Technogym GROUP CYCLE Installation and user guide

REV.6.4

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
EVEN WITH THE
MACHINE 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 Group Cycle™ trademark is property of Technogym S.p.A.

GROUP CYCLE: Service & Maintenance manual rev. 6.4
Page i
Contents
1GENERAL NOTICES.............................................................................................................................................1.1
1.1 INTRODUCTION...................................................................................................................................................1.1
1.2 RECOMMENDATIONS ..........................................................................................................................................1.1
1.3 GENERAL RULES FOR REPAIR PROCEDURES ........................................................................................................1.2
2TECHNICAL SPECIFICATIONS.........................................................................................................................2.1
2.1 PRODUCT CODES.................................................................................................................................................2.1
2.2 PRODUCT CHARACTERISTICS..............................................................................................................................2.2
2.3 MECHANICAL CARACHTERISTICS.......................................................................................................................2.2
2.3.1 Overall dimensions in use ......................................................................................................................2.2
2.3.2 PACKING Dimensions (Europe and Overseas).....................................................................................2.3
2.4 AMBIENT SPECIFICATIONS..................................................................................................................................2.3
2.5 CONFORMITY TO REGULATIONS .........................................................................................................................2.3
3ACCESSORIES .......................................................................................................................................................3.1
3.1 FLYWHEEL LOCK SYSTEM...................................................................................................................................3.1
3.2 HANDLEBAR PROTECTION ..................................................................................................................................3.2
3.3 WIRELESS CONSOLE...........................................................................................................................................3.3
4INSTALLATION AND HANDLING INSTRUCTIONS .....................................................................................4.1
4.1 SPECIFICATIONS AND REQUIREMENTS ................................................................................................................4.1
4.2 INSTALLATION....................................................................................................................................................4.1
4.3 EQUIPEMENT MOVING ........................................................................................................................................4.2
5TROUBLESHOOTING ..........................................................................................................................................5.1
5.1 THE CADENCE READING (RPM) IS INCORRECT ...................................................................................................5.1
5.2 E6 ERROR ON THE WIRELESS CONSOLE ...............................................................................................................5.2
6DISASSEMBLY OF COMPONENTS...................................................................................................................6.1
6.1 DISASSEMBLING HANDLEBAR.............................................................................................................................6.1
6.2 DISASSEMBLING SADDLE....................................................................................................................................6.2
6.3 DISASSEMBLING BUSHES ADJUSTMENT LEVER OF SEDDLE AND HANDLEBAR......................................................6.3
6.4 DISASSEMBLING THE GUARDS............................................................................................................................6.4
6.5 DISASSEMBLING PEDAL,PEDAL CAGE AND PEDAL CRANKS ................................................................................6.6
6.5.1 Disassembling the pedal.........................................................................................................................6.6
6.5.2 Assembling the pedal..............................................................................................................................6.7
6.5.3 Disassembling the pedal cage................................................................................................................6.9
6.5.4 Disassembling the pedal crank.............................................................................................................6.10
6.6 DISASSEMBLING THE PEDALS SHAFT ................................................................................................................6.14
6.7 DISASSEMBLING BRAKE ...................................................................................................................................6.16
6.7.1 Disassembling brake knob....................................................................................................................6.16
6.7.2 Disassembling brake pad .....................................................................................................................6.17
6.8 DISASSEMBLING AND REPLACING THE CHAIN...................................................................................................6.18
6.9 DISASSEMBLING THE FLYWHEEL AND THE PINION............................................................................................6.21
6.10 DISASSEMBLING THE BELT AND FLYWHEEL GROUP ..........................................................................................6.22
6.11 DISASSEMBLIN THE SECONDARY PULLEY .........................................................................................................6.24
6.12 DISASSEMBLING THE FEET................................................................................................................................6.25
6.13 DISASSEMBLING THE WIRELESS CONSOLE .......................................................................................................6.27
6.13.1 Disassembling the Console...................................................................................................................6.27
6.13.2 Disassembling the sensor.....................................................................................................................6.28
6.13.3 Battery replacing..................................................................................................................................6.29
7ADJUSTMENT........................................................................................................................................................7.1
7.1 ADJUSTING THE CHAIN TENSION AND FLYWHEEL PARALLELISM ......................................................................7.1

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7.2 ADJUSTING THE BELT TENSION.........................................................................................................................7.4
7.3 ADJUSTING THE FLYWHEEL PARALLELISM (BELT VERSION)...............................................................................7.5
7.4 SADDLE PLAY ADJUSTMENT...............................................................................................................................7.7
7.5 ADJUSTING THE SPRING TENSION OF THE BINDING..........................................................................................7.8
7.6 ADJUSTING THE BRAKING RESISTANCE...............................................................................................................7.9
7.7 THE MACHINES IS NOT FLAT .............................................................................................................................7.10
8SCHEDULED MAINTENANCE ...........................................................................................................................8.1
9REQUIRED TOOLS ...............................................................................................................................................9.1

GROUP CYCLE: Service & Maintenance manual rev. 6.4
Page 1.1
1GENERAL 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.
CAUTION: non observance may cause damage to the machine.
Information about the operation in progress.
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.
The tool sizes quoted in this manual are expressed in mm.

