Technogym Bike MED User manual

SERVICE & MAINTENANCE MANUAL
REV. 1.0

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
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 Bike MED™ trademark is property of Technogym S.p.A.

BIKE MED: Service & Maintenance Manual - rev. 1.0
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. PRODUCT CODES...............................................................................................................................................2.1
2.2. MECHANICAL CHARACTERISTICS .....................................................................................................................2.2
2.3. FUNCTIONS AND CHARACTERISTICS TABLE ......................................................................................................2.3
2.4. AMBIENT SPECIFICATIONS................................................................................................................................2.3
2.5. CONFORMITY TO REGULATIONS........................................................................................................................2.4
2.6. WIRING DIAGRAM ............................................................................................................................................2.5
2.7. CABLES ............................................................................................................................................................2.6
3. PRINCIPLES OF OPERATION..........................................................................................................................3.1
3.1. BLOCK DIAGRAM..............................................................................................................................................3.1
3.1.1. ARM display board ..............................................................................................................................3.1
3.1.2. CSafe Board.........................................................................................................................................3.2
3.1.3. TGS reader...........................................................................................................................................3.2
3.1.4. Hand sensor board...............................................................................................................................3.2
3.1.5. Cardio receiver ....................................................................................................................................3.2
3.1.6. Brake board..........................................................................................................................................3.2
3.1.7. Brake 3.3
3.1.8. Speed sensor.........................................................................................................................................3.3
3.1.9. Power entry module .............................................................................................................................3.3
3.2. BRAKE CONTROL..............................................................................................................................................3.4
3.2.1. Mechanics ............................................................................................................................................3.4
3.2.2. Control 3.4
3.2.3. The signals involved.............................................................................................................................3.6
4. ACCESSORIES .....................................................................................................................................................4.1
4.1. CARDIO THEATER CONNECTION........................................................................................................................4.1
4.2. PC LINK FOR PROGRAMMING............................................................................................................................4.1
4.3. MONITOR PLUG FOR CSAFE PORT.....................................................................................................................4.2
5. INSTALLATION INSTRUCTIONS....................................................................................................................5.1
5.1. SPECIFICATIONS AND REQUIREMENTS ..............................................................................................................5.1
5.2. INSTALLATION..................................................................................................................................................5.1
5.3. FIRST POWER-ON ..............................................................................................................................................5.1
6. TROUBLESHOOTING ........................................................................................................................................6.1
6.1. SERVICE TROUBLESHOOTING MENU..................................................................................................................6.2
6.1.1. Automatic Test......................................................................................................................................6.2
6.1.1.1. I2C Devices Test.............................................................................................................................................................6.3
6.1.1.2. LED Test (not on 700iE models)....................................................................................................................................6.3
6.1.1.3. Serial Ports Test..............................................................................................................................................................6.3
6.1.2. Manual Test..........................................................................................................................................6.3
6.1.2.1. Man. Keyboard Test........................................................................................................................................................6.4
6.2. THE DISPLAY FAILS TO ILLUMINATE .................................................................................................................6.5
6.3. “THE EQUIPMENT IS BLOCKED” MESSAGE ON THE DISPLAY ...................................................................6.7
6.4. ERROR DETECTED BY BRAKE BOARD ................................................................................................................6.8
6.4.1. Error 1 on brake board........................................................................................................................6.8
6.4.2. Error 2 on brake board........................................................................................................................6.8
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BIKE MED: Service & Maintenance Manual - rev. 1.0
Page ii
6.4.3. Error 4 on brake board........................................................................................................................6.8
6.4.4. Error 8 on the brake board..................................................................................................................6.9
6.4.5. Error 16 or 32 on the brake board.......................................................................................................6.9
6.4.6. Error 128 on brake board....................................................................................................................6.9
6.5. THERE IS NO RESISTANCE ...............................................................................................................................6.10
6.6. THE RESISTANCE IS INCORRECT......................................................................................................................6.11
6.7. THE SPEED SIGNAL IS INCORRECT ...................................................................................................................6.13
6.8. THE MACHINE DOES NOT READ THE TGS .........................................................................................................6.15
6.9. THERE IS NO HEART RATE SIGNAL...................................................................................................................6.17
6.9.1. HFU telemetric receiver.....................................................................................................................6.17
6.9.2. Hand sensor .......................................................................................................................................6.18
6.10.THE TELEMETRIC HR SIGNAL IS INCORRECT....................................................................................................6.20
7. DISASSEMBLY OF COMPONENTS.................................................................................................................7.1
7.1. DISASSEMBLING THE DISPLAY..........................................................................................................................7.1
7.2. DISASSEMBLING THE CIRCUIT BOARDS ON THE DISPLAY...................................................................................7.2
7.3. DISASSEMBLING THE KEYBOARD......................................................................................................................7.3
7.4. DISASSEMBLING THE CARDIO RECEIVER...........................................................................................................7.4
7.5. DISASSEMBLING THE HANDLEBAR....................................................................................................................7.6
7.6. DISASSEMBLING THE SENSORS .........................................................................................................................7.7
7.7. DISASSEMBLING THE GUARDS ..........................................................................................................................7.8
7.8. DISASSEMBLING THE SEAT GROUP....................................................................................................................7.9
7.9. DISASSEMBLING THE ADJUSTING KNOB ..........................................................................................................7.11
7.10.DISASSEMBLING THE ELECTRONIC BOX ..........................................................................................................7.12
7.11.DISASSEMBLING THE BELT .............................................................................................................................7.13
7.12.DISASSEMBLING THE PEDALS AND THE PEDAL CRANKS ..................................................................................7.14
7.13.DISASSEMBLING THE PULLEY .........................................................................................................................7.15
7.14.DISASSEMBLING THE BRAKE WINDING............................................................................................................7.16
7.15.DISASSEMBLING THE BRAKE GROUP...............................................................................................................7.17
7.16.DISASSEMBLING THE SPEED SENSOR...............................................................................................................7.19
7.17.DISASSEMBLING THE PLATFORMS WITH CSAFE BOARD CONNECTORS AND POWER ENTRY MODULE ...............7.20
8. ADJUSTMENTS....................................................................................................................................................8.1
8.1. BELT TENSION ..................................................................................................................................................8.1
8.2. PLAY OF SADDLE STEM.....................................................................................................................................8.2
8.3. SPEED SENSOR POSITION...................................................................................................................................8.3
8.4. BRAKE WINDING ASSEMBLY.............................................................................................................................8.4
9. MACHINE CONFIGURATION..........................................................................................................................9.1
9.1. USER MENU CONFIGURATION ...........................................................................................................................9.1
9.1.1. Language..............................................................................................................................................9.1
9.1.2. Distance................................................................................................................................................9.2
9.1.3. Priority setting......................................................................................................................................9.2
9.1.4. Maximum excercise time......................................................................................................................9.2
9.1.5. Pause time............................................................................................................................................9.3
9.1.6. Enable TGS ..........................................................................................................................................9.3
9.1.7. Enable keyboard...................................................................................................................................9.3
9.1.8. Modifiable target heart rate.................................................................................................................9.3
9.1.9. Enable custom messages......................................................................................................................9.4
9.1.10.Edit custom messages...........................................................................................................................9.4
9.1.11.Change messagges languages..............................................................................................................9.4
9.1.12.Enable multi-language mode ...............................................................................................................9.5
9.1.13.Resetting parameters to default values ................................................................................................9.5
9.1.14.SN 9.5
9.1.15.Communication protocols for external medical devices......................................................................9.5
9.2. SERVICE MENU CONFIGURATION ......................................................................................................................9.6
9.2.1. Low kit parameter ................................................................................................................................9.6
9.2.1.1. Read from low kit ...........................................................................................................................................................9.7
9.2.1.2. Write to low kit...............................................................................................................................................................9.7

