Technogym CROSS PERSONAL User manual

CROSS
PERSONAL
REV.1.1

The information contained in this manual is intended for QUALIFIED TECHNICIANS who have
completed a specific TECHNOGYM training course and are authorized to perform machine start-
up and adjustment procedures as well as extraordinary maintenance or repairs which require a
thorough knowledge of the machine, its operation, its safety devices and working procedures.
CAREFULLY READ THE INFORMATION CONTAINED IN
THIS MANUAL BEFORE PERFORMING ANY MAINTENANCE
PROCEDURES ON THE MACHINE
DANGEROUS VOLTAGES
PRESENT
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 Personal™ trademark is property of Technogym S.p.A.

CROSS PERSONAL: Service & maintenance manual - rev. 1.1
Page i
Contents
1. GENERAL NOTICES.............................................................................................................................................1.1
1.1. INTRODUCTION...................................................................................................................................................1.1
1.2. RECOMMENDATIONS ..........................................................................................................................................1.1
1.3. GENERAL RULES FOR REPAIR PROCEDURES ........................................................................................................1.2
2. TECHNICAL CHARACTERISTICS....................................................................................................................2.1
2.1. PRODUCT CODES.................................................................................................................................................2.1
2.2. SERIAL NUMBER STRUCTURE .............................................................................................................................2.2
2.3. TECHNICAL SPECIFICATION ................................................................................................................................2.3
2.4. MECHANICAL CHARACTERISTICS .......................................................................................................................2.3
2.5. DIMENSIONS ..................................................................................................................................................2.4
2.6. PACKING DIMENSIONS EUROPE AND OVERSEAS .............................................................................................2.4
2.7. AMBIENT SPECIFICATIONS..................................................................................................................................2.5
2.8. CONFORMITY TO REGULATIONS..........................................................................................................................2.5
2.9. WIRING DIAGRAMS.............................................................................................................................................2.6
2.10.CABLES ..............................................................................................................................................................2.7
2.10.1. CBQ Cables............................................................................................................................................2.7
2.10.2. WB Cables..............................................................................................................................................2.7
2.10.3. CU Cables..............................................................................................................................................2.7
3. PRINCIPLES OF OPERATION............................................................................................................................3.1
3.1. BLOCK DIAGRAM................................................................................................................................................3.1
3.2. ELECTRONIC COMPONENTS.................................................................................................................................3.2
3.2.1. CPU board.............................................................................................................................................3.2
3.2.1.1. BackUp battery............................................................................................................................................................................ 3.2
3.2.2. LCD inverter ..........................................................................................................................................3.3
3.2.3. Digital/Analog tuner board....................................................................................................................3.3
3.2.4. LAN network board (integrated)............................................................................................................3.3
3.2.5. Wireless network board (without cables)...............................................................................................3.4
3.2.6. Audio/Video external device connector board.......................................................................................3.5
3.2.7. Jack cuffie...............................................................................................................................................3.5
3.2.8. Scheda C-Safe (integrata)......................................................................................................................3.5
3.2.9. Porta USB di servizio (integrata)...........................................................................................................3.5
3.2.10. Capacitive Touch Screen control board.................................................................................................3.5
3.2.11. Power Supply board...............................................................................................................................3.5
3.2.12. Secondary ON/OFF switch ....................................................................................................................3.6
3.2.13. Audio Amplifier board............................................................................................................................3.6
3.2.14. Hand Sensor board ................................................................................................................................3.6
3.2.15. Cardio receiver HR................................................................................................................................3.7
3.2.16. iPod docking station...............................................................................................................................3.7
3.2.17. Client USB port......................................................................................................................................3.8
3.2.18. Dual TGS reader....................................................................................................................................3.8
3.2.19. Brake Board ...........................................................................................................................................3.8
3.2.20. Electromagnetic brake ...........................................................................................................................3.9
3.2.21. Speed sensor...........................................................................................................................................3.9
3.2.22. Power entry module ...............................................................................................................................3.9
3.3. BRAKE CONTROL..............................................................................................................................................3.10
3.3.1. Mechanics ............................................................................................................................................3.10
3.3.2. Controls................................................................................................................................................3.10
3.3.3. The signals involved.............................................................................................................................3.12
3.4. AUDIO SIGNAL AND AUDIO OUT CONTROL........................................................................................................3.13
3.4.1. Control .................................................................................................................................................3.13
3.4.2. The signals involved.............................................................................................................................3.14

