Technogym Top 600 XTPRO User manual

S
ERVICE & MAINTENANCE MANUAL
R EV . 2.0

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 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 Top 600 XTPRO™ trademark is property of Technogym S.p.A.

TOP 600 XTPRO: Service & Maintenance Manual - rev. 2.0
Contents
1. GENERAL NOTICES...........................................................................................................................................1.1
1.1. I NTRODUCTION .................................................................................................................................................1.1
1.2. R ECOMMENDATIONS ........................................................................................................................................1.1
1.3. G ENERAL RULES FOR REPAIR PROCEDURES ......................................................................................................1.2
2. TECHNICAL CHARACTERISTICS..................................................................................................................2.1
2.1. M ECHANICAL CHARACTERISTICS .....................................................................................................................2.1
2.2. E LECTRICAL CHARACTERISTICS .......................................................................................................................2.1
2.3. A MBIENT SPECIFICATIONS ................................................................................................................................2.1
2.4. C ONFORMITY TO REGULATIONS ........................................................................................................................2.1
2.5. W IRING DIAGRAM WITH NON - CODED RECEIVER ...............................................................................................2.2
2.5.1. Connectors........................................................................................................................................2.3
2.5.2. Wiring ...............................................................................................................................................2.3
2.6. W IRING DIAGRAM WITH CODED RECEIVER .......................................................................................................2.6
3. PRINCIPLES OF OPERATION..........................................................................................................................3.1
3.1. B LOCK DIAGRAM ..............................................................................................................................................3.1
3.1.1. Display..............................................................................................................................................3.1
3.1.2. Cardio transmitter ............................................................................................................................3.2
3.1.3. RJ45-RS232 board............................................................................................................................3.2
3.1.4. Power supply.....................................................................................................................................3.2
3.1.5. Alternator interface board................................................................................................................3.2
3.1.6. Alternator..........................................................................................................................................3.3
3.1.7. Power resistor...................................................................................................................................3.3
3.2. A LTERNATOR 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. C ONNECTING TO THE TGS................................................................................................................................4.1
4.2. C ONNECTING TO THE C ARDIO T HEATER ...........................................................................................................4.1
5. INSTALLATION INSTRUCTIONS....................................................................................................................5.1
5.1. S PECIFICATIONS AND REQUIREMENTS ..............................................................................................................5.1
5.2. I NSTALLATION ..................................................................................................................................................5.1
5.3. F IRST POWER - ON ..............................................................................................................................................5.2
6. TROUBLESHOOTING........................................................................................................................................6.1
6.1. T HE DISPLAY DOES NOT ILLUMINATE ................................................................................................................6.2
6.2. T HERE IS NO RESISTANCE .................................................................................................................................6.5
6.3. T HE RESISTANCE IS INCORRECT ........................................................................................................................6.6
6.4. T HE RPM VALUE IS INCORRECT .......................................................................................................................6.8
6.5. T HERE IS NO HEART RATE SIGNAL ...................................................................................................................6.10
6.6. T HE TELEMETRIC HEART RATE SIGNAL IS INCORRECT .....................................................................................6.11
7. DISASSEMBLY OF COMPONENTS.................................................................................................................7.1
7.1. D ISASSEMBLING THE DISPLAY ..........................................................................................................................7.1
7.2. D ISASSEMBLING THE EPROM..........................................................................................................................7.2
7.3. D ISASSEMBLING THE CPU BOARD ...................................................................................................................7.3
7.4. D ISASSEMBLING THE KEYBOARD ......................................................................................................................7.4
7.5. D ISASSEMBLING THE ARMS ..............................................................................................................................7.5
7.6. D ISASSEMBLING THE RIGHT AND LEFT SIDE CASINGS ........................................................................................7.6
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7.7. D ISASSEMBLING THE CARDIO RECEIVER ...........................................................................................................7.7
7.8. D ISASSEMBLING THE ELECTRONIC CIRCUIT BOARDS .........................................................................................7.8
7.9. D ISASSEMBLING THE ALTERNATOR ..................................................................................................................7.9
7.10. D ISASSEMBLING THE BELT .............................................................................................................................7.10
7.11. D ISASSEMBLING THE CHAIN ...........................................................................................................................7.12
7.12. D ISASSEMBLING THE PULLEY .........................................................................................................................7.13
7.13. D ISASSEMBLING THE PRIMARY SHAFT ............................................................................................................7.14
7.14. D ISASSEMBLING THE SADDLE AND STEM GUARD ............................................................................................7.15
7.15. D ISASSEMBLING THE HANDLES .......................................................................................................................7.16
7.16. D ISASSEMBLING THE ALTERNATOR BRUSHES .................................................................................................7.17
8. ADJUSTMENTS....................................................................................................................................................8.1
8.1. B ELT ALIGNMENT .............................................................................................................................................8.1
8.2. B ELT TENSION ..................................................................................................................................................8.2
8.3. C HAIN ALIGNMENT ...........................................................................................................................................8.3
8.4. C HAIN TENSION ................................................................................................................................................8.4
8.5. P LAY OF SADDLE STEM .....................................................................................................................................8.5
8.6. W EAR OF BRUSHES ...........................................................................................................................................8.6
9. CONFIGURING THE MACHINE......................................................................................................................9.1
9.1. U SER SETTING PARAMETERS .............................................................................................................................9.1
9.1.1. Language used..................................................................................................................................9.1
9.1.2. Measurement system.........................................................................................................................9.1
9.1.3. Maximum time...................................................................................................................................9.2
9.1.4. Activating the “+” and “ − ” keys......................................................................................................9.2
9.1.5. Disabling the function keys...............................................................................................................9.2
9.1.6. Enabling the “ENTER” key..............................................................................................................9.3
9.1.7. Setting the priority ............................................................................................................................9.3
9.2. T ECHNICAL SETTING PARAMETERS ...................................................................................................................9.3
9.2.1. Enabling use of the hand sensor.......................................................................................................9.3
9.2.2. Enabling the display mode................................................................................................................9.4
9.3. M AINTENANCE INFORMATION ..........................................................................................................................9.4
9.3.1. Hours on ...........................................................................................................................................9.4
9.3.2. Hours of use......................................................................................................................................9.4
9.4. C HANGING THE MAINTENANCE INFORMATION ..................................................................................................9.5
9.4.1. Hours on ...........................................................................................................................................9.5
9.4.2. Hours of use......................................................................................................................................9.5
10. SCHEDULED MAINTENANCE.......................................................................................................................10.1
10.1. E XTERNAL CLEANING OPERATIONS ................................................................................................................10.1
10.1.1. Setting up the operation ..................................................................................................................10.1
10.1.2. Cleaning operations........................................................................................................................10.1
10.2. R OUTINE MAINTENANCE OPERATIONS ............................................................................................................10.2
10.2.1. Setting up the operation ..................................................................................................................10.2
10.2.2. Cleaning operations........................................................................................................................10.2
10.3. S PECIAL 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. Performing the routine maintenance procedure .............................................................................10.3
10.3.4. Checking the wiring and connections..............................................................................................10.3
10.3.5. Checking the display .......................................................................................................................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

