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1. a 2 VS f I ra SE uL gt aaa ln msn mem mem AE aan AA Page 20 Chapter 4 Using Test Mode e The software version displays in the Elapsed Time field as bnnn The b indicates BikeMax and nnn is the version number In Figure 4 2 the version is 007 It may be different on your bike e The feedback frequency in the Calories Burned field should read between 3 595 and 3 605 kHz 3 60 15 shown This information is for factory use it is not adjustable in the field e The Speed field shows the pedal RPM as reported by the RPM sensor If this changes correctly as you speed up or slow down you know the sensor is working Figure 4 1 shows a pedal speed of 40 RPM You can change the pedal resistance by pressing the Up Arrow or Down Arrow key m Heart Monitor Information If your BikeMax has a Polar heart rate receiver the field indicator small red light for Heart Rate Level lights if the BikeMax detects the pulse rate signal from the Polar transmitter Testing Display LEDs If you want to test the LEDs on your display console press one of these keys e Start Enter Light all LEDs e Endurance Light vertical columns df LED segments e Strength Light individual LED segments Press the
2. Optional External Power Suppl 1 mE 4 Wall Transformer Battery Permanent Connection ENS uA 0 pug end Header It Plug and Header Batte Push on Terminals Part 61518 6 Screw Terminals Pi 0 2520625242523 SO E HO oai gd i d i OCC NU dua Bunoouseignoi Ll 70498105040 pL 9654 BikeMax 1000 3000 Service Manual Page 15 Isolating Mechanical Noise The best tool for troubleshooting a mechanical noise is a long screwdriver You can place the tip of the screwdriver on the component to check then rest your ear against the handle to amplify the sound the screwdriver works like a simple stethoscope The following three sections describe how to isolate the source of noise in three general areas of the BikeMax mechanism the crank arm area the second stage pulley area and the alternator Y as You may be able to hear a mechanical noise generated in one area of the BikeMax while E listening to another area Use the methods below to identify the source of the noise Kj KA Mechanical Noise in the Crank Arm Area Components include the crank arm assembly primary pulley 3 grooved pulley and idler pulley The crank arm assembly includes the one piece crank arm and the bearings seated in the engine casting The primary pulley is mounted to the crank arm assembly The primary pulley transfers rotati
3. aw aan 2 700 886 500 C R Service Manual ZT 22 H 1 0 1 pt 14 DL T rea Tabie of Contents CHAPTER 1 INTRODUCTION We re Here to Help CHAPTER 2 ASSEMBLY Unpack BikeMax Assembling the Upright BikeMax BMU Attach the Display Upri ght Attach the Display Console Attach the Handlebar Assembling the Recumbent BikeMax BMR Attach the Seat Back Assembly Attach the Display Upright Attach the Display Console Install the Optional Polar Heart Rate Receiver Plugging in the BikeMax Connecting Bikes for Racing CHAPTER 3 TROUBLESHOOTING Where to Start Electrical Cabling Isolating Mechanical Noise Mechanical Noise in the Crank Arm Area Mechanical Noise in the Second Stage Pulley Area Mechanical Noise in the Alternator Area CHAPTER 4 USING TEST MODE BikeMax 3000 Test Mode Field Indicators Testing Display LEDs Advanced Diagnostic Information Odometer Leaving Test Mode BikeMax 1000 Test Mode The Test Mode Display Heart Monitor Information Testing Display LEDs Leaving Test Mode CHAPTER 5 COMPONENT REPAIR AND REPLACEMENT Cover Removal External Power Supply First Stage Drive o OO MU ARA WH OU bawat wah pond NI M ON 17 17 17 17 18 19 19 19 19 20 20 20 21 22 23 Page ii URL O m Table
4. 3a fghisup YES ka NO wil NO Sen 6255160492 58515 040 as 88 charge Pad No 38 aN padi Display voltage lt 9 2 VDC is present RB SS on 56 R18 x 2 NA ron x NG Padi ad Naa Padi Bitemalvokage n YES lt BpresentonACBQ NN D11 D147 x Pe INO NC i Replace ACB 64 68 960 9 6666 8 5 69 6 66 486 68 01 i lt 2 7 lt Etemel Tes M te re O E P d 4 9 5 moa Pe a 8 9 6 6 S i Replace extemal powercabb ii Re place extemal i powertransfomer Nasi et PULI 20 os 8 ID e xem Display Voltage gt M Q2VOC ispesat NY son 015 3 Cine t j p Ni bm Replace display Cape Replace display lt has shorted DE alle malice o iYES Nes 3b i ee YE
5. Permanent connection Plug and header Receiver Optional Ms li 195 Cardio Touch a JP1 Heart rate Board JPS J3 7 Optional External Power Supply d Push on terminals Screw terminals Page 13 Keypanel Overlay 2 Alternator Part 61539 External Display Power Comm A C B Alternator a E Alternator Cabie Eia Alternator Control Board Part 70418 1 Q Load r part 61520 Battery Part 61518 L BMXVECHSERVBm xblock 10060 m onualporiratt C OR Figure 3 1 BikeMax Electrical Connections Post October 1998 Alternator Bikes saxyig 4 777242716 866 4290130 2144 SUOYIIUUO 71797479917 21719217 Z o4n31J ILAN Y i Heart rate 55 Displa Board english i optiona J5 Part 61536 0 2 Part 71108 BMR Part 61535 BM1000 Part 50059 000 Part 71098 BMU pee Display External Power Cable Plate Assembl Part 61521 BM JP2 m onm 000 Ummm oD ee Part 61541 BMU UP7 Power PAY Alternator Power Alternator JP1 Input Part 61539 npu ACB Alternator Alternator Control Board 6 Rs 232 Part 70391 Bag RPM Sensor RS 232 Communication Ports RPM Part 61520 Battery JP3
6. ector 5 6 m Table 3 1 ACB Connectors and Related Components ACB Rev 10060 A Post October 1998 Alternator Bikes Related Component B Alternator mounted to the bike frame JP2 Display board connected to the ACB with 2 ribbon cables 1 in the display upright tube 1 on the bike frame 7 8 JP JP JP JP JP JP External power source connector mounted on the switchplate JP SmartLink Communications connector mounted on the switchplate Table 3 2 ACB Connectors and Related Components Pre October 1998 Alternator Bikes If all cable connections are correct and secure but the bike still won t power up you may want to continue with Appendix B Advanced Electrical Troubleshooting You should perform the procedures described there only if you are familiar with using a volt ohm meter and other electrical diagnostic procedures d J Display board connected to the ACB with 2 ribbon cables 1 in the display RE SmartLink Communications connector mounted on the external power plate BikeMax 1000 3000 Service Manual CO TA Polar Heart rate Cardi To uch i Handgrips Optional External Power Plate Assembly Part 61521 External Power Comm Cable External Power RS 232 Communication Ports Wall Transformer Part 13018 110 VAC Part 13019 220 VAC
7. do if you have trouble with CT heart rate readout is clean the hand grips with alcohol to remove built up perspiration and other dirt a If cleaning the grips does not fix the problem you need to examine the individual components of the CT system Besides the hand grips the system includes a cable that terminates at a connector under the back of the seat on the recumbent bike outside the balance bar on the upright extrusion tube and upright tube cables recumbent bike only and the CT circuit board The CT cable is a 2 conductor cable The end of the cable that connects to the CT board has a brown 4 pin connector The key to troubleshooting CT is to isolate each component and test each component independent of the other components The test process requires the use of a volt ohm meter and can involve partial disassembly of the bike The most common cause of failure with CT is due to a pinched or disconnected cable at the console or in the display upright tube To check for this problem 1 Remove the console and verify that the CT board is installed onto the display board 2 Make sure the 4 pin connector on the CT cable 1s plugged into the 4 pin connector on the CT board Refer to the system block diagram 3 Make sure the CT cable is not pinched or cut where it exits the top of the display upright tube 4 Make sure the wires are not separated from the 4 pin connector If the CT board is installed and the cable integr
8. 11 Make sure the pulley shaft rotates freely in the bearings If it does not replace the engine see page 29 12 Install the primary and secondary belts See pages 24 and 27 13 Replace the bike covers See page 22 Repair and Replacement BikeMax 1000 3000 Service Manual Page 29 Engine Assembly Tools Needed 2 Phillips Screwdriver 72 box end or open end wrench 2 Socket and wrench The main engine assembly is the connection between the moving components and the frame of the bike If replacement is necessary a complete assembly including the engine casting primary secondary idler and 3 grooved pulleys and bearings is available Follow the procedures below to remove and replace the engine assembly PG The engine assembly is bulky and can be awkward to maneuver in and out of the bike i frame Be very careful to avoid injury during the replacement For your reference there is an exploded view of the engine assembly at the end of this section Removing the Engine Assembly l If the bike is equipped with the optional AC adapter unplug the adapter from the bike 2 Remove the bike covers See page 22 3 Remove the secondary belt e Slowly rotate the secondary pulley on the left side of the bike e Carefully move the belt to the outside edge of the pulley then off the pulley Remove the remainder of the belt from the small alternator pulley 4 Remove the pedal and cover plate from the left si
9. and display If the problem still exists or if the cable passes the continuity test replace the display board Once the proper diagnosis and repairs are complete test Polar again to verify integrity of the Polar system BikeMax 1000 3000 Service Manual Page 45 Extrusion Tube Removal and Installation BikeMax R Only Tools Needed 2 Phillips screwdriver 3 16 hex Allen wrench V box end or open end 2 socket and wrench wrench 1 piece of Scotch tape This section also includes the removal and installation of the seat shuttle assembly 1 If the bike is equipped with the optional AC adapter unplug the adapter from the bike 2 Remove the rectangular end cap from the rear of the extrusion tube by removing the four Phillips screws that secure it 3 Remove the seat shuttle from the bike Remove the 3 16 hex screw and its nut from the right rear corner of the extrusion tube If the bike is equipped with a Polar receiver remove the receiver from the tube Phillips screws on either side at the front of the seat shuttle secure a brake plate Remove the two Phillips screws and the brake plate from the shuttle Lift the blue locking handle of the seat shuttle and carefully slide the seat shuttle to the rear most position of the extrusion tube If the bike is equipped with CardioTouch unplug the flex cable from the connector located on the bottom of the rear most location on the seat shut
