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

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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.

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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

BIKERACE: Service & Maintenance Manual -rev. 1.1
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• Alternator interface board
name type of connectorconnection
CN1 AMP MATE-N-LOCK 15-pin F. to CPU board
CN2 AMP MATE-N-LOCK 6-pin F. to alternator
CN3 AMP MODU I 4-pin M. to power supply
CN4 AMP MODU I 8-pin M. to serial ports
2.5.2. WIRING
BK-1: Internal connecting cable
CPU Board –alternator interface board
CPU board
CN1 Signal Color Alternator interface board
CN1
1 +12 Vdc White 1
2 +5 Vdc Gray 1 2
3 ground Black 3
4 ground Orange 4
5 Alternator RPM X 6 Pink 5
6 PFM alternator resistance Red 6
7 --7
8 Loop Blue 1 8
9 CTS Blue 2 9
10 Master –Slave selection Purple 1 10
11 Y –bus Purple 2 11
12 Z –bus Brown 1 12
13 -12 Vdc Yellow-
Green 13
14 A –bus Gray 2 14
15 B –bus Brown 2 15
On some machines, the signal designated +12 Vdc in the above table is actually 10.5 Vdc.
BK-3A: High voltage power supply
Power input socket –ON-OFF Switch
Power entry Signal Color ON-OFF Switch
Red Faston Live Blue Red Faston
Red Faston Neutral Black Red Faston

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BK-3B: High voltage power supply
ON-OFF Switch –Power supply
ON-OFF Switch Signal Color Power supply
CN1
Red Faston Live Blue 4
Red Faston Neutral Black 6
The above description of cable BK-3 is simplified and does not detail the ground node connections.
BK-5: Alternator cable
Alternator interface board -Alternator –Resistor
Alternator
interface
board
CN2
Signal Color Alternator Resistor
1 Alternator RPM X 6 Purple Red eyelet 4 -
2 Blue -
-Resistor -Blue Yellow eyelet 4
5 ground Black Yellow eyelet 6 -
3 Red Yellow eyelet 4
-Resistor + Red Yellow eyelet 6
4 Excitation Orange Red Faston -
BK-6: Low voltage power supply cable
Power supply –Alternator interface board
Power supply
CN2 Signal Color Alternator interface board
CN3
2 +5 Vdc Yellow 4
5 +12 Vdc Red 2
6-7-4 ground Black 3
8 -12 Vdc Blue 1
BK-7: Heart rate meter cable
CPU Board -Cardio receiver
CPU board
CN3 Signal Color Receiver
1 +5 Vdc Red 1
2 Pulse per beat Blue 2
3 ground Black 3

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Page 2.5
BK-8: Serial ports cable
Alternator interface board –Serial ports
Alternator
interface board
CN4
Signal Color Serial ports
1 Y –bus White 1
2 Z –bus Orange 2
3 A –bus Brown 3
4 B –bus Yellow 4
5 CTS Green 5
6 +5 Vdc Red 6
7 ground Blue 7
8 --8
BK-4: Race cable
Serial port –Serial port
Serial ports Signal Color Serial ports
1 Y –bus White 1
2 Z –bus Orange 2
3 A –bus Brown 3
4 B –bus Yellow 4
7 ground Shield 7

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BIKERACE: Service & Maintenance Manual -rev. 1.1
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3. PRINCIPLES OF OPERATION
3.1. BLOCK DIAGRAM
The block diagram of the machine is shown in the figure below:
(1) 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. There are 2 types of transmitter:

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Page 3.2
• Non-coded: this is the standard product;
• Coded: this is the product which, utilizing Personal Coded Device technology, transmits
the heart rate together with a code that identifies the transmitter in question. In this way,
the coded receiver on the machine can identify the source of the heart rate signal, thereby
avoiding interference problems.
(2) CARDIO RECEIVER
It is connected to the machine’s CPU board and receives the pulses sent by the transmitter.
There are 2 types of receiver:
• Non-coded: this is the standard product. If used in conjunction with a coded transmitter, it
may provide an incorrect heart rate reading;
• Coded: this is the product which, utilizing Personal Coded Device technology, receives
the heart rate together with a code that identifies the transmitter in question. In this way
the machine can identify the source of the heart rate signal, thereby avoiding interference
problems.
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 area, the receiver becomes saturated and stops receiving any signal. If it is non-
coded and there are 2 transmitters within its area of reception, it will receive signals from
both, and may produce an error or irregular reading.
(3) DISPLAY
This is the heart of the machine, which controls all the machine functions by executing the
program stored in EPROM. It receives information from the user (age, weight, etc.) during
set-up of the training session, from the cardio receiver (user’s heart rate) and from the
alternator interface board for displaying workload data (Watt and RPM). It controls the
difficulty level selected with the “+” “−” keys or according to the chosen training program.
It consists of 2 circuit boards:
• CPU board: contains the microprocessor, and all the logic circuits for controlling the
machine and the LCD;
• LED board: contains the circuits pertaining to the display and indicators: LEDs and 7-
segment display.
The CPU board contains 2 banks of 4 dip-switches one and 2 dip-switches the other, which
are used for configuring the machine.
On the CPU boards of TGS adapted machines there is a jumper J2 which sets the transmission
mode of the serial port.
• J2 in position 1-2: sets the RS 485 serial port in full duplex mode;
• J2 in position 2-3: sets the RS 485 serial port in half duplex mode.