GROUP CYCLE: Service & Maintenance manual rev. 6.4
Page 2.1
2TECHNICAL SPECIFICATIONS
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 14 alphanumeric
characters arranged as follows:
Characters
Description
Key to values
1,2,3,
Machine type
D91 = Group Cycle
4, Product version
H = Home Environment
P = Professional Environment
5, Transmission colour
C= CHAIN transmission
B= BELT transmission
6,
(Not used)
N
7, Country Localization
E= European
U= U.S.A.
8,
Certification
0= None
-
-
-
9,10,
Frame colour
AA
= Aluminium
11,12,
Saddle
01 = Type I “Velo”
13,14.
Guards colour
NC = Black RAL 7011
Both for ITALIAN and OTHER COUNTRIES market, the machine is partially disassembled
and packaged into a cartoon box,which contains the assemblyinstruction sheet.
For example, a possible product code would be:
D91PBNE0 – AA01NC
which is interpreted as follows:
D91 PB N E 0 - AA 01 NC
Machine Type: GROUP CYCLE
Product Version: Professional
Transmission: Belt
Not used
Localizzation: European
Certification: None
-
Frame colour: Alluminium
Saddle: Type 1 "Velo"
Guard colour: Black RAL 7011

GROUP CYCLE: Service & Maintenance manual rev. 6.4
Page 2.2
2.2 PRODUCT CHARACTERISTICS
Min – max user height
140-240cm / 4,6” – 6,9”
Max user weight
160Kg / 320lbs
Q factor
180mm / 7”
Transmission
Chain
Frame
Aluminium
Dual-sided SPD pedals
STANDARD
Lock system for home environment
OPTIONAL
2.3 MECHANICAL CARACHTERISTICS
Width
595 mm / 23”
Length
1375 mm / 54”
Height
1200 mm / 47”
Weight
60 Kg / 132 lbs
2.3.1 OVERALL DIMENSIONS IN USE

GROUP CYCLE: Service & Maintenance manual rev. 6.4
Page 2.3
2.3.2 PACKING DIMENSIONS (EUROPE AND OVERSEAS)
2.4 AMBIENT SPECIFICATIONS
Temperature
Operating
to 5° a 35° C
Storage
to -10 a 70° C
Humidity
Operating
to 30% a 80% non-condensing
Storage
to 5% a 85% non-condensing
2.5 CONFORMITY TO REGULATIONS
The machine conforms to the following standards:
EUROPE
USA
EMI
Inapplicable
Inapplicable
Safety
EN957-1 (2005)
EN957-10 (2005)
Directives
2006/42/CE
Moreover:
•Electrical isolation class: Inapplicable;
•Protection rating: IP20.

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GROUP CYCLE: Service & Maintenance manual rev. 6.4
Page 3.1
3ACCESSORIES
3.1 FLYWHEEL LOCK SYSTEM
Figure 3.1-1
The accessories supplied with the equipment, are indicated in the User Manual with the
relative indications of use.

GROUP CYCLE: Service & Maintenance manual rev. 6.4
Page 3.2
3.2 HANDLEBAR PROTECTION
Figure 3.2-1
This rubber protection is used to preserve the handlebar, in case of the equipment is
positioned as in figure below:
Figure 3.2-2

GROUP CYCLE: Service & Maintenance manual rev. 6.4
Page 3.3
3.3 WIRELESS CONSOLE
A0000488
Group Cycle Wireless Console
CAUTION: It is advisable to use ANT+ type chest belts. An analogue chest belt may be
subject to interferences from nearby users.
If using analogue chest belts, the equipment must be placed at least 170cm from each other as
shown in the picture, in order to avoid interferences.
To disassembling the group, carry out the procedure described in the paragraph:
6.13“Disassembling the Wireless Console”.

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GROUP CYCLE: Service & Maintenance manual rev. 6.4
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4INSTALLATION AND HANDLING
INSTRUCTIONS
4.1 SPECIFICATIONS AND REQUIREMENTS
For correct machine installation, make sure that:
•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.
•The place of installation is free of dust and sand.
•The place of installation meets the operating temperature and humidity conditions specified
in paragraph: 2.4“Ambient specifications”.
4.2 INSTALLATION
The equipment’s installation and assembly procedure, are detailed on the relative
manual, supplied with the machine delivery.

GROUP CYCLE: Service & Maintenance manual rev. 6.4
Page 4.2
4.3 EQUIPEMENT MOVING
Movement and positioning of the equipment on the ground must be done with great
caution, because there may be a loss of stability of it.
Figure 4.3-1
1. The equipment is equipped of fixed front wheel. To move should lift slightly and push forward
or backward, as shown in Figure.
CAUTION: If floor conditions do not allow the use of the wheels, the shift must be made
with standard lifting and transportation equipment.

GROUP CYCLE: Service & Maintenance manual rev. 6.4
Page 5.1
5TROUBLESHOOTING
5.1 THE CADENCE READING (RPM) IS INCORRECT
1. If the cadence reading (RPM) is incorrect, verify that the display receiver and the transmitter
have the same code.
2. If the codes match, replace the transmitter batteries.
3. If the data are still incorrect after replacing the batteries, proceed with tuning.
a. Remove the batteries from the display.
b. Insert the same batteries again while keeping any key depressed.
c. Press the RETURN key and check the code appearing on the lower frame of the display.
This code must match the code printed on the transmitter.
d. Press and hold the PLAY key; the display visualises code 0000.
e. Set the same code as that appearing on the transmitter: press the INCREASE or
DECREASE key to modify the single digit; press the PLAY key to skip to the next digit.

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Page 5.2
5.2 E6 ERROR ON THE WIRELESS CONSOLE
The error E6 is displayed in case of the communication is missing between the receiver in the
display and the transmitter on the flywheel.
If the error appear, follow the below procedure to fix it.
1. Remove the batteries from the display.
2. Insert the same batteries again while keeping any key depressed.
3. Press the RETURN key and check the code appearing on the lower frame of the display. This
code must match the code printed on the transmitter.
4. Press and hold the PLAY key; the display visualises code 0000.
5. Set the same code as that appearing on the transmitter: press the INCREASE or DECREASE
key to modify the single digit; press the PLAY key to skip to the next digit.