.1. TGS adapted machines......................................................................................................................4.1
4.1.2. TGS non-adapted machines..............................................................................................................4.1
4.2. CONNECTING TO THE PRINTER..........................................................................................................................4.2
4.3. CONNECTING TO AN EXTERNAL DEVICE (ECG AND/OR METABOLIC MONITOR)................................................4.3
4.3.1. Calibrating the interface...................................................................................................................4.4
5. INSTALLATION INSTRUCTIONS....................................................................................................................5.1
5.1. SPECIFICATIONS AND REQUIREMENTS...............................................................................................................5.1
5.2. INSTALLATION..................................................................................................................................................5.1
5.3. FIRST POWER-ON ..............................................................................................................................................5.2
6. TROUBLESHOOTING.........................................................................................................................................6.1
6.1. THE DISPLAY DOES NOT ILLUMINATE................................................................................................................6.2
6.2. THERE IS NO RESISTANCE.................................................................................................................................6.5
6.3. THE RESISTANCE IS INCORRECT........................................................................................................................6.6
6.4. THE RPM VALUE IS INCORRECT.......................................................................................................................6.8
6.5. THE MACHINE DOES NOT PRINT ......................................................................................................................6.10
6.6. THE MACHINE DOES NOT OPERATE IN MASTER -SLAVE MODE ........................................................................6.12
6.7. THERE IS NO HEART RATE SIGNAL...................................................................................................................6.14
6.8. THE HEART RATE SIGNAL IS INCORRECT .........................................................................................................6.15
7. DISASSEMBLY OF COMPONENTS.................................................................................................................7.1
7.1. DISASSEMBLING THE DISPLAY ..........................................................................................................................7.1
7.2. DISASSEMBLING THE EPROM..........................................................................................................................7.2
7.3. DISASSEMBLING THE CPU BOARD....................................................................................................................7.3
7.4. DISASSEMBLING THE KEYBOARD......................................................................................................................7.5
7.5. DISASSEMBLING THE CARDIO RECEIVER ...........................................................................................................7.7
7.6. DISASSEMBLING THE RIGHT AND LEFT SIDE GUARDS.........................................................................................7.8
7.7. DISASSEMBLING THE ELECTRONIC CIRCUIT BOARDS.........................................................................................7.9

BIKERACE: Service & Maintenance Manual -rev. 1.1
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7.8. DISASSEMBLING THE ALTERNATOR.................................................................................................................7.10
7.9. DISASSEMBLING THE BELT..............................................................................................................................7.11
7.10.DISASSEMBLING THE CHAIN............................................................................................................................7.13
7.11.DISASSEMBLING THE PULLEY..........................................................................................................................7.14
7.12.DISASSEMBLING THE PEDAL CRANK GROUP....................................................................................................7.15
7.13.DISASSEMBLING THE ALTERNATOR BRUSHES .................................................................................................7.16
8. ADJUSTMENTS....................................................................................................................................................8.1
8.1. ALIGNING THE BELT..........................................................................................................................................8.1
8.2. BELT TENSION ..................................................................................................................................................8.2
8.3. CHAIN ALIGNMENT ...........................................................................................................................................8.3
8.4. CHAIN TENSION ................................................................................................................................................8.5
8.5. PLAY OF SADDLE STEM.....................................................................................................................................8.6
8.6. WEAR OF ALTERNATOR BRUSHES .....................................................................................................................8.7
8.7.PLAY OF THE PEDAL GROUP ..............................................................................................................................8.8
8.8. ADJUSTING THE LCD BACKLIGHTING...............................................................................................................8.9
8.9. ADJUSTING THE BUZZER TONE........................................................................................................................8.10
9. CONFIGURING THE MACHINE ......................................................................................................................9.1
9.1. MACHINE HW CONFIGURATION .......................................................................................................................9.1
9.1.1. Machine No. configuration...............................................................................................................9.1
9.1.2. Alternator configuration...................................................................................................................9.1
10.SCHEDULED MAINTENANCE.......................................................................................................................10.1
10.1.EXTERNAL CLEANING OPERATIONS.................................................................................................................10.1
10.1.1. Setting up the operation ..................................................................................................................10.1
10.1.2. Cleaning operations........................................................................................................................10.1
10.2.INTERNAL CLEANING OPERATIONS..................................................................................................................10.2
10.2.1. Setting up the operation ..................................................................................................................10.2
10.2.2. Cleaning operations........................................................................................................................10.2
10.3.SPECIAL MAINTENANCE OPERATIONS..............................................................................................................10.3
10.3.1. Setting up the operation ..................................................................................................................10.3
10.3.2. Checking the working conditions ....................................................................................................10.3
10.3.3. Checking the wiring and connections..............................................................................................10.3
10.3.4. Checking the display........................................................................................................................10.3
10.3.5. Checking the wear of the rubber handlebar cover..........................................................................10.3
10.3.6. Checking the state of wear of the chain...........................................................................................10.4
10.3.7. Lubrication......................................................................................................................................10.4
10.3.8. Checking the state of wear of the alternator belt.............................................................................10.4
10.3.9. Checking the play of the saddle stem...............................................................................................10.4
10.3.10. Checking the operation of the cardio receiver................................................................................10.4
10.3.11. Checking the resistance setting .......................................................................................................10.4
10.3.12. Checking the noise of the brushes ...................................................................................................10.4
11.APPENDIX...........................................................................................................................................................11.1
11.1.TECHNICAL NOTES ON CARDIO RECEIVERS .....................................................................................................11.1
11.1.1. Type of ASIC....................................................................................................................................11.2
11.1.2. Presence of electromagnetic fields..................................................................................................11.2
11.1.3. Reducing receiver sensitivity...........................................................................................................11.3
11.1.4. Mechanical vibrations.....................................................................................................................11.4
11.1.5. Position of the receiver....................................................................................................................11.4
11.1.6. Routing of cables.............................................................................................................................11.5
11.2.PERSONAL CODED DEVICE.............................................................................................................................11.6
11.2.1. Operating modes .............................................................................................................................11.6
11.2.2. Upgrade of machines already installed...........................................................................................11.7
11.3.SPECIAL FUNCTIONS .......................................................................................................................................11.8
11.3.1. Displaying the selected type of alternator.......................................................................................11.8