10. checks the battery and charging system Finally it tests the RPM coil If all of these components function correctly the problem must be in the ACB Two revisions of ACB are covered by the troubleshooting procedure ACB rev 10060B new style may be identified as the module on which the battery is mounted PC board and resistor are smaller than the previous revision For ACB rev 10050A the battery is mounted to the frame of the BikeMax separately The procedure references headers by their designation on the 10060B ACB The equivalents for the 10050A ACB are given in the following table Global Changes of ACB Headers Rev 10050A old Rev 10060A new JP1 JA ALTERNATOR JP3 BATTERY JP6 1 2 LOAD RESISTOR JP2 DISPLAY HP5 RPM JP7 J8 J3 External Power amp MELLE Communications JP13 Edgecard An EPROM revision number MAXII 3 04 or greater 1s required for ACB revision 10050A and MAXII 3 11 or greater for ACB revision 10060B When replacing a 10050A ACB with a 10060B ACB remember to update the EPROM also Before You Begin The troubleshooting procedure makes the assumption that a field failure has occurred the BikeMax functioned correctly before the failure Caution The troubleshooting procedure assumes there is a single fault to be isolated in the BikeMax system Multiple problems may complicate troubleshooting by causing false inferences as a result of any test You should have the following tools before you begin e An
11. grip fails the continuity test no needle movement or change in the numeric display the problem is in one of the CT components To determine which one you will check the connections and continuity of the CT cables in the display upright and extrusion tube and the flex cable that connects the extrusion tube cable to the seat shuttle 4 Unbolt and remove the display upright tube from the base Carefully hold the tube and verify that the 2 conductor cable from the extrusion tube is plugged into the 2 conductor cable that connects to the CT board in the console If the cables are connected disconnect them and repeat the continuity test for each hand grip and wire within the 2 conductor cable exiting the front of the extrusion tube If the hand grips and 2 conductor cable in the extrusion tube pass the continuity test then the 2 conductor cable in the upright tube is defective Replace the cable and test CT again 5 If the continuity test fails remove the seat shuttle 2 conductor CT extrusion tube cable and flex cable refer to Extrusion Tube Removal and Installation BikeMax R Only on page 45 Perform continuity tests on the 2 conductor CT extrusion tube cable and flex cable independently of each other l If either cable fails the continuity test replace it and test CT again 6 If both the CT cable and flex cable pass the continuity test then test continuity between the hand grips and the connector on the bottom of the seat shu
12. of Contents Idler Pulley RN 26 Second Stage Drive E 2T Replacing the Secondary Belt 27 Adjusting the Secondary Belt 21 Replacing the Second Stage Assembly 28 Engine Assembly 29 Removing the Engine Assembly B 29 Installing the New Engine Assembly T3 30 Alternator po x 32 Removing the Alternator s 32 Installing the New Alternator 33 RPM Sensor 35 Alternator Control Board l 38 Battery 39 CardioTouch Heart Rate Receiver 40 Recumbent Bike CardioTouch Troubleshooting E 41 Upright Bike CardioTouch Troubleshooting _ 42 Polar Heart Rate Receiver 43 Recumbent Bike Polar 1 43 Upright Bike Polar Troubleshooting D 44 Extrusion Tube Removal and Installation BikeMax R Only 45 APPENDIX A PARTS LIST 47 APPENDIX 8 ADVANCED ELECTRICAL TROUBLESHOOTING 49 The Power Up Sequence 49 Troubleshooting Procedure 50 Before You Begin i 50 Troubleshooting Flowchart for Dead Alternator BikeMax 52 The Troubleshooting Sequence 53 APPENDIX C ENGINEERING DRAWINGS 57 00 8 CHAPTER 1 INTRODUCTION Welcome to the BikeMax 1000 3000 Service Manual This book can help Tectrix trained service personnel diagnose and correct almost any problem with a BikeMax alternator bike In addition to this introduction it covers the following subjects Chapter 2 Chapter 3 Chapter 4 Chapter 5 Appendix A Appendix B Appendix
13. the frame Installing the New Engine Assembly 8 9 With a recumbent bike you must rotate the right crank arm so it points to the rear of the bike before you start the installation For an upright bike the left crank arm must point toward the rear of the bike From the left side of the bike place the primary crank arm pulley and engine assembly through the frame and toward the front of the bike Rotate the casting so the rear of the casting can be seated into the center of the diagonal frame member Lift the front of the engine assembly and position the casting into the semi circular frame mounting bracket Insert the two 2 bolts and washers through the brass colored mounting plate and into the frame Do not tighten the bolts yet Place a 42 bolt and washer through the rear engine mounting plate Lift the rear of the engine casting and align the holes in the casting with the holes in the frame Insert the bolt through the casting and bike frame so the plate is properly positioned on the frame Insert the second 42 mounting bolt and washer through the mounting plate casting and bike frame Install the four Phillips screws through the mounting plate into the diagonal frame member Do not tighten the screws yet Install the two nuts on the two rear Vo bolts Do not tighten the nuts and bolts yet Tighten the front two 2 bolts at an even rate so the mounting plate is fully seated against its mount
14. the primary belt The 3 inch diameter grooved pulley drives the second stage pulley through the pulley shaft The second stage pulley transfers rotational motion to the alternator flywheel through the secondary belt To check for problems in the second stage pulley area AM 1 Remove the secondary belt that runs from the second stage pulley to the alternator flywheel 2 Rotate the second stage pulley 3 While rotating the pulley use the screwdriver to listen for noise from E me 3 The pulley shaft and bearings If there is noise from the bearings the engine assembly e The area surrounding the bracket that secures the engine casting to the rear diagonal frame member of the bike if the bracket is loose tighten it 4 See page 26 for instructions on replacing the secondary belt Mechanical Noise in the Alternator Area Alternator area components include the secondary belt alternator and alternator flywheel To diagnose mechanical problems in the alternator area siga 1 Make sure the bolts that secure the alternator to the frame are tight The bolt that secures the top of the alternator to the frame threads into the aluminum alternator case so make sure you don t strip the hole in the alternator 2 Remove the secondary belt from the second stage pulley and alternator flywheel 3 Make sure the flywheel is fully seated on the alternator shaft and the nut that secures t
15. 2 b drw 3 70384 8 o ASSY SEAT SHUTTLE BMR A1 CT BikeMax 1000 3000 Service Manual Page 61 Update items 2 3 5 amp 7 Added item 18 and added additional ttem 13 Deleted notes PJP 10 20 97 DECIMALS xxx 4010 per ECN 1048 xxx 14005 pdate Item 1 per ECN 01085 RPM 12 9 97 Ae hos xh rie Removed screws washers amp nuts per ECN 01210 06 15 98 DRAWN OY DAR 7 10 97 MAIERAL SEE INDIVIDUAL DRAWINGS 209996 SEE INDIVIDUAL DRAWINGS Rovisod items 2 amp 8 pes ECN 01055 weidment Hom bag kam 12 Kick plate Bam 24 foot parte 01 Revisod item 36 Removed 2 nuts Item 22 plot 20965 CCN OI i o G5 E Addod new atlemotor Assy tern 13 on shee 3 and extemal pwr NAKED BMR sheal 1 Added 59 DETALA And now format pot 01825 me M E ua BASE CT 8 20 wii nme 5 Blw 70853 E 110 wheats 2 plocos and on engine heri 5 Page 62 Appendix C Engineering Drawings NAKED BMR A1 BASE CT jelve 7 Te XA Ta OI pu GL oe lt lt ee Ta ANAE woe EY BikeMax 1000 3000 Service Manual P age 63 now Assy carn 4 Roplocoo oki 9 por 01117 foot kom 10 and lack plato kom 42 Romovod 2 nuts bom 22 por ECN 01110 Added axxo kom 43 bohind tom whoob 2 places ond on ongno ECN 11 2 Gltornotor Any com B on sh
16. 3000 Test Mode Display ee Clear Key e The Elapsed Time field indicates the feedback frequency It should read between 1 000 adjustable in the field KHz and 3 600 KHz 3 60 is shown This information is for factory use only it is not e The Calories Burned field shows the alternator output in volts DC It should be at least 9 0 volts DC as shown when pedaling the bike at 40 to 45 RPM with 40 watts of power requested e The RPM field shows the power requested by the current resistance setting This is 40 watts in Figure 4 1 You can change this amount in steps of 5 by pressing the Up Arrow or Down Arrow key This information is for factory use only e The Heart Rate field shows the current power output of your pedaling This can be from 40 to 600 watts in Figure 4 1 it is 40 e As you pedal the Speed field shows the pedal RPM as reported by the RPM sensor If this changes correctly as you speed up or slow down you know the sensor is working Figure 4 1 shows a pedal speed of 40 RPM me ee a reece You can also read the BikeMax s odometer in Test Mode press the Switch Display key to do so Leaving Test Mode E To leave Test Mode press the Clear key twice BikeMax 1000 Test Mode 1 NG 505 3 NGA fe KOK KON T pore Y AR 3 2 a 2 Bm s d aa es vau LE 2772 A v 4 ng v VA g
17. 58 Appendix C Engineering Drawings Engineering Drawings Post October 1998 Alternator Bikes 65 Fairbanks EA 105 5958 Tolerances CA 82618 4 DECIMALS d ASSY EXTERNAL POWER T PLATE BMU A1 2 73 sa SCALE 61003 7 SEE INDIVIDUAL DRAWINGS SEE INDIVIDUAL DRAWINGS REVISIONS A Revise 50108c to 50108d per ECN 01085 BikeMax 1000 3000 Service Manual Page 59 5 Tolerances PJP 8 20 97 DECIMALS Phono 714 m ANGLES ah pa Added washers p n 43015 ttem 12 amp 43231 Item 14 Changed nut was p n PJP 0 14 9 x ASSY SEAT 42063 is 42033 13 per ECN 1043 SHUTTLE BMR MN Ki 0 FEE A 1703798 703798 b drw Pane 0 3 70379 5 68 Fathanks Irvino CA 92618 Phono 714 380 8082 ud Fax 714 580 8710 57 ASSY SEAT 5 7 SHUTTLE BMR LA 703792 1b asml 703792 b drw i SCAM pan o PARTS Uv non 2 3 70379 8 Page 60 Appendix C Engineering Drawings __ Adik V Engineering Drawings sv Dat A Revised bill of materials per ECN 001002 DPS 8 25 97 8 Added washers p n 43015 Item 18 amp 43231 Item 20 Changed nut was p n PJP 0 13 9 3 42063 ts p n 42033 ttem 19 per ECN 1043 xs Paka DAWG 70384
18. 70879 Page 66 Appendix C Engineering Drawings OSE PPENINY Engineering Drawings Revised bill of materials per ECN 001002 B Added washers p n 43015 Item 18 amp 43231 Item 20 Changed nui was p n PJP 10 13 9 42063 5 p n 42033 item 19 per ECN 1043 ASSY SEAT SHUTILE BMR A1 CT PIN 3 LEFT ASSY SEAT SHUTTLE BMR A1 CT Treat Fli gt 70384 Ib asm 70384 b drw J VELL Pade A __BikeMax 1000 3000 Service Manual Page 67 DATE H Tolerances CA Got R aaa 10 20 97 12 9 97 DAN 7 10 97 STE Pan ras WAG fab A 70380 b asm 03807 b drw HERR e 70380 1 BY 4 Update Items 2 3 5 amp 7 Added Item 18 and added additional Item 13 Deleted notes PJP per ECN 1048 pdate item per ECN 01085 RPM DETAIL 8 SCALE 1 4 iniiai Release per ECN 01070 A Revised tiems 2 5 B per ECN 01085 B Revised weldment Hem 1 Exinston Assy Hem 12 Kick piate Item 24 foot PEU Item 38 Removed 2 nuts liem 22 per ECN 01110 trum NAKED AE r Jo SCALE 3 SF DETAILD aw ES 82 SCALE 1 4 Page 68 Appendix C Engineering Drawings DETAIL H SCALE 1 4 DETAIL E SCALE 1 4 NAKED BMR DETAIL G BASE CT SCALE 1 4 DETAIL K SCALE 1 4 DETAIL M SCALE 1 3 DETAIL J SCALE 1 3 DETAIL L SCALE 1 3 BikeMa
