biostrength training 21 ing manual

SERVICE & MAINTENANCE MANUAL

REV. 2.1

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 start-up 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 and 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 Biostrength™ trademark is property of Technogym S.p.A.

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1

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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 SPECIFICATIONS .......................................................................................................................2.1 2.1. MECHANICAL CHARACTERISTICS ......................................................................................................................2.1

2.1.1. Abdominal Crunch................................................................................................................................2.1 2.1.2. Lower Back ...........................................................................................................................................2.1 2.1.3. Leg Extension .......................................................................................................................................2.2 2.1.4. Leg Curl................................................................................................................................................2.2 2.1.5. Vertical Traction...................................................................................................................................2.2 2.1.6. Shoulder Press......................................................................................................................................2.3 2.1.7. Chest Press ...........................................................................................................................................2.3 2.1.8. Rowing Torso........................................................................................................................................2.3 2.1.9. Leg Press ..............................................................................................................................................2.4

2.2. ELECTRICAL CHARACTERISTICS ........................................................................................................................2.4 2.3. AMBIENT SPECIFICATIONS.................................................................................................................................2.5 2.4. CONFORMITY TO REGULATIONS ........................................................................................................................2.5 2.5. UNIFIED BOARD VERSION..................................................................................................................................2.6

2.5.1. Type A wiring diagram .........................................................................................................................2.6 2.5.2. Type B wiring diagram .......................................................................................................................2.12 2.5.3. Type C wiring diagram.......................................................................................................................2.19 2.5.4. Type D wiring diagram.......................................................................................................................2.26

2.6. SEPARATED BOARD VERSION ..........................................................................................................................2.34 2.6.1. Type A wiring diagram .......................................................................................................................2.34 2.6.2. Type B wiring diagram .......................................................................................................................2.41 2.6.3. Type C wiring diagram.......................................................................................................................2.50 2.6.4. Type D wiring diagram.......................................................................................................................2.59

3. OPERATING PRINCIPLE ...................................................................................................................................3.1 3.1. BLOCK DIAGRAM ..............................................................................................................................................3.1

3.1.1. Power Entry..........................................................................................................................................3.2 3.1.2. Power Switch ........................................................................................................................................3.2 3.1.3. Fuses.....................................................................................................................................................3.2 3.1.4. Filter .....................................................................................................................................................3.2 3.1.5. Voltage selector board..........................................................................................................................3.2 3.1.6. Power supply ........................................................................................................................................3.2 3.1.7. Transformer ..........................................................................................................................................3.2 3.1.8. Display..................................................................................................................................................3.3 3.1.9. Bio Servo Board....................................................................................................................................3.3 3.1.10. LP driver board ....................................................................................................................................3.4 3.1.11. Wire encoder.........................................................................................................................................3.5 3.1.12. Solenoid ................................................................................................................................................3.5 3.1.13. Weight stack motor ...............................................................................................................................3.5 3.1.14. Seat motor.............................................................................................................................................3.5 3.1.15. LP seat motor........................................................................................................................................3.6 3.1.16. Zero sensor ...........................................................................................................................................3.6 3.1.17. Safety device .........................................................................................................................................3.6

3.2. SOLENOID MANAGEMENT..................................................................................................................................3.8 3.2.1. Mechanics.............................................................................................................................................3.8 3.2.2. Controls ................................................................................................................................................3.8


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3.2.3. The signals involved .............................................................................................................................3.9 3.3. WEIGHT STACK MOTOR MANAGEMENT ...........................................................................................................3.12

3.3.1. Mechanics...........................................................................................................................................3.12 3.3.2. Controls ..............................................................................................................................................3.13 3.3.3. The signals involved ...........................................................................................................................3.14

3.4. SEAT MOTOR MANAGEMENT ...........................................................................................................................3.18 3.4.1. Mechanics...........................................................................................................................................3.18 3.4.2. Controls ..............................................................................................................................................3.18 3.4.3. The signals involved ...........................................................................................................................3.20

3.5. SEAT MOTOR MANAGEMENT FOR LEG PRESS ..................................................................................................3.24 3.5.1. Mechanics...........................................................................................................................................3.24 3.5.2. Controls ..............................................................................................................................................3.24 3.5.3. The signals involved ...........................................................................................................................3.26

3.6. WIRE ENCODER MANAGEMENT .......................................................................................................................3.30 3.6.1. Mechanics...........................................................................................................................................3.30 3.6.2. Controls ..............................................................................................................................................3.30 3.6.3. The signals involved ...........................................................................................................................3.30

4. ACCESSORIES......................................................................................................................................................4.1

5. INSTALLATION INSTRUCTIONS ....................................................................................................................5.1 5.1. SPECIFICATIONS AND REQUIREMENTS ...............................................................................................................5.1 5.2. INSTALLATION ..................................................................................................................................................5.1 5.3. FIRST POWER-ON...............................................................................................................................................5.1

6. TROUBLESHOOTING.........................................................................................................................................6.1 6.1. MANUAL COMPONENTS TEST ...........................................................................................................................6.2

6.1.1. Weight stack motor ...............................................................................................................................6.2 6.1.2. Zero sensor status .................................................................................................................................6.3 6.1.3. Seat motor.............................................................................................................................................6.4 6.1.4. Solenoid ................................................................................................................................................6.5

6.2. AUTOMATIC COMPONENTS TEST .......................................................................................................................6.7 6.2.1. Monitoring communication between the Bio servo board and the CPU board....................................6.7 6.2.2. Counter display.....................................................................................................................................6.8

6.3. RESET PROCEDURE ...........................................................................................................................................6.9 6.3.1. Buffer battery test .................................................................................................................................6.9 6.3.2. TGS interface test .................................................................................................................................6.9 6.3.3. FPGA test .............................................................................................................................................6.9 6.3.4. Solenoid test........................................................................................................................................6.10 6.3.5. Weight stack motor test.......................................................................................................................6.10 6.3.6. Seat motor test ....................................................................................................................................6.12

6.4. TEST PROCEDURE DURING USE........................................................................................................................6.14 6.4.1. Weight stack motor failure..................................................................................................................6.14 6.4.2. Seat motor test ....................................................................................................................................6.14

6.5. THE LCD DISPLAYS THE MESSAGE “HW FAULT: CHECK BATTERY” ...............................................................6.16 6.6. THE LCD DISPLAYS THE MESSAGE “HW FAULT: CHECK TGS” ......................................................................6.17 6.7. THE LCD DISPLAYS THE MESSAGE “HW FAULT: CHECK FPGA”....................................................................6.19 6.8. THE LCD DISPLAYS THE MESSAGE “ADD-ON WEIGHT PROBLEM = MAGNET”..................................................6.20 6.9. THE LCD DISPLAYS THE MESSAGE “WEIGHT STACK PROBLEM = FAIL” ..........................................................6.24 6.10. THE LCD DISPLAYS THE MESSAGE “WEIGHT STACK PROBLEM = MOTOR”......................................................6.25 6.11. THE LCD DISPLAYS THE MESSAGE “WEIGHT STACK PROBLEM = ENCODER” ..................................................6.28 6.12. THE LCD DISPLAYS THE MESSAGE “WEIGHT STACK PROBLEM = LIMIT SWITCH SENSOR”...............................6.30 6.13. THE LCD DISPLAYS THE MESSAGE “SEAT PROBLEM = FAIL” ..........................................................................6.32 6.14. THE LCD DISPLAYS THE MESSAGE “EMERGENCY ACTIVATED” ......................................................................6.33 6.15. THE LCD DISPLAYS THE MESSAGE “SEAT PROBLEM = MOTOR”......................................................................6.35

6.15.1. For Leg Press .....................................................................................................................................6.35 6.15.2. For Leg Extension, Leg Curl, Vertical Traction, Shoulder Press, Chest Press and Rowing Torso....6.38

6.16. THE LCD DISPLAYS THE MESSAGE “SEAT PROBLEM = ENCODER” ..................................................................6.40


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6.16.1. For Leg Press .....................................................................................................................................6.40 6.16.2. For Leg Extension, Leg Curl, Vertical Traction, Shoulder Press, Chest Press and Rowing Torso....6.43

6.17. THE DISPLAY DOES NOT TURN ON ...................................................................................................................6.45 6.18. THE MACHINE DOES NOT READ THE TGS: THE RED LED ON THE KEY READER IS NOT LIT ..............................6.50

