Service & Maintenance Manual

SERVICE

MAINTENANCE MANUAL

Rev. 1.0

The information contained in this manual is intended for QUALIFIED TECHNICIANS who have completed a specific TECHNOGYM training course and are authorized to perform machine startup and adjustment procedures as well as extraordinary maintenance or repairs which require a thorough knowledge of the machine, its operation, its safety devices and working procedures.

CAREFULLY READ THE INFORMATION CONTAINED IN
THIS MANUAL BEFORE PERFORMING ANY MAINTENANCE
PROCEDURES ON THE MACHINE

DANGEROUS VOLTAGES PRESENT EVEN WHEN THE MACHINE IS TURNED OFF

NOTE

The information contained in this document is subject to change without notice. Technogym does not guarantee this documentation in any way. Technogym shall not be held responsible for any errors contained in this manual and declines all liability for accidents or damages resulting from the supply, characteristics or use of this manual.

This document contains proprietary information that is protected by copyright. All rights reserved. No part of this document may be photocopied, reproduced or translated into another language without the prior written consent of Technogym.

The Technogym^®trademark is property of Technogym S.p.A. The Personal Selection TÜV^™trademark is property of Technogym S.p.A.

Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0

Contents

1. GENERAL NOTICES........................................................................................................................................... 1.1

1.1. INTRODUCTION................................................................................................................................................... 1.1 1.2. RECOMMENDATIONS .......................................................................................................................................... 1.1 1.3. GENERAL RULES FOR REPAIR PROCEDURES ........................................................................................................ 1.2

2. TECHNICAL CHARACTERISTICS.................................................................................................................. 2.1

2.1. PRODUCT CODE: MACHINES................................................................................................................................ 2.1 2.2. CODIFICA DI PRODOTTO: PANCHE ...................................................................................................................... 2.1 2.3. EQUIPMENTS: MECHANICAL CHARACTERISTICS.................................................................................................. 2.3

2.3.1. D6946 – Upper Back......................................................................................................................... 2.3 2.3.2. D6950 – Rotary Torso....................................................................................................................... 2.3 2.3.3. D6951 – Leg Press ............................................................................................................................ 2.4 2.3.4. D6957 – Abdominal Crunch.............................................................................................................. 2.4 2.3.5. D6958 – Lower Back......................................................................................................................... 2.5 2.3.6. D6971 – Vertical Traction ................................................................................................................ 2.5 2.3.7. D6980 – Low Ro w . ............................................................................................................................ 2.6 2.3.8. D6990 – Leg Curl.............................................................................................................................. 2.6 2.3.9. D6991 – Leg Extension ..................................................................................................................... 2.7

2.4. BENCH: MECHANICAL CHARACTERISTICS........................................................................................................... 2.8

2.4.1. D6P915 – Crunch Bench................................................................................................................... 2.8 2.4.2. D6P920 – Adjustable Bench.............................................................................................................. 2.8

2.5. AMBIENT SPECIFICATIONS .................................................................................................................................. 2.9 2.6. CONFORMITY TO REGULATIONS.......................................................................................................................... 2.9

3. INSTALLING AND MOVING THE MACHINES ............................................................................................ 3.1

3.1. SPECIFICATIONS AND REQUIREMENTS ................................................................................................................ 3.1 3.2. MOVING ............................................................................................................................................................. 3.3

3.2.1. Moving without wheel s . ..................................................................................................................... 3.3 3.2.2. Moving with wheel s . .......................................................................................................................... 3.3

4. ACCESSORIES ..................................................................................................................................................... 4.1 5. WHAT IF …........................................................................................................................................................... 5.1

5.1. THE WEIGHT STACK DOES NOT SLIDE SMOOTHLY ............................................................................................... 5.1 5.2. THE WEIGHT STACK CABLE IS NOT TAUT............................................................................................................. 5.2

5.2.1. Adjusting the tension of the cable with crimped fitting ..................................................................... 5.2 5.2.2. Adjusting the tension of the cable with doubling pulle y . ................................................................... 5.2

5.3. THE MACHINE IS NOT FLAT ................................................................................................................................. 5.4 5.4. THE LEVERS OF DUAL-AXIS MACHINES ARE NOT ALIGNED.................................................................................. 5.5 5.5. THE SLIDING BARS OF THE LEG PRESS SEAT ARE NOT ALIGNED .......................................................................... 5.6

5.6. THE TUBE START

WABBLE ........................................................................................................................... 5.7

6. HOW TO DISASSEMBLE THE …..................................................................................................................... 6.1

6.1. FRONT WEIGHT STACK CASING ........................................................................................................................... 6.1 6.2. TOP .................................................................................................................................................................... 6.2 6.3. SEAT ON LOW MACHINES.................................................................................................................................... 6.3 6.4. SEAT ON TALL MACHINES ................................................................................................................................... 6.5 6.5. LEG PRESS SEAT................................................................................................................................................. 6.7 6.6. EASY START FOR TALL MACHINES ...................................................................................................................... 6.9 6.7. RELEASE LEVER................................................................................................................................................ 6.11 6.8. SELECTOR SWITCH FOR ADDITIONAL WEIGHT................................................................................................... 6.13

6.8.1. Machines with cross with crimped cable fitting .............................................................................. 6.13 6.8.2. Machines with cross with doubling pulley ...................................................................................... 6.14

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6.9. DISASSEMBLING UNLOCKING LEVER ON ABDUCTOR - ADDUCTOR ................................................................... 6.16

7. SPECIAL OPERATIONS..................................................................................................................................... 7.1

7.1. LOCKING DOWN THE CABLE FIXING DOWELS ...................................................................................................... 7.1 7.2. LOCKING DOWN THE PULLEYS ............................................................................................................................ 7.2

8. WEIGHT STACK CABLE................................................................................................................................... 8.1

8.1. LENGTH OF THE WEIGHT STACK CABLE .............................................................................................................. 8.1 8.2. ROUTING OF THE WEIGHT STACK CABLE............................................................................................................. 8.2

8.2.1. D6946 – Upper Back......................................................................................................................... 8.2 8.2.2. D6950 – Rotary Torso....................................................................................................................... 8.2 8.2.3. D6951 – Leg Press ............................................................................................................................ 8.3 8.2.4. D6957 – Abdominal Crunch.............................................................................................................. 8.3 8.2.5. D6958 – Lower Back......................................................................................................................... 8.4 8.2.6. D6971 – Vertical Traction ................................................................................................................ 8.4 8.2.7. D6980 – Low Ro w . ............................................................................................................................ 8.5 8.2.8. D6990 – Leg Curl.............................................................................................................................. 8.5 8.2.9. D6991 – Leg Extension ..................................................................................................................... 8.6

9. MAINTENANCE................................................................................................................................................... 9.1

9.1. DAILY MAINTENANCE OPERATIONS .................................................................................................................... 9.1

9.1.1. Cleaning upholstery .......................................................................................................................... 9.1

9.2. WEEKLY MAINTENANCE OPERATIONS ................................................................................................................ 9.2

9.2.1. Cleaning the frame and painted part s . .............................................................................................. 9.2 9.2.2. Cleaning the chrome-plated part s . .................................................................................................... 9.2

9.3. MONTHLY MAINTENANCE OPERATIONS.............................................................................................................. 9.3

9.3.1. Check the cross, bars and weight stack plates .................................................................................. 9.3 9.3.2. Check the cable s . ............................................................................................................................... 9.3 9.3.3. Check the mechanisms....................................................................................................................... 9.3 9.3.4. Check the gas springs........................................................................................................................ 9.3 9.3.5. Check the weight stack stops ............................................................................................................. 9.4 9.3.6. Check the Leg Press seat mechanis m . ............................................................................................... 9.4 9.3.7. Checking the seat mechanism on low machines................................................................................ 9.4 9.3.8. Checking the seat mechanism on tall machines ................................................................................ 9.4 9.3.9. Checking the upholstery .................................................................................................................... 9.4 9.3.10. Checking various rubber parts.......................................................................................................... 9.4

9.4. TWICE-YEARLY MAINTENANCE OPERATIONS...................................................................................................... 9.5

9.4.1. Checking the additional weigh t . ........................................................................................................ 9.5 9.4.2. Check the pulleys............................................................................................................................... 9.5 9.4.3. Check the cam grou p . ........................................................................................................................ 9.5 9.4.4. Check the lever stop s . ........................................................................................................................ 9.5 9.4.5. Replacing the cables.......................................................................................................................... 9.5 9.4.6. Lubricating the release systems......................................................................................................... 9.5 9.4.7. Screw and bolt chec k . ........................................................................................................................ 9.5 9.4.8. Checking for mechanism play ........................................................................................................... 9.6 9.4.9. Checking cross alignment.................................................................................................................. 9.6

10. FUNCTIONAL TESTS ....................................................................................................................................... 10.1

10.1.WEIGHT STACK CABLE ASSEMBLY TEST ........................................................................................................... 10.1 10.2.HOUSING ASSEMBLY TEST ................................................................................................................................ 10.1 10.3.MECHANICAL RESISTANCE DEVICE ASSEMBLY TEST......................................................................................... 10.1 10.4.SEAT GROUP ASSEMBLY TEST ........................................................................................................................... 10.2

11. APPENDIX........................................................................................................................................................... 11.1

11.1.WHAT TO ORDER TO AUGMENT THE WEIGHT STACK ......................................................................................... 11.1 11.2.UPHOLSTERY.................................................................................................................................................... 11.3 11.3.TOOLS TO USE .................................................................................................................................................. 11.4

Page ii

1. GENERAL NOTICES

1.1. INTRODUCTION

This document is reserved for Technogym Service technicians, and is intended to provide authorized personnel with the necessary information to correctly carry out repairs and maintenance. A thorough knowledge of the technical information contained in this manual is essential for completing the professional training of the operator.

In order to facilitate consultation, the paragraphs are accompanied by schematic drawings which illustrate the procedure being described.

This manual contains notices and symbols which have a specific meaning:

WARNING: non observance may result in accident or injury. ATTENTION: non observance may cause damage to the machine. Information about the operation in progress. OBSERVE: observation about the operation in progress.

1.2. RECOMMENDATIONS

Technogym recommends the following steps for planning repair procedures: • Carefully evaluate the customer’s description of the machine malfunction and ask all the necessary questions to clarify the symptoms of the problem.

• Clearly diagnose the causes of the problem. This manual provides the fundamental theoretical basis, which must then be integrated by personal experience and attendance at the training courses periodically offered by Technogym.

• Rationally plan the repair procedure so as to minimize the downtime necessary for procuring spare parts, preparing tools, etc.

• Access the component to be repaired, avoiding any unnecessary operations. In this regard it will be useful to refer to the disassembly sequence described in this manual.

1.3. GENERAL RULES FOR REPAIR PROCEDURES

1. Always mark any parts or positions which may be confused with each other at the time of reassembly.

2. Use original Technogym spare parts and lubricants of the recommended brands. 3. Use special tools where specified. 4. Consult the Technical Newsletters, which may contain more up-to-date information on adjustments and maintenance than those contained in this manual.

5. Before starting the repair procedure, make sure that the recommended tools are available and in good condition.

6. For the procedures described in this manual, use only the specified tools.

OBSERVE: The tool sizes quoted in this manual are expressed in mm.

2. TECHNICAL CHARACTERISTICS

The Personal Selection TÜV machine code is a sequence of alphanumeric characters arranged as follows:

2.1. PRODUCT CODE: MACHINES

PERSONAL SELECTION TÜV

D69 = machine

See Table 2-1

0 = standard

1,2,3 4,5
Personal Selection TÜV Machine code

3 = enhanced

-7,8 9,10 11 12,13 14
Frame colour

AL = Silver R0 = Brillant green C = grey GG = RAL 7024 K = Kg

Upholstery colour Front casing colour Plastic parts colour Unit of measurement

Service & Maintenance Manual

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