TOP 600 XTPRO: Service & Maintenance Manual - rev. 2.0
11. APPENDIX...........................................................................................................................................................11.1
11.1. T ECHNICAL 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
11.2. P ERSONAL C ODED D EVICE .............................................................................................................................11.6
11.2.1. Operating modes .............................................................................................................................11.6
12. TOP 600 XTPRO IFI...........................................................................................................................................12.1
12.1. D ISASSEMBLY OF COMPONENTS .....................................................................................................................12.2
12.1.1. Disassembling seat..........................................................................................................................12.2
12.1.2. Disassembling the stem guard.........................................................................................................12.3
12.1.3. Disassembling the seat bar..............................................................................................................12.4
12.1.4. Disassembling the lower casing......................................................................................................12.6
12.2. A DJUSTMENTS ................................................................................................................................................12.7
12.2.1. Play of seat bar................................................................................................................................12.7
12.2.2. Seat assembly sliding.......................................................................................................................12.8
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TOP 600 XTPRO: Service & Maintenance Manual - rev. 2.0
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.
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TOP 600 XTPRO: Service & Maintenance Manual - rev. 2.0
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.

TOP 600 XTPRO: Service & Maintenance Manual - rev. 2.0
2. TECHNICAL CHARACTERISTICS
2.1. MECHANICAL CHARACTERISTICS
Width 67 cm
Length 140 cm
Height 152 cm
Weight 98 Kg
2.2. ELECTRICAL CHARACTERISTICS
Mains voltage 115 / 230 VAC
Frequency 50 - 60 Hz
Consumption ~ 160 Watt – 1.71 / 0.86 A
Fuses 5x20 3 A fast-blow
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
EN 957-5
Directive 73/23/CEE
93/68/CEE
89/336/CEE
UL 2601-1
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TOP 600 XTPRO: Service & Maintenance Manual - rev. 2.0
Page 2.2
2.5. WIRING DIAGRAM WITH NON-CODED RECEIVER