BIKERACE: Service & Maintenance Manual -rev. 1.1
Page 1.1
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.
In order to facilitate consultation, the paragraphs are accompanied by schematic drawings which
illustrate the procedure being described.
This manual contains notices and symbols which have a specific meanings:
WARNING: non observance may result in accident or injury.
ATTENTION: non observance may cause damage to the machine.
Information about the operation in progress.
OBSERVE: observation about the operation in progress.
1.2. RECOMMENDATIONS
Technogym recommends the following steps for planning repair procedures:
• Carefully evaluate the customer’s description of the machine malfunction and ask all the
necessary questions to clarify the symptoms of the problem.
• Clearly diagnose the causes of the problem. This manual provides the fundamental theoretical
basis, which must then be integrated by personal experience and attendance at the training
courses periodically offered by Technogym.
• Rationally plan the repair procedure so as to minimize the downtime necessary for procuring
spare parts, preparing tools, etc.
• Access the component to be repaired, avoiding any unnecessary operations. In this regard it will
be useful to refer to the disassembly sequence described in this manual.

BIKERACE: Service & Maintenance Manual -rev. 1.1
Page 1.2
1.3. 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.
5. Before starting the repair procedure, make sure that the recommended tools are available and in
good condition.
6. For the procedures described in this manual, use only the specified tools.
OBSERVE: The tool sizes quoted in this manual are expressed in mm.

BIKERACE: Service & Maintenance Manual -rev. 1.1
Page 2.1
2. TECHNICAL CHARACTERISTICS
2.1. MECHANICAL CHARACTERISTICS
Width 58 cm
Length 140 cm
Height 140 cm
Weight 86 Kg
2.2. ELECTRICAL CHARACTERISTICS
Mains voltage 115 / 230 VAC
Frequency 50 -60 Hz
Consumption ~ 60 Watt – 0.6 / 0.3 A
Fuses 5x20 3.15 A fast-blow
The mains voltage is set by means of a special jumper on the power supply circuit board.
An incorrect voltage setting can cause irreversible damage to the power supply unit.
Before changing the mains voltage setting, the machine must be turned off and the
mains lead unplugged from the wall output.
2.3. AMBIENT SPECIFICATIONS
Operating from 5° to 35° C
Temperature Storage from -20 to 55° C
Operating from 30% to 80% non-condensing
Humidity Storage from 5% to 85% non-condensing
2.4. CONFORMITY TO REGULATIONS
The machine conforms to the following directives:
Europe USA
EMI EN 60601-1-2
Safety EN 60601-1
EN 957-1
Directive 73/23/CEE
93/68/CEE
89/336/CEE
UL 2601-1

BIKERACE: Service & Maintenance Manual -rev. 1.1
Page 2.2
2.5. WIRING DIAGRAM
2.5.1. CONNECTORS
• CPU board
name type of connector connection
CN1 AMP MATE-N-LOCK 12-pin F. to alternator interface board
CN3 AMP MODU II 4-pin M. to cardio receiver
• Power supply
name type of connector connection
CN1 PANDUIT 6-pin to mains power supply
CN2 PANDUIT 8-pin to alternator interface board