19. A A battery which measures at least 3 0 VDC may still be rechargeable using the external power supply Leave the external power supply plugged into the BikeMax for at least one hour a full charge may require two or three hours The voltage across a battery should rise slowly to a plateau of 6 9 VDC while charging but may still require two hours thereafter to reach a full charge For revision 10060B with battery mounted on the ACB if the battery measures less than 6 0 VDC after you attempt to charge it replace the ACB 3B For revision 10050A ACB if the battery measures less than 6 0 VDC after you attempt to charge it perform the following test to see if battery charge voltage is present on the ACB Unplug the battery cable from the ACB at connector JP3 With external voltage applied measure the charging voltage available at JP3 If the voltage is less than 6 6 VDC or greater than 7 2 VDC replace the ACB and charge the battery on external power If the voltage at JP3 is correct 6 6 7 2 VDC the battery is refusing to accept a charge so replace the battery Put the BikeMax back into Test Mode on external power To check the RPM sensor pedal about 60 RPM and observe the Speed field on the display console It should accurately show pedal RPM 4A If no RPM displays in the Speed field remove the covers and make sure the coil is in the correct position with respect to the alternator flywheel If it is correctly positioned check the RPM s
20. C We re Here to Help Assembly instructions Basic troubleshooting procedures for electrical and mechanical problems and instructions on where to go next How to use BikeMax s test mode feature A series of short segments on each component of the BikeMax describing how to check and if necessary replace it Parts list Advanced electrical troubleshooting techniques Engineering drawings If you have any questions about any of the information in this book or if you re still having problems with your BikeMax after following all of the appropriate instructions please contact us so we can help you get riding again You can reach our technical support department in any of three ways e By phone Monday through Friday call 800 767 8082 or 508 533 4300 and ask for Technical Support e Send us a fax at 508 533 5183 CHAPTER 2 ASSEMBLY It s easy to assemble BikeMax it will probably take about 45 minutes You need these common tools e 3 16 Hex Allen wrench e 2 Phillips screwdriver e 12 box end or open end wrench if you have the optional Polar heart rate monitor Here s an overview of the steps in the assembly 1 Unpack BikeMax and make sure you have all the parts 2 Follow the detailed assembly instructions There are separate sections on assembling the recumbent BikeMax R and upright BikeMax U bikes 3 If you choose to plug in your BikeMax with the optional external power supply 4 If you have m
21. S Charge voltages 7 jPeplece battery Present on ACE CE 4 A 48 Jes Kc wN 7C ROM 0 TM NO I 7 YES i n Est Mode ve NES i i RPM coii igt ghi 4 ME een Maid ro ipa N Replace ACR 3 ma power Pua 2 A 5 na YES 5a JL py P Membr YES ouput OKT 47 58 ACB sippii S YES que Ee No E 25 Aca 8 pu Y hitema pis V YES E Keplac e N NN rtm MM Repiac e AC Ble is OK pa BikeMax 1000 3000 Service Manual Page 53 The Troubleshooting Sequence E The troubleshooting procedure listed below is extensive and can involve recharging the battery which can take up to three hours Certain steps in the troubleshooting procedure can require two people to perform the procedure Also some steps can be performed only on the BikeMax 3000 not j the 1000 1 The purpose of step 1 is to get the display board into Test Mode using external power Power up the BikeMax in Test Mode using an external power adapter To power up in Test Mode press and hold the top HR Control key while plugging in the external power adapter You don t need to pedal to light the display console when external power is a
22. able CT Display Upright Tube BMR 14157 4135 Cable Polar Display Upright Tube BMU 4134 Cable Ribbon Frame BMR Display Upright Assembly 14154 BMU Cable Ribbon Display Upright Assembly BMR Frame 14159 Cable SmartLink Switchplate BMR for use with 70418 14001 Cable SmartLink Switchplate BMU for use with 70418 14000 CardioTouch Board Cable Polar Extrusion Tube BMR 4123 Cable Polar Display Upright Tube BMR u 1503 Clutch Pulley 62021 1533 1486 1535 1536 2022 J NO c 0380 3018 3019 0060 0049 0068 1108 1098 2019 CAT VI Page 46 Appendix Parts List Part Seat Back Assembly BMR 61309 Seat Shuttle BMR non CT 70379 Seat Shuttle BMR CT 70384 Secondary Pulley Assembly 2018 Switchplate Assembly BMR for use with 70418 61003 Switchplate Assembly BMU for use with 70418 61003 61521 Switchplate Assembly BMU for use with 70391 61541 Wheel Front Transport 50029 eb un AE OD me JE 2 e 5 gt S c Un e O y g m gt NM 2 Z lt ee 5 2 m A h gt Ba NI UJ NO TORR gt ETE
23. and how to adjust the belt s tension 18 Important Proper primary belt tension is set at the factory If you need to remove and I replace the belt you should normally do so without relaxing the tension on the belt If you do need to change the tension see the instructions below Adjustment slot Adjustment bolt Pivot bolt Poy Primary 3 grooved pulley pulley Idler pulley Figure 5 1 First Stage Drive Components To remove and replace the primary belt ge 1 If the bike is equipped with the optional external power adapter unplug the adapter from the bike 2 Remove the bike covers See page 22 3 Rotate the primary pulley clockwise and carefully move the primary belt off the outside edges of the primary pulley idler pulley and 3 grooved pulley Doa r ma gt lt lt aanak anna GA aisa pana Page 24 ae 8 NG E Chapter 5 Component Repair and Replacement zu BikeMax 1000 3000 Service Manual Page 25 MMMM M M M 4 E 3 1 Loop the new belt around the idler and 3 grooved pulleys first as shown in Figure 5 1 then wrap the belt around the primary pulley while rotating the primary pulley counter clockwise to pull the belt up onto the surface Make sure the belt is centered in the grooves on all
24. board in the console If the cables are connected disconnect them Repeat the continuity test on each wire of the 3 conductor cable in the extrusion tube If the 3 conductor cable in the extrusion tube passes the continuity test then the 3 conductor cable in the upright tube is defective Replace the cable and test Polar again If the 3 conductor cable in the extrusion tube fails the continuity test replace it and test Polar again If the problem still exists replace the display board Once the diagnosis and repairs are complete test Polar again to verify integrity of the Polar system Upright Bike Polar Troubleshooting If the AC adapter is installed unplug it from the bike Unplug the 3 conductor connector from the display board Unscrew and remove the Polar receiver module from the display upright tube Disconnect the 3 conductor connector from the receiver module Set the volt ohm meter to the 200 ohm setting Place one meter lead on one of the wires in the 3 conductor connector at the top of the display upright tube Place the other meter lead on the same wire in the 3 conductor cable at the other end of the cable Observe the meter for continuity zero ohms or a low ohms reading 10 or less If continuity 1s present for the first wire verify the same for the other wire If either wire in the cable fails the continuity test replace the cable and test the Polar system for proper heart rate detection
25. cable into the hole in the top of the extrusion tube and attach the cable to its corresponding 2 conductor cable at the front of the extrusion tube Place the flex cable on the top of the tube with approximately 3 4 inch of the cable extending beyond the back of the tube Secure the flex cable to the top of the tube with the piece of Scotch tape Replace the cable clamp on the extrusion tube and tighten the two Phillips screws e If applicable feed the Polar cable through the length of the extrusion tube e Clip the alternator cable to the underside of the extrusion tube e Place the tube on the bike frame and secure it with the 12 bolts e Replace the ACB Follow the instructions in step 5 above in reverse order e Replace the seat shuttle and Polar receiver if the bike has one Follow the instructions in step 3 above in reverse order If the bike has CardioTouch install the flex cable into its connector on the rear underside of the seat shuttle before sliding the rear most rollers onto the extrusion tube KA po 7 Re attach the end cap using the four Phillips screws Before replacing the covers test the bike to make sure it s operating properly 1 If the bike has the optional external power supply plug it into the switchplate 2 Pedal the bike and make sure you can enter various program modes If the bike does not have an external power supply you must pedal at least 40 RPM Make sure the resistance increases w
26. connector J6 Connect the red meter lead from the VDC connector to the white wire on connector J6 A fully charged battery will indicate 6 0 to 6 3 VDC A battery with less than 5 7 VDC will not activate the bike The technician or customer can attempt to charge the battery with the optional AC adapter If the AC adapter is available plug the adapter into the circular connector on the switchplate The adapter will charge the battery in approximately 2 hours but the bike may be used at once while charging Page 40 SYAY y Chapter 5 Component Repair and Replacement CardioTouch Heart Rate Receiver Tools Needed Phillips screwdriver Volt ohm meter with test leads Optional AC adapter if 3 16 hex wrench available CT heart rate detection uses special rubber hand grips to sense the heart rate The heart rate signal is transmitted through electrical cabling to a CT circuit board mounted on the display board in the console The user must keep both hands on the rubber hand grips during the workout so CT can consistently detect the heart rate On the recumbent bike the rubber hand grips are mounted to handlebars on each side of the seat On the upright bike the hand grips are on a balance bar directly below the console The most common cause of an inconsistent or non existent readout is that the user does not have his her hands on the hand grips or that the grips are covered with perspiration The first thing to
27. de of the bike e Remove the pedal from the left crank arm e Remove the three Phillips screws fromi the cover plate that surrounds the left crank arm e Remove the cover plate from the bike 5 Onarecumbent BikeMax you may need to remove the primary belt then remove the 3 grooved pulley pulley shaft and secondary pulley before removing the engine If you need to do this see Replacing the Second Stage Assembly on page 28 6 Remove the two 12 bolts and washers from the brass colored mounting plate that secures the front of the engine casting to the semi circular frame mounting bracket 7 Remove the four Phillips screws that hold the brass colored rear engine mounting plate to the right side of the bike frame Remove the mounting plate During the next step you must support the rear of the engine assembly before you remove the second 52 bolt that secures the engine to the bike frame 8 Remove the two 12 bolts and nuts that secure the rear of the engine casting to the bike frame _ Page 30 9 Chapter 5 Component Repair and Replacement Rotate the right crank arm so it points toward the rear of the bike While supporting the front of the engine casting carefully rock the rear of the engine assembly toward the top of the diagonal frame member The front of the casting will drop away from its semi circular frame mounting bracket 10 When the engine assembly is free within the frame remove it from the left side of
28. e ACB 1 If the bike is equipped with the optional AC adapter unplug the adapter from the bike 2 Remove the bike covers See page 22 3 Disconnect the electrical cables from connectors JP3 JAP JPS and JP7 4 Remove the ACB assembly from the frame by unscrewing the two Phillips head screws 5 Attach the new ACB assembly to the frame 6 Reconnect the leads If you need to refer to Tables 3 1 and 3 2 or Figures 3 1 and 3 2 7 Replace the bike cover See page 22 mde ia GN i M MM A i Cot BikeMax 1000 3000 Service Manual Page 39 eS YU 00 6 Battery Tools Needed 2 Phillips screwdriver Volt ohm meter with test leads Optional AC adapter if available The battery must be functional in order to activate the bike A fully charged battery will have 6 0 to 6 3 VDC present when it is plugged into connector 6 Rev 10060A or JP3 Rev 10050A on the ACB To test the battery 1 2 3 Remove the bike covers See page 22 Verify that the battery is plugged into the ACB Set the volt ohm meter to sense DC volts using the 20 volt scale if the meter has this setting available Make sure the red lead is connected to the VDC connector on the meter and the black lead is connected to the GND connector on the meter Connect the black meter lead from the GND connector to the black wire on
29. e holder you must still screw the three screws into the open holes in the back plate to protect the electronics from the environment Attach the Handlebar Use the 3 16 hex wrench to attach the handlebar 4 to the console back plate with four 5 16 button head screws 5 and lock washers 6 Page 6 7 t Chapter 2 Assembly Assembling the Recumbent BikeMax BMR Polar cable 3 wire 1 DETAILA Location of top cover screw Figure 2 2 Attach the Seat Back Assembly pi See Figure 2 2 Attach the seat back assembly 2 to the seat shuttle with four 5 16 x 1 3 4 button head cap screws 9 and lock washers 12 using a 3 16 hex wrench If you have A difficulty aligning the screws loosen the four button head cap screws on the back of the seat ES Attach seat supports to the seat shuttle and fully tighten then tighten screws on seat back Attach the Display Upright All of the cable connections are shown in detail A of Figure 2 2 Connect the two ends of the ribbon cable 5 and 6 which emerge from the bike base and the display upright 3 Connect ends of Polar cable 4 and 11 and CardioTouch cable 7 and 10 if applicable To help support the display upright move the seat forward and rest the handlebar of the upright on the seat BikeMax 1000 3000 Service Manual Page 7 Loosen the top cover screw see detail A Feed excess cable into the upright Slide the disp
30. e terminal where the black wire is connected A good field winding has a DC resistance of about four ohms If the meter reads less than two ohms the alternator s field winding is at least partially shorted If so replace the alternator immediately The bad alternator may have caused the failure of the original ACB and it may cause the replacement ACB to fail as well a 6 When the BikeMax can power up properly without external power perform a final check for x pedal resistance Lack of pedal resistance should not cause a dead BikeMax but the test verifies functionality of the alternator and ACB Enter Test Mode press the Advanced Options key you can do this only on the BikeMax 3000 and then press the Up Arrow key 5 to command 300W of power With enough pedal power it should require substantial effort x the Actual Power field the Heart Rate field in Test Mode should also read 300W Also the V alt Calories Burned field should read 15 0 VDC or greater If there 1s no pedal resistance see if the large ribbed load resistor on the ACB is plugged in at header JP6 If it is replace the ACB BikeMax 1000 3000 Service Manual Page 57 APPENDIX C ENGINEERING DRAWINGS Beginning on the next page this appendix contains a number of the engineering drawings for both recumbent and upright BikeMax models These drawings may help you perform the diagnostic and repair procedures found in this manual Page
31. e the key the fields at the top of the display should show BIKE TEST n nn The n nn refers to the version of software installed in the bike Field Indicators The field indicators the small red lights by each field provide the following information while in test mode e Elapsed Time indicates Smart Link communications output e Time Remaining indicates Smart Link communication input Standb Blinking MR o Oli e Heart Rate lights when the circuitry detects the pulse rate transmitted by a Polar or CardioTouch heart rate monitor Testing Display LEDs If you want to test the LEDs on your display console press one of these keys e Start Enter Light all LEDs e Top HR Control Light vertical columns of LEDs and individual whole readouts e Bottom HR Control Light horizontal rows of LEDs and individual readout segments Page 18 i Chapter 4 Using Test Mode PG SEP P SEA BA Advanced Diagnostic Information Press the Advanced Options key to display diagnostic information as shown in Figure 4 1 Alternator Power Power E Feedback Voltage Requested Output MEE Frequency Volts DC Watts Watts owitch Display Key Pedal opeed CA tig y A aap AGA pi mu ROLE eg e US 2 2 222 Advanced Options Top HR Control Key Key Figure 4 1 BikeMax
32. ensor itself Unplug it from connector J7 on the ACB Set the voltmeter to a 10 VAC or 20 VAC alternating current range and probe the two conductors at the plug on the end of the sensor s cable Measure the voltage produced while someone else pedals the BikeMax at 60 RPM or greater If this voltage 15 less than 2 5 VAC replace the RPM coil If the RPM sensor passes this test measure its DC resistance while it is unplugged from the ACB and no one is pedaling A good RPM sensor should measure about 850 ohms of DC resistance If the sensor measures less than 750 ohms or more than 1000 ohms replace it If the RPM sensor is good and positioned correctly but you didn t get an RPM display while pedaling in Test Mode replace the ACB Unplug the external power supply and try to start the BikeMax in Test Mode Pedal faster than 40 RPM while holding down the top HR Control key If the BikeMax display lights up go to step 5A Otherwise If the still won t light up on pedal power alone replace the ACB a BikeMax 1000 3000 Service Manual Page 55 l SA If the BikeMax enters Test Mode without external power but the display remains dim and after you press the Advanced Options key the V alt field reads no more than 6 0 VDC the alternator is not being energized This indicates a bad ACB bad alternator cable or bad alternator Unfortunately it is quite possible that both the alternator and ACB are bad Do
33. external AC adapter wall transformer with an output of 10 16 VAC or 12 18 VDC 1500mA The AC adapter is available from Tectrix in either 110 or 230 AC input voltage configurations see page 23 e A simple digital or analog volt ohm meter e 2 Phillips screwdriver e A flashlight BikeMax 1000 3000 Service Manual Page 51 Unless otherwise specified all voltages described in this document are direct current DC referenced to circuit ground and made on the ACB Make sure your voltmeter is on an appropriate DC scale Circuit ground is available on the anode of D1 the end of D1 not marked with a stripe near the center of the ACB just under the large header for the alternator cable J4 Left right top and bottom refer to the ACB as viewed with the lettering right side up Whenever these instructions refer to a Test Mode feature please see Chapter 4 Using Test Mode For instructions on removing and replacing the various components if needed see Chapter 5 Before you start the troubleshooting procedure study the BikeMax system block diagram in chapter 3 and the troubleshooting procedure flowchart Page 52 Appendix 8 Advanced Electrical Troubleshooting 254 1 Troubleshooting Flowchart for Dead Alternator BikeMax i Dead Be 2 l ACB Rev 10060B EPROM Rev 3 11 or greater and i 07 ACB Rev 10050A 100504 EPROM Rev 3 04 or greater 323128 at eee 1 3 a IN
34. h a white polar label near one end must be routed from the largest of these openings up through the upright and attached to the display console Feed the unlabeled end into the large round opening and up until it comes out the top of the upright Plug the end of the cable with the white label into the connector on the receiver Verify that the tab on the connector locks the brown 3 conductor cable connector into place Position the receiver so the locking tab on the connector is on top nearest to the console If there is an UP ARROW on the receiver it should be pointing toward the console Secure the receiver to the display upright tube with 2 Phillips screws supplied with the kit Attach the Display Console Remove the display console from the configuration kit Attach the ribbon cable from the display upright to the back of the display board The connector is keyed so you cannot insert it backwards Attach the green ground cable to the single flat connector next to the ribbon cable connector Make sure the cables are firmly connected before continuing If you have the CardioTouch or Polar heart rate monitor option attach the heart rate v monitor cable to the back of the console Use the four Phillips head screws from the configuration kit to attach the display console to the console back plate See Figure 2 3 Attach the water bottle holder to the back plate using three screws Important if you choose not to install the water bottl
35. he flywheel to the shaft is tight 4 Rotate the flywheel and use the screwdriver to listen for noise in the alternator If noise 1s present replace the alternator Any alternator will make a buzzing noise when the alternator shaft is operating at high speed This is true for any alternator whether it is installed in an automobile or stationary bike lt EE am Fert EL Qi ete m y rte s LOLA ue ye n RI tte ar Meum eee ere da ele er eter a AR e rr i lt c R AA m aa nan cam Page 16 na dA C Chapter 3 Troubleshooting CHAPTER 4 USING TEST MODE The BikeMax s test mode lets you test various aspects of the bike s electrical system by pressing the correct key and checking the resulting display While test mode is very similar on the BikeMax 3000 and BikeMax 1000 there are enough differences that each one has its own section BikeMax 3000 Test Mode To enter test mode press and hold the top HR Control key while applying power to the display console You can apply power either by beginning to pedal faster than 40 RPM from a stop or by plugging in an external power source When you releas
36. he console within 30 seconds 5 If either heart rate sensor is not working make sure all cables are attached securely Once you know the bike is working correctly unplug the external power supply if it has one and replace the covers See page 22 589932 gt pa 8 Chapter 5 Component Repair and Replacement ee pone nepar and nepiacement Alternator Tools Needed 2 Phillips screwdriver J2 box end or open end wrench Flat blade screwdriver 3 4 box end or open end wrench 3 4 socket and wrench 7 8 socket The alternator provides the pedaling resistance the rider feels The pulley which connects the alternator with the secondary belt also functions as a flywheel and RPM sensor encoder Removing the Alternator 1 If the bike is equipped with the optional AC adapter unplug the adapter from the bike 2 Remove the bike covers See page 22 3 Remove the secondary belt e Slowly rotate the secondary pulley on the left side of the bike e Carefully move the belt to the outside edge of the pulley then off the pulley e Remove the remainder of the belt from the small alternator pulley 4 Remove the RPM sensor from the alternator case e Remove the 12 bolt and washer that secures the sensor to the alternator e Move the sensor away from the area surrounding the alternator 5 Carefully insert a flat blade screwdriver through one of the six openings in the alternator pulley and rest the tip against the ho
37. he flywheel e Check the bracket to make sure the RPM sensor coil is not bent into or away from the flywheel Check the air gap between the center core of the RPM sensor and the back of the flywheel The air gap should be in a range of 020 to 060 or 5mm to 1 5mm If necessary carefully bend the sensor bracket to achieve the desired air gap See the picture below Sensor gap 6 Test the RPM sensor Reese at ee BikeMax 1000 3000 Service Manual Page 37 e Press and hold the top HR Control button on the console e Pedal the bike at 40 RPM or greater to activate the console or plug in the optional AC adapter e Verify that the Speed field on the console indicates your pedal speed If the value is zero or non existent make sure the RPM sensor is plugged into connector JP5 on the Alternator Control Board ACB If the value is still zero or non existent replace the RPM sensor 7 Replace the bike covers See page 22 Page 38 i Chapter 5 Component Repair and Replacement eee Alternator Control Board Tools Needed 2 Phillips screwdriver You may need to replace the Alternator Control Board ACB if the electrical troubleshooting procedure in Chapter 3 recommends it or if the group race feature is not working for a set of linked bikes Discrepancies in the bikes ACBs can keep group racing from working If this is the case you should replace the ACB on each linked bike To replace th
38. he new alternator is the same as removing the old one in reverse 1 Place the alternator in position 2 Insert the 34 bolt and nut that secure the alternator to the frame bracket 3 Insert the 42 bolt and washer into the slotted frame bracket and carefully thread it into the mounting hole in the alternator 4 If you marked the old alternator s position on the belt tension adjustment slot place the alternator in the same position so the secondary belt tension will be correct Tighten the V2 bolt that secures the alternator to the slotted frame bracket Tighten the 34 bolt and nut that secure the alternator to the frame bracket 5 Do one of the following depending on the bike model e Recumbent Clip the alternator cable to the bottom of the extrusion tube e Upright Clip the alternator cable to the right side of the diagonal frame member 6 Plug the alternator cable into connector JP1 on the Alternator Control Board ACB 7 Carefully place the flywheel on the alternator shaft Make sure the half moon key on the alternator shaft fits into the notch on the flywheel 8 Install the washer and 7 8 retaining nut on the alternator shaft 9 Carefully insert a flat blade screwdriver through one of the six openings in the alternator pulley and rest the tip against the housing This will keep the pulley from moving Tighten the 7 8 retaining nut 10 Place the RPM sensor in position and insert and tighten the 1 2 bolt and washer
39. he primary belt can slip off the three pulleys Tools Needed 9 16 socket and wrench 9 16 box end or open end wrench Flat blade screwdriver 8 Please refer to Figure 5 1 on page 24 for the location of the first stage drive components E referred to below To remove the idler pulley 1 If the optional AC transformer is installed unplug it from the bike 2 Remove the bike covers See page 22 3 Loosen the idler bracket pivot bolt located behind the primary pulley 4 Place the flat blade screwdriver i in the adjustment slot of the idler bracket above the adjustment bolt Rest the tip of the screwdriver on the engine casting 5 Loosen the idler bracket adjustment bolt and let the bracket rest against the shaft of the screwdriver Slowly remove the screwdriver from the adjustment slot 6 Rotate the primary pulley counter clockwise and remove the primary belt from the primary pulley 3 grooved pulley and idler pulley 7 Remove the bolt washer and nut that secure the idler pulley to the idler pulley bracket 8 Remove the idler pulley To install the idler pulley The idler pulley comes with the bushing pre installed by the factory The bushing is exposed on the back side of the pulley The mounting bolt and washer are installed through the front side of the pulley 1 Install the bolt and washer through the idler pulley 2 Place the idler pulley against the idler pulley bracket so the bushing contacts
40. he second stage assembly in order to remove or install the engine assembly into the bike The second stage assembly includes the secondary pulley pulley shaft and 3 grooved pulley 1 If the bike 5 equipped with the optional AC adapter unplug the adapter from the bike 2 Remove the bike covers See page 22 3 Remove the primary belt see page 24 and the secondary belt see page 27 The pulley shaft 15 attached to the second stage pulley with a nut Do not unscrew sy the pulley shaft from the nut unless you are replacing the pulley and not the shaft 3 Using the flat blade screwdriver carefully pry up on the c clip that secures the 3 grooved pulley to the pulley shaft 4 Remove the two washers on the outside edge of the 3 grooved pulley Slide the pulley off the pulley shaft 5 Remove the remaining two washers from the pulley shaft 6 Carefully slide the second stage pulley and pulley shaft out of the bearings in the engine casting 7 Carefully slide the new second stage pulley and pulley shaft into the bearings of the engine casting 8 Place two washers on the pulley shaft 9 Install the 3 grooved pulley on the pulley shaft The pulley should go on so it will freewheel in a counter clockwise direction when viewed from the right side of the bike the side it s on The small arrow on the hub of the pulley goes toward the bike frame 10 1nstall the other two washers and c clip on the pulley shaft
41. hen you press the Up Arrow and decreases when you press the Down Arrow 3 If the bike has a CardioTouch heart rate sensor pedal the bike and place your hands on the rubber coated CardioTouch grips The bike should sense your heart rate and display a flashing shield in the upper right of the display Your heart rate should appear on the console within 30 seconds 4 If the bike has a Polar heart rate sensor use a Polar chest strap or Polar test transmitter The bike should sense your heart rate and display a flashing shield in the upper right of the display Your heart rate should appear on the console within 30 seconds 5 If either heart rate sensor is not working make sure all cables are attached securely Once you know the bike is working correctly unplug the external power supply if it has one and replace the covers See page 22 APPENDIX PARTS LIST This appendix lists the parts making up the BikeMax 1000 and or 3000 Parts found in only the upright or recumbent bike are marked with BMU or BMR respectively All other parts are found in both types of bike Description Part 1539 Alternator Control Board Toa Cable Alternator Cable Battery ON lt 0 5 COIN OO Cable CT Flex Extrusion Tube BMR 50116 Cable CT Extrusion Tube BMR 14155 C
42. ing surface on the semi circular frame bracket Tighten the four Phillips screws to secure the rear mounting plate to the frame Tighten the two 12 bolts and nuts to secure the rear of the engine casting to the frame Install the secondary belt as described in Replacing the Secondary Belt on page 27 10 Install the cover plate and pedal as listed in Step 3 in reverse order The new engine is now installed Before replacing the covers test the bike to make sure it s operating properly 1 If the bike has the optional external power supply plug it into the switchplate 2 Pedal the bike and make sure you can enter various program modes If the bike does not have an external power supply you must pedal at least 40 RPM Make sure the resistance increases when you press the Up Arrow is pressed and decreases when you press the Down Arrow 1 QT E BikeMax 1000 3000 Service Manual Page 31 3 If the bike has a CardioTouch heart rate sensor pedal the bike and place your hands on the rubber coated CardioTouch grips The bike should sense your heart rate and display a flashing shield in the upper right of the display Your heart rate should appear on the console within 30 seconds 4 If the bike has a Polar heart rate sensor use a Polar chest strap or Polar test transmitter The bike should sense your heart rate and display a flashing shield in the upper right of the display Your heart rate should appear on t
43. ity and installation is correct test the CT system as follows 1 Plug the AC adapter if available into the bike or pedal the bike to activate the console 2 Place your hands on the CT rubber hand grips BikeMax 1000 3000 Service Manual Page 41 3 If CT is operating correctly a flashing indicator will appear in the top right corner of the display This indicates that CT has sensed your heart rate 4 Within 30 seconds a digital readout of your heart rate will display If the flashing indicator doesn t appear or if it does appear but your heart rate doesn t display replace the CT circuit board and test CT again If a new CT board does not correct the problem troubleshoot the problem as described below There are different procedures for the recumbent and upright bikes Recumbent Bike CardioTouch Troubleshooting 1 If the AC adapter is installed unplug it from the bike 2 Unplug the 4 pin connector cable from the CT board 3 Set the volt ohm meter to the 200 ohms setting Place one meter lead on one of the CT rubber hand grips and the other meter lead on one of the wires in the 4 pin connector One wire in the connector is dedicated to each hand grip so observe the meter for continuity a change in the numeric display or needle movement If continuity is present the connection between that hand grip and the connector is good Verify the same for the other hand grip and wire in the connector If either wire or hand
