Technogym Step XT User manual

SERVICE & MAINTENANCE MANUAL
PRELIMINARY

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.r.l.
The Step XT™ trademark is property of Technogym S.r.l.

STEP XT: Service & Maintenance Manual - rev. 2.0
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. MECHANICAL CHARACTERISTICS...................................................................................................................2.1
2.2. ELECTRICAL CHARACTERISTICS.....................................................................................................................2.1
2.3. AMBIENT SPECIFICATIONS.............................................................................................................................2.1
2.4. CONFORMITY TO REGULATIONS.....................................................................................................................2.1
2.5. WIRING DIAGRAM.........................................................................................................................................2.2
2.5.1.Connectors.........................................................................................................................................2.2
2.5.2.Wiring................................................................................................................................................2.3
3. PRINCIPLES OF OPERATION ......................................................................................................................3.1
3.1. BLOCK DIAGRAM..........................................................................................................................................3.1
4. ACCESSORIES.................................................................................................................................................4.1
4.1. CONNECTING TO THE TGS .............................................................................................................................4.1
5. INSTALLATION INSTRUCTIONS.................................................................................................................5.1
5.1. SPECIFICATIONS AND REQUIREMENTS ............................................................................................................5.1
5.2. INSTALLATION .............................................................................................................................................5.1
5.3. FIRST POWER-ON..........................................................................................................................................5.2
6. TROUBLESHOOTING....................................................................................................................................6.1
6.1. THE DISPLAY DOES NOT ILLUMINATE.............................................................................................................6.2
6.2. THE RESISTANCE IS INCORRECT .....................................................................................................................6.5
6.3. THE SPM VALUE IS INCORRECT.....................................................................................................................6.8
6.4. THERE IS NO HEART RATE SIGNAL................................................................................................................6.10
6.5. THE HEART RATE SIGNAL IS INCORRECT.......................................................................................................6.11
7. DISASSEMBLY OF COMPONENTS..............................................................................................................7.1
7.1. DISASSEMBLING THE DISPLAY .......................................................................................................................7.1
7.2. DISASSEMBLING THE EPROM .........................................................................................................................7.2
7.3. DISASSEMBLING THE CPU BOARD...................................................................................................................7.3
7.4. DISASSEMBLING THE KEYBOARD ...................................................................................................................7.4
7.5. DISASSEMBLING THE CARDIO RECEIVER.........................................................................................................7.5
7.6. DISASSEMBLING THE UPRIGHT GUARD ...........................................................................................................7.7
7.7. DISASSEMBLING THE ELECTRONIC CIRCUIT BOARDS .......................................................................................7.8
7.8. DISASSEMBLING THE FRAME GUARD ..............................................................................................................7.9
7.9. DISASSEMBLING THE HANDLEBARS..............................................................................................................7.10
7.10.DISASSEMBLING THE BASE SUPPORTS...........................................................................................................7.11
7.11.DISASSEMBLING THE PEDAL SPRING - CHAIN..............................................................................................7.12
7.12.DISASSEMBLING THE PEDAL JOINT ...............................................................................................................7.13
7.13.DISASSEMBLING THE PEDALS AND THE PEDAL GROUP....................................................................................7.14
7.14.DISASSEMBLING THE PEDAL CONNECTING RODS...........................................................................................7.16
7.15.DISASSEMBLING THE LEVERS.......................................................................................................................7.17
7.16.DISASSEMBLING THE LEVER FRAME .............................................................................................................7.18
7.17.DISASSEMBLING THE PRIMARY SHAFT - SECONDARY SHAFT CHAIN ................................................................7.19
7.18.DISASSEMBLING THE PRIMARY SHAFT ..........................................................................................................7.20