7. DISASSEMBLY OF COMPONENTS .................................................................................................................7.1 7.1. ABDOMINAL CRUNCH .......................................................................................................................................7.1

7.1.1. Disassembling the display ....................................................................................................................7.1 7.1.2. Removing the electronic display boards...............................................................................................7.2 7.1.3. Removing the EPROM..........................................................................................................................7.4 7.1.4. Disassembling the TLCBR chip ............................................................................................................7.5 7.1.5. Disassembling the main keyboard ........................................................................................................7.6 7.1.6. Disassembling the plexiglas weight stack guard ..................................................................................7.7 7.1.7. Disassembling the weight stack pulleys................................................................................................7.8 7.1.8. Disassembling the weight stack cover ..................................................................................................7.9 7.1.9. Disassembling the additional weight ..................................................................................................7.11 7.1.10. Disassembling the encoder .................................................................................................................7.12 7.1.11. Disassembling the solenoid ................................................................................................................7.13 7.1.12. Disassembling the selector brush .......................................................................................................7.14 7.1.13. Disassembling the zero sensor............................................................................................................7.15 7.1.14. Disassembling the weight stack selection system................................................................................7.16 7.1.15. Disassembling the weight stack selection chain .................................................................................7.17 7.1.16. Disassembling the weight stack motor................................................................................................7.18 7.1.17. Disassembling the cross stops ............................................................................................................7.19 7.1.18. Disassembling the cross......................................................................................................................7.20 7.1.19. Disassembling the sinker ....................................................................................................................7.21 7.1.20. Disassembling the weight stack plates................................................................................................7.22 7.1.21. Disassembling the bars.......................................................................................................................7.23 7.1.22. Disassembling the seat guard .............................................................................................................7.24 7.1.23. Disassembling the electrical box ........................................................................................................7.25 7.1.24. Disassembling the electronic components of the electrical box .........................................................7.26 7.1.25. Disassembling the bell guard .............................................................................................................7.28 7.1.26. Disassembling the weight stack frame guard .....................................................................................7.29 7.1.27. Disassembling the weight stack cable.................................................................................................7.30 7.1.28. Disassembling the bell ........................................................................................................................7.31 7.1.29. Disassembling the primary shaft - secondary shaft chain ..................................................................7.32 7.1.30. Disassembling the primary shaft ........................................................................................................7.33 7.1.31. Disassembling the secondary shaft.....................................................................................................7.35 7.1.32. Disassembling the weight stack frame pulley .....................................................................................7.37 7.1.33. Disassembling the mat........................................................................................................................7.38 7.1.34. Disassembling the power entry...........................................................................................................7.39 7.1.35. Disassembling the starter plate and fuses ..........................................................................................7.40

7.2. LOWER BACK..................................................................................................................................................7.41 7.2.1. Disassembling the display ..................................................................................................................7.41 7.2.2. Removing the electronic display boards.............................................................................................7.42 7.2.3. Removing the EPROM........................................................................................................................7.44 7.2.4. Disassembling the TLCBR chip ..........................................................................................................7.45 7.2.5. Disassembling the main keyboard ......................................................................................................7.46 7.2.6. Disassembling the plexiglas weight stack guard ................................................................................7.47 7.2.7. Disassembling the weight stack pulleys..............................................................................................7.48 7.2.8. Disassembling the weight stack cover ................................................................................................7.49 7.2.9. Disassembling the additional weight ..................................................................................................7.51 7.2.10. Disassembling the encoder .................................................................................................................7.52 7.2.11. Disassembling the solenoid ................................................................................................................7.53 7.2.12. Disassembling the selector brush .......................................................................................................7.54 7.2.13. Disassembling the zero sensor............................................................................................................7.55 7.2.14. Disassembling the weight stack selection system................................................................................7.56 7.2.15. Disassembling the weight stack selection chain .................................................................................7.57


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7.2.16. Disassembling the weight stack motor................................................................................................7.58 7.2.17. Disassembling the cross stops ............................................................................................................7.59 7.2.18. Disassembling the cross......................................................................................................................7.60 7.2.19. Disassembling the sinker ....................................................................................................................7.61 7.2.20. Disassembling the weight stack plates................................................................................................7.62 7.2.21. Disassembling the bars.......................................................................................................................7.63 7.2.22. Disassembling the seat guard .............................................................................................................7.64 7.2.23. Disassembling the electrical box ........................................................................................................7.65 7.2.24. Disassembling the electronic components of the electrical box .........................................................7.66 7.2.25. Disassembling the bell guard .............................................................................................................7.68 7.2.26. Disassembling the weight stack frame guard .....................................................................................7.69 7.2.27. Disassembling the weight stack cable.................................................................................................7.70 7.2.28. Disassembling the release lever cable................................................................................................7.71 7.2.29. Disassembling the bell ........................................................................................................................7.73 7.2.30. Disassembling the primary shaft - secondary shaft chain ..................................................................7.74 7.2.31. Disassembling the primary shaft ........................................................................................................7.75 7.2.32. Disassembling the secondary shaft.....................................................................................................7.77 7.2.33. Disassembling the weight stack frame pulley .....................................................................................7.79 7.2.34. Disassembling the mat........................................................................................................................7.80 7.2.35. Disassembling the power entry...........................................................................................................7.81 7.2.36. Disassembling the starter plate and fuses ..........................................................................................7.82

7.3. LEG EXTENSION..............................................................................................................................................7.83 7.3.1. Disassembling the display ..................................................................................................................7.83 7.3.2. Removing the electronic display boards.............................................................................................7.84 7.3.3. Removing the EPROM........................................................................................................................7.86 7.3.4. Disassembling the TLCBR chip ..........................................................................................................7.87 7.3.5. Disassembling the main keyboard ......................................................................................................7.88 7.3.6. Disassembling the seat keyboard........................................................................................................7.89 7.3.7. Disassembling the Plexiglas weight stack guard................................................................................7.90 7.3.8. Disassembling the weight stack pulleys..............................................................................................7.91 7.3.9. Disassembling the weight stack cover ................................................................................................7.92 7.3.10. Disassembling the additional weight ..................................................................................................7.94 7.3.11. Disassembling the encoder .................................................................................................................7.95 7.3.12. Disassembling the solenoid ................................................................................................................7.96 7.3.13. Disassembling the selector brush .......................................................................................................7.97 7.3.14. Disassembling the zero sensor............................................................................................................7.98 7.3.15. Disassembling the weight stack selection system................................................................................7.99 7.3.16. Disassembling the weight stack selection chain ...............................................................................7.100 7.3.17. Disassembling the weight stack motor..............................................................................................7.101 7.3.18. Disassembling the cross stops ..........................................................................................................7.102 7.3.19. Disassembling the cross....................................................................................................................7.103 7.3.20. Disassembling the sinker ..................................................................................................................7.104 7.3.21. Disassembling the weight stack plates..............................................................................................7.105 7.3.22. Disassembling the bars.....................................................................................................................7.106 7.3.23. Disassembling the seat guard ...........................................................................................................7.107 7.3.24. Disassembling the seat motor ...........................................................................................................7.108 7.3.25. Disassembling the electrical box ......................................................................................................7.110 7.3.26. Disassembling the electronic components of the electrical box .......................................................7.111 7.3.27. Disassembling the bell guard ...........................................................................................................7.113 7.3.28. Disassembling the weight stack frame guard ...................................................................................7.114 7.3.29. Disassembling the weight stack cable...............................................................................................7.115 7.3.30. Disassembling the bell ......................................................................................................................7.116 7.3.31. Disassembling the primary shaft - secondary shaft chain ................................................................7.117 7.3.32. Disassembling the primary shaft ......................................................................................................7.118 7.3.33. Disassembling the secondary shaft...................................................................................................7.120 7.3.34. Disassembling the weight stack frame pulley ...................................................................................7.122 7.3.35. Disassembling the mat......................................................................................................................7.123 7.3.36. Disassembling the power entry.........................................................................................................7.124


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7.3.37. Disassembling the starter plate and fuses ........................................................................................7.125 7.4. LEG CURL.....................................................................................................................................................7.126