44. key again for the next segment Leaving Test Mode To leave Test Mode press the Clear key twice ee a CHAPTER 5 COMPONENT REPAIR AND REPLACEMENT This chapter contains a number of individual sections Fach describes how to check adjust and or replace an individual component of your BikeMax To make it easy to find any section each one starts on a new page The page numbers are in the list below The first section describes how to remove the cover from your bike this section is referred to by many of the others Section Page Cover Removal 22 External Power 23 First Stage Drive 24 Idler Pulley 26 Second Stage Drive 26 Engine Assembly 29 Alternator 32 RPM Sensor 35 Alternator Board 38 Battery 39 CardioTouch Monitor 40 Polar Heart Rate Monitor 43 Extrusion Tube 45 Before beginning any procedure please carefully read the entire instructions for it Page 22 3 BEEN PED for EBE Chapter 5 Component Repair and Replacement Cover Removal 5 the bike is equipped with the optional AC adapter unplug the adapter from the bike On the upright BikeMax only you must detach the seat bellows from the cover before removing the cover Raise the seat as high as it will go Grasp the rubber accordion bellows and gently pull upward to unsnap it from the plastic bike cover Remove the ten Phillips head screws that secure the cover halves to the bike frame Rotate the right a
45. lay upright down over the neck of the chassis taking care not to pinch the cables Fasten the display console assembly using three 5 16 18 x 3 8 button head cap screws 8 and lock washers 12 Tighten the top cover screw at the front of the bike Attach the Display Console See Figure 2 3 Remove the display console 3 from the configuration kit Attach the ribbon cable from the display upright to the back of the display board The connector is keyed so you cannot insert it backwards Attach the green ground cable to the single flat connector next to the ribbon cable connector Make sure the cables are firmly connected before continuing CT cable Polar cable ribbon cable ground cable Figure 2 3 DETAIL A If you have the CardioTouch or Polar heart rate monitor option attach the heart rate monitor cable to the back of the console See Figure 2 3 detail A Use the four Phillips head screws from the configuration kit to attach the display console to the console back plate See Figure 2 3 Attach the water bottle holder to the back plate using three screws Important if you choose not to install the water bottle holder you must still screw the three Screws into the open holes in the back plate to protect the electronics from the environment Page8 ARX piede ve Chapter 2 Assembly u Install the Optional Polar Heart Rate Receiver Tools needed 2 Phillips screwdriver 2 box end
46. mits it to a recelver module Depending of the type of BikeMax the receiver is connected to the display board with one or two 3 conductor electrical cable s e On the recumbent bike the receiver module is inside the extrusion tube at the back of the bike It is connected to a 3 conductor cable in the extrusion tube which exits at the front of the tube A second 3 conductor cable connects to the cable at the front of the extrusion tube and carries the heart rate signal to the display board in the console On the upright bike the receiver module is mounted on the display upright tube below the console On both bikes the end of the Polar cable that connects to the display board has a brown 3 conductor connector PG On the upright bike the Polar cable has a white label at one end The labeled end of the Vaz cable plugs into the Polar receiver module If the Polar display indicates an erratic heart rate verify the positioning of the ribbon and Polar cables under the console The cables should be kept separate from one another and excess cabling should be within the upright tube If no heart rate value is displayed make sure the Polar cable is plugged into the 3 conductor male connector on the display board Verify the operation of the Polar chest strap by testing the receiver with another chest strap or with a Polar test transmitter If possible swap the receiver module and test Polar again If the heart rate is s
47. nce you know the bike is working correctly unplug the external power supply if it has one and replace the covers See page 22 4 n D ET gt PS EL mm ee m BikeMax 1000 3000 Service Manual Page 35 _ SOO YE 3 RPM Sensor Tools Needed 2 Phillips screwdriver 1 2 box end wrench Feeler gauges standard or metric The RPM sensor must be adjusted properly near the metal alternator flywheel The edge of the flywheel must pass over the metal center part of the sensor and the gap between the sensor and the flywheel must be between 0 020 and 0 060 inches To adjust the RPM sensor 1 If the bike is equipped with the optional AC adapter unplug the adapter from the bike 2 Remove the bike covers See page 22 3 Loosen the 1 2 bolt that secures the RPM sensor to the alternator 4 Look at the face of the flywheel and RPM sensor Position the sensor so one half of the sensor s center core is covered by the flywheel as shown in the drawing below Coil X magnet X NN TN A dl 2 d Ne P 4 a Flywheel Alignment of RPM Coil with Flywheel On Tectrix Alternator BikeMax 1 2 bolt Sensor coverage 4 Tighten the 1 2 bolt Do not overtighten the bolt or you may strip the threaded hole in the alternator 5 Verify the air gap between the sensor and t
48. not operate the BikeMax indefinitely in this condition It is operating on battery power only and the battery will eventually discharge In this case L go to step 5B If the display is normal in brightness and the V alt field reads 9 0 VDC or more go to step 6 P 5B To see if the problem is the ACB and cable or in the alternator itself disconnect the TE white field wire from the alternator Leave the black and red wires of the cable connected to the alternator Connect the voltmeter to the loose ring terminal on the white wire at the end of the alternator cable You can ground the meter at the alternator terminal where oe d the black wire is connected Pedal the BikeMax and read the voltmeter while pedaling at P least 40 RPM fast enough to light the display to its dim state If the meter reads more than 4 0 VDC replace the alternator Otherwise check the continuity of the three l conductors in the alternator cable If the cable lacks full continuity repair or replace it 7 and retest If the ACB will not supply 4 0 VDC to the alternator with a good cable replace the ACB 5C Before attempting to operate the BikeMax check for a shorted field winding in the alternator With the white field wire still disconnected measure the DC resistance of the field winding of the alternator Set the meter to the lowest resistance scale Measure from the screw terminal on the alternator where the white wire was connected to th
49. oltage 9 2 VDC across C1 an electrolytic capacitor nearest the display cable header If the display voltage 15 present replace the display board If not present replace the display cable 2 Verify correct operation of the BikeMax while operating normally on external power Press g the Clear key twice to exit Test Mode If the only problem is a discharged battery you may be able to recharge it by leaving it on external power However there is most likely a problem in the bike that caused the discharged battery To continue troubleshooting remove the BikeMax covers as described on page 22 3 Make sure the battery is good using the voltmeter A good battery should measure 6 0 VDC x minimum open cell voltage neither charging nor discharging do not pedal or apply external power If the battery measures less than this go to step 3A mM mtm Doc RM MMM M M M Page 54 a e Appendix 8 Advanced Electrical Troubleshooting Check that the battery is correctly wired and plugged into the ACB at connector J6 For 10050A boards the battery must be plugged into connector JP3 NOT JP7 The white wire of the battery cable goes to the positive terminal of the battery Note the mark on the battery 1s not visible while the battery is mounted to the assembly you can determine battery polarity with the voltmeter If the battery checks out O K go to step 4 3
50. onal motion to the 3 grooved pulley through the primary belt The idler pulley provides consistent belt tension to the primary pulley and 3 grooved pulley If you hear a noise in the pedal or crank arm area of the bike 1 Remove the primary belt This isolates the primary pulley idler pulley and crank arm 2 Rotate the idler pulley If it binds or wobbles replace it as described on page 26 3 While rotating the crank arm assembly use the screwdriver to listen for noise in the assembly e If there is noise around the bracket that secures the engine casting to the frame of the bike the bracket is loose and needs to be tightened e If there is noise in the crank arm assembly make sure the two hex screws securing the bearing assembly to the engine casting are tight e Make sure the large collar nut and lock nut that secure the crank arm to the bearing assembly are tight 4 Recheck the area for noise if noise is still present replace the engine assembly 3 See page 23 for instructions on replacing the primary belt Mechanical Noise in the Second Stage Pulley Area Components in the second stage pulley area include the second stage pulley pulley shaft and 3 inch diameter grooved pulley The second stage pulley and 3 inch diameter grooved pulley are mounted on the pulley shaft which rides on bearings at the rear of the engine assembly The 3 inch diameter grooved pulley receives rotational force from the primary pulley through
51. oot 2 Adcod now exto nat ow pinto amp capio tam 3 on shoo 1 now format por 01155 whoo 50029 with now whoo 50026 ECO 1271 DETAIL D SCALE 1 4 9 par ERN 01117 Bovizod foc tom 10 ano tick piro Horn 42 Qamoved 2 nu s Bum 22 por ECN 01110 Addod orn 43 bahind whoo 2 ploces and an ongino ECN na now 0 Assy lom 6 on shoot 2 Addod now external plate ASI Aay Pan 4 conio Ciam 45 on thou 1 amp now tormo por 01155 NAKED 8 E Reapiccod cid wheol 50029 Docs a ECC 127 smi BMU Al 8 6 70990 6 Page 64 Appendix C Engineering Drawings Engineering Drawings Pre October 1998 Alternator Bikes NOTES UNLESS OTHERWISE SPECIFIED 1 NUT TEM 40 IS SUPPLIED WITH CABLE TEM 4 2 VERIFY POWER JACK THREADS ARE INSULATED FROM POWER PLATE 68 Fakbanks Fax 714 320 8710 ASSY EXTERNAL POWER PLATE BMU Al PAM Rul 01085 1 2 62020 AP A Pa BikeMax 1000 3000 Service Manual B Added washers p n 43015 tem 12 amp 43231 Hem 14 Changed nut was p n PJP 42063 is 42033 diem 13 per ECN 1043 4 5 xx Page 65 ASSY SEAT SHUTTLE BMR A PARERE 7 SS 70 68 Fairbanks CA 92618 714 380 8082 Fax 714 380 8710 ASSY SEAT SHUTTLE BMR irvine Phone