BIKE MED: Service & Maintenance Manual - rev. 1.0
9.2.1.3. Default Setting................................................................................................................................................................9.7
9.2.1.4. Configuration parameters table.......................................................................................................................................9.8
9.2.2. Operating data.....................................................................................................................................9.8
9.2.2.1. Read from low kit ...........................................................................................................................................................9.9
9.2.2.2. Write to low kit...............................................................................................................................................................9.9
9.2.2.3. Machine usage data.........................................................................................................................................................9.9
9.2.3. Errors log.............................................................................................................................................9.9
9.2.3.1. Read from low kit .........................................................................................................................................................9.10
9.2.3.2. Reset Errors...................................................................................................................................................................9.10
9.2.3.3. COM.Fault ....................................................................................................................................................................9.10
9.2.3.4. View Errors...................................................................................................................................................................9.11
9.2.4. Standard settings................................................................................................................................9.11
9.2.5. Low kit menu ......................................................................................................................................9.11
9.2.5.1. Low kit version.............................................................................................................................................................9.12
9.2.5.2. Low Kit fault code........................................................................................................................................................9.12
9.2.6. High kit version..................................................................................................................................9.12
9.2.7. BOOT version.....................................................................................................................................9.12
10.SCHEDULED MAINTENANCE.......................................................................................................................10.1
10.1.DAILY MAINTENANCE OPERATIONS................................................................................................................10.1
10.1.1.Setting up the operation .....................................................................................................................10.1
10.1.2.External cleaning operations .............................................................................................................10.1
10.2.MONTHLY MAINTENANCE OPERATIONS..........................................................................................................10.2
10.2.1.Play of the saddle stem.......................................................................................................................10.2
10.2.2.Check wear of foot straps...................................................................................................................10.2
10.2.3.Checking the operation of the cardiotester receiver..........................................................................10.2
10.2.4.Checking the operation of the hand sensor receiver..........................................................................10.2
10.3.TWICE-YEARLY MAINTENANCE OPERATIONS..................................................................................................10.3
10.3.1.Carrying out the monthly maintenance procedure.............................................................................10.3
10.3.2.Setting up the operation .....................................................................................................................10.3
10.3.3.Cleaning operations...........................................................................................................................10.3
10.3.4.Checking the working conditions.......................................................................................................10.3
10.3.5.Checking the wear of rubber parts.....................................................................................................10.3
10.3.6.Checking the belt................................................................................................................................10.3
10.3.7.Checking the display ..........................................................................................................................10.3
10.3.8.Checking the wiring and connections ................................................................................................10.3
11.FUNCTIONAL TESTS .......................................................................................................................................11.1
11.1.ELECTRICAL SAFETY TEST..............................................................................................................................11.1
11.2.START-UP CHECK............................................................................................................................................11.2
11.3.CHECKING THE ASSEMBLY OF THE TRANSMISSION SYSTEM .....................................................11.3
11.4.CHECKING THE ASSEMBLY OF THE SEAT COMPONENTS..............................................................11.3
11.5.CHECKING THE ASSEMBLY OF THE GUARDS.......................................................................................11.3
12.APPENDIX...........................................................................................................................................................12.1
12.1.LIST OF CRITICAL SPARE PARTS ......................................................................................................................12.1
12.2.UPDATING THE SW ........................................................................................................................................12.1
12.3.REQUIRED TOOLS ...........................................................................................................................................12.2
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BIKE MED: Service & Maintenance Manual - rev. 1.0
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BIKE MED: Service & Maintenance Manual - rev. 1.0
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.
Page 1.1