7.4.1. Disassembling the display ................................................................................................................7.126 7.4.2. Removing the electronic display boards...........................................................................................7.127 7.4.3. Removing the EPROM......................................................................................................................7.129 7.4.4. Disassembling the TLCBR chip ........................................................................................................7.130 7.4.5. Disassembling the main keyboard ....................................................................................................7.131 7.4.6. Disassembling the seat keyboard......................................................................................................7.132 7.4.7. Disassembling the plexiglas weight stack guard ..............................................................................7.133 7.4.8. Disassembling the weight stack pulleys............................................................................................7.134 7.4.9. Disassembling the weight stack cover ..............................................................................................7.135 7.4.10. Disassembling the additional weight ................................................................................................7.137 7.4.11. Disassembling the encoder ...............................................................................................................7.138 7.4.12. Disassembling the solenoid ..............................................................................................................7.139 7.4.13. Disassembling the selector brush .....................................................................................................7.140 7.4.14. Disassembling the zero sensor..........................................................................................................7.141 7.4.15. Disassembling the weight stack selection system..............................................................................7.142 7.4.16. Disassembling the weight stack selection chain ...............................................................................7.143 7.4.17. Disassembling the weight stack motor..............................................................................................7.144 7.4.18. Disassembling the cross stops ..........................................................................................................7.145 7.4.19. Disassembling the cross....................................................................................................................7.146 7.4.20. Disassembling the sinker ..................................................................................................................7.147 7.4.21. Disassembling the weight stack plates..............................................................................................7.148 7.4.22. Disassembling the bars.....................................................................................................................7.149 7.4.23. Disassembling the seat guard ...........................................................................................................7.150 7.4.24. Disassembling the seat motor ...........................................................................................................7.151 7.4.25. Disassembling the electrical box ......................................................................................................7.153 7.4.26. Disassembling the electronic components of the electrical box .......................................................7.154 7.4.27. Disassembling the bell guard ...........................................................................................................7.156 7.4.28. Disassembling the weight stack frame guard ...................................................................................7.157 7.4.29. Disassembling the weight stack cable...............................................................................................7.158 7.4.30. Disassembling the bell ......................................................................................................................7.159 7.4.31. Disassembling the primary shaft - secondary shaft chain ................................................................7.160 7.4.32. Disassembling the primary shaft ......................................................................................................7.161 7.4.33. Disassembling the secondary shaft...................................................................................................7.163 7.4.34. Disassembling the weight stack frame pulley ...................................................................................7.165 7.4.35. Disassembling the mat......................................................................................................................7.166 7.4.36. Disassembling the power entry.........................................................................................................7.167 7.4.37. Disassembling the starter plate and fuses ........................................................................................7.168

7.5. VERTICAL TRACTION.....................................................................................................................................7.169 7.5.1. Disassembling the display ................................................................................................................7.169 7.5.2. Removing the electronic display boards...........................................................................................7.170 7.5.3. Removing the EPROM......................................................................................................................7.172 7.5.4. Disassembling the TLCBR chip ........................................................................................................7.173 7.5.5. Disassembling the main keyboard ....................................................................................................7.174 7.5.6. Disassembling the seat keyboard......................................................................................................7.175 7.5.7. Removing the seat .............................................................................................................................7.176 7.5.8. Disassembling the front guard..........................................................................................................7.177 7.5.9. Disassembling the electrical box ......................................................................................................7.178 7.5.10. Disassembling the electronic components of the electrical box .......................................................7.179 7.5.11. Disassembling the upright guard......................................................................................................7.181 7.5.12. Disassembling the seat motor ...........................................................................................................7.182 7.5.13. Disassembling the prestart cable......................................................................................................7.183 7.5.14. Disassembling the rear guard...........................................................................................................7.185 7.5.15. Disassembling the solenoid ..............................................................................................................7.186 7.5.16. Disassembling the selector brush .....................................................................................................7.187 7.5.17. Disassembling the weight stack cable...............................................................................................7.188 7.5.18. Disassembling the pulleys.................................................................................................................7.189


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7.5.19. Disassembling the zero sensor..........................................................................................................7.190 7.5.20. Disassembling the weight stack selection system..............................................................................7.191 7.5.21. Disassembling the weight stack selection chain ...............................................................................7.193 7.5.22. Disassembling the weight stack motor..............................................................................................7.194 7.5.23. Disassembling the rear lever guard..................................................................................................7.195 7.5.24. Disassembling the lever cable ..........................................................................................................7.196 7.5.25. Disassembling the cam group...........................................................................................................7.197 7.5.26. Disassembling the levers ..................................................................................................................7.198 7.5.27. Disassembling the front lever guard.................................................................................................7.199 7.5.28. Disassembling the weight stack cover ..............................................................................................7.200 7.5.29. Disassembling the column extension ................................................................................................7.201 7.5.30. Disassembling the columns...............................................................................................................7.202 7.5.31. Disassembling the additional weight ................................................................................................7.203 7.5.32. Disassembling the encoder ...............................................................................................................7.204 7.5.33. Disassembling the bars.....................................................................................................................7.205 7.5.34. Disassembling the cross and weight stack plates .............................................................................7.206 7.5.35. Disassembling the sinker ..................................................................................................................7.207 7.5.36. Disassembling the mats ....................................................................................................................7.208 7.5.37. Disassembling the display support ...................................................................................................7.209 7.5.38. Disassembling the power entry.........................................................................................................7.210 7.5.39. Disassembling the starter plate and fuses ........................................................................................7.211

7.6. SHOULDER PRESS .........................................................................................................................................7.212 7.6.1. Disassembling the display ................................................................................................................7.212 7.6.2. Removing the electronic display boards...........................................................................................7.213 7.6.3. Removing the EPROM......................................................................................................................7.215 7.6.4. Disassembling the TLCBR chip ........................................................................................................7.216 7.6.5. Disassembling the main keyboard ....................................................................................................7.217 7.6.6. Disassembling the seat keyboard......................................................................................................7.218 7.6.7. Removing the seat .............................................................................................................................7.219 7.6.8. Disassembling the front guard..........................................................................................................7.220 7.6.9. Disassembling the electrical box ......................................................................................................7.221 7.6.10. Disassembling the electronic components of the electrical box .......................................................7.222 7.6.11. Disassembling the upright guard......................................................................................................7.224 7.6.12. Disassembling the seat motor ...........................................................................................................7.225 7.6.13. Disassembling the prestart cable......................................................................................................7.226 7.6.14. Disassembling the rear guard...........................................................................................................7.228 7.6.15. Disassembling the solenoid ..............................................................................................................7.229 7.6.16. Disassembling the selector brush .....................................................................................................7.230 7.6.17. Disassembling the weight stack cable...............................................................................................7.231 7.6.18. Disassembling the pulleys.................................................................................................................7.232 7.6.19. Disassembling the zero sensor..........................................................................................................7.233 7.6.20. Disassembling the weight stack selection system..............................................................................7.234 7.6.21. Disassembling the weight stack selection chain ...............................................................................7.236 7.6.22. Disassembling the weight stack motor..............................................................................................7.237 7.6.23. Disassembling the rear lever guard..................................................................................................7.238 7.6.24. Disassembling the lever cable ..........................................................................................................7.239 7.6.25. Disassembling the cam group...........................................................................................................7.240 7.6.26. Disassembling the levers ..................................................................................................................7.241 7.6.27. Disassembling the front lever guard.................................................................................................7.242 7.6.28. Disassembling the weight stack cover ..............................................................................................7.243 7.6.29. Disassembling the column extension ................................................................................................7.244 7.6.30. Disassembling the columns...............................................................................................................7.245 7.6.31. Disassembling the additional weight ................................................................................................7.246 7.6.32. Disassembling the encoder ...............................................................................................................7.247 7.6.33. Disassembling the bars.....................................................................................................................7.248 7.6.34. Disassembling the cross and weight stack plates .............................................................................7.249 7.6.35. Disassembling the sinker ..................................................................................................................7.250 7.6.36. Disassembling the mats ....................................................................................................................7.251


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7.6.37. Disassembling the display support ...................................................................................................7.252 7.6.38. Disassembling the power entry.........................................................................................................7.253 7.6.39. Disassembling the starter plate and fuses ........................................................................................7.254

