Technogym Steprace User manual

SERVICE & MAINTENANCE MANUAL
REV. 1.2

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 Steprace™trademark is property of Technogym S.r.l.

STEPRACE: Service & Maintenance Manual -rev. 1.2
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
3.2. ALTERNATOR 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. CONNECTING TO THE TGS................................................................................................................................4.1
4.1.1. TGS adapted machines......................................................................................................................4.1
4.1.2. TGS non-adapted machines..............................................................................................................4.1
4.2. CONNECTING TO THE PRINTER..........................................................................................................................4.2
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. THERE IS NO RESISTANCE.................................................................................................................................6.5
6.3. THE RESISTANCE IS INCORRECT........................................................................................................................6.6
6.4. THE SPM VALUE IS INCORRECT........................................................................................................................6.9
6.5. THE MACHINE DOES NOT PRINT ......................................................................................................................6.11
6.6. THE MACHINE FAILS TO READ THE STEPPING MODE ........................................................................................6.13
6.7. THE MACHINE DOES NOT OPERATE IN MASTER -SLAVE MODE ........................................................................6.15
6.8. THERE IS NO HEART RATE SIGNAL...................................................................................................................6.17
6.9. THE HEART RATE SIGNAL IS INCORRECT .........................................................................................................6.18
7. DISASSEMBLY OF COMPONENTS.................................................................................................................7.1
7.1. DISASSEMBLING THE DISPLAY ..........................................................................................................................7.1
7.2. DISASSEMBLING THE EPROM..........................................................................................................................7.3
7.3. DISASSEMBLING THE CPU BOARD....................................................................................................................7.4
7.4. DISASSEMBLING THE KEYBOARD......................................................................................................................7.6
7.5. DISASSEMBLING THE CARDIO RECEIVER ...........................................................................................................7.8
7.6. DISASSEMBLING THE UPRIGHT GUARD..............................................................................................................7.9
7.7. DISASSEMBLING THE ELECTRONIC CIRCUIT BOARDS.......................................................................................7.10
7.8. DISASSEMBLING THE SIDE GUARDS.................................................................................................................7.11

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7.9. DISASSEMBLING THE CHAIN GUARD................................................................................................................7.12
7.10.DISASSEMBLING THE HANDLEBARS ................................................................................................................7.13
7.11.DISASSEMBLING THE PEDAL JOINT..................................................................................................................7.14
7.12.DISASSEMBLING THE PEDALS AND PEDAL GROUP............................................................................................7.15
7.13.DISASSEMBLING THE PEDAL CONNECTING RODS.............................................................................................7.17
7.14.DISASSEMBLING THE LEVERS..........................................................................................................................7.18
7.15.DISASSEMBLING THE PEDAL CHAINS...............................................................................................................7.19
7.16.DISASSEMBLING THE PRIMARY SHAFT -SECONDARY SHAFT CHAIN.................................................................7.20
7.17.DISASSEMBLING THE PRIMARY SHAFT GROUP.................................................................................................7.21
7.18.DISASSEMBLING THE PRIMARY DRIVE SPROCKETS..........................................................................................7.22
7.19.DISASSEMBLING THE SECONDARY DRIVE SPROCKETS.....................................................................................7.23
7.20.DISASSEMBLING THE SLIDE DRIVE SPROCKET .................................................................................................7.24
7.21.DISASSEMBLING THE SECONDARY SHAFT .......................................................................................................7.25
7.22.DISASSEMBLING THE BELT..............................................................................................................................7.27
7.23.DISASSEMBLING THE ALTERNATOR.................................................................................................................7.29
7.24.DISASSEMBLING THE ALTERNATOR BRUSHES .................................................................................................7.30
7.25.DISASSEMBLING THE SPRINGS.........................................................................................................................7.31
7.26.DISASSEMBLING THE SPRING PULLEYS............................................................................................................7.33
7.27.DISASSEMBLING THE SLIDE BARS....................................................................................................................7.34
7.28.DISASSEMBLING THE SELECTION KNOB...........................................................................................................7.35
7.29.DISASSEMBLING THE SELECTION KNOB PIN.....................................................................................................7.36
7.30.DISASSEMBLING THE MICROSWITCH ...............................................................................................................7.38
8. ADJUSTMENTS....................................................................................................................................................8.1
8.1. ALIGNING THE BELT..........................................................................................................................................8.1
8.2. BELT TENSION ..................................................................................................................................................8.2
8.3. ALIGNING THE PRIMARY SHAFT -SECONDARY SHAFT CHAIN.............................................................................8.3
8.4. PRIMARY SHAFT -SECONDARY SHAFT CHAIN TENSION .....................................................................................8.4
8.5. ADJUSTING THE ALIGNMENT OF THE PRIMARY DRIVE SPROCKET ......................................................................8.5
8.6. WEAR OF ALTERNATOR BRUSHES .....................................................................................................................8.6
8.7. ALIGNING THE PEDALS......................................................................................................................................8.7
8.8. ADJUSTING THE POSITION OF THE SLIDE AND BARS ...........................................................................................8.8
8.9. ADJUSTING THE MICROSWITCH POSITION..........................................................................................................8.9
8.10.ADJUSTING THE LCD BACKLIGHTING.............................................................................................................8.10
8.11.ADJUSTING THE BUZZER TONE........................................................................................................................8.11
9. CONFIGURING THE MACHINE ......................................................................................................................9.1
9.1. MACHINE HW CONFIGURATION .......................................................................................................................9.1
9.1.1.Machine No. configuration...............................................................................................................9.1
9.1.2. Alternator configuration...................................................................................................................9.1
9.1.3. Microswitch configuration................................................................................................................9.1
10.SCHEDULED MAINTENANCE.......................................................................................................................10.1
10.1.EXTERNAL CLEANING OPERATIONS.................................................................................................................10.1
10.1.1. Setting up the operation ..................................................................................................................10.1
10.1.2. Cleaning operations........................................................................................................................10.1
10.2.ROUTINE MAINTENANCE OPERATIONS ............................................................................................................10.2
10.2.1. Setting up the operation ..................................................................................................................10.2
10.2.2. Internal cleaning .............................................................................................................................10.2
10.2.3. Lubrication......................................................................................................................................10.2
10.2.4. Checking the state of wear of the pedal chains ...............................................................................10.2
10.2.5. Checking the amount of play on the ball joints...............................................................................10.2
10.3.SPECIAL 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

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10.3.6. Checking the wear of the rubber handlebar covers.........................................................................10.4
10.3.7. Checking the operation of the stepping mode selection knob and slide..........................................10.4
10.3.8. Checking the alternator belt............................................................................................................10.4
10.3.9. Checking the primary shaft chain....................................................................................................10.4
10.3.10. Checking the wear of the pulleys.....................................................................................................10.4
10.3.11. Checking the play of the lever and pedal group..............................................................................10.4
10.3.12. Checking the operation of the cardio receiver................................................................................10.4
10.3.13. Checking the resistance setting .......................................................................................................10.5
10.3.14. Checking the noise of the brushes ...................................................................................................10.5
11.APPENDIX...........................................................................................................................................................11.1
11.1.TECHNICAL 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
11.1.6. Routing of cables.............................................................................................................................11.5
11.2.PERSONAL CODED DEVICE.............................................................................................................................11.6
11.2.1. Operating modes .............................................................................................................................11.6
11.2.2. Upgrade of machines already installed...........................................................................................11.7
11.3.SPECIAL FUNCTIONS .......................................................................................................................................11.8
11.3.1. Displaying the selected type of alternator.......................................................................................11.8

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STEPRACE: Service & Maintenance Manual -rev. 1.2
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.

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

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Page 2.1
2. TECHNICAL CHARACTERISTICS
2.1. MECHANICAL CHARACTERISTICS
Width 66.5 cm
Length 142 cm
Height 151 cm
Weight 154 Kg
2.2. ELECTRICAL CHARACTERISTICS
Mains voltage 115 / 230 VAC
Frequency 50 -60 Hz
Consumption ~ 60 Watt – 0.6 / 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:
Europe USA
EMI EN 60601-1-2
Safety EN 60601-1
EN 957-1
Directive 73/23/CEE
93/68/CEE
89/336/CEE
UL 2601-1

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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
CN3 AMP MODU II 4-pin M. to cardio receiver
• Power supply
name type of connector connection
CN1 PANDUIT 6-pin to mains power supply
CN2 PANDUIT 8-pin to alternator interface board

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Page 2.3
• 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
CN4 AMP MODU I 8-pin M. to serial ports
2.5.2. WIRING
ST-1: Internal connecting cable
CPU Board –alternator interface board
CPU board
CN1 Signal Color Alternator interface board
CN1
1 +12 Vdc White 1
2 +5 Vdc Black-Gray 2
3 ground Black 3
4 ground Orange 4
5 Alternator RPM X 6 Pink 5
6 PWM alternator resistance Red 6
7 --7
8 Selection knob position Black-Blue 8
9 CTS Blue 9
10 Master –Slave selection Purple 10
11 Y –bus Green 11
12 Z –bus Brown 12
13 -12 Vdc Yellow 13
14 A –bus Orange-gray 14
15 B –bus Yellow-
green 15
On some machines, the signal designated +12 Vdc in the above table is actually 10.5 Vdc.
ST-3: High voltage power supply
Power input socket –Power supply
Power entry 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 ST-3 is simplified and does not detail the ground node connections.

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Page 2.4
ST-5: Alternator cable
Alternator interface board –Alternator –Resistor
Alternator
interface
board
CN2
Signal Color Alternator Resistor
1 Alternator RPM X 6 Purple Red eyelet 4 -
2 Blue -
-Resistor -Blue Yellow eyelet 4
5 ground Black Yellow eyelet 6 -
3 Red Yellow eyelet 4
-Resistor + Red Yellow eyelet 6
4 Excitation Orange Red Faston -
ST-5M: Microswitch cable
Microswitch –Alternator interface board –PE
Microswitch Signal Color Alternator
interface board
CN2
PE
1 ground Brown 6 -
2 NC Yellow-
green -Yellow eyelet 4
ST-6: Low voltage power supply cable
Power supply –Alternator interface board
Power supply
CN2 Signal Color Alternator interface board
CN3
2 +5 Vdc Yellow 4
5 +12 Vdc Red 2
6-7-4 ground Black 3
8 -12 Vdc Blue 1
ST-7: 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
3 ground Black 3

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Page 2.5
ST-8: Serial ports cable
Alternator interface board –Serial ports
Alternator
interface board
CN4
Signal Color Serial ports
1 Y –bus White 1
2 Z –bus Orange 2
3 A –bus Brown 3
4 B –bus Yellow 4
5 CTS Green 5
6 +5 Vdc Red 6
7 ground Blue 7
8 --8

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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. There are 2 types of transmitter:
• Non-coded: this is the standard product;

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Page 3.2
• 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.
(2) 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:
• Non-coded: this is the standard product. If used in conjunction with a coded transmitter, it
may provide an incorrect heart rate reading;
• 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.
(3) DISPLAY
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.
It consists of 2 circuit boards:
• CPU board: contains the microprocessor, and all the logic circuits for controlling the
machine and the LCD;
• LED board: contains the circuits pertaining to the display and indicators: LEDs and 7-
segment display.
The CPU board contains 2 banks of 4 dip-switches one and 2 dip-switches the other, which
are used for configuring the machine.
On the CPU boards of TGS adapted machines there is a jumper J2 which sets the transmission
mode of the serial port.
• J2 in position 1-2: sets the RS 485 serial port in full duplex mode;
• J2 in position 2-3: sets the RS 485 serial port in half duplex mode.
(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.

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(5) ALTERNATOR INTERFACE BOARD
Receives from the display a square-wave signal whose frequency is proportional to the
selected level of difficulty, and sends it to the alternator. Receives the RPM signal from the
alternator, which it filters and sends to the display for calculating the speed of exercise (SPM).
(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.
Starting from the model manufactured by MAGNETI MARELLI, the excitation
circuit is equipped with a series-connected thermal cutout, which is normally
closed and opens when the temperature exceeds an established threshold.
(7) POWER RESISTOR
Has the function of dissipating the energy produced by the alternator.
(8) SELECTION KNOB
This knob is used for selecting the stepping mode:
• mode A: independent stepping motion. The user must maintain a “floating” position by
moving the pedals at a rate which depends on the difficulty level of the workout.
• mode B: dependent stepping motion. When one pedal goes up the other comes down and
vice versa. The user must move the pedals at the speed indicated by a pacer, which
determines the difficulty level of the workout.
The selection knob operates a microswitch:
• mode A: the knob is in the “out” position and the microswitch is in its normal released
state. In this condition the electrical contact is closed.
• mode B: the knob is pushed “in” and the microswitch lever is pressed. In this condition
the electrical contact is open.
By reading the state of the microswitch signal, the machine is able to detect the selected
stepping mode and control the resistance accordingly.
The microswitch is installed on machines starting from SN 206.

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3.2. ALTERNATOR CONTROL
3.2.1. MECHANICS
The movement of the pedals imparts a rotation to the primary shaft via the chain connected to the 2
pedals. The chain turns on a sprocket which is attached to a slide that can move up and down along
2 guide bars. The other side of the slide is connected to 2 springs which provide an elastic
connection between the slide and the machine frame.
The primary shaft is coupled to the secondary shaft by means of a chain, and the secondary shaft is
coupled to the alternator by means of a belt. In this way, the movement of the pedals is transmitted
to the alternator.
The stepping mode selection knob determines the type of movement of the slide:
• mode A: the slide is free to move, with the springs acting as dampers. The downward movement
of a pedal causes a downward movement of the slide, which is damped by the action of the
springs. In this way neither pedal is affected by the changes in position of the other pedal.
• mode B: the slide is locked into place and the springs are not in use. The downward movement
of one pedal causes the upward movement of the other due to the fixed length of the chain.
3.2.2. CONTROL
To control the difficulty level of the workout, the machine adjusts the excitation of the alternator
which generates a resistance to the movement that is proportional to the excitation level. To do this,
the CPU board transmits a PWM (Pulse Width Modulation) signal to the alternator interface board
which the alternator interface board passes directly to the alternator itself. The alternator filters the
incoming PWM signal to extract its dc component: in other words, the alternator sees the PWM
signal as an analog voltage. The higher this voltage (corresponding to a duty cycle of the PWM
signal close to 100%), the higher the alternator excitation signal will be and hence the greater the
resistance.
The alternation rotates in the field produced by the excitation signal, generating electrical energy
which is dissipated by the power resistor.
The rotation of the alternator also generates a square wave signal proportional to its speed, with 6
pulses corresponding to one complete rotation of the alternator. This signal enters on the interface
alternator board where it is filtered and sent to the CPU board.
If the CPU board does not receive the speed signal, which means that the alternator is
not rotating, it does not transmit any PWM signal. Therefore the alternator does not
receive the excitation signal and there is no resistance at all.
The alternator control differs depending on the selected stepping mode:
• mode A: In this stepping mode, the user moves at a constant speed (which increases with
increasing difficulty level) in order to maintain a “floating” position on the pedals. By using the