BIKE MED: Service & Maintenance Manual - rev. 1.0
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.

BIKE MED: Service & Maintenance Manual - rev. 1.0
2. TECHNICAL CHARACTERISTICS
2.1. PRODUCT CODES
The machine codes take into account all the possible variants and options available for the products.
The machine code, which does not include the Serial Number, consists of 16 alphanumeric
characters arranged as follows:
Characters description key to values
1,2,3 Machine type: Bike D82
4 Product version 7= Bike MED
5 Type of power supply M= multi-voltage EU
U= multi-voltage UL
6 Type of display L = LED display
7 Device for downloading data used by the Wellness
System N = not available
T = TGS
8, 9 Color of the frame AL = aluminum
10, 11 Color of paddings AG = gray
M0 = bordeaux
12 Guard color G= gray
13 Type of TV model 0= none
14,15 Language
IT = Italian
DE = German
FR = French
US = American English
NL = Dutch
BR = Portuguese
JP = Japanese
UK = British English
ES = Spanish
16 Type of packaging
I = Italy
E = standard international
S = overseas international
0= none
The above coding is used for the entire Excite line. For this reason, options not relevant
to the Bike MED machine have also been included.
Page 2.1

BIKE MED: Service & Maintenance Manual - rev. 1.0
Page 2.2
For example, a possible product code would be:
D827MLTALM0G0UKE
which is interpreted as follows:
D82 7 M L T AL M0 G 0 UK E
standard international packing
British English language
no TV model
gray guards
burgundy paddings
aluminum frame color
interfaced to TGS key reader
LED display
mains powered supply with multi-voltage inlet EU
MED model
Bike
2.2. MECHANICAL CHARACTERISTICS
BIKE MED
Width 52 cm - 20.5 in
Length 120 cm - 47.3 in
Height 150 cm - 59.1 in
Weight 67 kg - 147 lbs