7.7. CHEST PRESS ................................................................................................................................................7.255 7.7.1. Disassembling the display ................................................................................................................7.255 7.7.2. Removing the electronic display boards...........................................................................................7.256 7.7.3. Removing the EPROM......................................................................................................................7.258 7.7.4. Disassembling the TLCBR chip ........................................................................................................7.259 7.7.5. Disassembling the main keyboard ....................................................................................................7.260 7.7.6. Disassembling the seat keyboard......................................................................................................7.261 7.7.7. Disassembling the rear Plexiglas weight stack guard ......................................................................7.262 7.7.8. Disassembling the front plexiglas weight stack guard......................................................................7.263 7.7.9. Disassembling the weight stack pulley .............................................................................................7.264 7.7.10. Disassembling the weight stack cover ..............................................................................................7.265 7.7.11. Disassembling the additional weight ................................................................................................7.267 7.7.12. Disassembling the encoder ...............................................................................................................7.268 7.7.13. Disassembling the solenoid ..............................................................................................................7.269 7.7.14. Disassembling the selector brush .....................................................................................................7.270 7.7.15. Disassembling the zero sensor..........................................................................................................7.271 7.7.16. Removing the seat .............................................................................................................................7.272 7.7.17. Disassembling the upright guard......................................................................................................7.273 7.7.18. Disassembling the closing panels .....................................................................................................7.274 7.7.19. Disassembling the weight stack selection system..............................................................................7.275 7.7.20. Disassembling the weight stack selection chain ...............................................................................7.276 7.7.21. Disassembling the weight stack motor..............................................................................................7.277 7.7.22. Disassembling the cross stops ..........................................................................................................7.278 7.7.23. Disassembling the cross....................................................................................................................7.279 7.7.24. Disassembling the sinker ..................................................................................................................7.280 7.7.25. Disassembling the weight stack plates..............................................................................................7.281 7.7.26. Disassembling the bars.....................................................................................................................7.282 7.7.27. Disassembling the seat motor ...........................................................................................................7.283 7.7.28. Disassembling the electrical box ......................................................................................................7.284 7.7.29. Disassembling the electronic components of the electrical box .......................................................7.285 7.7.30. Disassembling the pulleys.................................................................................................................7.287 7.7.31. Disassembling the weight stack cable...............................................................................................7.288 7.7.32. Disassembling the lever cable ..........................................................................................................7.289 7.7.33. Disassembling the doubling cable ....................................................................................................7.290 7.7.34. Disassembling the cam group...........................................................................................................7.291 7.7.35. Disassembling the front guard..........................................................................................................7.292 7.7.36. Disassembling the prestart cable......................................................................................................7.293 7.7.37. Disassembling the levers ..................................................................................................................7.295 7.7.38. Disassembling the mats ....................................................................................................................7.296 7.7.39. Disassembling the display support ...................................................................................................7.297 7.7.40. Disassembling the power entry.........................................................................................................7.298 7.7.41. Disassembling the starter plate and fuses ........................................................................................7.299

7.8. ROWING TORSO ............................................................................................................................................7.300 7.8.1. Disassembling the display ................................................................................................................7.300 7.8.2. Removing the electronic display boards...........................................................................................7.301 7.8.3. Removing the EPROM......................................................................................................................7.303 7.8.4. Disassembling the TLCBR chip ........................................................................................................7.304 7.8.5. Disassembling the main keyboard ....................................................................................................7.305 7.8.6. Disassembling the seat keyboard......................................................................................................7.306 7.8.7. Disassembling the rear plexiglas weight stack guard ......................................................................7.307 7.8.8. Disassembling the front plexiglas weight stack guard......................................................................7.308 7.8.9. Disassembling the weight stack pulley .............................................................................................7.309 7.8.10. Disassembling the weight stack cover ..............................................................................................7.310 7.8.11. Disassembling the additional weight ................................................................................................7.312 7.8.12. Disassembling the encoder ...............................................................................................................7.313


Page viii

7.8.13. Disassembling the solenoid ..............................................................................................................7.314 7.8.14. Disassembling the selector brush .....................................................................................................7.315 7.8.15. Disassembling the zero sensor..........................................................................................................7.316 7.8.16. Disassembling the mats ....................................................................................................................7.317 7.8.17. Disassembling the prestart levers.....................................................................................................7.318 7.8.18. Disassembling the upright guard......................................................................................................7.319 7.8.19. Disassembling the weight stack selection system..............................................................................7.321 7.8.20. Disassembling the weight stack selection chain ...............................................................................7.322 7.8.21. Disassembling the weight stack motor..............................................................................................7.323 7.8.22. Disassembling the cross stops ..........................................................................................................7.324 7.8.23. Disassembling the cross....................................................................................................................7.325 7.8.24. Disassembling the sinker ..................................................................................................................7.326 7.8.25. Disassembling the weight stack plates..............................................................................................7.327 7.8.26. Disassembling the bars.....................................................................................................................7.328 7.8.27. Disassembling the electrical box ......................................................................................................7.329 7.8.28. Disassembling the electronic components of the electrical box .......................................................7.330 7.8.29. Disassembling the pulleys.................................................................................................................7.332 7.8.30. Disassembling the weight stack cable...............................................................................................7.333 7.8.31. Disassembling the doubling cable ....................................................................................................7.334 7.8.32. Disassembling the cam group...........................................................................................................7.335 7.8.33. Disassembling the levers ..................................................................................................................7.336 7.8.34. Disassembling the chest rest release knob........................................................................................7.337 7.8.35. Disassembling the lever guard .........................................................................................................7.338 7.8.36. Disassembling the lever cable ..........................................................................................................7.339 7.8.37. Disassembling the lever shaft ...........................................................................................................7.340 7.8.38. Disassembling the seat guard ...........................................................................................................7.341 7.8.39. Disassembling the seat motor ...........................................................................................................7.342 7.8.40. Disassembling the power entry.........................................................................................................7.343 7.8.41. Disassembling the starter plate and fuses ........................................................................................7.344

7.9. LEG PRESS ....................................................................................................................................................7.345 7.9.1. Disassembling the display ................................................................................................................7.345 7.9.2. Removing the electronic display boards...........................................................................................7.347 7.9.3. Removing the EPROM......................................................................................................................7.349 7.9.4. Disassembling the TLCBR chip ........................................................................................................7.350 7.9.5. Disassembling the main keyboard ....................................................................................................7.351 7.9.6. Disassembling the seat keyboard......................................................................................................7.352 7.9.7. Disassembling the weight stack cover ..............................................................................................7.353 7.9.8. Disassembling the plexiglas weight stack guard ..............................................................................7.354 7.9.9. Disassembling the weight stack pulleys............................................................................................7.355 7.9.10. Disassembling the encoder ...............................................................................................................7.356 7.9.11. Disassembling the weight stack cover frame ....................................................................................7.357 7.9.12. Disassembling the additional weight ................................................................................................7.358 7.9.13. Disassembling the solenoid ..............................................................................................................7.359 7.9.14. Disassembling the selector brush .....................................................................................................7.360 7.9.15. Disassembling the zero sensor..........................................................................................................7.361 7.9.16. Disassembling the weight stack selection system..............................................................................7.362 7.9.17. Disassembling the weight stack selection chain ...............................................................................7.363 7.9.18. Disassembling the weight stack motor..............................................................................................7.364 7.9.19. Disassembling the cross stops ..........................................................................................................7.365 7.9.20. Disassembling the cross....................................................................................................................7.366 7.9.21. Disassembling the sinker ..................................................................................................................7.367 7.9.22. Disassembling the weight stack plates..............................................................................................7.368 7.9.23. Disassembling the bars.....................................................................................................................7.369 7.9.24. Disassembling the rear guard...........................................................................................................7.370 7.9.25. Disassembling the central guard ......................................................................................................7.371 7.9.26. Disassembling the main electrical box .............................................................................................7.372 7.9.27. Disassembling the electronic components of the main electrical box ..............................................7.373 7.9.28. Disassembling the secondary electrical box.....................................................................................7.375


Page ix

7.9.29. Disassembling the electronic components of the secondary electrical box ......................................7.376 7.9.30. Disassembling the seat motor photocell ...........................................................................................7.377 7.9.31. Disassembling the seat motor brushes..............................................................................................7.378 7.9.32. Disassembling the seat movement limitation microswitch................................................................7.379 7.9.33. Disassembling the seat motor unit....................................................................................................7.380 7.9.34. Removing the seat .............................................................................................................................7.382 7.9.35. Disassembling the seat sliding bars..................................................................................................7.383 7.9.36. Disassembling the shoulder rest group release cable ......................................................................7.384 7.9.37. Disassembling the shoulder rest group.............................................................................................7.386 7.9.38. Disassembling the tachogenerator guard.........................................................................................7.388 7.9.39. Disassembling the front guard..........................................................................................................7.389 7.9.40. Disassembling the lever mat rubber .................................................................................................7.390 7.9.41. Disassembling the levers ..................................................................................................................7.391 7.9.42. Disassembling the lever cable ..........................................................................................................7.392 7.9.43. Disassembling the weight stack frame guard ...................................................................................7.393 7.9.44. Disassembling the weight stack cable...............................................................................................7.394 7.9.45. Disassembling the doubling cable ....................................................................................................7.395 7.9.46. Disassembling the cam group...........................................................................................................7.396 7.9.47. Disassembling the weight stack frame pulleys..................................................................................7.397 7.9.48. Disassembling the starter plate and fuses ........................................................................................7.398 7.9.49. Disassembling the mat......................................................................................................................7.399 7.9.50. Disassembling the power entry.........................................................................................................7.400

