LeMond Fitness G-Force RT Troubleshooting Guide

LeMond® Fitness Inc.
17280 Woodinville-Redmond Rd.
Building B, Suite 888
(425) 482-6773
Fax: (425) 482-6724
www.LeMondfitness.com
LeMond g-Force RT
Troubleshooting Guide
Seat Assy .............................................................................. 1
Complaint: Seat Moves, Rattles, Rocks, Creaks ..............................................1
Determine if movement is: .............................................................................1
Seat bottom relative to seat frame .............................................................1
Seat Frame relative to seat carrier .............................................................1
Rotating portion of carrier relative to sliding portion ...................................2
Sliding portion relative to the track .............................................................3
If it is a little bit of movement front to back..............................................3
If it is more than ½ inch front to back ......................................................4
If it is side to side movement of 2mm or more(0-2mm is normal) ...........4
If the front of the slider moves more than 2mm up and down .................4
Carrier end caps loose ...............................................................................5
Complaint: Seat Unintentionally Moves.............................................................5
Question: Is it moving forward and back, and how much?............................5
Question: Is it unintentionally rotating? .........................................................5
Complaint: Scraping sound when adjusting seat front and back ......................5
Complaint: Seat Carrier will not release. ..........................................................6
Complaint: Seat Rotation will not release or engage........................................6
Complaint: Seat Mesh is Too Loose.................................................................7
Complaint: Seat tilts too far back......................................................................8
Console Assy ........................................................................ 8
Complaint: RPM seems too low ........................................................................8
Complaint: RPM seems too high .......................................................................9
Complaint: Part of console won’t light up ..........................................................9
Complaint: All of console won’t light up .............................................................9
If customer is trying to operate console without pedaling ..............................9
If console will not light up while pedaling .....................................................10
This document contains confidential and proprietary information of LeMond Fitness, Inc. and shall not be
duplicated or distributed or otherwise transferred to a third party without the express written consent of
LeMond Fitness.
© LeMond Fitness, Inc. 2006 All Rights Reserved.
Complaint: Dead Button .................................................................................10
Complaint: Doesn’t remember my user profile ...............................................10
Complaint: Garbled Message .........................................................................11
Complaint: Program sticks .............................................................................11
Complaint: Program time input and end time are different .............................11
Complaint: Heart Rate inaccurate ..................................................................11
Complaint: Heart Rate Program varies too much ...........................................11
Determining Software(Firmware) Version .......................................................11
Heart Rate........................................................................... 12
Complaint: Goes very high initially .................................................................12
Complaint: Chest Strap won’t pick up.............................................................12
Complaint: Contact HR Handles will not work ................................................12
Stability................................................................................ 13
Complaint:
Complaint:
Complaint:
Complaint:
Unit Rocks/Tips ............................................................................13
Creaking noise .............................................................................14
Plastic sleeve pushed out when I installed stabilizer ....................14
Mounting holes will not line up .....................................................14
Handlebar/Contact HR Grips .............................................. 14
Complaint: Handle bar is loose.......................................................................14
Complaint: HR Grip is cracked .......................................................................15
Complaint: HR Grip Fell off ............................................................................15
Pedals ................................................................................. 15
Complaint:
Complaint:
Complaint:
Complaint:
Complaint:
Make Grinding Noise....................................................................15
Pedal Wobbles .............................................................................15
Can’t Adjust Strap ........................................................................15
Can’t install left pedal ...................................................................16
Pedal is broken ............................................................................16
Covers................................................................................. 16
Complaint: Screw boss Broken ......................................................................16
Complaint: Screw boss deformed...................................................................17
Metal decal peeling off of front cover...............................................................17
Oil/Grease/Mystery Fluid near Seat Track Front .............................................18
General Noise ..................................................................... 18
“NORMAL” noise level.....................................................................................18
Complaint: Noisy ............................................................................................18
Complaint: Rough...........................................................................................18
This document contains confidential and proprietary information of LeMond Fitness, Inc. and shall not be
duplicated or distributed or otherwise transferred to a third party without the express written consent of
LeMond Fitness.
© LeMond Fitness, Inc. 2006 All Rights Reserved.
Seat Assy
Complaint: Seat Moves, Rattles, Rocks, Creaks
Try to determine if movement is:
Seat bottom relative to seat frame
Probable Cause: Seat bottom screws are loose.