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Page ii
4. ACCESSORIES.......................................................................................................................................................4.1
4.1. CARDIO THEATER CONNECTION..........................................................................................................................4.1
4.2. MONITOR PLUG FOR C-SAFE PORT......................................................................................................................4.2
5. INSTALLATION INSTRUCTIONS......................................................................................................................5.1
5.1. SPECIFICATIONS AND REQUIREMENTS ................................................................................................................5.1
5.2. MOVING THE EQUIPMENT ...................................................................................................................................5.2
5.3. RECOMMENDED ANTENNA SIGNAL REQUIREMENTS............................................................................................5.3
5.4. INSTALLATION....................................................................................................................................................5.3
5.5. FIRST POWER-ON ................................................................................................................................................5.3
6. TROUBLESHOOTING ..........................................................................................................................................6.1
6.1. TROUBLESHOOTING MENU..................................................................................................................................6.2
6.2. THE DISPLAY STAYS OFF.....................................................................................................................................6.3
6.3. NO AUDIO SOUND ...............................................................................................................................................6.8
6.4. NO TV PICTURE................................................................................................................................................6.12
6.5. THE TOUCH SCREEN DOES NOT WORK /IT’S NOT CALIBRATED ..........................................................................6.12
6.6. THE RADIO DOES NOT PLAY ..............................................................................................................................6.12
6.7. THE IPOD DOES NOT WORK...............................................................................................................................6.13
6.8. “THE EQUIPMENT IS LOCKED (COM)” MESSAGE ON DISPLAY.................................................................6.15
6.9. THE BRAKE BOARD HAS DETECTED AN ERROR.................................................................................................6.16
6.10.THERE IS NO RESISTANCE.................................................................................................................................6.19
6.11.THE RESISTANCE IS NOT CORRECT ....................................................................................................................6.22
6.12.THE SPEED SIGNAL IS NOT CORRECT .................................................................................................................6.24
6.13.THE MACHINE DOES NOT READ THE TGS KEY ..................................................................................................6.26
6.14.THERE IS NO HEART RATE SIGNAL.....................................................................................................................6.28
6.14.1. Hand sensor .........................................................................................................................................6.28
6.14.2. Chest belt..............................................................................................................................................6.32
6.15.THE TELEMETRIC HEART RATE SIGNAL IS INCORRECT.......................................................................................6.35
6.15.1. Chest belt..............................................................................................................................................6.35
6.15.2. Hand Sensor.........................................................................................................................................6.39
7. PART DISASSEMBLY...........................................................................................................................................7.1
7.1. DISASSEMBLY OF THE REAR DISPLAY COVER......................................................................................................7.1
7.2. DISMANTLING THE WHOLE DISPLAY...................................................................................................................7.2
7.3. DISMANTLING THE TOUCH SCREEN....................................................................................................................7.3
7.4. DISMANTLING THE DISPLAY BOARDS.................................................................................................................7.4
7.5. DISMANTLING THE SECONDARY ON SWITCH CARD ............................................................................................7.5
7.6. DISMANTLING THE FRONT GUARDS ....................................................................................................................7.6
7.7. DISMANTLING THE AMPLIFIER/SPEAKERS ..........................................................................................................7.7
7.8. DISMANTLING THE TOTAL LEVERS.....................................................................................................................7.8
7.9. DISMANTLING THE TWEETER FROM THE TOTAL LEVER ......................................................................................7.9
7.10.DISMANTLING THE PLATFORM LEVER..............................................................................................................7.10
7.11.DISMANTLING THE MECHANICS/CRANK ASSEMBLY.........................................................................................7.11
7.12.DISMANTLING THE CRANK ASSEMBLY BELT.....................................................................................................7.12
7.13.DISASSEMBLY OF THE REAR GUARDS................................................................................................................7.13
7.14.DISMANTLING THE BRAKE BELT ......................................................................................................................7.14
7.15.DISMANTLING THE BRAKE BELT PULLEY.........................................................................................................7.15
7.16.DISMANTLING THE LOW KIT,POWER CARD,BRAKE AND FLYWHEEL..............................................................7.16
8. ADJUSTMENTS......................................................................................................................................................8.1
8.1.MECHANICS/CRANK ASSEMBLY SHAPING ..........................................................................................................8.1
8.2. BRAKE BELT TENSION.........................................................................................................................................8.4
8.3. LEVELLING.........................................................................................................................................................8.5
9. EQUIPMENT CONFIGURATION.......................................................................................................................9.1
9.1. CONFIG.: VISIO -VISIOWEB USER MENÙ ....................................................................................................9.1
9.2. SERVICE MENU CONFIG.: VISIO -VISIOWEB ..........................................................................................9.3