8. ADJUSTMENTS ....................................................................................................................................................8.1 8.1. ADJUSTING THE WEIGHT STACK PLATE SELECTION............................................................................................8.1

8.1.1. OFFSET................................................................................................................................................8.1 8.1.2. Distance between plates .......................................................................................................................8.2 8.1.3. Weight stack motor inertia....................................................................................................................8.3

8.2. ADJUSTING THE MECHANISMS PHASING ............................................................................................................8.4 8.2.1. Abdominal Crunch................................................................................................................................8.4 8.2.2. Lower Back ...........................................................................................................................................8.6 8.2.3. Leg Extension .......................................................................................................................................8.8 8.2.4. Leg Curl..............................................................................................................................................8.10 8.2.5. Vertical Traction.................................................................................................................................8.12 8.2.6. Shoulder Press....................................................................................................................................8.13 8.2.7. Chest Press .........................................................................................................................................8.14 8.2.8. Rowing Torso......................................................................................................................................8.17 8.2.9. Leg Press ............................................................................................................................................8.19

8.3. ADJUSTING THE POSITION OF THE CROSS LIMIT SWITCH...................................................................................8.20 8.4. ADJUSTING THE WEIGHT STACK CABLE TENSION .............................................................................................8.21 8.5. ADJUSTING THE PRESTART CABLE TENSION.....................................................................................................8.22

8.5.1. Adjusting the primary prestart cable tension......................................................................................8.22 8.5.2. Adjusting the secondary prestart cable tension ..................................................................................8.23

8.6. ADJUSTING THE LEVER CABLE ........................................................................................................................8.24 8.7. ADJUSTING THE DOUBLING CABLE ..................................................................................................................8.25 8.8. ADJUSTING THE ZERO SENSOR POSITION..........................................................................................................8.26 8.9. ADJUSTING THE POSITION OF THE WEIGHT STACK SELECTION SYSTEM ............................................................8.27 8.10. ADJUSTING THE TENSION OF THE WEIGHT STACK SELECTION CHAIN................................................................8.28 8.11. ADJUSTING THE PRIMARY SHAFT - SECONDARY SHAFT CHAIN ALIGNMENT .....................................................8.29 8.12. ADJUSTING THE PRIMARY SHAFT - SECONDARY SHAFT CHAIN TENSION...........................................................8.30 8.13. ADJUSTING THE RELEASE CABLE TENSION.......................................................................................................8.31 8.14. ADJUSTING THE CURRENT LIMIT ON THE WSMI AND SAMI BOARD...............................................................8.32 8.15. LCD CONTRAST..............................................................................................................................................8.33 8.16. BUZZER TONE .................................................................................................................................................8.34

9. CONFIGURING THE MACHINE.......................................................................................................................9.1 9.1. CONFIGURING PARAMETER DEFAULTS...............................................................................................................9.1 9.2. CONFIGURING THE TECHNICAL PARAMETERS ....................................................................................................9.1


Page x

9.2.1. Machine code........................................................................................................................................9.2 9.2.2. Offset zero sensor .................................................................................................................................9.2 9.2.3. Number of pulses for weight stack selection.........................................................................................9.3 9.2.4. Weight stack motor inertia....................................................................................................................9.3 9.2.5. Weight stack motor selection window...................................................................................................9.4 9.2.6. Distance between plates .......................................................................................................................9.4 9.2.7. Number of pulses for seat selection ......................................................................................................9.5 9.2.8. Seat offset position 0.............................................................................................................................9.6 9.2.9. Seat offset position 9.............................................................................................................................9.6 9.2.10. Seat motor inertia .................................................................................................................................9.7 9.2.11. Minimum ROM length ..........................................................................................................................9.7 9.2.12. Default ROM start ................................................................................................................................9.8 9.2.13. Default ROM length..............................................................................................................................9.8 9.2.14. %ROM first rep.....................................................................................................................................9.9

9.3. CONFIGURING THE USER PARAMETERS............................................................................................................9.11 9.3.1. Language ............................................................................................................................................9.11 9.3.2. Unit of measure ..................................................................................................................................9.11 9.3.3. Using the additional weight................................................................................................................9.12 9.3.4. Using the function keys.......................................................................................................................9.12 9.3.5. Number of which repetition to use for ROM acquisition ....................................................................9.12 9.3.6. “Time-out” setting..............................................................................................................................9.12 9.3.7. Setting the default seat position..........................................................................................................9.13 9.3.8. Enable pacer.......................................................................................................................................9.13 9.3.9. Pacer speed.........................................................................................................................................9.14 9.3.10. Time before load.................................................................................................................................9.14 9.3.11. Perform auto-configuration procedure ..............................................................................................9.14

9.4. TABLE OF FACTORY SETTINGS.........................................................................................................................9.16 9.4.1. User parameters .................................................................................................................................9.16 9.4.2. ROM Parameters ................................................................................................................................9.16 9.4.3. BOSCH weight stack motor parameters .............................................................................................9.16 9.4.4. Plate distance .....................................................................................................................................9.17 9.4.5. Seat motor parameters........................................................................................................................9.17

9.5. DISPLAYING WORKING PARAMETERS ..............................................................................................................9.18 9.5.1. Weight stack motor running time........................................................................................................9.18 9.5.2. Weight stack motor test cycles ............................................................................................................9.18 9.5.3. Number of relay switching cycles to move the weight stack motor upward........................................9.18 9.5.4. Number of relay switching cycles to move the weight stack motor downward...................................9.18 9.5.5. Number of fail signals produced by the weight stack motor interface board .....................................9.19 9.5.6. Seat motor running time .....................................................................................................................9.19 9.5.7. Seat motor test cycles..........................................................................................................................9.19 9.5.8. Number of relay switching cycles to move the seat motor upward.....................................................9.19 9.5.9. Number of relay switching cycles to move the seat motor downward ................................................9.20 9.5.10. Number of fail signals produced by the seat motor interface board...................................................9.20 9.5.11. Number of solenoid relay switching cycles.........................................................................................9.20 9.5.12. Machine running time.........................................................................................................................9.20 9.5.13. Number of repetitions carried out on the machine .............................................................................9.21 9.5.14. Total weight lifted using the machine .................................................................................................9.21

9.6. EDITING THE WORKING PARAMETERS..............................................................................................................9.22 9.6.1. Weight stack motor running time........................................................................................................9.22 9.6.2. Weight stack motor test cycles ............................................................................................................9.22 9.6.3. Number of relay switching cycles to move the weight stack motor upward........................................9.22 9.6.4. Number of relay switching cycles to move the weight stack motor downward...................................9.23 9.6.5. Number of fail signals produced by the weight stack motor interface board .....................................9.23 9.6.6. Seat motor running time .....................................................................................................................9.23 9.6.7. Seat motor test cycles..........................................................................................................................9.23 9.6.8. Number of relay switching cycles to move the seat motor upward.....................................................9.23 9.6.9. Number of relay switching cycles to move the seat motor downward ................................................9.24 9.6.10. Number of fail signals produced by the seat motor interface board...................................................9.24


Page xi

9.6.11. Number of solenoid relay switching cycles.........................................................................................9.24 9.6.12. Machine running time.........................................................................................................................9.24 9.6.13. Number of repetitions carried out on the machine .............................................................................9.25 9.6.14. Total weight lifted using the machine .................................................................................................9.25

10. SCHEDULED MAINTENANCE........................................................................................................................10.1 10.1. EXTERNAL CLEANING .....................................................................................................................................10.1

10.1.1. Preparing working conditions ............................................................................................................10.1 10.1.2. Cleaning operations ...........................................................................................................................10.1

10.2. INTERNAL CLEANING.......................................................................................................................................10.2 10.2.1. Preparing working conditions ............................................................................................................10.2 10.2.2. Cleaning operations ...........................................................................................................................10.2

