Replacing the Seat Cushion

1. Remove the old cushion by cranking the seat all the way forward and removing the front 2 screws securing the seat cushion to the underside of the ERGYS chair box. Crank the seat all the way backward and remove the back 2 screws securing the seat cushion to the underside of the chair box. (Refer to the new seat cushion for the position of these 4 screws.)
2. Place the new seat cushion on the chair box and position the cushion so that the front is lined up with the front of the chair box.
3. Line up the back 2 threaded inserts on the bottom of the seat cushion with the 2 holes at the back of the chair box. Loosely attach the back of the seat cushion with 2 screws. Take care to thread the screws straight in to the threaded inserts of the seat cushion.
4. ine up the front 2 threaded inserts on the bottom of the seat cushion with the 2 holes at the front of the chair box. Loosely attach the front of the seat cushion with the 2 screws. Take care to thread the screws straight in to the threaded inserts of the seat cushion.
5. Tighten all 4 screws securing the seat cushion to the chair box. Take care not to over-tighten the screws, as this can strip the threaded inserts.

Replacing the Leg Restraint Arm

1) Unscrew the cap at the outboard end of the Leg Restraint Hub Assembly. Remove the hub assembly from the end of the leg restraint arm assembly.

NOTE: Older systems may not have a cap at the end of the hub extension (the cylindrical part with numbers). These assemblies have a hub extension that is actually two pieces threaded together with the joint falling at the groove nearest the "6" stamped in the extension.

2) Using a 5/16" hex  wrench, hold the bolt in the main joint while removing the nut on the inside of the chair assembly. Do not allow the bolt to turn as this may result in damage to the bearing assembly.

3) Insert the new arm assembly into the hole in the chair and fasten with the flat washer, lock washer,  and nut.  Finger tighten the nut. Now hold the nut with a 3/4" wrench and tighten the bolt with a 5/16" hex wrench. Finally, hold the bolt in place so it doesn't rotate and tighten the nut completely. Verify that the shoulder and elbow joints rotate smoothly.

4) Re-insert the hub assembly into the hole in the end of the arm assembly and replace the cap. Check for smooth operation of the new assembly.

Replacing the ERGYS Lower Back Cushion

1. Before removing the lower back cushion, make note of the size of the gap between the seat cushion and the lower back cushion. Duplicate this spacing when installing the new lower back cushion. Placing the lower back cushion too low may make it difficult to recline the ERGYS seat.

ERGYS Console Removal

1) Turn off the ERGYS and disconnect the power cord from the wall outlet.

2) Remove the Console by unfastening the two screws located below the pedestal box. Gently tilt the Console (while still resting it on the pedestal) to gain access to the cables that are routed through the pedestal. Disconnect the three cables from the connector plate in the bottom of the Console.

To disconnect the cables, proceed as follows:

- Push the connector at the end of the cable all the way into the mating connector. This will allow the locking tabs to be disengaged.

- Squeeze the two locking tabs in towards the sides of the connector shell.

- While continuing to squeeze the locking tabs, pull on the connector shell until it releases from the mating connector.

CAUTION: Pull only on the connector shell. Do not pull on the cables themselves as this may cause damage to one or more of the conductors in the cable.

3) Once all cables are disconnected, remove the Console and set it aside for packaging.

Calibrating after an Error 28 or 29

This procedure should be performed any time an ERGYS Console has been serviced. Also use this procedure for future reference to periodically check the calibration of your ERGYS, especially after moving the system.

Re-attaching the Console

1) Turn off the ERGYS and UNPLUG IT FROM THE WALL OUTLET. Re-attach the Console to ERGYS frame by inserting the 3 connectors into the Console bottom and inserting and tightening the 2 screws that hold the Console to the ERGYS frame.

2) Remove the Console lid by removing the top 2 screws from the Console's front panel and the top two 2 screws from the back panel. Lift the lid straight up and off.

NOTE: If you have the ERGYS2se you will need to set the P10 jumper on the Stimulus Control Board to "FIELD TEST".

3) Plug the system's power cord into AC power source and turn the Console on. 4) After the system performs the SELF TEST and the initial display changes to "ERGYS Rehabilitation System", a password must be entered with the keypad to advance to the field test and calibration mode. The password "TAFFY" is entered one letter at a time using the INC key and the CONT (or NEXT) keys as follows: A) Push INC until the letter "T" appears in the upper left corner of the display. B) Push CONT (or NEXT) to move on to the next letter in the password sequence. The original letter will disappear from the screen. C) Repeat this sequence until all letters of the password have been entered. Remember to press CONT (or NEXT) after each letter is displayed. D) After entering the 'Y', the last letter, press CONT (or NEXT) twice. The display will change to

NOTE: If you accidentally enter the wrong letter or somehow get the password out of sequence, you must then press STOP then press END then press CONT or NEXT and the system will return to the SELF TEST and you must re-enter the password from the beginning.

L) Press CONT or NEXT again and you will enter the "Resolver" screen. This calibration screen is error #26 related and you will need technical assistance for this.

M) Push CONT or NEXT again and you will enter the "Target Torque" and "Actual Torque" screen.

NOTE: At this point do not press any more keys. This is the calibration screen you need.

5) Locate the part marked "R78" on the board. It is a small square blue device with a screwdriver slot on the top of it, located along the right side of the circuit board toward the back as you face the display. 6) Observe or write down the "Actual Torque" reading that is displayed on the screen. 7) Unlock the pedals and rotate them by hand slowly forward (normal pedaling motion) and observe or write down the "Actual Torque" reading. 8) Allow the pedals to come to a complete stop. 9) Rotate the pedals slowly in reverse and observe or write down the "Actual Torque" reading. The number displayed may be negative or positive. 10) Keep pedaling very slowly in reverse and while observing the "Actual Torque" reading, adjust "R78" on the circuit board until "Actual Torque" displays a positive "1". (To increase numbers, turn "R78" counter clockwise. To decrease number, turn "R78" clockwise.) 11) Now pedal slowly forward again and verify that "Actual Torque" does not exceed "21". That is what causes an error #29. 12) Now pedal slowly in reverse again to see if "Actual Torque" is still calibrated. (A reading of "1" or "0" is a good calibration number.) If something other than '1' or "0" is displayed, keep pedaling in reverse while adjusting "R78" until "Actual Torque" reads "1" or "0". 13) Repeat steps 11 and 12 until system is calibrated. 14) Once your system is calibrated, you may turn the system power off and re-attach the Console lid and operate system normally.

IMPORTANT SERVICE NOTE: If you continue to get error #28 or #29 after performing this calibration procedure, re-enter the FIELD TEST and go to the "Actual Torque" screen and observe the reading to see if the number has drifted out of calibration. Leave the system on this screen for several hours and occasionally check for any change or fluctuation of this number. If the "Actual Torque" reading is changing by itself with no pedal motion or "R78" adjustment, call Therapeutic Alliances, Inc. for technical assistance.

Replacing the Keypad Membrane

Remove six (6) screws from back of keypad case. Feed cable up tube to loosen case from neck fitting. Separate case in half and unplug membrane from cable.

Note: Observe how cable is routed in the bottom half of case.

Carefully peel off the old keypad membrane from the front of the case. If necessary, use mineral spirits to remove excess tape gum. (DO NOT USE HEAVY SOLVENTS!)

Peel release paper from back of new membrane. Insert blue connector and ribbon cable through slot on face of case. Align top and sides of new membrane with recessed rim of case. Then align bottom and press into place. Plug connector into membrane aligning pin one indicator of blue connector with pin one of black connector. (Yellow wire is pin one.)

Note: Do not fold ribbon sharply as you can cause a breakage of inner conductors.

Now place case together so that it is completely closed and feed cable back down tube and insert case into neck fitting, aligning screw holes. Attach neck fitting to case using two (2) 4-40 x 3/8 inch machine screws. Now attach case together on all four corners with #4 x 1/4 inch sheet metal screws.