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9.2.1.1. Table of configuration parameters .............................................................................................................................................. 9.4
10.UPDATING THE SW............................................................................................................................................10.1
11.SCHEDULED MAINTENANCE.........................................................................................................................11.1
12.APPENDIX.............................................................................................................................................................12.1
12.1.MENU PASSWORD TABLE..................................................................................................................................12.1
12.2.REQUIRED TOOLS .............................................................................................................................................12.2

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CROSS PERSONAL: Service & maintenance manual - rev. 1.1
Page 1.1
1. GENERAL NOTICES
1.1. INTRODUCTION
This document is reserved for Technogym Service technicians, and is intended to provide
authorized personnel with the necessary information to correctly carry out repairs and maintenance.
A thorough knowledge of the technical information contained in this manual is essential for
completing the professional training of the operator.
In order to facilitate consultation, the paragraphs are accompanied by schematic drawings which
illustrate the procedure being described.
This manual contains notices and symbols which have a specific meanings:
WARNING: non observance may result in accident or injury.
ATTENTION: non observance may cause damage to the machine.
Information about the operation in progress.
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 disassembling sequence described in this manual.

CROSS PERSONAL: Service & maintenance manual - rev. 1.1
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 adjusts
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.

CROSS PERSONAL: Service & maintenance manual - rev. 1.1
Page 2.1
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
D94 = Run Personal
4,
Model
7 = 700
5,
Power supply type
3= Powered
6,
Display type
Y= VISIOWEB
7,
Accessories
F= Full
8, 9,
Colour of the frame
00 = None
10, 11,
Colour of the upholstery
00 = None
12,
Colour of the guards
R= Renault Grey
13, TV standard receiver
C= DVB-T
A= ATSC
I= ISDB-T
14, 15,
Language
00 = Multilanguage
16. Type of packaging.
A, B, C, D, E, F, G, H, I, J, K, S, U
See the following table.
For example, a possible product code would be:
D9573YF0000RD00E
all of the machines will be shipped with the specific power cable for the destination
country. In particular this means a cable with the standard plug used in the
installation country.

CROSS PERSONAL: Service & maintenance manual - rev. 1.1
Page 2.2
This implementation also means a change in the product code. Specifically the last character of the
product code will be characterised based on the options shown in the table below:
16th Character
Product code
Main country
of use
Plug standard
Type of
packaging
A
Australia
A S/NZS 3112
Overseas
B
Brazil
NBR 14136
Overseas
C
China
CPC S-CCC
Overseas
D
South Africa
SANS 164-2
Overseas
E
Europe (EC)
EEC 7/16
European
F USA (UL 250 V)
NEMA 5-15/
NEMA 5-20
Overseas
G
Great Britain
BS1363
European
H
Argentina
IRAM 2073
Overseas
I
Italy
EEC 7/16
Italy
J
Japan
JIS 8303
Overseas
K
Great Britain
BS1363
Overseas
S
Europe (EC)
EEC 7/16
Overseas
U
USA (UL 110 V)
NEMA 6-15/ NEMA 6-20
Overseas
As shown in the table above, the 16th character also identifies the type of packaging depending on
the destination country, i.e. D9573YF0000RD00E.
2.2. SERIAL NUMBER STRUCTURE
The Serial Number, consists of 14 alphanumeric characters arranged as follows:
Characters
Description
key to values
1,2,3,4,5,6, Product type,
D957 = Cross Personal
3=Powered
Y= VISIO WEB
7,8,
Year of production,
13 = 2013
9,10,11,12,13,14.
Progressive.
000001
For example, a possible product code would be:
D9573Y13000001