10.3. MECHANICAL OPERATIONS .............................................................................................................................10.3 10.3.1. Preparing working conditions ............................................................................................................10.3 10.3.2. Check the weight stack selection system.............................................................................................10.3 10.3.3. Check the weight stack plate springs ..................................................................................................10.3 10.3.4. Check the cross, bars and weight stack plates....................................................................................10.3 10.3.5. Check the additional weight ...............................................................................................................10.4 10.3.6. Check the cables .................................................................................................................................10.4 10.3.7. Check the mechanisms........................................................................................................................10.4 10.3.8. Check the gas springs .........................................................................................................................10.4 10.3.9. Check the pulleys ................................................................................................................................10.4 10.3.10. Check the cam group .......................................................................................................................10.4 10.3.11. Check the primary and secondary shaft connection chain ..............................................................10.4 10.3.12. Check the lever limit switch buffers .................................................................................................10.5 10.3.13. Check the cross limit switch.............................................................................................................10.5 10.3.14. Check the Leg Press seat mechanism...............................................................................................10.5 10.3.15. Check the seat mechanism for other machines ................................................................................10.5 10.3.16. Check the Leg Press back and shoulder rest ...................................................................................10.5 10.3.17. Check the wire encoder....................................................................................................................10.5

10.4. ELECTRICAL/ELECTRONIC OPERATIONS...........................................................................................................10.6 10.4.1. Preparing working conditions ............................................................................................................10.6 10.4.2. Check the wiring and connections ......................................................................................................10.6 10.4.3. Check the display................................................................................................................................10.6 10.4.4. Check wear on components ................................................................................................................10.6 10.4.5. Check the component functions ..........................................................................................................10.7

10.5. SOFTWARE CONFIGURATION ...........................................................................................................................10.8 10.5.1. Preparing working conditions ............................................................................................................10.8 10.5.2. Configuration check ...........................................................................................................................10.8

11. APPENDIX ...........................................................................................................................................................11.1 11.1. CONFIGURATION PARAMETERS FOR EXERCISE ROM ACQUISITION..................................................................11.1 11.2. CALCULATING REPETITIONS ............................................................................................................................11.1 11.3. LOCATING THE SERIAL NUMBER......................................................................................................................11.2


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Page 1.1

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 illustrations highlighting the topic covered. 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.


Page 1.2

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 circulars, 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.


Page 2.1

2. TECHNICAL SPECIFICATIONS

2.1. MECHANICAL CHARACTERISTICS

The sizes quoted in the following figures must be considered as minimum dimensions easily reachable disassembling some parts of the machines such as seat, footboard, and casing or display holder.

OBSERVE: The sizes quoted in the following figures are expressed in mm.

2.1.1. ABDOMINAL CRUNCH

2.1.2. LOWER BACK


Page 2.2

2.1.3. LEG EXTENSION

2.1.4. LEG CURL

2.1.5. VERTICAL TRACTION


Page 2.3

2.1.6. SHOULDER PRESS

2.1.7. CHEST PRESS

2.1.8. ROWING TORSO


Page 2.4

2.1.9. LEG PRESS

In the following table, the dimensions are calculated including the space occupied when levers are moving:

MACHINE Length mm

Width mm

Height mm

Abdominal Crunch 1400 1000 1450 Lower Back 1400 1000 1450 Leg Extension 1550 1000 1450 Leg Curl 1550 1000 1450 Vertical Traction 2000 1200 1960 Shoulder Press 2000 1200 1960 Chest Press 1950 1200 1450 Rowing Torso 1650 1050 1550 Leg Press 2670 1020 1600

2.2. ELECTRICAL CHARACTERISTICS

MACHINE Mains voltage

Frequency Consumption Fuses

Abdominal Crunch 115 – 230 Vac 50 - 60 Hz 100 VA 5x20 1.6 A slow blow Lower Back 115 – 230 Vac 50 - 60 Hz 100 VA 5x20 1.6 A slow blow Leg Extension 115 – 230 Vac 50 - 60 Hz 200 VA 5x20 2.0 A slow blow Leg Curl 115 – 230 Vac 50 - 60 Hz 200 VA 5x20 2.0 A slow blow Vertical Traction 115 – 230 Vac 50 - 60 Hz 200 VA 5x20 2.0 A slow blow Shoulder Press 115 – 230 Vac 50 - 60 Hz 200 VA 5x20 2.0 A slow blow Chest Press 115 – 230 Vac 50 - 60 Hz 200 VA 5x20 2.0 A slow blow Rowing Torso 115 – 230 Vac 50 - 60 Hz 200 VA 5x20 2.0 A slow blow Leg Press 115 – 230 Vac 50 - 60 Hz 400 VA 5x20 5.0 A slow blow


Page 2.5

2.3. AMBIENT SPECIFICATIONS

Operating 5° to 35° C Temperature Storage -20 to 55° C Operating 30% to 80% non-condensing Humidity Storage 5% to 85% non-condensing

2.4. CONFORMITY TO REGULATIONS

The machine conforms to the following directives:

Europe USA EMI EN 60601-1-2

Safety EN 60601-1 EN 957-1

Directive 73/23/CEE 93/68/CEE

89/336/CEE

UL 2601-1

Moreover: • Machines do not produce electromagnetic disturbances. • Class 1 machines. • Machines with Type B applied parts. • Ordinary machines not protected against water penetration. • Machine not suitable for use in presence of an inflammable anesthetic mixture of air, oxygen or

protoxide nitrogen. • Machines for continual use.


Page 2.6

2.5. UNIFIED BOARD VERSION

2.5.1. TYPE A WIRING DIAGRAM This diagram is for Abdominal Crunch and Lower Back.


Page 2.7

2.5.1.1. Connectors • Power socket

Name Type of connector Connection CN11 3 male Faston 6.3x0.8 110/220 Vac line: phase, neutral, earth

• Power switch

Name Type of connector Connection CN13 2 male Faston 6.3x0.8 110/220 Vac line: phase, neutral CN14 2 male Faston 6.3x0.8 110/220 Vac line: phase, neutral

• Fuse


• Filter

Name Type of connector Connection CN17 3 male Faston 6.3x0.8 110/220 Vac line: phase, neutral, earth CN18 2 male Faston M5 screw slot 110/220 Vac line: phase, neutral, earth

• Voltage selector board (labeled GF990505 - order code 0WQ123)

Name Type of connector Connection CN1 3-pin female AMP MNL 110/220 Vac line: phase, neutral CN2 3-pin terminal board transformer input line: phase, neutral

• Power supply (order code 0WA040)

Name Type of connector Connection CN1 6-pin male PANDUIT 110/220 Vac line: phase, neutral, earth CN2 6-pin male PANDUIT Low voltage: +12 Vdc, +5 Vdc, ground CN7 Male Faston for printed circuit 6.3x0.8 Earth contact

• CPU Board (labeled GF961223 - order code 0WQ067)

Name Type of connector Connection K1 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground K3 6-pin male AMP MODU II Serial: RS-232 to FPGA K4 9x2-pin male AMP MODU II Signals: I/O connection K5 4x2-pin male AMP MODU II Signals: I/O connection K6 4-pin male AMP MODU II TLCBR K15 6-pin male AMP MODU II External serial port


Page 2.8

• Bio Servo board (labeled GF981005 - order code 0WQ121)

Name Type of connector Connection CN1 6-pin male AMP MINIFIT 24 Vdc weight stack motor with reed CN3 6-pin male AMP MODU II Encoder and Solenoid CN4 2-pin male AMP MINIFIT Zero sensor signal CN7 18-pin male AMP MODU II Signals: CPU connection CN8 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground CN9 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground CN10 2-pin terminal board 18 Vac 10A power supply CE1 2-pin male AMP MODU II Signals: safety device input

• Patch cords

Name Type of connector Connection CN21 6-pin open male AMP MINIFIT 24 Vdc weight stack motor with reed CN23 6-pin open male AMP MODU II Encoder signals CN24 4-pin open male AMP MODU II Solenoid power supply CN25 4-pin open female AMP MODU II Solenoid power supply CN26 4-pin open male AMP MODU II Solenoid power supply CN27 2-pin open male AMP MODU II Zero sensor signal

2.5.1.2. Cables

BS-11: High-voltage power cable Power socket – Power switch – Earth node

Power socket CN11

Signal Color Power switch CN13

PE

Faston Earth Yellow–green - Slot Faston Neutral Black Faston - Faston Phase Black Faston -

BS-12: High-voltage power cable Power switch – Fuses

Power switch CN14

Signal Color Fuses CN15

Faston Neutral Black Faston Faston Phase Black Faston


Page 2.9

BS-13: High-voltage power cable

Fuses – Filter – Earth node Fuses CN16

Signal Color Filter CN17

PE

Faston Neutral Black Faston - Faston Phase Black Faston -

- Earth Yellow–green

Faston Slot

BS-14/S: High-voltage power cable Filter – Power supply – 110/230 Selector switch

Filter CN18

Signal Color Power supply CN1

Selector switch CN1

Slot Ground Yellow 1 - 4 - Faston Neutral Blue - 2 6 - Faston Phase Black - 1

BS-7/L: Low-voltage power cable Power supply – Bio Driver Board

Power supply CN2 CN7

Signal Color Bio driver board CN9

1 - + 12 Vdc Red 1 3 - + 5 Vdc Orange 4 4 - Ground Gray 3 5 Faston Earth Black 2

The connection between connector CN7 and pin 5 on connector CN2, both on the power supply, serves to ground the low voltage grounding socket (0 V).

BS-4: Low voltage cable Bio Driver Board – CPU Board

Bio driver board CN8

Signal Color CPU Board K1

1 + 12 Vdc Black 1 2 Ground Red 2 3 Ground White 3 4 + 5 Vdc Green 4


Page 2.10

BS-6/2: Signal cable

CPU Board – Bio Driver Board CPU Board

K4 K3 K5

Signal Color Bio Driver Board CN7

1 Ground Black 1 2 Ground Purple 2 3 Weight stack motor up Blue 3 5 Weight stack motor down Black 5 7 Weight stack motor alarm White–red 7 9 Weight stack motor pulses White–green 9

15 Solenoid status Green 15 17 Solenoid enable White 13 3 Tx from FPGA to CPU White–yellow 12 6 Reset to FPGA Yellow-red 18 3 + zero sensor White–black 17

BS-00: Zero sensor extension cable Bio Driver Board – Patch

Bio Driver Board CN4

Signal Color Open CN27

1 Signal White 1 2 Ground Black 2

BS-0: Zero sensor cable Zero sensor – Patch

Zero sensor Signal Color Open CN27

Signal White 1 Output Ground Black 2

BS-2/2R: Weight stack motor cable Bio Driver Board – Patch cord



1 + motor Black 1 2 - motor Red 2 4 + 12 Vdc White 4 5 Pulses Green 5 6 Ground Orange 6


Page 2.11

CAUTION: On some equipment this cable could be divided into two parts.

BS-9/2: Weight stack cable Bio Driver Board – Patch cord

Open Bio Driver Board CN3

Signal Color CN23 CN24

1 Channel A Black 1 - 2 Channel B Red 2 - 3 +12 Vdc White 3 - 4 Ground Green 4 - 5 + solenoid Orange - 4 6 Solenoid ground Blue - 3

BS-10: Solenoid extension cord Patch – Patch

Patch CN25


3 + solenoid Blue 3 4 Solenoid ground Red 4

BS-232: Serial output cable CPU Board – Serial connector

CPU Board K15

Signal Color Serial connector

2 ground Black 5 3 Tx to PC Yellow 2 4 Rx from PC Green 3

BS-TLCBR: TGS connector cable CPU Board – TLCBR

CPU Board K6

Signal Color TLCBR

1 + 12 Vdc Red 8 2 ground Black 6 3 Tx to TGS Yellow 2 4 Rx from TGS Green 1


Page 2.12

2.5.2. TYPE B WIRING DIAGRAM This diagram is for Leg Curl, Vertical Traction, Shoulder Press, Chest Press and Rowing Torso.


Page 2.13



• Power switch


• Fuse


• Filter









Page 2.14


Name Type of connector Connection CN1 6-pin male AMP MINIFIT 24 Vdc weight stack motor with reed CN2 6-pin male AMP MINIFIT 24 Vdc seat adjustment motor with reed CN3 6-pin male AMP MODU II Encoder and Solenoid CN4 2-pin male AMP MINIFIT Zero sensor signal CN7 18-pin male AMP MODU II Signals: CPU connection CN8 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground CN9 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground CN10 2-pin terminal board 18 Vac 10A power supply CE1 2-pin male AMP MODU II Signals: safety device input

• Patch cords

Name Type of connector Connection CN21 6-pin open male AMP MINIFIT 24 Vdc weight stack motor with reed CN22 6-pin open male AMP MINIFIT 24 Vdc seat adjustment motor with reed CN23 6-pin open male AMP MODU II Encoder signals CN24 4-pin open male AMP MODU II Solenoid power supply CN25 4-pin open female AMP MODU II Solenoid power supply CN26 4-pin open male AMP MODU II Solenoid power supply CN27 2-pin open male AMP MODU II Zero sensor signal

2.5.2.2. Cables


Power socket CN11


PE



Power switch CN14




Page 2.15

BS-13: High-voltage power cable Fuses – Filter – Earth node

Fuses CN16

Signal Color CN17 Filter

PE



Faston Slot


Filter CN18


Selector switch CN1





1 - + 12 V Red 1 3 - + 5 V Orange 4 4 - Ground Gray 3 5 Faston Earth Black 2







Page 2.16

BS-6/2: Signal cable CPU Board – Bio Driver Board

CPU Board

K4 K3 K5


1 Ground Black 1 2 Ground Purple 2 3 Weight stack motor up Blue 3 4 Seat motor up Brown 4 5 Weight stack motor down Black 5 6 Seat motor down Yellow 6 7 Weight stack motor alarm White–red 7 8 Seat motor Alarm Pink 8 9 Weight stack motor pulses White–green 9

10 Seat motor Pulses Red 10 15 Solenoid status Green 15 17 Solenoid enable White 13 3 Tx from FPGA to CPU White–yellow 12 6 Reset to FPGA Yellow-red 18 3 + zero sensor White–black 17

CAUTION: On the Chest Press, the Vertical Traction and the Shoulder Press, the BS-4

and BS-6 cables are divided into two parts.









Page 2.17

BS-2/2R: Weight stack motor cable

Bio Driver Board – Patch cord Bio Driver

Board CN1




BS-2/2S: Seat motor cable Bio Driver Board – Patch cord



1 + motor White 1 2 - motor Blue 2 5 Pulses Red 5 6 Ground Black 6







Page 2.18

BS-10: Solenoid extension cord

Patch – Patch Patch CN25




CPU Board K15




CPU Board K6

Signal Color TLCBR

1 + 12 V Red 8 2 ground Black 6 3 Tx to TGS Yellow 2 4 Rx from TGS Green 1


Page 2.19

2.5.3. TYPE C WIRING DIAGRAM This diagram is for Leg Extension.


Page 2.20



• Power switch


• Fuse


• Filter









Page 2.21


Name Type of connector Connection CN1 6-pin male AMP MINIFIT 24 Vdc weight stack motor with reed CN2 6-pin male AMP MINIFIT 24 Vdc seat adjustment motor with reed CN3 6-pin male AMP MODU II Encoder and Solenoid CN4 2-pin male AMP MINIFIT Zero sensor signal CN7 18-pin male AMP MODU II Signals: CPU connection CN8 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground CN9 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground CN10 2-pin terminal board 18 Vac 10A power supply CE1 2-pin male AMP MODU II Signals: safety device input

• Sensor interface board (labeled GF991031 - order code 0WQ00007)

Name Type of connector Connection CN1 2-pin open male AMP MINIFIT Safety sensor input signal CN2 4-pin male AMP MODU II Safety sensor input signal to driver board CN3 2-pin male AMP MODU II Reset

• Patch cords

Name Type of connector Connection CN21 6-pin open male AMP MINIFIT Weight stack motor and reed power

supply CN23 6-pin open male AMP MODU II Encoder signals CN24 4-pin open male AMP MODU II Solenoid power supply CN25 4-pin open female AMP MODU II Solenoid power supply CN26 4-pin open male AMP MODU II Solenoid power supply CN27 2-pin open male AMP MODU II Zero sensor signal CN28 2-pin open female AMP MINIFIT Safety sensor signal CN29 2-pin open male AMP MINIFIT Safety sensor signal