52. or open end wrench Remove the plate at the rear of the bike 3 Plug the cable already inside the seat rail into the Polar receiver 2 Loosen the 2 nut 4 on inside of seat rail and slide the Polar receiver bracket onto the bolt 8 shaft Tighten the nut to secure the bracket and replace the rear plate 3 1 Plugging in the BikeMax Figure 2 4 Because of its alternator design you do not need to plug BikeMax into a wall socket it generates all the electricity it needs from the power of your pedaling An optional power adapter part number 13018 110 volt part number 13019 230 volt lets you plug the BikeMax in if you want this makes some features easier to use Simply plug the adapter into the outlet on the front wheel side of the BikeMax There is no power switch you may unplug the adapter to turn off the display normally you can leave it on all the time Connecting Bikes for Racing BikeMax offers a group race feature where two to eight users compete against each other To use this feature you need to use the telephone style SmartLink cables attach the bikes You can link up to 8 bikes 18 this manner Figure 2 5 BikeMax 1000 3000 Service Manual Page 9 Fach BikeMax 15 shipped with a termination plug already inserted in one of the communications sockets You may need to remove this plug before making the connections described below Place a termination plug in the left
53. ore than one BikeMax connect the communications ports to allow group racing Unpack BikeMax Cut and remove the nylon tie straps holding the chassis feet to the pallet Remove all the other parts from the shipping carton Page 4 ER 7 Chapter 2 Assembly Assembling the Upright BikeMax BMU Figure 2 1 Attach the Display Upright Position the display upright 3 over the chassis and plug the ribbon cable from the upright to the ribbon cable in the chassis Tuck the cables inside the neck of the chassis 2 to make sure they don t get pinched when you attach the display upright Slide the display upright 3 down over the neck on the chassis Using a 3 16 hex wrench secure them with two 5 16 by 1 button head screws 7 and washers 8 etm 5 XA BikeMax 1000 3000 Service Manual Page 5 If your bike has a CardioTouch heart rate monitor Remove the upper three round plugs from the display upright Feed the cable from the CardioTouch handlebars through the large hole in the display upright until it emerges through the hole in the display console mounting plate Attach the handlebars to the display upright with two 1 2 screws If your bike has a Polar heart rate receiver Remove the 3 circular plastic plugs that are installed in a vertical pattern on the display upright tube there are 2 small plugs surrounding a larger plug The Polar cable a short cable wit
54. pplied After you release the HR Control key the console should display BIKE TEST n nn The n nn indicates the software EPROM version installed in the bike This display verifies a good display board and display cable If the display powers up with external voltage proceed to step 2 If the display does not light up with external power applied the dead BikeMax must have a bad ACB display cable or display board or there is more than one problem 2 1 Remove the covers Look for display voltage 9 2 VDC on the ACB at the right side of R18 10060B upper left corner 10050A upper right If present proceed to step 1B Make sure the external voltage AC or DC is present at the anode of D14 upper HA right of the ACB referenced to the anode of D11 If external voltage is present replace the ACB If the voltage isn t present unplug the external power cable from J3 of the ACB and check for a bad external power transformer or bad external power cable If the external power transformer no longer has any output it may have blown a fuse probably not replaceable due to a bad ACB In this case replace the ACB or be prepared to lose another external power transformer Also check for a bad interconnect board on the external power plate 1B If display voltage is present on the ACB the BikeMax must have a bad display cable or bad display board Access the rear side of the display board and check for display v
55. px RG APPENDIX 8 ADVANCED ELECTRICAL TROUBLESHOOTING One of the features of the BikeMax is that it doesn t require external power an internal alternator mo uses the power generated by pedaling to light the BikeMax display and to generate the needed resistance to the pedals If the display fails to light and no resistance is felt when you pedal at more than 40 RPM a condition known as a dead bike it indicates a problem somewhere in the BikeMax s electrical system In fact a dead bike may be the most common symptom for a BikeMax electrical problem The following sections first describe the process that goes on inside a BikeMax during the normal power up when a user begins to pedal Then they lead you through the procedure to ps diagnose the cause of a dead bike The Power Up Sequence In normal operation the BikeMax powers up when a user begins to pedal at more than 40 RPM The components involved in power up are the RPM coll alternator Alternator Control Board ka ACB and battery display console and their interconnecting cables These are the steps in the power up sequence 1 The user begins to pedal generating a small AC current in the RPM coil Besides sensing Pi alternator RPM the coil is also a tiny electrical generator 2 At about 20 RPM or less the exact RPM depends largely on the gap between the coil magnet and the fluted edge of the flywheel the coil generates enough current to activa
56. s if you were sitting on the bike crank arm to the 12 o clock position Grasp the bottom of the right cover half and pull it away from the frame Gently lift the cover over the crank arm and off the bike Rotate the left crank arm to the 12 o clock position and remove the left cover half To replace the covers perform these steps in reverse order BikeMax 1000 3000 Service Manual Page 23 Eee External Power Supply The optional external power adaptor can be very useful as a troubleshooting tool It allows easy recharging of the battery and makes Test Mode easier to use The table below gives the part numbers and descriptions of the AC adapters available from Tectrix Tectrix Part Number Description 13018 Adapter 110 VAC input 10 VAC output 13019 Adapter 230 VAC input 10 VAC output Plug the AC adapter into the circular connector on the switchplate The switchplate is located at the front of the bike above the stationary axle First Stage Drive Tools Needed 9 16 socket and wrench 9 16 open end wrench Flat blade screwdriver 2 Phillips screwdriver _ The 13 primary pulley which is attached to the pedal crank arm begins the transfer of pedaling power to the drive engine of the bike It turns the 10 groove primary belt which turns the 3 grooved pulley This assembly which includes other parts is called the first stage drive This section describes how to remove and replace the primary belt
57. socket of the first bike Run a SmartLink cable from the right socket on that bike to the left socket on the second Run another cable from the right socket on the second bike to the left socket on the third See the dotted lines on Figure 2 5 Continue in this way until you reach the last bike Place a termination plug in the right socket of the last bike While the SmartLink cables look like standard telephone cables their internal wiring is different You cannot use telephone cables to connect the bikes you must use SmartLink cables CHAPTER 3 TROUBLESHOOTING The BikeMax is designed so you can find and fix most mechanical and electrical problems in one hour or less This chapter helps you diagnose what s troubling your BikeMax to go from it doesn t work or something seems wrong to I need to replace this part and everything will be fine After you finish the procedures here you can turn to Chapter 5 and perform the required replacement or adjustment Where to Start When you encounter a problem the first thing to do is check for the most likely causes 1 2 Remove the covers of the bike See page 22 Make sure the primary and secondary belts are centered on all pulleys and they are not slack See pages 24 and 27 Verify that the black conductors on both ends of the 1 ohm load resistor attached to the Alternator Control Board ACB are firmly screwed to the resistor Make sure all elec
58. te 311 a semiconductor switch on the ACB This switch applies battery power to the ACB and makes about 5 7 VDC available to the display board 3 When the display board has at least 5 0 VDC available the microprocessor begins to operate However the display board does not yet light or give any outward indication that it is operating Instead it continues to monitor pedal RPM 4 At 40 RPM the display board commands the ACB to supply field current to the e alternator which then outputs the minimum nine volts required for normal BikeMax e operation The display board lights and the battery is no longer required for source current In fact the battery is now being recharged The BikeMax is fully operational and the user can select workout programs from the opening prompt pa Failure of any of the components involved at any step in the power up sequence can keep the BikeMax from powering up at all and cause a dead bike Knowledge of the power up sequence 15 very helpful in following the troubleshooting procedure below E E z e edt 827 EA Page 50 Appendix 8 Advanced Electrical Troubleshooting ___ _ vanced Elecincal troubleshooting Troubleshooting Procedure The troubleshooting procedure below checks each of the components involved in power up First it verifies the display board display cable and the display voltage regulator section of the ACB Next it
59. that secures the sensor to the alternator 11 Adjust the RPM Sensor as described on page 35 12 Install the secondary belt as described on page 27 If necessary adjust the belt s tension as shown in that section The new engine is now installed Before replacing the covers test the bike to make sure it s operating properly 1 If the bike has the optional external power supply plug it into the switchplate Page 34 pao Chapter 5 Component Repair and Replacement 5 fz 901615 Component Repair and Replacement 2 Pedal the bike and make sure you can enter various program modes If the bike does not have an external power supply you must pedal at least 40 RPM Make sure the resistance increases when you press the Up Arrow and decreases when you press the Down Arrow 3 If the bike has a CardioTouch heart rate sensor pedal the bike and place your hands on the rubber coated CardioTouch grips The bike should sense your heart rate and display a flashing shield in the upper right of the display Your heart rate should appear on the console within 30 seconds 4 If the bike has a Polar heart rate sensor use a Polar chest Strap or Polar test transmitter The bike should sense your heart rate and display a flashing shield in the upper right of the display Your heart rate should appear on the console within 30 seconds 5 If either heart rate sensor is not working make sure all cables are attached securely O
60. the bracket Install the nut on the bolt and tighten the nut Spin the idler pulley and verify that it does not bind on the bushing 4 Install the primary belt and adjust the belt tension See page 24 5 Replace the bike covers See page 22 Se a rn aaa pan ama AR AK a M M 9 a a EEE GGG Page 27 BikeMax 1000 3000 Service Manual Second Stage Drive The 13 secondary pulley applies pedaling power to the alternator through the secondary belt This section describes how to remove and replace the secondary belt adjust the belt tension and replace the entire second stage assembly secondary pulley pulley shaft and 3 grooved pulley Replacing the Secondary Belt 1 Tf the bike is equipped with the optional AC adapter unplug the adapter from the bike Remove the bike covers See page 22 Slowly rotate the secondary pulley on the left side of the bike Carefully move the belt to the outside edge of the pulley then off the pulley Remove the remainder of the belt from the small alternator pulley ON A N Install the new belt by looping it around the alternator pulley then around the secondary pulley as you slowly turn the pulley in either direction Make sure the belt is centered on both pulleys 8 Replace the bike covers See page 22 fs Important You should remove and replace the secondary belt wi
61. the pulleys Replace the bike covers See page 22 To change tension on the primary belt If the bike is equipped with the optional external power adapter unplug the adapter from the bike Remove the bike covers See page 22 Loosen the idler arm pivot bolt located behind the primary pulley Some BikeMax models have a hole in the primary pulley to make access to this bolt easier as shown in Figure 5 1 Loosen the idler arm adjustment bolt located just above the idler pulley Place the flat blade screwdriver in idler pulley adjustment slot above the adjustment bolt Make sure the blade of the screwdriver rests on the engine casting Carefully move the idler arm upward to apply tension to the belt Apply tension so the belt is tight but not so tight that the idler pulley is distorted sideways Hold the screwdriver in place and tighten the adjustment bolt then tighten the pivot bolt Rotate the crank arm to ensure the belt is tracking in the center of the primary pulley and 3 grooved pulley Replace the bike covers See page 22 Page 26 nay Chapter 5 Component Repair and Replacement ee ee ee ee Idler Pulley The idler pulley is part of the first stage drive it maintains constant tension on the primary belt The primary belt transfers pedal motion to the 3 grooved pulley and idler pulley If the bushing Inside the idler pulley is worn the pulley will start to wobble and t
62. thout relaxing the tension on the belt Proper tension 18 set at the factory and should normally remain correct If you do need to change the tension see the instructions below Adjusting the Secondary Belt Tools Needed 34 box end or open end wrench 34 Socket wrench Flat blade screwdriver 2 Phillips screwdriver 72 box end or open end wrench 1 If the bike is equipped with the optional AC adapter unplug the adapter from the bike Remove the bike covers See page 22 Loosen the bolt that secures the alternator to the slotted frame bracket Loosen the 34 bolt and nut that secure the alternator to the frame bracket UC N Using your hands carefully move the alternator in the direction necessary to apply tension to the secondary belt 6 When the tension from the secondary belt provides enough resistance to stop movement of the alternator tighten the V2 adjustment bolt Do not overtighten the bolt or you may strip the threaded hole in the alternator 7 Tighten the 24 pivot bolt and nut mm n 69628 Chapter 5 Component 8 Rotate the second stage pulley and make sure the belt does not overlap the edges of either pulley 9 Verify the alignment of the RPM sensor to the alternator See page 35 10 Replace the bike covers See page 22 Replacing the Second Stage Assembly Tools Needed Flat blade screwdriver You may need to remove t
63. till not displayed troubleshoot the problem as described below There are different procedures for the recumbent and upright bikes Recumbent Bike Polar Troubleshooting 1 the AC adapter is installed unplug it from the bike 2 Unplug the 3 conductor connector from the display board 3 Remove the end cap from the back of the extrusion tube loosen the 12 nut and hex screw and remove the Polar receiver Unplug the receiver from the 3 conductor cable and carefully pull about 2 inches of the cable out of the tube 4 Set the volt ohm meter to the 200 ohms setting Place one meter lead on one of the wires in the 3 conductor connector at the top of the display upright tube Place the other meter lead on one of the wires in the 3 conductor cable at the end of the extrusion tube Page 44 Chapter 5 Component Repair and Replacement Observe the meter for continuity zero ohms or a low ohms reading 10 or less If continuity is present verify the same for the other wire in the cables If either wire within the cables fails the continuity test there is probably a disconnected cable or broken wire within a cable You need to verify good connections and continuity of the Polar cables in the display upright and extrusion tube Unbolt and remove the display upright tube from the base Carefully hold the tube and verify that the 3 conductor cable from the extrusion tube is plugged into the 3 conductor cable that connects to the display
64. tle Carefully slide the seat shuttle off the extrusion tube 4 Remove the covers from the bike See page 22 5 Remove the Alternator Control Board ACB and load resistor Unplug all electrical connectors from the ACB except connector JP6 this cable connects the load resistor to the ACB Remove the two Phillips screws that secure the ACB and resistor to the frame and remove the ACB and resistor 6 Remove the extrusion tube from the bike Two bolts on the underside of the extrusion tube secure it to the frame These bolts are secured to a removable threaded retainer Note the position of the retainer within the tube Then using the 12 socket and wrench remove the front bolt then the rear one While the tube is still positioned on the frame remove the two Phillips screws that secure the cable clamp to the top of the tube The gray CardioTouch cable is a 2 conductor cable the gray Polar cable is a 3 conductor cable From the front of the extrusion tube carefully pull the CardioTouch cable and or Polar cable from the tube Disconnect the CardioTouch cable from its mating 2 conductor signal cable Page 46 Chapter 5 Component Repair and Replacement 110011111 110081 ana e Lift the extrusion tube from the frame and unclip the alternator cable from the bottom of the extrusion tube 6 Install the new extrusion tube e If applicable feed the CardioTouch
65. trical cables are connected in the correct locations and all connections are secure See Electrical Cabling on page 12 If nothing is obviously wrong in these areas continue with the section indicated for your symptom in this table Symptom Section of Manual Page Bike does not power up when Electrical Cabling 12 608161 RPM Sensor 35 Battery 39 Power up Sequence 49 Bike powers up but does not Electrical Cabling 12 provide resistance to the pedals Test Mode 17 Mechanical noise from the bike Isolation of Mechanical Noise 15 No CardioTouch heart rate readout CardioTouch Heart Rate Receiver 40 No Polar heart rate readout Polar Heart Rate Receiver 43 Some diagnosis sections also include information on correcting the problem For others after finding the problem you can turn to Chapter 5 which has a section on adjusting or replacing each component The beginning of that chapter lists each component and the page where its information begins _ Page 12 dex c c RE o Chapter 3 Troubleshooting Electrical Cabling If the bike fails to power up when pedaled or powers up but doesn t provide any resistance to the pedals the problem may be a loose or misplaced cable connection Remove the covers from the bike as described on page 22 then check all connections Tables 3 1 and 3 2 and Figures 3 1 and 3 2 show where each cable should be attached Related Component __ Alternator mounted to the bike frame
66. ttle If a hand grip and a wire in the connector on the bottom of the seat shuttle fail the continuity test replace the seat shuttle and test CT again Page 42 Chapter 5 Component Repair and Replacement agn EE YANIPOHENLABPAI eu 8 7 Once the diagnosis and repairs are complete test CT again to verify integrity of the CT system Upright Bike CardioTouch Troubleshooting 1 the AC adapter is installed unplug it from the bike 24 Unplug the 4 pin connector cable from the CT board 3 Set the volt ohm meter to the 200 ohms setting Place one meter lead on one of the CT rubber hand grips and the other meter lead on one of the wires in the 4 pin connector One wire in the connector is dedicated to each hand grip so observe the meter for continuity a change in the numeric display or needle movement continuity 1s present the connection between that hand grip and the connector is good Verify the same for the other hand grip and wire in the connector If either hand grip or wire in the balance bar fails the continuity test the CT balance bar 1s defective and must be replaced 4 Replace the defective CT balance bar and test CT again to verify integrity of the CT System BikeMax 1000 3000 Service Manual Page 43 Polar Heart Rate Receiver Tools Needed 2 Phillips screwdriver 1 2 open end wrench 3 16 hex wrench Polar heart rate detection uses a chest strap that detects the heart rate and trans
67. using This will keep the pulley from moving 6 Loosen and remove the 7 8 retaining nut and washer from the alternator shaft 7 Carefully remove the alternator pulley from the alternator shaft Do not lose the half moon shaped key that fits into the alternator shaft the key prevents the pulley from spinning freely on the shaft 8 Unplug the alternator cable from connector JP1 on the Alternator Control Board ACB 9 Doone of the following depending on the bike model e Recumbent Unclip and remove the alternator cable from the bottom of the extrusion tube Upright Unclip and remove the alternator cable from the ri ght side of the diagonal frame member 10 Before removing the alternator you may want to mark its location on the belt tension adjustment slot This will make it easier to install the new alternator in the correct position 11 Loosen the 2 bolt that secures the alternator to the slotted frame bracket L gu BikeMax 1000 3000 Service Manual Page 33 12 Support the alternator in place and remove the 12 bolt from the slotted frame bracket WARNING To avoid personal injury you need to support the alternator on the BMR before you remove the 34 bolt securing the alternator to the frame bracket 13 Remove the 34 bolt and nut that secure the alternator to the frame bracket 14 Remove the alternator from the frame Installing the New Alternator Essentially installing t
68. x 1000 3000 Service Manual Page 69 initic Rolecso ERN 01112 A Revisod too Hom 10 and kick plato Hem 42 Rom ovod 2 nuts tem 22 pes ECN 01110 Wii n 177 7 DETAIL H DETAIL M SCALE 1 3 SCALE1 2 N T 7777 CA DETAILG SEA SCALE 1 3 T WO e c pa 10 Trotter Drive e Medway Massachusetts 02053 1 888 GO CYBEX FAX 508 533 5500 Copyright 1999 Cybex International Inc All rights reserved 03084 September 1999

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