Expresso Bikes S2 Service Guide 1a

Expresso Fitness Corporation S2 Service Guide 1

S2 Service Guide

Expresso Fitness Corporation 845 Stewart Drive, Suite D Sunnyvale, CA 94085 USA Phone: +1 (408) 746-9122 E-mail: [email protected] October 2006

S2 Service Guide Expresso Fitness Corporation

May 15, 2007 Page 2

Table of Contents

Safety instructions 4 Loss of heart rate 5 Steering Issues 6 Shifter Issues 8 Console Issues 9 RPM Issues 10 Speed Issues 11 Resistance Issues 12 Audio Issues 13 Video Issues 14 TV Issues 15 Power Issues 16 Checking Heart Rate 17 Steering Configuration 17 Steering & shifter connection check 18 Interconnect connection check 18 Console connection checks 18 RPM Optical Sensor connection check 19 MRD Speed connection check 19 28V MRD check 19


May 15, 2007 Page 3

CAUTION: Any changes or modifications to this equipment by other than authorized personnel will void the product warranty.

While every attempt was made to verify the information in this document at the time of writing, the information in this document is provided as is without warranty of any kind and is subject to change without notice.

Copyright 2005 by Expresso Fitness Corporation. All rights reserved. No part of the contents of this document may be reproduced or transmitted in any form or by any means without written consent of the publisher.

Expresso Fitness and the Expresso Fitness logo are trademarks of Expresso Fitness Corporation.

All other designated trademarks, registered trademarks, copyrights and brands are the property of their respective owners.

Part identifier 2500.0012.01

Table of Contents Continued

Console Audio jack check 20 Music Menu Bar check 20 TV Enable check 21 TV Channel configuration check 21 Monitor VGA connection check 22 System connection checks 22 Console Replacement 23 Steering Assembly Replacement 24 Shifter Replacement 27 MRD Replacement 29 1st Stage Drive Belt Replacement (Cogged belt) 33 2nd Stage Drive Belt Replacement (V belt) 36 Monitor Replacement 38


May 15, 2007 Page 4

Safety instructions Installation/movement

DANGER: Never open the S2 computer pedestal. This may expose you to risk of shock, fires or injury.

DANGER: To reduce risk of burns or shocks only use grounded (three prong) power cords.

DANGER: To reduce the risk of electrical shock, always unplug the S2 before attempting any maintenance activity.

CAUTION: Keep the power cord away from heated surfaces. Do not pull the equipment by the power cord or use the cord as a handle.

CAUTION: If the electrical cord is damaged, it must be replaced by the manufacturer, an authorized service agent or a similarly qualified person to avoid a hazard.

CAUTION: Never operate a S2 with the air vents blocked. Keep air openings free of lint, hair or any obstructing materials.

CAUTION: Do not use this product in areas where aerosol spray products are being used or where oxygen is administered. Such substances create the danger of combustion and explosion.

CAUTION: Do not install the S2 outdoors, near swimming pools or in areas of high humidity.

CAUTION: Any changes or modifications to this equipment by other than authorized personnel could void the product warranty.

Usage Before using the S2, Expresso Fitness strongly

recommends seeing a medical specialist, particularly if you are suffering from any of the following: heart disease (angina pectoris, myocardial infarction), hypertension, diabetes, respiratory disease (asthma, chronic bronchitis, pulmonary emphysema, etc.), articular metamorphosis, rheumatism, gout, or other diseases and physical complaints. Pregnant women should also consult their doctor before beginning a training program.

If you are not used to regular physical activity, it may be dangerous to suddenly engage in strenuous activity. Increase your exercise level gradually.

If you feel sick or sense that something is wrong with your body during exercise, stop immediately.

Health-related injuries may result from incorrect or excessive use of exercise equipment. Expresso also recommends consulting a fitness professional on the correct use of this product.

Use the S2 only as described in this guide. Children or developmentally-challenged individuals

must be monitored while using S2. Never place containers filled with liquids directly on

the unit, except in the water bottle holders. Containers should be covered with lids.

Carefully mount the S2 when starting to exercise, and dismount carefully when youre finished, especially if you are tired.

Wear shoes with rubber or high-traction soles. Do not use shoes with heels, leather soles, cleats, or spikes. Do not use the S2 with bare feet.

Keep all loose clothing, shoelaces, and towels away from moving parts.

Do not reach into, or underneath, the S2; and do not tip the S2 on its side during operation.

Keep the area around the S2 clear of any obstructions, including walls and furniture. Provide at least three feet of clearance behind the unit.

Use caution when stepping on or off of the S2 bike. Never face backward while using the S2 bike.

This equipment has been certified to comply with the limits for a Class B computing device, pursuant to Subpart J of Part 15 of FCC Rules.

Yes No!


May 15, 2007 Page 5

Lose of heart rate

Start

Heart Rate gripnot working orlost heart rate

messagedisplayed?

Wireless HRworking?

No

Replace console.See page 23

NoYes

Yes

Replace steeringassembly.

See page 24

Problemfixed?

No

Finish

Yes

Problemfixed?

Contact ExpressoSupport

NoYes


May 15, 2007 Page 6

Steering Issues

Start

Does steeringrespond in

route?

Yes

Yes

Problemfixed?

No

Finish

Yes

Calibrate steeringSee page 17

Continue on page 7

No

Checking steeringconnector& wires.

See page 18

Problemfixed?

Replace SteeringUnit.

See page 24


May 15, 2007 Page 7

Steering Issues continued

Start

Does steeringdrift or doesn't

stay centered inroute?

Yes

Problemfixed?

No

Finish

Yes

Calibrate steeringSee page 17

FinishedNo

Replace steeringassembly.

See page 24

Problemfixed?


Yes

No


May 15, 2007 Page 8

Shifter Issues

Start

Is gear shifterworking?

No Verify Shifterconnections.See page 18

No

Yes

Yes

Verify Connectionto console.See page 18

No

Yes Problemfixed?

Replace shifter.See page 27

No

Yes

Finish

Problemfixed?

Problemfixed?



May 15, 2007 Page 9

Console Issues

Start

Is consoleresponding?

NoPower bike off,

wait 20 seconds &power on.

See page 22

No

Yes

Yes

Verify Connection atinterconnect &

console.See page 18

No

Yes Problemfixed?


No

Yes

Finish

Problemfixed?

Problemfixed?



May 15, 2007 Page 10

RPM Issues

Start

Is thereRPM?

NoVerify Connectionat interconnect &

console.See page 18

No

Yes

Yes


No

Yes Problemfixed?

Verify RPM opticalsensor connected &

check pins.See page 19

No

Yes

Finish

Problemfixed?

Problemfixed?



May 15, 2007 Page 11

Speed Issues

Start

Is thereSpeed?

NoVerify Connectionat interconnect &

console.See page 18

No

Yes

Yes


No

Yes Problemfixed?

Verify speedconnection on

MRD.See page 19

No

Yes

Finish

Problemfixed?

Problemfixed?



May 15, 2007 Page 12

Resistance Issues

Start

No Verify Connectionat interconnect .

See page 18

No

Yes

Yes

Verify 28 v DCfrom CPU.See page 18

No

Yes Problemfixed?

Verify 28v to MRDand Verify

thermocouple 1/3ohms (orange/white).

See page 19

Yes

Finish

Problemfixed?

Problemfixed?

Check Consoleconnections (ribbon

& Large bottom)See page 18

Problemfixed?

Yes Contact Expressosupport.

No

No

Is there fullresistance?


May 15, 2007 Page 13

Audio Issues

Start

Does Musicmenu load?

Yes

Does consolejack show anywear or tear?

No

Finish

Yes

Check console jackfor wear and tear.

See page 20

Check to make surethat all musicgroups display

artist and titles.See page 20

No

Checking Systemaudio connection.

Problemfixed?

No

Yes


Yes


Do all groupsdisplay songs?

No


May 15, 2007 Page 14

Video Issue

Yes

Start

Is there aVideo Issue?

Yes

Finish

Check to see if bikeis powered on

see page 22

Problemfixed?

No

YesCheck power to

monitor.

Yes

NoDoes consoleBeep?

Problemfixed?

No

Check VGAconnection on monitor

and system.see page 22

Problemfixed?

No

Contact ExpressoSupport.

Yes


May 15, 2007 Page 15

TV Issues

Start

Is there TV?

Yes

Is TV clear?

Finish

Check to see ifchannels are

configured correctly.see page 21

Check to see ifTV is enabled.

See page 21

No

Checking TV cable isconnected (75 ohm

cable).See page 22

Problemfixed?

No

Yes

Enable TV.

Yes

Was TVenabled?

No

Were channelsconfiguredcorrectly?

Problemfixed?

No

Configure thecorrect channels.

Problemfixed?

No


No

Yes


May 15, 2007 Page 16

Power Issues

Start

Is there aPower Issue?

Yes

Finish

Check to see if bikeis powered on

See page 22

Problemfixed?

No

Yes

Verify 120v fromsource.

Yes

No

Is Bikepowered on?

No

Power bike on.

Problemfixed?

No

Verify fuseinstalled or good.

see page 22

Yes

Problemfixed?

Verify 120v thrupower cord.see page 22

Problemfixed?


Finish

Yes

No


May 15, 2007 Page 17

Checking Heart rate

1. Put hands on the handlebar sensors and check BPM function. 2. Check the BPM function using the Polar pulse simulator.

Steering Calibration

Log into Configuration Mode (7913) Press to select Calibrate steering If steering bar is not centered then

press and follow instructions to calibrate steering.

If steering bar is centered go to next step.

Properly calibrated steering makes the virtual bike go down the road straight when the steering is centered.


May 15, 2007 Page 18

Checking Steering and Shifter Connectors

Interconnect connectors

Console Connectors

Shifter Connector

Heart Rate Connector (4-wire connector)

Steering Connector

(3-wire connector)

Connector A (MRD) (Large red cables 28v)

Connector B (Console/Shifter/Steering)

MRD ConnectorGame Controller

(Shifter/Steering/Heart Rate)

All Other Connector


May 15, 2007 Page 19

RPM Optical Sensor Connector and Check

MRD Speed control connector

28v check on MRD

RPM Optics Board Connector

MRD Speed control connector

28v for MRD


May 15, 2007 Page 20

Audio Console Jack check

Music menu Bar check

Audio Jack (Headset jack)

Music Menu


May 15, 2007 Page 21

TV Enable/Disable screen

TV Channel Configuration screen


May 15, 2007 Page 22

Monitor VGA connection check

System connection checks

Coax connector (TV)

AC Power plug RJ-45 Ethernet

Power switch

System Fuse

USB Port


May 15, 2007 Page 23

1. Re-install screws on back of console.

2. Remove cables from back of console.

3. Remove screws from back of console.

4. Re-install cables on back of console.

Tools Needed #2 Phillips screw driver

Console Replacement


May 15, 2007 Page 24

Tools Needed #2 Phillips screw driver#2 metric Allen #5 metric Allen 3/32 Allen Torque wrench Loctite Red

3. Remove shifter.

Note: Do not let shifter hang by wire.

1. Remove water bottle holder.

2. Remove shifter cover.

Steering assembly replacement


May 15, 2007 Page 25

6. Remove steering assembly screws. Use Metric #5 first if it does not fit then it may be a 3/16 Allen.

5. Unplug steering wires.

4. Unplug shifter wire.

7. Remove steering assembly.

8. Re-install new steering assembly.

Note: Make sure steering assembly handles face up and wires are not pinched.

Steering assembly replacement continued


May 15, 2007 Page 26

14. Re-install water bottle holder.

13. Re-install shifter covers.

9. Re-install steering assembly screws using torque wrench set to 55 inch-lbs.

Note: Make sure to use Loctite red on screws.

10. Re-connect shifter

11. Re-connect steering assembly wires.*

12. Re-install shifter.

*Note: make sure 4-wire plug isinstalled on 4-wire plug & 3-wire plug onto 3 wire plug.

Steering assembly replacement continued


May 15, 2007 Page 27

2. Remove shifter cover

Tools Needed #2 Phillips screw driver3/32 Allen

4. Unplug shifter wire.

3. Remove shifter.

Note: Do not let shift hang by wires.

1. Remove water bottle holder.

Shifter Replacement


May 15, 2007 Page 28

8. Re-install water bottle holder.

7. Re-install shifter cover.

6. Install new shifter.

5. Connect wire to new shifter.

Note: Do not let shift hang by wires.

Shifter Replacement Continued


May 15, 2007 Page 29

Tools Needed #3 metric Allen #8 metric Allen Crank puller

1. Remove kick plate.

2. Remove right side cover.

3. Remove left side crank arm.

MRD Replacement


May 15, 2007 Page 30

6. Disconnect wires and move wires out of the way of MRD.

7. Loosen tension arm on left side by using socket extension.

4. Remove left side cover.

Note: When removing left cover use caution, there is a fan on cover that needs to be unplugged.

5. Remove tie wraps on wire to MRD.

Note: Use caution not to cut wires when cutting tie wraps.

MRD Replacement continued


May 15, 2007 Page 31

8. Remove 2nd stage Vee belt.

11. Re-install belt and tighten the tension arm screws.

Note: the belt tension is created by the spring.

10. Re-install new MRD. Note: It is important that the proper alignment of the MRD is used. To align MRD looking from the front of bike the left side of MRD plate should line up with the bike frame plate as it looks in photo to the right.

9. Remove four (4) bolts holding MRD.



May 15, 2007 Page 32

15. Re-install right side cover.

16. Re-install kick plate.

14. Re-install left side crank arm.

13. Re-install left side cover and connect the fan.

12. Re-install all wires and tie wraps the wires.



May 15, 2007 Page 33


2. Remove right side cover.

3. Loosen 1st stage tension arm aliens.

Tools Needed #3 metric Allen #5 metric Allen #6 metric Allen #8 metric box wrench #12 metric box wrench

1st Stage drive belt Replacement (Right side cogged belt)


May 15, 2007 Page 34

5. Remove drive belt.

6. Install new drive belt.

7. Tighten tension arm bolt until the correct tension is on drive belt, tighten lock nut.

4. Loosen lock nut and remove tension are idle arm.

1st Stage drive belt replacement (Right side cogged belt) continued


May 15, 2007 Page 35

8. Tighten Allen bolts on tension arm.

9. Re-install right side cover.


1st stage Drive Belt replacement (Right side cogged belt) continued


May 15, 2007 Page 36

Tools Needed #3 metric Allen #8 metric Allen Socket extension Socket wrench Crank puller



3. Remove left side cover. Note: When removing left cover use caution, there is a fan on cover that needs to be unplugged.

2nd Stage Drive Belt Replacement (left side V belt)


May 15, 2007 Page 37

4. Loosen tension arm using a socket extension and remove V belt.

5. Loosen tension arm using a socket extension and install new V belt.

6. Re-install left side cover making sure that cove fan in reconnected.


2nd Stage Drive Belt Replacement (left side V belt) continued


May 15, 2007 Page 38

Tools Needed #2 Phillips screw driver Straight edge screw driver #2 metric Allen

1. Remove Allen screws from rear monitor cover.

2. Disconnect power and VGA cable from monitor.

3. Remove monitor mount screws.

Monitor Replacement


May 15, 2007 Page 39

4. Install new monitor.

5. Install power and VGA cable.

6. Re-install rear cover.

Monitor Replacement continued


May 15, 2007 Page 40

Expresso Bikes S2 Service Guide 1a

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