BIKE MED: Service & Maintenance Manual - rev. 1.0
2.3. FUNCTIONS AND CHARACTERISTICS TABLE
BIKE MED
Power supply Multitension 90-260 Vac
Frequency 50 - 60 Hz
Resistance 10-1000 Watt
Consumption 100 W
Hand sensor YES
Touch sensor YES
CSafe YES
HR receiver HFU
Difficulty level 1-30
Program training
Quick start
Goal
6 profiles
Training Zone
CPR
Weight Loss
Custom program
Constant Power
Constant Torque
Sub Maximal Test
Fitness
Single stage
Multistage
PWC test
PWC test modified
YMCA test
Maximal Test
Technogym maximal test
Custom maximal test
Astrand
McArdle
Anaerobic power test
CHARACTERISTICS
Military Test Air Force PRT
2.4. AMBIENT SPECIFICATIONS
Operating from 5° to 35° C
Temperature Storage from -10° to 70° C
Operating from 30% to 80% non-
condensing
Humidity Storage from 5% to 85% non-
condensing
Page 2.3

BIKE MED: Service & Maintenance Manual - rev. 1.0
Page 2.4
2.5. CONFORMITY TO REGULATIONS
The machine conforms to the following standards:
Europe USA
Safety
EN 957-1
EN 957-5 classe SA
EN 60601-1
EN 60601-1-2
UL 60601-1
In addition:
• Electrical isolation class: Class I;
• Marks and Certificates: CE – GM (TUV) and UL;
• Protection rating: IP20.

BIKE MED: Service & Maintenance Manual - rev. 1.0
2.6. WIRING DIAGRAM
DISPLAY
HAND
SENSOR
BOARD
ARM DISPLAY BOARD
KEYBOARD
CSAFE
BOARD
HFU
RECEIVER
CN7
CN8
CN1
TGS
BOARD
CN1
CN9CN1
CN3
CN2
BRAKE
POWER
ENTRY
MODULE
BRAKE
BOARD
CN4
CN3CN1
CN2
SPEED
SENSOR
CU122
Patch
Conn. 2
CN4J3J2-J4
L UPPER
SENSOR
R LOWER
SENSOR
L LOWER
SENSOR
R UPPER
SENSOR
CBQ-30
RIGHT
TOUCH
SENSOR
CN6
LEFT
TOUCH
SENSOR
CN5
Patch
Conn. 1
CU106
CU108
VAC
CB-4 CB-3
CB-51
CB-26
CBQ-25-1
CBQ-32
CBQ-13
CN
FE
FE
Page 2.5

BIKE MED: Service & Maintenance Manual - rev. 1.0
Page 2.6
2.7. CABLES
CB-3: Cable connecting upper and lower assemblies
Brake board – Display board
Brake board
CN1 Signal Color Display Board CN1
2 Digital Gnd White 2
3 Power Gnd Orange 3
4 - sensing +5 Vdc digital Red 4
6 +12 Vdc Black 6
7 +5 Vdc Green 7
8 +sensing +5 Vdc digital Blue 8
CB-4: Serial communication cable between upper and lower assemblies
Brake board – Display board
Brake board
CN4 Signal Color Display Board CN9
1 Digital Gnd Orange-White 1
2 Digital Gnd Orange 2
3 NC Green-White 3
4 Download Blue 4
5 Reset Blue-White 5
6 NC Green 6
7 485 Tx/Rx + Brown-White 7
8 485 Tx/Rx - Brown 8
CB-26: Touch sensor cable
Display board – Touch sensor
Display board
CN5 / CN6 Signal Color Touch sensor
1 + 5Vdc White 1
2 Lever button Brown 3
4 Reference Green 4
CB-51: Brake supply cable
Brake board – Brake – Speed sensor
Brake board
CN2 Signal Color Brake Speed sensor
1 Brake supply + Brown 10
2 Brake supply - Pink 5
3 RPM Orange Faston connected
to brown cable
4 RPM reference Blue eyelet

BIKE MED: Service & Maintenance Manual - rev. 1.0
CBQ-13: CSafe board cable
Display Board – CSafe Board
Display Board
CN8 Signal Color CSafe Board CN1
1 Digital #1 Flat cable 1
… … … …
14 Digital #14 Flat cable 14
CBQ-25-1: Hand sensor board cable
Display Board – Hand Sensor Board
Display Board
CN4 Signal Color Hand sensor board
J3
1 +5 Vdc power supply Red 2
5 Pulse out Blue 3
6 Reference Black 1
CBQ-30: Sensor cable
Hand Sensor Board - Sensors
Hand sensor
board Sensors
J2 - J4
Signal Color
RH 1 RH 2 LH 1 LH 2
1 Right sensor signal Red up up - -
2 Sensor signal reference White down down - -
3 Gnd Shield - - - -
4 Left sensor signal Black - - up up
5 Sensor signal reference Green - - down down
6 Gnd Yellow/green - - - -
CBQ-32: TGS cable
Display Board – TGS Board
Display Board
CN7 Signal Color TGS Board CN1
1 +12 Vdc power supply Yellow 1
3 Rx White 8
5 Tx Green 7
9 Gnd Brown 3
Page 2.7