TOP 600 XTPRO: Service & Maintenance Manual - rev. 2.0
2.5.1. CONNECTORS
• CPU board
Name type of connector connection
CN1 AMP MATE-N-LOCK 12 -pin F. to alternator interface board
CN2 Flat 10-pin to RJ45-RS232 board
CN4 AMP MODU II 6-pin M. to cardio receiver
• RJ45-RS232 board
Name type of connector connection
CN1 Male panel connector DB9 to TGS reader
CN2 Panel RJ45 to Cardio Theater
CN3 Female panel connector DB9 to external device (not used)
CN4 Flat 10-pin to CPU board
• Power supply
Name type of connector connection
CN1 PANDUIT 6-pin to mains power supply
CN2 PANDUIT 7-pin to alternator interface board
FG Faston to ground
• Alternator interface board
Name type of connector connection
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
2.5.2. WIRING
TX-1: Internal connecting cable
CPU board – Alternator interface board
CPU board
CN1 Signal Color Alternator interface board
CN1
1 +12 Vdc Red 1
2 + 5 Vdc Orange 2
3 Ground Black 3
4 -12 Vdc Blue 13
5 Alternator RPM X 6 Violet 5
6 Alternator control frequency Brown 6
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TOP 600 XTPRO: Service & Maintenance Manual - rev. 2.0
Page 2.4
TX-3/L: High voltage power supply cable
Power input socket – Filter
Power entry Signal Color Filter
Faston Live Blue Faston
Faston Neutral Black Faston
Faston Ground Yellow-
green Faston
BX-4/L: High voltage power supply cable
Filter – Power supply
Filter Signal Color Power supply
CN1
Faston Live Blue 4
Faston Neutral Black 6
TX-5/L: Alternator cable
Alternator interface board – Alternator – Resistor
Alternator
interface board
CN2
Signal Color Alternator Resistor
1 Alternator RPM X 6 Violet Red
eyelet 4 -
2 Resistor - Blue
Blue
Yellow
eyelet 6 Yellow eyelet 4
3 Resistor + Red
Red
Yellow
eyelet 6
5 Ground Black - Yellow
eyelet 4
4 Excitation Orange Red Faston
RT-6/L: Low voltage power supply cable
Power supply – Alternator interface board
Power supply
CN2 FG
Signal Color Alternator
interface board
CN3
2 + 5 Vdc Yellow 4
3 Ground Black 3
4 Faston Ground Yellow -
5 + 12 Vdc Red 2

TOP 600 XTPRO: Service & Maintenance Manual - rev. 2.0
XC-1: Output ports cable
CPU board – RJ45-RS232 board
CPU board
CN2 Signal Color RJ45-RS232 board
CN4
1 +12 Vdc flat 1
2 +12 Vdc flat 2
3 Tx to TGS flat 3
4 +5 Vdc flat 4
5 Rx from TGS flat 5
6 Tx to PC flat 6
7 Ground flat 7
8 Rx from PC flat 8
9 Ground flat 9
10 Ground flat 10
CR-XT: Non coded heart rate meter cable
CPU board – Cardio receiver
CPU board
CN4 Signal Color Receiver
1 +5 Vdc Red 1
2 Pulse per beat Blue 2
6 Ground Black 3
The above description of cables does not detail the ground node connections.
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TOP 600 XTPRO: Service & Maintenance Manual - rev. 2.0
Page 2.6
2.6. WIRING DIAGRAM WITH CODED RECEIVER
The only difference compared to the model with non-coded receiver is the NSC-XT cable between
the CPU board and the coded receiver, which is described below:

TOP 600 XTPRO: Service & Maintenance Manual - rev. 2.0
NSC-XT: Non coded heart rate meter cable
CPU board – Cardio receiver
CPU board
CN4 Signal Color Receiver
1 +5 Vdc Red 2
2 Pulse per beat Blue 1
6 Ground Black 3
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TOP 600 XTPRO: Service & Maintenance Manual - rev. 2.0
3. PRINCIPLES OF OPERATION
3.1. BLOCK DIAGRAM
The block diagram of the machine is shown in the figure below:
3.1.1. DISPLAY
It consists of various components that will be individually described below:
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:
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TOP 600 XTPRO: Service & Maintenance Manual - rev. 2.0
Page 3.2
• Non-coded: this is the standard product.
• 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.
CPU BOARD
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 and/or the HS interface board (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.
3.1.2. 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:
• 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.
3.1.3. RJ45-RS232 BOARD
This circuit board provides the machine connections to external devices:
• 1 serial port for connecting to the TGS reader;
• 1 serial port, currently not used, for future connections;
• 1 RJ45 port for the power supply to the portable Cardio Theater unit.
3.1.4. 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.
The machine uses only +5 Vdc and +12 Vdc.
3.1.5. ALTERNATOR INTERFACE BOARD
Receives from the display a square-wave signal whose frequency is proportional to the selected
level of difficulty, and converts it into a DC excitation voltage for the alternator. Receives the RPM
signal from the alternator, which it filters and sends to the display for calculating the speed.