Potential Cause: Metal inserts in seat bottom plastic have pulled out.
Seat Frame relative to seat carrier
Probable Cause: Screws at front of seat not tight.
Probable Cause: Seat carrier tabs are bent. If there is a very small gap between
the tabs in the carrier and the bar that slides under them, seat
may rattle. If tabs cannot be bent to remove gap, replace the
seat carrier assembly.
Potential Cause: Seat frame mounting bar welded crooked
This mounting bar on the bottom of the
seat frame should be parallel to a
straightedge held across the bottom of
the seat
Main G-Force Troubleshooting Guide
Document #300116 Rev. A
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April 5, 2006
Rotating portion of carrier relative to sliding portion
Probable Cause: For movement near the back pivot, tighten the seat pivot
screws. If this does not solve the problem remove rotating
portion of the carrier and check for broken or cracked seat pivot
bushings.
Seat Pivot Screw
Probable Cause: If it is in the front, remove the front covers from the seat carrier
and inspect the return springs to see if they are missing or
broken. If they are OK check the pawls for wear.
Rotating Pawl
Return Spring
Main G-Force Troubleshooting Guide
Document #300116 Rev. A
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April 5, 2006
Sliding portion relative to the track
If it is a little bit of movement front to back
Probable Cause: Selector rod undersized. Shim to size to reduce play.
Shim installed
on seat selector
Potential Cause: Pivot screw for the seat selector lever is missing or broken or
the lever return spring missing.
Seat Selector
Pivot Screw
Main G-Force Troubleshooting Guide
Document #300116 Rev. A
Lever
Return
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April 5, 2006
If it is more than ½ inch front to back
Probable cause: Selector lever is not engaging. Check if the Pivot screw for the
seat selector lever is missing or broken or the lever return
spring missing. (see picture above)
Potential cause: Set screw below the lever return spring is more than 1-2
threads below the weldment. It should be installed
approximately flush.
CORRECT
SCREW NOT DEEP ENOUGH
Unlikely cause: Seat selector bar (comb like piece attached to track) is missing,
or the screws holding it are stripped out.
If it is side to side movement of 2mm or more
Probable Cause: Wheel carriers are not fully seated. Loosen acorn nuts ½ turn
and use wrench to rotate the wheel assy firmly against the top
rail, then tighten nut. If this does not solve the problem, replace
wheel carriers.
Unlikely Cause: If the nut is over-tightened on the threaded portion of wheel
carrier it can partially break the stud allowing the nut to tighten
but not hold the wheels in place.
If the front of the slider moves more than 2mm up and down
Probable Cause: Wheel carriers not fully seated. Loosen acorn nuts ½ turn and
use wrench to rotate the wheel assy firmly against the top rail,
then tighten nut.
Unlikely Cause: If the nut is over-tightened on the threaded portion of wheel
carrier it can partially break the stud allowing the nut to tighten
but not hold the wheels in place
Main G-Force Troubleshooting Guide
Document #300116 Rev. A
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April 5, 2006
Carrier end caps loose
Probable Cause: Loose screws.
Potential Cause: Broken screw boss behind the lower screws.
Complaint: Seat Unintentionally Moves
Question: Is it moving forward and back, and how much?
If it slides back on the track more than 15mm see “If it is more than ½ inch front
to back” above.
If it is only 1/8 inch or so, see “If it is a little bit of movement front to back” above
Question: Is it unintentionally rotating?
Probable Cause: The pawls are not fully engaging.
Probable Cause: The seat rotation handle return spring is missing or broken.
Remove top front cover and check spring.
Seat rotation
handle return
spring
Potential Cause: The pawls are very worn. Would indicate as noticeable slop
between pawls.
Complaint: Scraping sound when adjusting seat front and back
Probable Cause: Seat selector lever is too long and scratches on the track.
Main G-Force Troubleshooting Guide
Document #300116 Rev. A
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April 5, 2006
Complaint: Seat Carrier will not release.
Probable Cause: Something is wedged in the wheels. Try moving in both
directions.
Probable Cause: If the handle won’t move, the selector lever return spring may
be fully compressed. The set screw has been installed too
deep. Back it off until one or two threads are protruding.
No Space
between spring
coils
Screw installed too
deep – no threads
showing.
CORRECT
Complaint: Seat Rotation will not release or engage.
Probable Cause: The nut that keeps the rotating pawl on its axle is over tight
and binding the pawl. Loosen the nut ¼ to ½ turn.
