Technogym CROSS FORMA User manual

SERVICE &MAINTENANCE MANUAL
REV.2.1

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
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 Cross Forma™ trademark is property of Technogym S.p.A.

CROSS FORMA: Service & Maintenance Manual - rev. 2.1
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. CHARACTERISTICS..............................................................................................................................................2.1
2.2. MECHANICAL CHARACTERISTICS........................................................................................................................2.1
2.3. ELECTRICAL CHARACTERISTICS..........................................................................................................................2.1
2.4. AMBIENT SPECIFICATIONS..................................................................................................................................2.2
2.5. CONFORMITY TO REGULATIONS..........................................................................................................................2.2
2.6. PRODUCT CODES ................................................................................................................................................2.3
2.7. WIRING DIAGRAM...............................................................................................................................................2.4
2.8. CABLES ..............................................................................................................................................................2.5
3. PRINCIPLES OF OPERATION............................................................................................................................3.1
3.1. BLOCK DIAGRAM ................................................................................................................................................3.1
3.1.1. Display board.........................................................................................................................................3.2
3.1.2. CSafe Board ...........................................................................................................................................3.2
3.1.3. TGS Board..............................................................................................................................................3.2
3.1.4. Cardio receiver ......................................................................................................................................3.3
3.1.5. Brake board............................................................................................................................................3.3
3.1.6. Brake 3.4
3.1.7. Speed sensor...........................................................................................................................................3.4
3.1.8. Power entry module ...............................................................................................................................3.5
3.2. BRAKE CONTROL................................................................................................................................................3.6
3.2.1. The Mechanics........................................................................................................................................3.6
3.2.2. Control 3.6
3.2.3. The signals involved...............................................................................................................................3.8
4. ACCESSORIES........................................................................................................................................................4.1
4.1. CARDIO THEATER CONNECTION..........................................................................................................................4.1
4.2. PC LINK FOR PROGRAMMING ..............................................................................................................................4.1
4.3. PROGRAMMING PLUG FOR CSAFE BOARD ...........................................................................................................4.2
5. INSTALLATION INSTRUCTIONS......................................................................................................................5.1
5.1. SPECIFICATIONS AND REQUIREMENTS.................................................................................................................5.1
5.2. INSTALLATION ....................................................................................................................................................5.2
5.3. FIRST POWER-ON ................................................................................................................................................5.3
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...................................................................................................................................................................... 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..................................................................................................................................................... 6.3
6.2. THE DISPLAY FAILS TO ILLUMINATE ....................................................................................................................6.4
6.3. “THE EQUIPMENT IS BLOCKED” MESSAGE ON THE DISPLAY ......................................................................6.7
6.4. ERROR DETECTED BY BRAKE BOARD..................................................................................................................6.8
6.5. THERE IS NO RESISTANCE.................................................................................................................................6.11
6.6. THE RESISTANCE IS INCORRECT........................................................................................................................6.12