CROSS PERSONAL: Service & maintenance manual - rev. 1.1
Page 2.3
2.3. TECHNICAL SPECIFICATION
SPECIFICATIONS & PERFORMANCE
Power Supply
100-240 VAC – 50-60 Hz
Energy Consumption
160VA
Stand-By Consumption
47,9 Watt (97 VA)
Resistance
56-436 Watt ±10% (at 70 RPM)
Difficulty Level
1-25
Max user weight
160 Kg – 353 Lbs
Fast Track Control
SI
HR monitoring:
Hand sensor, Telemetria
Goal oriented display
YES
Wellness System:
YES
Total Number of
Programs
23
Quick-Start, Goal (Time, Distance, Calories), CPR, Profiles (6
predefined + 12 customizable), Custom, Training Zone, Weight Loss)
Sub-maximal Test:
Fitness test
Available Language
13
Italian, UK English, USA English, German, Spanish, French, Dutch,
Portuguese, Japanese, Chinese, Russian, Turkish, Danish
2.4. MECHANICAL CHARACTERISTICS
MECHANICAL CHARACTERISTICS
Length (mm – in)
1938 mm – 76”
Width (mm – in)
685 mm – 28”
Height (mm – in)
1756 mm – 69”
Weight (Kg – lbs)
145 Kg – 320 lbs

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2.5. DIMENSIONS
2.6. PACKING DIMENSIONS EUROPE AND OVERSEAS

CROSS PERSONAL: Service & maintenance manual - rev. 1.1
Page 2.5
2.7. AMBIENT SPECIFICATIONS
Temperature
Operating
from 10° to 25° C
Storage
from -10 to 70° C
Humidity
Operating
from 20% to 90% non-condensing
Storage
from 20% to 90% non-condensing
2.8. CONFORMITY TO REGULATIONS
EUROPE
USA
EMI regulations
EN61000-6-1 (2007)
EN61000-6-3 (2007)
EN61000-3-2 (2007)
EN61000-3-3 (2009)
-
Electrical safety
regulations
EN 60335-1 (2008) UL 1647
FCC 15
Mechanical safety
regulations
EN957-1 (2006)
EN957-6 (2003) -
Directives
2006/42/CE
2004/108/CE
2006/95/CE
-
Moreover:
Electrical isolation class: Class I;
Protection rating: IP20.

CROSS PERSONAL: Service & maintenance manual - rev. 1.1
Page 2.6
2.9. WIRING DIAGRAMS

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Page 2.7
2.10. CABLES
The colour of the cables can be changed, refer in particular to the Pin Out.
2.10.1. CBQ CABLES
CBQ32: TGS cable
(Patch conn.– CPU Board)
CPU Board
CN19
Signal Colour Patch conn.
1
+12 Vdc power supply
Red
8
3
Rx
Brown
1
5
Tx
Blue
2
9
Gnd
Black
6
2.10.2. WB CABLES
WB657: Flat Tuner Board cable
(CPU Board –TUNER Board)
CPU Board
J9
Signal
TUNER Board
J13
1
Capacitive Signal
flat
…50
Capacitive Signal
flat
2.10.3. CU CABLES
CU132: TGS signal cable
(Patch conn. –TGS Dual reader)
Patch conn. Signal Colour
TGS Dual reader
CN1
8
+12Vdc power supply
Black
2
1
RX
Green
1
2
TX
Black
4
6
GND
Black
5