Lock Nut
Rotating Pawl
Main G-Force Troubleshooting Guide
Document #300116 Rev. A
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April 5, 2006
Potential Cause: The set screws on the seat rotation handle have stripped out
the seat rotation bar. Try tightening screws or replacing
rotation bar.
Complaint: Seat Mesh is Too Loose
Probable Cause: Seat mesh has stretched. Have user remove seat back cover
and tighten pedal straps to tension seat back.
Probable Cause: If the pedal straps will not hold the tension, they may need to
be replaced.
Tighten Pedal straps
to increase mesh
Remove Seat Back Cover
Main G-Force Troubleshooting Guide
Document #300116 Rev. A
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April 5, 2006
Complaint: Seat tilts too far back
Probable Cause: Seat rotation stopper bar is missing (see picture). Seat back
will tilt to about 45-60 degrees from floor. Gas shock becomes
the stopper.
Seat Rotation
Stopper Bar
Console Assy
Complaint: RPM too low
Probable Cause: Magnet missing or bad. Remove right cover. Confirm that 2
magnets are installed. If both magnets present, move each
magnet past the sensor and listen for a faint tink/click/chirp
from both magnets. Replace magnet if it does not consistently
make the sound.
Probable Cause: If the RPM is zero, check that the sensor is plugged in and that
the wires are not damaged.
Main G-Force Troubleshooting Guide
Document #300116 Rev. A
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April 5, 2006
Complaint: RPM seems too high
Probable Cause: Sensor installed parallel to the floor. When installed parallel to
floor, the sensor will often pick up the magnet twice as it passes.
Incorrect RPM Sensor
Mounting – Sensor is
parallel to the floor.
Correct RPM Sensor
mounting – Sensor is
parallel to the frame
Complaint: Part of console won’t light up
Probable Cause: If any small portion of the board will not light up, replace
console assy.
Complaint: All of console won’t light up
If customer is trying to operate console without pedaling
Probable Cause: Confirm batteries are installed properly per diagram in battery
case. Note that they must be Double A (AA) Nickel-MetalHydride (Ni-MH) rechargeable batteries which are about 1.2
Volts when fully charged
Main G-Force Troubleshooting Guide
Document #300116 Rev. A
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April 5, 2006
Probable Cause: When first shipped batteries are not fully charged. Inform the
customer they will need to use the bike for 30-90 minutes to
charge the batteries to where they can power the console
without pedaling.
Probable Cause: STRESS THE IMPORTANCE OF USING Ni-MH (Nickel-MetalHydride) RECHARGABLE BATTERIES. Display will not work
with NON-Rechargeable batteries and other rechargeable
batteries are not recommended.
If console will not light up while pedaling
Probable Cause: STRESS THE IMPORTANCE OF USING Ni-MH (Nickel-MetalHydride) RECHARGABLE BATTERIES. Display will not work
with NON-Rechargeable batteries and other rechargeable
batteries are not recommended.
Probable Cause: Wire is unplugged. Remove the console from the mast and
confirm it is plugged in. If it is, remove the left cover and check
all of the wire connections. If they are all plugged in, try
another console and/or lower board.
Complaint: Dead Button
No way to troubleshoot. Replace console. Include return label and have
customer return bad board for evaluation.
Complaint: Doesn’t remember my user profile
Probable Cause: User profile defaults not loaded at manufacturer.
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Power up the console by pedaling the unit or press the “Power” button.
With the console lit, SIMULTANEOUSLY press the three buttons at the
top of the console.
“LeMond” should scroll across the large display.
Press the “+” or “-“button until the LCD screen says “Engineer Mode.” then
press ENTER. Press the “+” or “-“button until the LCD screen says
“Function Setup.” then press ENTER.
Press the “+” or “-“button until the LCD says “LOAD DEFAULT”
Main G-Force Troubleshooting Guide
Document #300116 Rev. A
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April 5, 2006
•
•
The LCD will display “Load Default ?”. The large display will say “NO”.
Press the “+” or “-“button to change the large display to “YES” and press
the Enter key. The message in the LCD should change to “Load Default”
(no question mark).
Press the “BACK” button several times to exit.
Complaint: Garbled Message
Probable Cause: Corrupt software. Return console for software update.
Complaint: Program sticks
Probable Cause: Corrupt software. Return console for software update.
Complaint: Program time input and end time are different
Probable Cause: Corrupt software. Return console for software update.
Complaint: Heart Rate inaccurate
Due to minor inaccuracies in signal and the way different programs calculate the
Heart Rate, there may be as much as 6BPM difference between the HR shown
on the display, on a third-party HR watch, and a manual counting of the HR. A
similar difference may be found between using the Contact HR grips and using a
Chest Strap.
Complaint: Heart Rate Program varies too much
Program is designed to maintain actual HR to within 5bpm of target HR . Note
that it is very difficult to create a program that will not overshoot the HR and to
determine how much and how quickly to vary the resistance in response to HR
changes.
Determining Software (Firmware) Version
•
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•
•
•
•
•
•
Power up the console by pedaling the unit or press the “Power” button.
With the console lit, SIMULTANEOUSLY press the three buttons at the
top of the console.
“LeMond” should scroll across the large display.
Press the “+” or “-“button until the LCD screen says “SYSTEM INFO.” then
press ENTER.
An icon of a file folder with an “i” on it should show in the large display.
Press the “+” or “-“button until the LCD says “FIRMWARE VER.” The
version should automatically display in the large screen.
The format will look like “V1.0.xxRE” where the “xx” is the software version.
Press the “BACK” button several times to exit.
Software/Firmware is a translation issue between Chinese/English with
the Chinese programmer.
Main G-Force Troubleshooting Guide
Document #300116 Rev. A
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April 5, 2006
Heart Rate
Complaint: Goes very high initially
Probable Cause: Corrupt software. Return console for software update.
Complaint: Chest Strap won’t pick up
Probable Cause: Customer using non Polar compatible chest strap
Complaint: Contact HR Handles will not work
Potential Cause: It may take as long as 15 seconds for the HR to display for
some people. This can be affected by low heart rates, dry
hands, individuals with a weak electrical signal. The flashing Hr
sign may go to zero, but it is still trying to acquire HR.
Potential Cause: The customer must place their hands on the grip such that the
metal portion of the upper sensor lies across the palm as in the
picture.
Main G-Force Troubleshooting Guide
Document #300116 Rev. A
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April 5, 2006
Potential Cause: Customer has attached the HR wires from the handle to each
other.
INCORRECT
CORRECT
Potential Cause: Wire connection broken. Check that the wires were not
damaged during installation of the seat. If necessary, check
the continuity between connections in the HR loop by using an
electric resistance (Ohm) meter to help determine the location
of the problem.
Stability
Complaint: Unit Rocks/Tips
Probable Cause: The floor is not level. Extend the leveler foot on the rear
stabilizer by turning counter-clockwise until the unit is stable.
Probable Cause: One of the plastic support sleeves was pushed out during
installation. Back out both of the screws holding the stabilizer to
the frame about 3-4 complete turns. Use a screwdriver or small
hex wrench to push the plastic sleeve as far into the unit as
possible. Re-tighten stabilizer screws.
Main G-Force Troubleshooting Guide
Document #300116 Rev. A
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April 5, 2006
Bushing pushed out.
Should be like other side.
Front Cover Removed for Clarity
Complaint: Creaking noise
Potential Cause: The screws holding the stabilizer in are not fully installed.
Confirm that there are star washers under the head of the
screws and tighten.
Potential Cause: Try and confirm that the noise is not coming from the seat.
Complaint: Plastic sleeve pushed out when stabilizer installed
Solution:
Back out both of the screws holding the stabilizer to the frame
about 3-4 complete turns. Use a screwdriver or small hex
wrench to push the plastic sleeve as far into the frame as
possible. Re-tighten stabilizer screws. See picture above.
Complaint: Mounting holes will not line up
Probable Cause: With the small locator screw on the stabilizers, they will only
align properly if the Rear Stabilizer is put in from the right side,
and the Front Stabilizer is put in from the left side as per the
directions.
Potential Cause: Note that the screws do not go into the unit parallel to the floor.
Handlebar/Contact HR Grips
Complaint: Handle bar is loose
Probable Cause: The screws holding the handle bar to the seat frame are not
fully tightened. Confirm star washers are under the head of the
screws and tighten. This may necessitate removing the seat to
get to the screws. If so, disconnect the heart rate wires before
removal and reconnect when finished.
Main G-Force Troubleshooting Guide
Document #300116 Rev. A
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April 5, 2006
Complaint: HR Grip is cracked
Probable Cause: Some cleaners can attach the plastic housings for the HR
contacts. Remove broken housings and replace.
Complaint: HR Grip Fell off
Potential Cause: Screw not installed or fell out. Check the boss for flaking or
damage like a screw pulled out. This can happen with multiple
tightening and loosening of the screw especially if the screw is
over tightened. If the boss is damaged replace sensors and
screws.
Potential Cause: If the screw is still in the boss, remove it and check that the
head of the screw will not go through the hole in the other half
of the sensor. If it will or if it looks like it has been pulled
through, send new sensors.
Pedals
Complaint: Make Grinding Noise
Confirm problem is the pedal by holding the crank stationary and spinning pedal.
Probable Cause: Bad Bearings. Send new pedals. Stress the importance or
fully installing the pedals and checking them for tightness after
first use and every 3 months thereafter.
Complaint: Pedal Wobbles
Probable Cause: Threaded hole for pedal in crank is not perpendicular to the
crank.
Complaint: Can’t Adjust Strap
Confirm strap is installed correctly.
Potential Cause: Ratcheting portion of the pedal can turn such that the strap
does not go straight through. Strap can wedge. Turn
ratcheting portion to align with strap.
Main G-Force Troubleshooting Guide
Document #300116 Rev. A
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April 5, 2006
Pedal Strap Ratchet
Complaint: Can’t install left pedal
Probable Cause: Left pedal is a reverse thread. Confirm that hole in crank has
not been damaged during installation.
Complaint: Pedal is broken
Replace the pedal per current warranty status.
Covers
Complaint: Screw boss Broken
Probable Cause: Screw installed with too much torque. Send a new cover.
Stress not putting more torque on the screw than what it takes
to fully seat the screw.
Potential Cause: Some cleaning agents, especially undiluted or commercial antibacterial cleansers can attack the plastic. Send a new cover if
needed. Determine what they are using to clean the unit, and
stress the use of a mild soap or wet rag to clean the unit.
Main G-Force Troubleshooting Guide
Document #300116 Rev. A
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April 5, 2006
Complaint: Screw boss deformed
Probable Cause: Screw is over tightened. Loosen screw and tighten
appropriately. Note that the initial over-tightening may leave a
permanent graying/whiteness near the deformation.
Metal decal peeling off of front cover
Probable Cause: Cover not cleaned before application of decals. Replace cover.
Main G-Force Troubleshooting Guide
Document #300116 Rev. A
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April 5, 2006
Oil/Grease/Mystery Fluid near Seat Track Front
Probable Cause: Lubricant may have been added to the wheel rolling surface.
Wipe the residue from the plastic and the track with household
cleaner.
General Noise
“NORMAL” noise level
When pedaling at 60 RPM there will be a constant low level noise – typically
quieter than a normal speaking conversation level. When the user stops
pedaling and the unit “coasts” the noise will be slightly louder and higher pitched.
This noise will be even louder if the user back-pedals when the system is
“coasting”. The speed sensor inside the cover makes a faint tink/click/chirp when
the right pedal is at the 4 and 10 o’clock positions when viewed from the right
side of the bike.
Complaint: Noisy
Intermittent clicks when pedaling fast only - the users shoe laces may be hitting
covers.
Clicks when pedaling at any speed, stops when pedaling stops - possibly the
crank bearings. Check for bearing roughness and that the lock nut is tight on
spindle.
Grinding Sound when pedaling, not when unit is coasting - bad pedal bearings or
bad crank axis bearings.
Grinding Sound when pedaling and when coasting - bearings in the generator.
Hissing sound when the unit is coasting, doesn’t change pitch when pedaling
backwards – loose wires touching the spinning generator.
Complaint: Rough
Thumping when pedaling, not from seat moving - belt damaged. Check for
missing ribs on belt, partially torn ribs.
Thumps when pedaling under high load - belt slippage. Check that belt is
properly tensioned.
Thumps when pedaling under load - Cranks are loose. Tighten crank bolt.
For telephone assistance, please contact your local distributor or the Customer Service Department of
LeMond Fitness Inc.. at 1-425-482-6773 from 0700AM – 1700PM PST
Monday through Friday.
©2005 LeMond Fitness Inc, g-Force RT, and LeMond are registered trademarks
Main G-Force Troubleshooting Guide
Document #300116 Rev. A
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April 5, 2006