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Page ii
6.7. THE SPEED SIGNAL IS INCORRECT .....................................................................................................................6.14
6.8. THE MACHINE DOES NOT READ THE TGS ...........................................................................................................6.16
6.9. THERE IS NO HEART RATE SIGNAL.....................................................................................................................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.....................................................................................7.3
7.3. DISASSEMBLING THE KEYBOARD........................................................................................................................7.4
7.4. DISASSEMBLING THE CARDIO RECEIVER .............................................................................................................7.5
7.5. DISASSEMBLING THE TIDY RACK.........................................................................................................................7.7
7.6. DISASSEMBLING THE GUARDS.............................................................................................................................7.8
7.7. DISASSEMBLING THE LEVERS............................................................................................................................7.12
7.8. DISASSEMBLING THE CRANK BELT....................................................................................................................7.15
7.9. DISASSEMBLING THE BRAKE BOARD.................................................................................................................7.17
7.10.DISASSEMBLING THE BELT................................................................................................................................7.18
7.11.DISASSEMBLING THE PEDALS............................................................................................................................7.19
7.12.DISASSEMBLING THE PRIMARY SHAFT ..............................................................................................................7.20
7.13.DISASSEMBLING THE SECONDARY SHAFT .........................................................................................................7.21
7.14.DISASSEMBLING THE BRAKE WINDING..............................................................................................................7.22
7.15.DISASSEMBLING THE SPEED SENSOR.................................................................................................................7.23
7.16.DISASSEMBLING THE FRONT PLATFORM............................................................................................................7.24
7.17.DISASSEMBLING THE REAR PLATFORM..............................................................................................................7.25
8. ADJUSTMENTS......................................................................................................................................................8.1
8.1. BELT TENSION ....................................................................................................................................................8.1
8.2. SPEED SENSOR POSITION.....................................................................................................................................8.2
8.3. BRAKE ASSEMBLY ..............................................................................................................................................8.3
8.4. CRANK BELT TENSION.........................................................................................................................................8.4
8.5. PHASE OF THE CRANK &OF THE CAM .................................................................................................................8.5
9. MACHINE CONFIGURATION ............................................................................................................................9.1
9.1. USER MENU CONFIGURATION..............................................................................................................................9.1
9.1.1. Language................................................................................................................................................9.1
9.1.2. Units of measurement.............................................................................................................................9.2
9.1.3. Maximum exercise time..........................................................................................................................9.2
9.1.4. Pause time..............................................................................................................................................9.2
9.1.5. Enable TGS ............................................................................................................................................9.3
9.1.6. Enable keyboard.....................................................................................................................................9.3
9.1.7. Modifiable target frequencies ................................................................................................................9.3
9.1.8. Enable custom messages........................................................................................................................9.4
9.1.9. Resetting parameters to default values...................................................................................................9.4
9.1.10.Format P&P key.....................................................................................................................................9.4
9.1.11.Reset Wellness Key.................................................................................................................................9.4
9.1.12.SN 9.4
9.2. SERVICE MENU CONFIGURATION.........................................................................................................................9.5
9.2.1. Low kit parameter ..................................................................................................................................9.5
9.2.1.1. Read from low kit ........................................................................................................................................................ 9.6
9.2.1.2. Write to low kit............................................................................................................................................................9.6
9.2.1.3. Default setting.............................................................................................................................................................. 9.6
9.2.1.4. Table of configuration parameters ...............................................................................................................................9.7
9.2.2. Operating data.......................................................................................................................................9.7
9.2.2.1. Read from low kit ........................................................................................................................................................ 9.8
9.2.2.2. Write to low kit............................................................................................................................................................9.8
9.2.2.3. Machine usage data......................................................................................................................................................9.8
9.2.3. Errors log...............................................................................................................................................9.8
9.2.3.1. Read from low kit ........................................................................................................................................................ 9.9
9.2.3.2. Reset Errors..................................................................................................................................................................9.9
9.2.3.3. COM.Fault...................................................................................................................................................................9.9
9.2.3.4. View Errors................................................................................................................................................................9.10
9.2.4. Standard settings..................................................................................................................................9.10

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Page iii
9.2.5. Low kit menu ........................................................................................................................................9.10
9.2.5.1. Low kit version ..........................................................................................................................................................9.11
9.2.5.2. Low Kit fault code .....................................................................................................................................................9.11
9.2.6. High kit version....................................................................................................................................9.11
9.2.7. BOOT version.......................................................................................................................................9.11
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.Checking the operation of the cardiotester 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.APPENDIX.............................................................................................................................................................11.1
11.1.UPDATING THE SW...........................................................................................................................................11.1
11.2.REQUIRED TOOLS..............................................................................................................................................11.2

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CROSS FORMA: Service & Maintenance Manual - rev. 2.1
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.

CROSS FORMA: Service & Maintenance Manual - rev. 2.1
Page 1.2
1.3. GENERAL RULES FOR REPAIR PROCEDURES
1. Always mark any parts or positions which may be confused with each other at the time of
reassembly.
2. Use original Technogym spare parts and lubricants of the recommended brands.
3. Use special tools where specified.
4. Consult the Technical Newsletters, which may contain more up-to-date information on
adjustments and maintenance than those contained in this manual.
5. Before starting the repair procedure, make sure that the recommended tools are available and in
good condition.
6. For the procedures described in this manual, use only the specified tools.
OBSERVE: The tool sizes quoted in this manual are expressed in mm.

CROSS FORMA: Service & Maintenance Manual - rev. 2.1
Page 2.1
2. TECHNICAL CHARACTERISTICS
2.1. CHARACTERISTICS
CHARACTERISTIC
Power
30-400 Watt
CSafe
YES
Cardio receiver
HFU
Training programs
Quick start
Goal
CPR
6 profiles
Test functions
Fitness test
2.2. MECHANICAL CHARACTERISTICS
Width
67 cm - 27 in
Length
192.5 cm - 76 in
Height
156.1 cm - 62 in
Weight
105 Kg - 232 lbs
2.3. ELECTRICAL CHARACTERISTICS
Europe
USA
Mains voltage
100 - 240 VAC
100 - 120 VAC
Frequency
50 - 60 Hz
60 Hz
Consumption
60 VA (max 0,6A)
Fuses
2 x 3.15 A (F)

CROSS FORMA: Service & Maintenance Manual - rev. 2.1
Page 2.2
2.4. AMBIENT SPECIFICATIONS
Temperature
Operating
from 5° to 35° C
Storage
from -10° to 70° C
Humidity
Operating
from 30% to 80% non-condensing
Storage
from 5% to 85% non-condensing
2.5. CONFORMITY TO REGULATIONS
The machine conforms to the following standards:
Europe
USA
EMI
EN 55014-1
EN 55014-2
EN 61000-3-2
EN 61000-3-3
UL 1647
Safety
EN 60335-1
EN 957-1
EN 957-9
Directives
73/23/CE
89/336/CE
98/37/CE
In addition:
•Electrical isolation class: Class I;
•Protection rating: IP20.

CROSS FORMA: Service & Maintenance Manual - rev. 2.1
Page 2.3
2.6. 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
1,2,3,4
Machine type: Cross Forma
D755
5
Type of power supply
3= multi-voltage (110-220)
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
00 = not available
12
Guard color
G= gray
13
Type of TV model
0= none
14,15 Language
DE = German
ES = Spanish
FR = French
IT = Italian
NL = Dutch
UK = British English
US = American English
16 Type of packaging
I = Italy
E = standard international
For example, a possible product code would be:
D7553LTAL00G0UKE
which is interpreted as follows:
D755
3
L
T
AL
M0
G
0
UK
E
standard international packing
British English language
no TV model
gray guards
No paddings
aluminum frame color
interfaced to TGS key reader
LED display
mains powered supply with multi-voltage inlet
Cross Forma

CROSS FORMA: Service & Maintenance Manual - rev. 2.1
Page 2.4
2.7. WIRING DIAGRAM
DISPLAY
DISPLAY BOARD
KEYBOARD
CSAFE
BOARD
HFU
RECEIVER
CN1
CN1
TGS
BOARD
CN7 CN2
CN8
CN9
BRAKE
BRAKE
BOARD
CN4
CN1 CN3
CN2
SPEED
SENSOR
CN1
CN3
Patch
conn. 1 Patch
conn. 3
POWER
ENTRY
MODULE
VAC
Patch
conn. 2
CF-03
CF-01
CF-04
CF-02
CF-00 CB-51
CF-05
CBQ-13
REC-00
CBQ-32

CROSS FORMA: Service & Maintenance Manual - rev. 2.1
Page 2.5
2.8. CABLES
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 -
White
5
3 RPM Yellow
Faston connected
to brown cable
4
RPM reference
Black
eyelet
CF-00: High voltage cable
Power entry module – Brake board
Power entry
module
Signal
Color
Brake board
CN4
N
Neutral
White
1
F
Line
Black
3
T
Earth
Green
5
CF-01: Cable connecting upper and lower assemblies
Brake board – Patch conn. 1
Brake board
CN1
Signal
Color
Patch conn. 1
2
Digital Gnd
White
2
3
Power Gnd
Yellow
3
4
- sensing +5 Vdc digital
Pink
4
6
+12 Vdc
Brown
6
7
+5 Vdc
Green
7
8
+sensing +5 Vdc digital
Grey
8
CF-02: Cable connecting upper and lower assemblies
Patch conn. 1 – Display board
Patch conn. 1
Signal
Color
Display Board
CN7
2
Digital Gnd
White
2
3
Power Gnd
Yellow
3
4
- sensing +5 Vdc digital
Pink
4
6
+12 Vdc
Brown
6
7
+5 Vdc
Green
7
8
+sensing +5 Vdc digital
Grey
8

CROSS FORMA: Service & Maintenance Manual - rev. 2.1
Page 2.6
CF-03: Serial communication cable between upper and lower assemblies
Brake board – Patch conn. 3
Brake board
CN3
Signal
Color
Patch conn. 3
1
NC
Brown
1
2
NC
Brown-White
2
3
Digital Gnd
Blue
3
4
Download
Blue-White
4
5
Reset
Green
5
6
Digital Gnd
Green-White
6
7
485 Tx/Rx +
Orange
7
8
485 Tx/Rx -
Orange-White
8
CF-04: Serial communication cable between upper and lower assemblies
Patch conn. 3 – Display board
Patch conn. 3
Signal
Color
Display Board
CN2
1
NC
Brown
1
2
NC
Brown-White
2
3
Digital Gnd
Blue
3
4
Download
Blue-White
4
5
Reset
Green
5
6
Digital Gnd
Green-White
6
7
485 Tx/Rx +
Orange
7
8
485 Tx/Rx -
Orange-White
8
CBQ-13: CSafe board cable
Display Board – CSafe Board
Display Board
CN1
Signal
Color
CSafe Board
CN1
1
Digital #1
Flat cable
1
…
…
…
…
14
Digital #14
Flat cable
14
CBQ-32: TGS cable
Display Board – TGS Board
Display Board
CN3
Signal
Color
TGS Board
CN1
1
+12 Vdc power supply
Yellow
1
3
Rx
White
8
5
Tx
Green
7
9
Gnd
Brown
3

CROSS FORMA: Service & Maintenance Manual - rev. 2.1
Page 2.7
REC-00: HFU receiver cable
Display board – HFU receiver
Display board
CN8
Signal
Color
HFU receiver
1
+5 Vdc power supply
Red
2
7
Pulse (beat to beat)
Blue
4
8
Gnd
Black
1

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CROSS FORMA: Service & Maintenance Manual - rev. 2.1
Page 3.1
3. PRINCIPLES OF OPERATION
3.1. BLOCK DIAGRAM
The machine block diagram is illustrated in the figure below:
POWER
ENTRY
MODULE
DISPLAY
DISPLAY BOARD
CSAFE
BOARD
BRAKE BOARD
HFU
CARDIO
VAC
KEYBOARD
SPEED
SENSOR
BRAKE

CROSS FORMA: Service & Maintenance Manual - rev. 2.1
Page 3.2
3.1.1. DISPLAY BOARD
The display contains:
•DISPLAY BOARD
The Display includes a single board which contains the CPU, an ARM microprocessor, the logic for
its operation and the EPROM FLASH containing the equipment's work program, and also acts as a
connection centre for all the display components and a connection point with the Brake Board.
The main functions of the board are:
manage and process the signals from:
(1) Keyboard;
(2) HR Receiver:
(3) C-Safe Board;
Optional:
(4) Dual TGS Reader.
distribute on the display the supplies it receives from the Brake Board;
exchange with the Brake Board the piloting commands for the brake on the RS-485 serial line;
manage the LEDs and the 7 display segments to provide feedback on operating.
There are some signal LEDs on the board:
LED Name
Colour
Description
LED1 GREEN
if ON, the +12Vdc power supply, provided by the Brake Board, is
reaching the board correctly.
LED2 YELLOW
if ON, the +5Vdc power supply, provided by the Brake Board, is
reaching the board correctly.
Nome Jumper
Stato
Descrizione
JP3
open Closed. HW setting, do not change.
3.1.2. CSAFE BOARD
This board makes available a communication port, on 2 externally accessible connectors, which can
be used for connecting compatible CSafe devices such as the CardioTheater readers. The connector
is situated on the back of the display.
These connectors can also be interfaced, by means of a special cable, to an external PC for
programming the FLASH EEPROM.
3.1.3. TGS BOARD
This board enables the machine to read the TGS key inserted by the user for doing workouts
programmed with the Wellness System.