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Page ii
7.19.DISASSEMBLING THE SECONDARY SHAFT .....................................................................................................7.21
7.20.DISASSEMBLING THE PULLEYS.....................................................................................................................7.23
7.21.DISASSEMBLING THE BELT ..........................................................................................................................7.24
7.22.DISASSEMBLING THE ALTERNATOR..............................................................................................................7.26
7.23.DISASSEMBLING THE ALTERNATOR BRUSHES................................................................................................7.27
8. ADJUSTMENTS...............................................................................................................................................8.1
8.1. BELT ALIGNMENT.........................................................................................................................................8.1
8.2. BELT TENSION..............................................................................................................................................8.2
8.3. ALIGNMENT OF PRIMARY SHAFT - SECONDARY SHAFT CHAIN ..........................................................................8.3
8.4. TENSION OF PRIMARY SHAFT - SECONDARY SHAFT CHAIN ...............................................................................8.4
8.5. WEAR OF ALTERNATOR BRUSHES...................................................................................................................8.5
9. CONFIGURING THE MACHINE...................................................................................................................9.1
9.1. CHANGING THE SETTINGS ON THE DISPLAY PANEL..........................................................................................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 ...............................................................................................................9.2
9.2. MAINTENANCE INFORMATION.......................................................................................................................9.3
9.2.1.Hours on............................................................................................................................................9.3
9.2.2.Hours of use.......................................................................................................................................9.3
9.3. CHANGING THE MAINTENANCE INFORMATION................................................................................................9.3
9.3.1.Hours on............................................................................................................................................9.3
9.3.2.Hours of use.......................................................................................................................................9.3
10.SCHEDULED MAINTENANCE....................................................................................................................10.1
11.APPENDIX......................................................................................................................................................11.1
11.1.TECHNICAL NOTES ON CARDIO RECEIVERS ...................................................................................................11.1
11.1.1...........................................................................................................................................type of ASIC
11.1
11.1.2......................................................................................................... Presence of electromagnetic fields
11.2
11.1.3..................................................................................................................Reducing receiver sensitivity
11.2
11.1.4............................................................................................................................Mechanical vibrations
11.3
11.1.5.......................................................................................................................... Position of the receiver
11.3
11.1.6....................................................................................................................................Routing of cables
11.5

STEP XT: Service & Maintenance Manual - rev. 2.0
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.

STEP XT: 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 circulars, 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.

STEP XT: Service & Maintenance Manual - rev. 2.0
Page 2.1
2. TECHNICAL CHARACTERISTICS
2.1. MECHANICAL CHARACTERISTICS
Width 64 cm
Length 130 cm
Height 139 cm
Weight 103 kg
2.2. ELECTRICAL CHARACTERISTICS
Mains voltage 115 - 230 VAC
Frequency 50 - 60 Hz
Consumption ~ 60 Watt – 0.3 A
Fuses 5x20 3.15 A fast-blow
The mains voltage is set by means of a special jumper on the power supply circuit board.
An incorrect voltage setting can cause irreversible damage to the power supply unit.
Before changing the mains voltage setting, the machine must be turned off and the
mains lead unplugged from the wall output.
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:
•EMC Directive 89/336/EEC.
•LVD Directive 73/23/EEC and 93/68/EEC.
And is therefore certified with the EC Mark.
The US version of the machine conforms to the UL 2601 standard.

STEP XT: Service & Maintenance Manual - rev. 2.0
Page 2.2
2.5. WIRING DIAGRAM
2.5.1. CONNECTORS
•CPU board
name type of connector connection
CN1 AMP MATE-N-LOCK 12-pin F. to alternator interface board
CN4 AMP MODU II 4-pin M. to cardio receiver

STEP XT: Service & Maintenance Manual - rev. 2.0
Page 2.3
•Power supply
name type of connector connection
CN1 PANDUIT 6-pin to mains power supply
CN2 PANDUIT 8-pin to alternator interface board
•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
SX-1: Internal connecting cable
CPU Board – alternator interface board
CPU/CN1 Signal Color Alter. board/
CN1
1+12 V Red 1
2+ 5 V Orange 2
3ground Black 3
4-12 V Blue 13
5Alternator RPM X 6 Violet 5
6Alternator control frequency Brown 6
On some machines, the signal designated +12 V in the above table is actually 10.5 V.
BK-7: Heart rate meter cable
CPU Board - Cardio receiver
CPU/CN4 Signal Color Receiver
1+5 V Red 1
2Pulse per beat Blue 2
3ground Black 3
SX-6: Low voltage power supply cable
Power supply – Alternator interface board
Power supply/
CN2 Signal Color Alter. interface board / CN3
2+ 5 V Yellow 4
5+ 12 V Red 2
6-7-4 ground Black 3
8- 12 V Blue 1