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(4) POWER SUPPLY
Receives the mains voltage at its input and outputs the DC voltages (+5 Vdc, +12 Vdc and
−12 Vdc) which supply the display and the alternator interface board.
(5) ALTERNATOR INTERFACE BOARD
Receives from the display a square wave signal (PWM) whose frequency is proportional to
the difficulty level setting, and converts it into an analogue excitation signal for the alternator.
Receives the RPM signal from the alternator, which it filters and sends to the display for
calculating the speed of exercise (RPM).
(6) ALTERNATOR
Is put into rotation by the user, and generates a resistance to the movement proportional to the
excitation voltage received from the alternator interface board. It also generates the RPM
signal (6 pulses per revolution) necessary for counting the number of revolutions and hence
measuring the speed. Its rotation produces energy which is dissipated by the power resistor.
Starting from SN 3175, the machines are equipped with a new alternator model
which makes it possible to obtain a lower minimum resistance value. Because the 2
alternators are of the same make (EFEL) and externally identical, the new model is
distinguished by a red mark affixed to the side opposite the flywheel.
Starting from the model manufactured by MAGNETI MARELLI, the excitation
circuit is equipped with a series-connected thermal cutout, which is normally
closed and opens when the temperature exceeds an established threshold.
(7) POWER RESISTOR
Has the function of dissipating the energy produced by the alternator.

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3.2. ALTERNATOR CONTROL
3.2.1. MECHANICS
The movement of the pedals turns the pedal crank which by means of a chain transmits the motion
to a pulley, which in turn transmits the motion to the alternator by means of a belt.
The pedal resistance perceived by the user results from a combination of 2 factors:
• electrical component: consisting of the resistance generated by the alternator, and which can be
measured as the electrical power dissipated on the resistor, also taking into consideration the
alternator efficiency;
• mechanical component: consisting of the mechanical efficiency of the linkages and more
generally of the mechanical friction of the system.
The alternator interface board is factory-calibrated by means of the 2 trimmers PT1 and
PT2 situated on the board itself. This is a purely electrical adjustment and should not be
modified, even in cases where the perceived resistance of adjacent machines is different.
3.2.2. CONTROL
To control the difficulty level of the workout, the machine adjusts the excitation of the alternator
which generates a resistance to the movement that is proportional to the excitation level. To do this,
the CPU board transmits a PFM (Pulse Frequency Modulation) signal. The alternator interface
board converts the PFM signal into an analogue signal which serves as the excitation signal for the
alternator. The higher the level of the alternator excitation signal, the greater will be the resulting
resistance.
The alternator rotates in the field produced by the excitation signal, generating electrical energy
which is dissipated by the power resistor.
There is a closed control loop between the alternator interface board, the alternator and the resistor.
In fact the alternator interface board regulates the excitation signal so that the voltage measured at
the resistor terminals matches the voltage programmed by the CPU board via the PFM signal.
If the excitation signal is not sufficient to generate the required resistance, the red LED
on the alternator interface board goes on.
The rotation of the alternator also generates a square wave signal proportional to its speed, with 6
pulses corresponding to one complete rotation of the alternator. This signal enters on the interface
alternator board where it is filtered and sent to the CPU board.
If the CPU board does not receive a speed signal greater or equal to 30 RPM, it does not
transmit any PFM signal. Therefore the alternator does not receive the excitation signal
and there is no resistance at all.

BIKERACE: Service & Maintenance Manual -rev. 1.1
Page 3.5
3.2.3. THE CONTROL SIGNALS
The machine controls the difficulty level of the workout by means of the CPU board, the alternator
interface board and the alternator, as illustrated in the figure below:
The following signals are involved in the control loop:
• Excitation signal (PFM and Ve)
This is the signal generated by the CPU board (pin 6-3 of connector CN1) for controlling the
resistance. It is a PFM signal, i.e. a square wave signal with variable frequency. The logic of this
control causes the frequency to increase with increasing resistance.
This signal enters the alternator interface board (pin 6-3 of connector CN1), and is converted in
analog signal and sent to the alternator (pin 4-5 of connector CN2 on the alternator interface
board) to supply its rotor via the brushes.
• Voltage across the resistor (Vr)
This is the dc voltage which the alternator dissipates on the resistor: the higher the excitation
signal, the higher the dissipated voltage. This signal provides an effective measure of the
electrical power generated by the alternator.
This signal reaches the alternator interface board (pin 3-2 of connector CN2), where it is read
and used as a feedback signal by the alternator interface board to adjust the excitation.
Alternator interface
board
CPU board
RPM
PFM
6
-
3
5
-
3
CN1
6
-
3
5
-
3
CN1
4
-
5
1
-
5
CN2
Alternator
RPM
Ve
Resistor
2
3
Vr

BIKERACE: Service & Maintenance Manual -rev. 1.1
Page 3.6
• RPM Signal
This is the speed signal output by the alternator. It enters the alternator interface board (pin 1-5
of connector CN2) and is a square wave which varies from –1 Vdc to a maximum value
dependent on the training speed, as illustrated in the figure below:
The signal is cleaned and level-converted before being sent from the alternator interface board
(pins 5-3 of connector CN1) to the CPU board (pins 5-3 of connector CN1) as a square wave
which varies between 0 and 5 Vdc, as illustrated in the figure below: