<p><strong>SERVICE </strong></p><p><strong>&amp;</strong></p><p><strong>MAINTENANCE MANUAL </strong></p><p>Rev. 1.0 </p><p>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. </p><p><strong>CAREFULLY READ THE INFORMATION CONTAINED IN </strong><br><strong>THIS MANUAL BEFORE PERFORMING ANY MAINTENANCE </strong><br><strong>PROCEDURES ON THE MACHINE </strong></p><p><strong>DANGEROUS VOLTAGES PRESENT EVEN WHEN THE MACHINE IS TURNED OFF </strong></p><p><strong>NOTE </strong></p><p>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. </p><p>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. </p><p>The Technogym<sup style="top: -0.46em;">® </sup>trademark is property of Technogym S.p.A. The Personal Selection TÜV<sup style="top: -0.46em;">™ </sup>trademark is property of Technogym S.p.A. </p><p><em>Personal Selection TÜV: Service &amp; Maintenance Manual - rev. 1.0 </em></p><p><strong>Contents </strong></p><p><strong>1. GENERAL&nbsp;NOTICES........................................................................................................................................... 1.1 </strong></p><p>1.1. INTRODUCTION................................................................................................................................................... 1.1 1.2. RECOMMENDATIONS .......................................................................................................................................... 1.1 1.3. GENERAL RULES FOR REPAIR PROCEDURES ........................................................................................................ 1.2 </p><p><strong>2. TECHNICAL&nbsp;CHARACTERISTICS.................................................................................................................. 2.1 </strong></p><p>2.1. PRODUCT CODE: MACHINES................................................................................................................................ 2.1 2.2. CODIFICA DI PRODOTTO: PANCHE ...................................................................................................................... 2.1 2.3. EQUIPMENTS: MECHANICAL CHARACTERISTICS.................................................................................................. 2.3 </p><p><em>2.3.1. D6946 &nbsp; – Upper Back......................................................................................................................... 2.3 2.3.2. D6950 &nbsp; – Rotary Torso....................................................................................................................... 2.3 2.3.3. D6951 &nbsp; – Leg Press ............................................................................................................................ 2.4 2.3.4. D6957 &nbsp; – Abdominal Crunch.............................................................................................................. 2.4 2.3.5. D6958 &nbsp; – Lower Back......................................................................................................................... 2.5 2.3.6. D6971 &nbsp; – Vertical Traction ................................................................................................................ 2.5 2.3.7. D6980 &nbsp; – Low Ro w . ............................................................................................................................ 2.6 2.3.8. D6990 &nbsp; – Leg Curl.............................................................................................................................. 2.6 2.3.9. D6991 &nbsp; – Leg Extension ..................................................................................................................... 2.7 </em></p><p>2.4. BENCH: MECHANICAL CHARACTERISTICS........................................................................................................... 2.8 </p><p><em>2.4.1. D6P915 &nbsp; – Crunch Bench................................................................................................................... 2.8 2.4.2. D6P920 &nbsp; – Adjustable Bench.............................................................................................................. 2.8 </em></p><p>2.5. AMBIENT SPECIFICATIONS .................................................................................................................................. 2.9 2.6. CONFORMITY TO REGULATIONS.......................................................................................................................... 2.9 </p><p><strong>3. INSTALLING&nbsp;AND MOVING THE MACHINES ............................................................................................ 3.1 </strong></p><p>3.1. SPECIFICATIONS AND REQUIREMENTS ................................................................................................................ 3.1 3.2. MOVING ............................................................................................................................................................. 3.3 </p><p><em>3.2.1. Moving &nbsp; without wheel s . ..................................................................................................................... 3.3 3.2.2. Moving &nbsp; with wheel s . .......................................................................................................................... 3.3 </em></p><p><strong>4. ACCESSORIES&nbsp;..................................................................................................................................................... 4.1 5. WHAT&nbsp;IF …........................................................................................................................................................... 5.1 </strong></p><p>5.1. THE WEIGHT STACK DOES NOT SLIDE SMOOTHLY ............................................................................................... 5.1 5.2. THE WEIGHT STACK CABLE IS NOT TAUT............................................................................................................. 5.2 </p><p><em>5.2.1. Adjusting &nbsp; the tension of the cable with crimped fitting ..................................................................... 5.2 5.2.2. Adjusting &nbsp; the tension of the cable with doubling pulle y . ................................................................... 5.2 </em></p><p>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 </p><p>5.6. THE TUBE START </p><p>T</p><p>O</p><p>WABBLE ........................................................................................................................... 5.7 </p><p><strong>6. HOW&nbsp;TO DISASSEMBLE THE …..................................................................................................................... 6.1 </strong></p><p>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 </p><p><em>6.8.1. Machines &nbsp; with cross with crimped cable fitting .............................................................................. 6.13 6.8.2. Machines &nbsp; with cross with doubling pulley ...................................................................................... 6.14 </em></p><p>Page i </p><p><em>Personal Selection TÜV: Service &amp; Maintenance Manual - rev. 1.0 </em></p><p>6.9. DISASSEMBLING UNLOCKING LEVER ON ABDUCTOR - ADDUCTOR ................................................................... 6.16 </p><p><strong>7. SPECIAL&nbsp;OPERATIONS..................................................................................................................................... 7.1 </strong></p><p>7.1. LOCKING DOWN THE CABLE FIXING DOWELS ...................................................................................................... 7.1 7.2. LOCKING DOWN THE PULLEYS ............................................................................................................................ 7.2 </p><p><strong>8. WEIGHT&nbsp;STACK CABLE................................................................................................................................... 8.1 </strong></p><p>8.1. LENGTH OF THE WEIGHT STACK CABLE .............................................................................................................. 8.1 8.2. ROUTING OF THE WEIGHT STACK CABLE............................................................................................................. 8.2 </p><p><em>8.2.1. D6946 &nbsp; – Upper Back......................................................................................................................... 8.2 8.2.2. D6950 &nbsp; – Rotary Torso....................................................................................................................... 8.2 8.2.3. D6951 &nbsp; – Leg Press ............................................................................................................................ 8.3 8.2.4. D6957 &nbsp; – Abdominal Crunch.............................................................................................................. 8.3 8.2.5. D6958 &nbsp; – Lower Back......................................................................................................................... 8.4 8.2.6. D6971 &nbsp; – Vertical Traction ................................................................................................................ 8.4 8.2.7. D6980 &nbsp; – Low Ro w . ............................................................................................................................ 8.5 8.2.8. D6990 &nbsp; – Leg Curl.............................................................................................................................. 8.5 8.2.9. D6991 &nbsp; – Leg Extension ..................................................................................................................... 8.6 </em></p><p><strong>9. MAINTENANCE...................................................................................................................................................&nbsp;9.1 </strong></p><p>9.1. DAILY MAINTENANCE OPERATIONS .................................................................................................................... 9.1 </p><p><em>9.1.1. Cleaning &nbsp; upholstery .......................................................................................................................... 9.1 </em></p><p>9.2. WEEKLY MAINTENANCE OPERATIONS ................................................................................................................ 9.2 </p><p><em>9.2.1. Cleaning &nbsp; the frame and painted part s . .............................................................................................. 9.2 9.2.2. Cleaning &nbsp; the chrome-plated part s . .................................................................................................... 9.2 </em></p><p>9.3. MONTHLY MAINTENANCE OPERATIONS.............................................................................................................. 9.3 </p><p><em>9.3.1. Check &nbsp; the cross, bars and weight stack plates .................................................................................. 9.3 9.3.2. Check &nbsp; the cable s . ............................................................................................................................... 9.3 9.3.3. Check &nbsp; the mechanisms....................................................................................................................... 9.3 9.3.4. Check &nbsp; the gas springs........................................................................................................................ 9.3 9.3.5. Check &nbsp; the weight stack stops ............................................................................................................. 9.4 9.3.6. Check &nbsp; the Leg Press seat mechanis m . ............................................................................................... 9.4 9.3.7. Checking &nbsp; the seat mechanism on low machines................................................................................ 9.4 9.3.8. Checking &nbsp; the seat mechanism on tall machines ................................................................................ 9.4 9.3.9. Checking &nbsp; the upholstery .................................................................................................................... 9.4 9.3.10. Checking &nbsp; various rubber parts.......................................................................................................... 9.4 </em></p><p>9.4. TWICE-YEARLY MAINTENANCE OPERATIONS...................................................................................................... 9.5 </p><p><em>9.4.1. Checking &nbsp; the additional weigh t . ........................................................................................................ 9.5 9.4.2. Check &nbsp; the pulleys............................................................................................................................... 9.5 9.4.3. Check &nbsp; the cam grou p . ........................................................................................................................ 9.5 9.4.4. Check &nbsp; the lever stop s . ........................................................................................................................ 9.5 9.4.5. Replacing &nbsp; the cables.......................................................................................................................... 9.5 9.4.6. Lubricating &nbsp; the release systems......................................................................................................... 9.5 9.4.7. Screw &nbsp; and bolt chec k . ........................................................................................................................ 9.5 9.4.8. Checking &nbsp; for mechanism play ........................................................................................................... 9.6 9.4.9. Checking &nbsp; cross alignment.................................................................................................................. 9.6 </em></p><p><strong>10. FUNCTIONAL TESTS ....................................................................................................................................... 10.1 </strong></p><p>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 </p><p><strong>11. APPENDIX........................................................................................................................................................... 11.1 </strong></p><p>11.1.WHAT TO ORDER TO AUGMENT THE WEIGHT STACK ......................................................................................... 11.1 11.2.UPHOLSTERY.................................................................................................................................................... 11.3 11.3.TOOLS TO USE .................................................................................................................................................. 11.4 </p><p>Page ii </p><p><em>Personal Selection TÜV: Service &amp; Maintenance Manual - rev. 1.0 </em></p><p><strong>1. GENERAL&nbsp;NOTICES </strong></p><p><strong>1.1. INTRODUCTION </strong></p><p>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. </p><p>In order to facilitate consultation, the paragraphs are accompanied by schematic drawings which illustrate the procedure being described. </p><p>This manual contains notices and symbols which have a specific meaning: </p><p><strong>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. </strong></p><p><strong>1.2. RECOMMENDATIONS </strong></p><p>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. </p><p>• 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. </p><p>• Rationally plan the repair procedure so as to minimize the downtime necessary for procuring spare parts, preparing tools, etc. </p><p>• 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. </p><p>Page 1.1 </p><p><em>Personal Selection TÜV: Service &amp; Maintenance Manual - rev. 1.0 </em></p><p><strong>1.3. GENERAL&nbsp;RULES FOR REPAIR PROCEDURES </strong></p><p>1. Always&nbsp;mark any parts or positions which may be confused with each other at the time of reassembly. </p><p>2. Use&nbsp;original Technogym spare parts and lubricants of the recommended brands. 3. Use&nbsp;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. </p><p>5. Before&nbsp;starting the repair procedure, make sure that the recommended tools are available and in good condition. </p><p>6. For&nbsp;the procedures described in this manual, use only the specified tools. </p><p><strong>OBSERVE: The tool sizes quoted in this manual are expressed in mm. </strong></p><p>Page 1.2 </p><p><em>Personal Selection TÜV: Service &amp; Maintenance Manual - rev. 1.0 </em></p><p><strong>2. TECHNICAL&nbsp;CHARACTERISTICS </strong></p><p>The Personal Selection TÜV machine code is a sequence of alphanumeric characters arranged as follows: </p><p><strong>2.1. PRODUCT&nbsp;CODE: MACHINES </strong></p><p><strong>PERSONAL SELECTION TÜV </strong></p><ul style="display: flex;"><li style="flex:1"><strong>Characters description </strong></li><li style="flex:1"><strong>key to values </strong></li></ul><p><strong>D69 </strong>= machine </p><p><a href="#9_0">See Table 2-1 </a></p><p><strong>0 </strong>= standard </p><p>1,2,3 4,5 <br>Personal Selection TÜV Machine code </p><p></p><ul style="display: flex;"><li style="flex:1">6</li><li style="flex:1">Weight stack configuration </li></ul><p></p><p><strong>3 </strong>= enhanced </p><p>-7,8 9,10 11 12,13 14 <br>Frame colour </p><p><strong>AL </strong>= Silver <strong>R0 </strong>= Brillant green <strong>C </strong>= grey <strong>GG </strong>= RAL 7024 <strong>K </strong>= Kg </p><p>Upholstery colour Front casing colour Plastic parts colour Unit of measurement </p><p></p><ul style="display: flex;"><li style="flex:1"><strong>Code Machine </strong></li><li style="flex:1"><strong>Code Machine </strong></li></ul><p></p>