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CU331: iPod signal cable
(CPU Board– Docking Station)
Scheda CPU
CN26
Signal Colore Docking Station
1
+V bus USB
Black
14
2
GND bus USB
Black
13
3
TX - RX
Black
11
4
RX – TX
Black
12
5
CTS
Black
10
6
+5Vdc
Black
9
7
GND
Black
8
8
GND
Black
7
9
Video Gnd
Black
6
10
Video signal
Black
5
11
Audio L Gnd
Black
4
12
Audio L signal
Black
3
13
Audio R signal
Black
2
14
Audio R Gnd
Black
1
CU308: User USB port cable
(CPU Board –USB Port)
CPU Board
CN14
Signal Colour USB Port
1
+5 Vdc
Red
1
2
USB-
White
2
3
USB+
Black
3
4
GND
Green
4
5
Shield
Blue
5
CU611: HS board cable
(CPU Board –HS board)
CPU Board
CN24
Signal Colour
HS board:
HD4
1
+5 Vdc power supply
White
2
5
HS cardio signal
Brown
3
6
Gnd
Green
1

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CU613: IN/OUT Audio signal
(Amplifier - CPU Board – Headphone Jack)
Amplifier
J3 Signal Colour
Headphone
Jack
(Display)
Headphone
Jack
(Frame)
CPU
J5
1
Audio IN R
Yellow
2
2
Audio IN L/Power OFF
White
5
3
Gnd
Grey
1
4
Audio OUT L
Brown
4
5
Audio OUT R
Green
3
6
Power OFF
Brown
4
7
Audio OUT R
White
1
8
Audio OUT L/Power OFF
Brown
4
9
Gnd
Green
3
10
Audio IN L/Power OFF
White
5
11
Audio IN R
Green
2
12
Gnd
Yellow
1
CU614: AUX Audio/Video & Antenna signal cable
(CPU Board –AUX connector /Tuner Board – Antenna connector)
CPU Board
CN27 Signal Colour
AUX connector
board
1
n.c.
-
1
2
Audio IN LEFT
Black
2
3
Gnd IN LEFT
Black
3
4
Audio IN RIGHT
Black
4
5
Gnd IN RIGHT
Black
5
6
IN Video
Black
6
7
Gnd IN Video
Black
7
8
n.c.
-
8
Tuner
Segnale
Colore
Conn. Antenna
J12
Antenna
White
-
CU615: Amplifier power supply cable
(CPU board – Amplifier)
CPU board
CN15
Signal Colour
Amplifier:
J5
3
Gnd
White
2
6
+12 Vdc Power supply
Brown
1

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CU616: Audio/HS signal Upper levers cable
(CPU board– Amplifier – frame speakers – Patch Conn.)
CPU
HS
Receiver
Frame
speakers
Ampl. Signal Colour Patch.
Conn.2 Patch. Conn.3
CN31
CN29
CN1
DX
SX
J2
1
+5 Vdc Fast Track +
White
7
2
Fast Track + Signal
Green
3
4
Gnd Fast Track +
Brown
6
1
+5 Vdc Fast Track -
White
7
2
Fast Track - Signal
Green
3
4
Gnd Fast Track -
Brown
6
1
Left UP HS
White
1
2
Left DOWN HS
Brown
5
3
Left HS shield
-
-
4
Right UP HS
White
1
5
Right DOWN HS
Brown
5
6
Right HS shield
-
-
1
3
Gnd Right
Black
4
2
4
OUT R amplified
Red
8
1
2
Gnd Left
Black
4
2
1
OUT L amplified
Red
8
CU617: Total Lever cable
(Patch connector 2/3– HS board, Fast Track and Lever Tweeter)
Patch Connector
(2) and (3) Signal Colour
RIGHT LEVER
LEFT LEVER
HS
Fast
Track
Tweeter
1
High HS signal
White
Fast-on
2
Shield
Shield
-
3
Fast Track signal
Green
2
4
Gnd. Audio
Black
1
5
Low HS signal
Brown
Fast-on
6
Gnd. Fast Track
Brown
4
7
+ 5Vdc Fast Track
White
1
8
Audio signal
Red
2