STEP XT: Service & Maintenance Manual - rev. 2.0
Page 2.4
SX-5: Alternator cable
Alternator interface board - Alternator – Resistor
Alter, interface
board / CN2 Signal Color Alternator Resistor
1Alternator RPM X 6 Violet Red
eyelet 4 -
2Resistor - Blue Yellow
Blue eyelet 6 Yellow eyelet 4
3Resistor + Red Yellow
Red eyelet 6 Yellow
5ground Black -eyelet 4
4Excitation Orange Red Faston
SX-3: High voltage power supply
Power input socket – Power supply
Input socket Signal Color Power supply
CN1
Yellow Faston Ground Yellow 1
Red Faston Live Blue 4
Red Faston Neutral Black 6
The above description of cable SX-3 is simplified and does not detail the ground node connections.

STEP XT: Service & Maintenance Manual - rev. 2.0
Page 3.1
3. PRINCIPLES OF OPERATION
3.1. BLOCK DIAGRAM
The block diagram of the machine is shown in the figure below:
(1) 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.

STEP XT: Service & Maintenance Manual - rev. 2.0
Page 3.2
(2) CARDIO RECEIVER
It is connected to the machine’s CPU board and receives the pulses sent by the transmitter. Its
reception area is approximated by a circle with a 50 cm 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 there are 2 transmitters
within its area of reception, it will receive signals from both.
(3) 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 (user’s heart rate) and from the
alternator interface board for displaying workload data (Watt and SPM). It controls the
difficulty level selected with the “+” “−” keys or according to the chosen training program.
(4) POWER SUPPLY
Receives the mains voltage at its input and outputs the DC voltages (+5 V, +12 V and −12 V)
which supply the display and the alternator interface board.
(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 of rotation.
(6) ALTERNATOR
Is put into rotation by the user, and generates a resistance to the movement proportional to the
excitation voltage received from the alternator interface board. It also generates the RPM
signal (6 pulses per revolution) necessary for counting the number of revolutions and hence
measuring the speed. Its rotation produces energy which is dissipated by the power resistor.
(7) POWER RESISTOR
Has the function of dissipating the energy produced by the alternator.

STEP XT: Service & Maintenance Manual - rev. 2.0
Page 4.1
4. ACCESSORIES
4.1. CONNECTING TO THE TGS
The machine can be connected to the Technogym System by means of the 9-pin D-connector
situated on the back of the display, which provides the RS 232 serial port for connecting the TGS
reader.
The serial port is connected to the CPU by the cable described below, which is supplied in the
upgrade kit:
TGSRN2XT: Internal cable
CPU - 9 pin connector
CPU/CN2 Signal Color DB9 male
1+ 12 V yellow 1
2Tx brown 3
5Rx white 2
6ground green 5
To prevent interference with the cardio receiver, route the cable behind cable SX-1 and
connector CN1 of the CPU board, as described in paragraph 11.1. .
For all further information, including troubleshooting, refer to the following manual: “Technogym
System: Installation Guide”.

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STEP XT: Service & Maintenance Manual - rev. 2.0
Page 5.1
5. INSTALLATION INSTRUCTIONS
5.1. SPECIFICATIONS AND REQUIREMENTS
For correct machine installation, make sure that:
1. 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.
2. The environment is dust or sand free.
3. The environment meets the operating temperature and humidity conditions specified in paragraph
2.3. .
4. The machine is not positioned close to sources of heat, sources of electromagnetic noise
(television sets, electric motors, antennas, high voltage lines, appliances etc…) or medical
equipment.
5. To eliminate any interference with the cardio receiver, there should not be any transmitters at a
distance of 100 cm from the display.
6. The mains voltage must match the value specified on the machine rating plate.
7. The electrical system must be provided with an efficient ground connection.
8. The wall output used should be reserved for the machine and have a rating of at least 60 Watt.
9. The machine can be connected in cascade with other machines. It is recommended to connect
only machines of the same type in cascade, up to a maximum of 5 machines. In this case, make
sure that the wall output has a power rating of at least 300 Watt.
10. Position the mains lead of the machine where is will not be underfoot. For this purpose, it is
recommended to use the special trackways supplied with the machine.
5.2. INSTALLATION
To correctly install the machine, proceed as follows:
1. Ensure that the specifications and requirements for installation have been met (see paragraph 5.1.
).
2. Remove the machine from its packing materials: one carton fixed to a wooden pallet for overseas
shipment, one nylon bag for Italy. On machines which are shipped in a carton, the center
handlebar is disassembled and placed on the machine inside the packing material.
3. Position the machine as specified above, on a level surface that is free of vibrations and has
sufficient carrying capacity for the combined weight of the machine and the user.
4. For machines shipped in a carton, it is necessary to reassemble the components that were
removed for transport. Carry out the procedure for reassembling the center handlebar described
in the "Operator and Service manual" supplied with each machine.
5. Connect the mains lead to the input socket on the machine.
6. Place the on/off switch in the “0” position.
7. Plug the mains lead into the electrical output.

STEP XT: Service & Maintenance Manual - rev. 2.0
Page 5.2
5.3. FIRST POWER-ON
After completing the installation procedure, the machine is ready to be powered up. To turn on the
machine, simply toggle the on/off switch from the 0 position to the 1 position.
When the machine is turned on it will perform a power-on test which:
•sounds the buzzer;
•lights all the LEDs.
At the end of the power-on test the machine enters standby mode, awaiting a keyboard command.
To check the correct operation of the machine:
•start exercising;
•check that the SPM value displayed varies accordingly;
•check that the effort level varies when the “+” and “−” keys are pressed, and that the
corresponding difficulty level LEDs come on and off;
•put on the heart rate transmitter and check that the machine correctly measures the heart rate
value.

STEP XT: Service & Maintenance Manual - rev. 2.0
Page 6.1
6. TROUBLESHOOTING
The troubleshooting procedures are shown in the form of flow charts. In order to facilitate
consultation, the following standard box shapes are used.
This type of box is the START point of the troubleshooting procedure. It
typically contains a description of the problem or malfunction.
This type of box represents a decision point in the troubleshooting procedure.
It typically contains a description of the CHECK to be made, with an outcome
that can be either a positive (YES) or negative (NO) response.
This type of box is a step in the troubleshooting procedure where an ACTION
must be carried out. It typically contains a description of the ACTION
necessary to resolve the problem. Therefore, after executing the specified
ACTION:
1. Check whether the problem has been resolved;
2. If the problem persists, it is recommended to resume the troubleshooting
procedure from the point before the action was carried out.
A circled number (such as that shown on the left) next to a box of the
troubleshooting procedure indicates that detailed instructions for performing
that particular check or action are provided below the flowchart.
A circled letter (such as that shown on the left) is used to highlight a point in
the procedure. Typically, this indicator is used in page changes.

STEP XT: Service & Maintenance Manual - rev. 2.0
Page 6.2
6.1. THE DISPLAY DOES NOT ILLUMINATE
Are the fuses OK?
Is the mains lead OK?
Does the wall output supply the
correct voltage?
Is the mains voltage present at
the output of the power input
socket?
Replace the blown
fuses
Replace the mains lead
Connect machine to a
suitable
electrical output
Replace the input
socket / on-off
switch block of the
machine
Replace cable SX-3
connecting the input
socket / on-off
switch block to the
power supply
THE DISPLAY
DOES NOT
ILLUMINATE
Is the mains voltage present at
the power supply input?
NO
YES
NO
YES
NO
YES
NO
YES
YES
12
NO
A
Continued on the following page.