BIKE MED: Service & Maintenance Manual - rev. 1.0
Page 2.8
CU106: HFU receiver cable
HFU receiver – Patch conn. 1
HFU receiver Signal Color Patch conn.1
1 +5 Vdc power supply Blue 1
2 Pulse (beat to beat) Red 2
4 Gnd Black 4
CU108: HFU receiver cable
Patch conn. 1 –Display board
Patch conn.1 Signal Color Display board
CN3
1 +5 Vdc power supply Blue 8
2 Pulse (beat to beat) Red 1
4 Gnd Black 7
CU122: High voltage cable
Power entry module – Brake board
Power entry
module Signal Color Brake board CN3
F Line Blue 1
N Neutral Brown 3
T Earth Yellow/Green 5

BIKE MED: Service & Maintenance Manual - rev. 1.0
3. PRINCIPLES OF OPERATION
3.1. BLOCK DIAGRAM
The machine block diagram is illustrated in the figure below:
POWER
ENTRY
MODULE
DISPLAY
DISPLAY BOARDS
CSAFE
BOARD
RIGHT
SENSORS
LEFT
SENSORS
HAND
SENSOR
BOARD
TGS BOARD
BRAKE
BOARD
CARDIO
RECEIVER
VAC
SPEED
SENSOR
BRAKE
KEYBOARD
TOUCH
SENSOR DX TOUCH SENSOR SX
3.1.1. ARM DISPLAY BOARD
This is the heart of the display: this is the circuit board which comprises the CPU, an ARM
microprocessor, its logic circuits and a FLASH EPROM containing the operating program for
the machine moreover, acts as the interconnection hub for all the components of the display
and serves as the point of connection with the electrical box. In fact it receives and process
signals from:
- Keyboard;
- Cardio receiver;
- TGS board;
- CSafe Board;
> distributes the voltages received from the Brake board to the display;
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BIKE MED: Service & Maintenance Manual - rev. 1.0
Page 3.2
> exchanges, via the RS-485 serial link to the Brake board, the commands for controlling the
brake;
> controls the LEDs and the 7-segment displays which provide feedback about the exercise
session.
The board includes the following indicator LEDs:
LED name Color Description
LED1 yellow
if ON the +5 Vdc power supply from the
Brake board correctly reaches the board.
LED2 green
if ON the +12 Vdc power supply from the
Brake board correctly reaches the board.
3.1.2. CSAFE BOARD
This board makes available a communication port, on 1 externally accessible connector, which can
be used for interfacing compatible CSafe devices such as the CardioTheater readers. This connector
is situated on the back of the display. Another free connector is available on the board.
These connectors can also be interfaced, using a special cable, to an external PC for programming
the FLASH EEPROM.
3.1.3. TGS READER
This board enables the machine to read and write on the user's TGS key for performing workouts
programmed with the Wellness System.
3.1.4. HAND SENSOR BOARD
This is the board which manages the hand sensors, interfacing them to the display board. It
processes the analogue signal received from the sensors and outputs one pulse for each heart beat
that is detected. The signal level is normally 5 Vdc; it goes to 0 Vdc when the user’s hands are
placed on the contacts, and a 5 Vdc pulse (having a width of approximately 30 msec) is output at
each detected heart beat.
3.1.5. CARDIO RECEIVER
This board manages the signal received from the telemetric transmitter used by the person
exercising. It receives the power supply signal from the display board and outputs a negative logic
pulse for every heart beat that is detected: the signal level is normally 5 Vdc, with a pulse at 0 Vdc
(having a width of approximately 30 msec) at each heart beat.
The receiver reception area is approximately a circle with a 1 m radius. If there is electromagnetic
noise (produced by high voltage lines, radio transmitters, monitors, motors etc.) within this area, the
receiver becomes saturated and no longer receives any signal.
3.1.6. BRAKE BOARD
There are 2 versions of the brake board, one which is used on the mains powered version and the
other on the self-powered version. In either case, the brake board consists of: