Technogym JOG EXCITE User manual

SERVICE &MAINTENANCE MANUAL
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 Jog Excite™ trademark is property of Technogym S.p.A.

JOG EXCITE: 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. FEATURES AND FUNCTIONS. ............................................................................................................................2.2
2.3. MECHANICAL CHARACTERISTICS.....................................................................................................................2.3
2.4. CONFORMITY REGULATIONS............................................................................................................................2.3
2.5. AMBIENT SPECIFICATIONS ...............................................................................................................................2.3
2.6. WIRING DIAGRAM............................................................................................................................................2.4
2.6.1. Lower assembly ................................................................................................................................2.4
2.6.2. Upper assembly: LED ARM version.................................................................................................2.5
2.7. WIRING............................................................................................................................................................2.6
3. PRINCIPLES OF OPERATION............................................................................................................................ 3.1
3.1. BLOCK DIAGRAM.............................................................................................................................................3.1
3.1.1. Display board...................................................................................................................................3.2
3.1.2. TGS reader .......................................................................................................................................3.2
3.1.3. HS / cardio receiver board...............................................................................................................3.2
3.1.4. Emergency switch.............................................................................................................................3.3
3.1.5. Belt motor.........................................................................................................................................3.3
3.1.6. Elevation motor ................................................................................................................................3.3
3.1.7. Limit switch.......................................................................................................................................3.3
3.1.8. AT driver...........................................................................................................................................3.3
3.1.8.1. AT driver board............................................................................................................................................................. 3.4
3.1.8.2. AT power supply board.................................................................................................................................................3.5
3.1.8.3. Fans................................................................................................................................................................................3.5
3.1.8.4. Breaking resistor ...........................................................................................................................................................3.5
3.1.9. Power supply box..............................................................................................................................3.5
3.2. TREAD BELT MOTOR DRIVE..............................................................................................................................3.6
3.2.1. Mechanics.........................................................................................................................................3.6
3.2.2. Controls............................................................................................................................................3.6
3.2.3. The signals involved .........................................................................................................................3.7
3.3. ELEVATION MOTOR DRIVE...............................................................................................................................3.8
3.3.1. Mechanics.........................................................................................................................................3.8
3.3.2. Control..............................................................................................................................................3.8
3.3.3. The reset procedure..........................................................................................................................3.9
3.3.4. The signals involved .........................................................................................................................3.9
3.4. EMERGENCY STOP MANAGEMENT..................................................................................................................3.11
3.4.1. Control............................................................................................................................................3.11
3.4.2. The signals involved .......................................................................................................................3.12
4. ACCESSORIES ....................................................................................................................................................... 4.1
4.1. CARDIO THEATER CONNECTION.......................................................................................................................4.1
4.2. PC LINK FOR PROGRAMMING ...........................................................................................................................4.1
4.3. MONITOR PLUG FOR CSAFE PORT ....................................................................................................................4.2
5. INSTALLATION INSTRUCTIONS...................................................................................................................... 5.1
5.1. SPECIFICATIONS AND REQUIREMENTS..............................................................................................................5.1
5.2. INSTALLATION.................................................................................................................................................5.2
5.3. FIRST POWER-ON .............................................................................................................................................5.2

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6. TROUBLESHOOTING .......................................................................................................................................... 6.1
6.1. TROUBLESHOOTING SERVICE MENU.................................................................................................................6.2
6.1.1. Automatic Tests.................................................................................................................................6.3
6.1.1.1. I2C Device Test.............................................................................................................................................................6.3
6.1.1.2. UpDown Test ................................................................................................................................................................ 6.3
6.1.1.3. Inverter Test ..................................................................................................................................................................6.3
6.1.1.4. LED Test .......................................................................................................................................................................6.4
6.1.1.5. Serial Ports Test.............................................................................................................................................................6.4
6.1.2. Manual Test......................................................................................................................................6.4
6.1.2.1. Man. Keyboard Test...................................................................................................................................................... 6.4
6.2. THE DISPLAY FAILS TO ILLUMINATE.................................................................................................................6.5
6.3. “PRESS AKEY” MESSAGE ON THE DISPLAY ..................................................................................................6.9
6.4. “THE EQUIPMENT IS BLOCKED” MESSAGE ON THE DISPLAY .................................................................6.10
6.5. AT DRIVER ERROR.........................................................................................................................................6.11
6.5.1. Error OH........................................................................................................................................6.13
6.5.2. Errors OC - OLi - OLm - Ot - OCH - MST - SHC .........................................................................6.14
6.5.3. Error UU........................................................................................................................................6.15
6.5.4. Error OU........................................................................................................................................6.16
6.5.5. Error OtM.......................................................................................................................................6.17
6.5.6. Error OLr .......................................................................................................................................6.18
6.5.7. Error PE.........................................................................................................................................6.19
6.5.8. Error EM ........................................................................................................................................6.20
6.6. TREAD BELT MOTOR IS JERKING.....................................................................................................................6.21
6.7. “GRADIENT NOT WORKING” MESSAGE ON THE DISPLAY .......................................................................6.22
6.8. THE MACHINE DOES NOT READ THE TGS.........................................................................................................6.24
6.9. THERE IS NO HEART RATE SIGNAL..................................................................................................................6.26
6.9.1. Telemetric receiver HFU................................................................................................................6.26
6.9.2. Hand sensor....................................................................................................................................6.27
6.10. THE TELEMETRIC HR SIGNAL IS INCORRECT ...................................................................................................6.29
7. DISASSEMBLY OF COMPONENTS................................................................................................................... 7.1
7.1. DISASSEMBLING THE DISPLAY .........................................................................................................................7.1
7.2. DISASSEMBLING THE CIRCUIT BOARDS OF THE DISPLAY ..................................................................................7.2
7.3. DISASSEMBLING THE KEYBOARD.....................................................................................................................7.3
7.4. DISASSEMBLING THE EMERGENCY BUTTON .....................................................................................................7.4
7.5. DISASSEMBLING THE CARDIO RECEIVER/HAND SENSOR BOARD .......................................................................7.5
7.6. DISASSEMBLING THE SENSORS.........................................................................................................................7.7
7.7. DISASSEMBLING THE READY TO RUN BOARD ..................................................................................................7.8
7.8. SMONTAGGIO MANIGLIONI ..............................................................................................................................7.9
7.9. DISASSEMBLING THE MOTOR GUARD.............................................................................................................7.10
7.10. DISASSEMBLING THE MOTOR COMPARTMENT FAN.........................................................................................7.11
7.11. DISASSEMBLING THE LIMIT SWITCH...............................................................................................................7.12
7.12. DISASSEMBLING THE ELECTRICAL BOX..........................................................................................................7.13
7.13. DISASSEMBLING THE ELECTRONICS BOARDS .................................................................................................7.14
7.14. DISASSEMBLING THE POWER SUPPLY BOX .....................................................................................................7.16
7.15. DISASSEMBLING THE TREAD BELT MOTOR.....................................................................................................7.17
7.16. DISASSEMBLING THE ELEVATION MOTOR ......................................................................................................7.18
7.17. DISASSEMBLING THE TREAD BELT GROUP......................................................................................................7.19
8. ADJUSTMENTS...................................................................................................................................................... 8.1
8.1. TENSIONING A NEW TREAD BELT .....................................................................................................................8.1
8.2. TENSIONING A USED TREAD BELT ....................................................................................................................8.2
8.3. CENTERING THE TREAD BELT...........................................................................................................................8.3
8.4. POSITION OF THE LIMIT SWITCH.......................................................................................................................8.4
9. MACHINE CONFIGURATION............................................................................................................................ 9.1
9.1. USER MENU CONFIGURATION...........................................................................................................................9.1
9.1.1. Language..........................................................................................................................................9.1
9.1.2. Distance............................................................................................................................................9.2

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9.1.3. Maximum exercise time ....................................................................................................................9.2
9.1.4. Pause time ........................................................................................................................................9.2
9.1.5. Default age .......................................................................................................................................9.3
9.1.6. Default weight...................................................................................................................................9.3
9.1.7. Default time ......................................................................................................................................9.3
9.1.8. Default calories ................................................................................................................................9.4
9.1.9. Default distance................................................................................................................................9.4
9.1.10. Enable TGS.......................................................................................................................................9.4
9.1.11. Enable keyboard...............................................................................................................................9.5
9.1.12. Modifiable target heart rate .............................................................................................................9.5
9.1.13. Enable custom messages ..................................................................................................................9.5
9.1.14. Enable up/down motor......................................................................................................................9.6
9.1.15. Resetting parameters to default values.............................................................................................9.6
9.1.16. Format P&P.....................................................................................................................................9.6
9.1.17. User Detect.......................................................................................................................................9.6
9.1.18. SN .....................................................................................................................................................9.7
9.1.19. Ready2Run........................................................................................................................................9.7
9.2. SERVICE MENU CONFIGURATION......................................................................................................................9.8
9.2.1. Low kit parameter.............................................................................................................................9.9
9.2.1.1. Read from low kit..........................................................................................................................................................9.9
9.2.1.2. Write to low kit..............................................................................................................................................................9.9
9.2.1.3. Default setting ............................................................................................................................................................... 9.9
9.2.1.4. Table of configuration parameters..............................................................................................................................9.10
9.2.2. UpDown settings.............................................................................................................................9.10
9.2.2.1. Read from low kit........................................................................................................................................................9.11
9.2.2.2. Write to low kit............................................................................................................................................................9.11
9.2.2.3. Default setting ............................................................................................................................................................. 9.11
9.2.3. Usage data......................................................................................................................................9.12
9.2.3.1. Read from low kit........................................................................................................................................................9.12
9.2.3.2. Write to low kit............................................................................................................................................................9.12
9.2.3.3. Machine usage data.....................................................................................................................................................9.13
9.2.4. Errors log .......................................................................................................................................9.13
9.2.4.1. Read from low kit........................................................................................................................................................9.13
9.2.4.2. Reset errors..................................................................................................................................................................9.14
9.2.4.3. COM.Fault................................................................................................................................................................... 9.14
9.2.4.4. View Errors .................................................................................................................................................................9.14
9.2.5. Standard settings ............................................................................................................................9.15
9.2.6. Low kit menu...................................................................................................................................9.15
9.2.6.1. Low kit version............................................................................................................................................................ 9.16
9.2.6.2. Config. registers ..........................................................................................................................................................9.16
9.2.7. High kit version ..............................................................................................................................9.20
9.2.8. BOOT version.................................................................................................................................9.20
9.2.9. Key Reader Version........................................................................................................................9.20
9.3. DRIVER AUTOTUNING....................................................................................................................................9.21
9.4. RECALL PARAMETERS....................................................................................................................................9.21
9.5. DEFAULT PARAMETERS .................................................................................................................................9.22
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. WEEKLY MAINTENANCE OPERATIONS............................................................................................................10.2
10.2.1. Checking the “Emergency stop”....................................................................................................10.2
10.2.2. Complete operation ........................................................................................................................10.2
10.3. MONTHLY MAINTENANCE OPERATIONS .........................................................................................................10.3
10.3.1. Internal cleaning operations ..........................................................................................................10.3
10.3.2. Checking the state of wear..............................................................................................................10.3
10.3.3. Checking the operation of the cardiotester receiver.......................................................................10.3
10.3.4. Checking the operation of the hand sensor receiver ......................................................................10.3
10.4. TWICE-YEARLY MAINTENANCE OPERATIONS.................................................................................................10.4
10.4.1. carrying out the monthly maintenance procedure..........................................................................10.4
10.4.2. Checking the working conditions....................................................................................................10.4

JOG EXCITE: Service & Maintenance Manual - rev. 1.1
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10.4.3. Checking the wiring and connections.............................................................................................10.4
10.4.4. Checking the wear and lubrication of the tread belt and running deck .........................................10.5
10.4.5. Checking the wear of the driving roller..........................................................................................10.5
10.4.6. Checking the wear of the rear roller ..............................................................................................10.5
10.4.7. Checking the shock absorbers........................................................................................................10.5
10.4.8. Checking the tread belt motor drive-belt........................................................................................10.5
10.4.9. Checking and centering the tread belt............................................................................................10.5
10.4.10. Checking the display.......................................................................................................................10.6
11. APPENDIX............................................................................................................................................................. 11.1
11.1. UPDATING THE SW.........................................................................................................................................11.1
11.2. TOOLS TO USE................................................................................................................................................11.2

JOG EXCITE: 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.
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.

JOG EXCITE: 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
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.

JOG EXCITE: 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 Machine type: Excite D4
3,4 Product version 43 = Jog Excite 700
5 Type of power supply E= European driver
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 = aluminium
10, 11 Color of the paddings 00 = none
12 Color of the guards 0= none
13 Type of TV model 0= none
14,15 Language
BR = portoguese
CN = chinese
DE = german
ES = spanish
FR = franch
IT = italian
JP = japanese
NL = dutch
RU = russian
UK = british english
US = american english
16 Type of packaging
I= Italy
E= international (standard)
S= international (overseas)
0= none
The above coding is used for the entire Excite line. For this reason, options not relevant
to the Jog machine have also been included.
For example, a possible product code would be:
D443ELNAL0000UKE
which is interpreted as follows:

JOG EXCITE: Service & Maintenance Manual - rev. 1.1
Page 2.2
D4 43 E L N AL 00 0 0 UK E
standard international packing
British English language
no TV model
guard color
no paddings
aluminum frame color
Not interfaced to TGS key reader
LED display
European driver
Jog 700 model
Excite
2.2. FEATURES AND FUNCTIONS.
VERSION
700
Mains voltage 180-260 Vac
Frequency 50-60 Hz
Consumption 2200 W
Speed 0.8-18 Km/h
0.5-12 mph
Incline 0-15 %
Fast track control NO
Hand sensor YES
Cardio receiver HFU
Ready to Run YES
Calorie coach YES
Runner Detection YES
Training
programs
Quick Start
Goal (Time, Distance, Calorie)
6 profiles
CPR
Test
CHARACTERISTIC
Test functions Fitness test

JOG EXCITE: Service & Maintenance Manual - rev. 1.1
Page 2.3
2.3. MECHANICAL CHARACTERISTICS
Width 85.9 cm - 34 in
Length 210 cm - 83 in
Height 141.5 cm - 56 in
Running deck height from the floor 21.5 cm – 8.5 in
Weight 164 Kg - 361 lbs
2.4. CONFORMITY REGULATIONS
The machine conforms to the following standards:
Europe USA
Standards
EN60335-1
EN55014-1
EN55014-2
EN61000-3-2
EN61000-3-3
EN957-1
EN957-6 class SA
Directives
73/23/CEE
89/336/CEE
98/37/CEE
UL 60601-1
In addition:
•Electrical isolation class under EN60335-1: Classe I;
•Protection rating: IP20.
2.5. AMBIENT SPECIFICATIONS
Operating from 10° to 25° C
Temperature Storage from -10 to 70° C
Operating from 20% to 90% non-condensing
Humidity Storage from 20% to 90% non-condensing

JOG EXCITE: Service & Maintenance Manual - rev. 1.1
Page 2.4
2.6. WIRING DIAGRAM
The machine consists of 2 assemblies which are connected together as illustrated below:
UPPER
ASSEMBLY LOWER
ASSEMBLY
CU133
Depending on the model, these 2 assemblies can have the different configurations illustrated below.
2.6.1. LOWER ASSEMBLY
AT DRIVER BOX
MAIN BOARD
POWER SUPPLY BOARD
J8
XPWR
LIMIT
SWITCH
MOTOR ELEVATION
MOTOR
Fan
24VDC
POWER
SUPPLYBOX
ON/OFF
SWITCH
C
I
R
C
U
I
T
B
R
E
A
K
E
R
VAC
C
I
R
C
U
I
T
B
R
E
A
K
E
R
FILTER
BOARD
J3J4J5J7
Fan
24VDC
J2
J1
RESISTANCE
XR1
XR2
JF
XPWR
XU2
XU2
XU1
XU1
Fan
24VDC
XV1
POWER
SUPPLY
SOCKET
CU143
CU143
IN2IN1
L4N1
LN
CU143
L3N2
CU177
FE
CU145
OUT1
OUT2
CU144 CU156
EAM2069 EAM2068
CU133
TRM-54
NCCOM

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Page 2.5
2.6.2. UPPER ASSEMBLY:LED ARM VERSION
EMERGENCY
BUTTON
DISPLAY
DISPLAY BOARD
KEYBOARD
HS / RECEIVER
BOARD
CN4
TGS
BOARD
CN1
CN7CN9
CN1
CN5
CN8
MICRO
L LOWER
SENSOR
R UPPER
SENSOR
L UPPER
SENSOR
R LOWER
SENSOR
READYtoRUN
BOARD
CU133
CU135
CU136
MICRO
CU138
CBQ-32
CU137
CN6
RJ45
HD4
HD3&2
HD1
NC
C
C
NC

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Page 2.6
2.7. WIRING
TRM-32: TGS Cable
Display Board – TGS reader
Display Board
CN3
Signal Color TGS reader
CN1
1 +12 Vdc power supply Yellow 1
3 Rx White 8
5 Tx Green 7
9 Gnd Brown 3
CU133: Cable connecting upper and lower assemblies
Display board – AT driver board
Display Board
CN7
Signal Color AT driver board
J3 or J4
1 Gnd +12 Vdc Black J3 – pin 2
2 Not connected - -
3 485 Tx/Rx + White/brown J4 – pin 7
4 485 Tx/Rx - Brown J4 – pin 8
5 +12 Vdc Red J3 – pin 6
6 Digital Gnd Light orange J4 – pin 6
7 Emergency Orange J3 – pin 9
8 Reset Purple J3 – pin 10
ATTENTION: The pins 1-2-3-4-5 on the J4 connector are engaged by cables not connected
anywhere.
The pins 3-4, 3-12, 6-11 and 7-8 are short-circuited each other.
CU135: HS / cardio receiver board cable
Display board - HS / cardio receiver board
Display Board
CN9
Signal Color HS / receiver
board
HD4
1 +5 Vdc power supply Brown 2
4 Pulse out White 3
5 Reference Green 1

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Page 2.7
CU136: Sensor Cable
Hand Sensor Board - Sensors
HS/receiver
board Sensors
HD3&2
Signal Color
RH LH
1 Right sensor signal Yellow up -
2 Sensor signal reference White down -
4 Left sensor signal Brown - up
5 Sensor signal reference Green - down
CU137: Ready to Run board cable
Display board – Ready to Run board.
Display board
CN1
Signal Color Ready to Run
board
1 +5 Vdc power supply Brown 1
4 Reference White 2
CU138: Emergency button cable
Display board – Microswitch
Display board
CN8 Signal Color Micro Micro
1 Emergency Brown C -
2 Reference White - C
- Bridge Black NC NC
CU143: High voltage cable
Power supply box – AT driver box
Filter
board
Signal Color AT driver
board
OUT1 Neutral Brown 1
OUT2 Line Blue 2
TRM-05: Motor compartment fan cable
AT driver board - Fan
ATmain board
J2
Signal Color Fan
1 24 Vdc power supply Red
2 Gnd Black internally
connected cable

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TRM-06: Belt motor cable
AT driver board - Motor
AT driver board
J5
Signal Color Motor
1 U Black 1
2 V Black 2
3 W Black 3
4 thermal cutout + Black 4
5 thermal cutout - Black 5
6 GND Black 6
internally
connected cable
TRM-08: Elevation motor cable
AT driver board – Elevation motor
AT driver board
J7
Signal Color Elevation motor
1 Motor - Black
2 Motor + Black
4 Gnd Black
5 +5 Vdc power supply for encoder Red
6 Pulses White
internally
connected cable
TRM-54: Limit switch cable
AT driver board – Limit switch
AT driver board
J8
Signal Color Limit switch
3 Contact White COM
8 Reference Brown NC
EAM2068: AT Driver board connecting cable
AT Power supply board – AT driver board
AT Power supply
board
XU2
Signal Color AT driver board
XU2
1 +12 Vdc power supply Blue 1
2 Gnd +12 Vdc Blue 2
3 + Sensing +5 Vdc Blue 3
4 - Sensing +5 Vdc Blue 4
5 +5 Vdc power supply Blue 5
6 Gnd +5 Vdc Blue 6

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EAM2069: AT Driver board connecting cable
AT Power supply board – AT driver board
AT Power supply
board
XU1
Signal Color AT driver board
XU1
1 +24 Vdc power supply Blue 1
2 Gnd +24 Vdc Blue 2
3 +5 Vdc power supply Blue 3
4 Gnd +5 Vdc Blue 4

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