2.5.3.2. Cables


Power socket CN11


PE



Page 2.22


Power switch CN14




Fuses CN16


PE



Faston Slot


Filter CN18


Selector switch CN1








Page 2.23

BS-4: Low voltage cable

Bio Driver Board – CPU Board Bio driver

board CN8




CPU Board

K4 K3 K5




BS-00: Zero sensor extension cable

Bio Driver Board – Patch Bio Driver

Board CN4




Page 2.24

BS-0: Zero sensor cable

Zero sensor – Patch Zero sensor Signal Color Open

CN27 Signal White 1 Output Ground Black 2





BS-2S: Seat motor cable Bio Driver Board – Motor


Signal Color Motor

1 + motor White 1 2 - motor Blue 2 5 Pulses Red 5 6 Ground Black 6






Page 2.25


Patch CN25




CPU Board K15




CPU Board K6

Signal Color TLCBR


BS-30: Signal sensor cable Bio Driver Board – Sensor interface Board

Bio Driver Board

CE1 CN10

Signal Color Sensor interface Board CN2

1 - +12 Vdc Red 1 2 - Alarm White 2 - 2 Ground Black 3

BS-31: Sensor cable Sensor Interface Board – Sensor

Sensor Interface Board CN1


1 + Signal White 1 2 - Signal Black 2


Page 2.26

2.5.4. TYPE D WIRING DIAGRAM This diagram is for Leg Press.


Page 2.27



• Power switch


• Fuse


• Filter









Page 2.28


Name Type of connector Connection CN1 6-pin male AMP MINIFIT 24 Vdc weight stack motor with reed CN3 6-pin male AMP MODU II Encoder and Solenoid CN4 2-pin male AMP MINIFIT Zero sensor signal CN6 6-pin male AMP MODU II Signals: LP driver board CN7 18-pin male AMP MODU II Signals: CPU connection CN8 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground CN9 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground CN10 2-pin terminal board 18 Vac 10A power supply CE1 2-pin male AMP MODU II Signals: safety device input

• LP driver board (labeled GF981027 - order code 0WQ00233AA)

Name Type of connector Connection CN1 2-pin male AMP MATE’N’LOCK 48Vdc LP seat motor CN2 2-pin terminal board 38 Vac 6A power supply CN3 6-pin male AMP MODU II Signals: servo board CN4 4x2-pin male AMP MODU II Encoder and microswitches CE1 2-pin male AMP MODU II Signals: safety device input

• Sensor interface board (labeled GF991031 - order code 0WQ00007)

Name Type of connector Connection CN1 2-pin open male AMP MINIFIT Safety sensor input signal CN2 4-pin male AMP MODU II Safety sensor input signal to driver board CN3 2-pin male AMP MODU II Reset

• Patch cords

Name Type of connector Connection CN21 6-pin open male AMP MINIFIT 24 Vdc weight stack motor with reed CN23 6-pin open male AMP MODU II Encoder signals CN24 4-pin open male AMP MODU II Solenoid power supply CN25 4-pin open female AMP MODU II Solenoid power supply CN26 4-pin open male AMP MODU II Solenoid power supply CN27 2-pin open male AMP MODU II Zero sensor signal CN28 2-pin open female AMP MINIFIT Safety sensor signal CN30 2-pin open female AMP MINIFIT Emergency button


Page 2.29

2.5.4.2. Cables


Power socket CN11


PE



Power switch CN14




Fuses CN16

Signal Color Filter CN17

PE



Faston Slot


Filter CN18


Selector switch CN1



Page 2.30




1 - + 12 Vdc Red 1 3 - + 5 Vdc Orange 4 4 - Ground Gray 3 5 Faston Earth Black 2







CPU Board

K4 K3 K5





Page 2.31

















Page 2.32

BS-10: Solenoid extension cord




BS-25/LP: LP seat motor cable Bio Driver Board – Patch cord


Signal Color Open

2 Motor up Red 2 3 Motor down White 3 4 Alarm Green 4 5 Pulses Orange 5 6 Ground Blue 6

BS-27/2ALP: LP seat motor cable LP Driver Board – Patch cord

LP Driver Board CN1

Signal Color Open

1 + motor Black 1 2 - motor Black 2

BS-28/2ALP: LP seat motor component cable LP Driver Board – Patch cord

LP Driver Board CN4

Signal Color Open

1 +5Vdc photocell Black 1 2 Rear switch Red 2 3 Pulses White 3 4 Front switch Green 4 5 Ground photocell Orange 5 6 Ground microswitches Blue 6

The connection cables between cable BS-27/2ALP and the seat motor and between cable BS-28/2ALP and the photocell and the 2 microswitches are not reported because easily described on the wiring diagram.


Page 2.33


CPU Board K15




CPU Board K6

Signal Color TLCBR

1 + 12 Vdc Red 8 2 ground Black 6 3 Tx to TGS Yellow 2 4 Rx from TGS Green 1

BS-30: Signal sensor cable LP Driver Board – Sensor interface Board

LP Driver Board

CE1 CN2



BS-SAFETY: Sensor-emergency button cable Sensor Interface Board – Emergency button - Sensor


Signal Color Emergency button CN28

Sensor

CN30 - Black 1 1 1 Signal + White 2 - 2 Signal - Red - 2

The cable BS-SAFETY is the union of the cables BS-38, BS-37, BS-36, BS-35, BS-33BUL and BS-33ABIS.


Page 2.34

2.6. SEPARATED BOARD VERSION

2.6.1. TYPE A WIRING DIAGRAM This diagram is for Abdominal Crunch and Lower Back.


Page 2.35



• Power switch


• Fuse


• Filter


• Selector switch

Name Type of connector Connection CN19 Contacts to be soldered 110/220 Vac line: phase, neutral






Page 2.36

• Solenoid interface board (labeled GF970405 - order code 0WQ080)

Name Type of connector Connection CN1 4-pin male AMP MODU II Signals: CPU connection CN2 2-pin female AMP MNL Solenoid CN3 2-pin terminal board 18 Vac 1A power supply

• Weight stack motor interface board (labeled GF970305 - order code 0WQ119)

Name Type of connector Connection CN1 6-pin male AMP MODU II Signals: CPU connection CN2 2-pin terminal board 18 Vac 5A power supply CN3 6-pin female AMP MNL 24 Vdc motor with reed

• FPGA Board (labeled GF970601 - order code 0WQ069)

Name Type of connector Connection CN1 8-pin male AMP MODU II Signals: connection with encoder CN2 6-pin male AMP MODU II RS-232 serial to CPU CN3 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground CN4 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground

• Patch cords

Name Type of connector Connection CN21 6-pin open male AMP MNLI Weight stack motor and reed power

supply CN23 6-pin open male AMP MODU II Encoder signals CN24 2-pin open male AMP MODU II Zero sensor signal CN25 2-pin open male AMP MODU II Zero sensor signal CN26 4-pin open male AMP MODU II Solenoid power supply CN27 4-pin open male AMP MODU II Solenoid power supply

2.6.1.2. Cables


Power socket CN11


PE

Faston Earth Yellow–green - Slot Faston Neutral Blue Faston - Faston Phase Black Faston -


Page 2.37


Power switch CN14


Faston Neutral Blue Faston Faston Phase Black Faston


Fuses CN16


PE

Faston Neutral Blue Faston - Faston Phase Black Faston -


Faston Slot

BS-14: High-voltage power cable Filter – Power supply – 110/230 Selector switch

Filter CN18


Selector switch CN19


BS-7/L: Low-voltage power cable Power supply – FPGA Board


Signal Color FPGA Board CN3




Page 2.38

BS-4: Low voltage cable FPGA Board – CPU Board

FPGA Board CN4


1 + 12 Vdc Red 1 2 Ground Black 2 3 Ground Gray 3 4 + 5 Vdc Orange 4

BS-6: Signal cable CPU Board – Low Kit

Solenoid signal cable CPU Board

K4 Signal Color SI board

CN1 17 Enable White 2 15 Status Green 3 12 Ground Gray 4

Weight stack motor signal cable CPU Board

K4 Signal Color WSMI board

CN1 3 Motor up Blue 2 5 Motor down Black 3 7 Alarm Gray–pink 4 9 Pulses White–green 5 1 Ground White–yellow 6

FPGA signal cable CPU Board

K3 Signal Color FPGA Board

CN2 3 Tx to CPU White–Blue 4 6 Reset White–brown 5 2 Ground Shield 2

Zero sensor cable CPU Board

K5 Signal Color Zero sensor

CN24 3 + zero sensor White–black 1 2 Zero sensor ground White–gray 2

BS-00: Zero sensor extension cable Patch – Patch

Patch CN24




Page 2.39

BS-0: Zero contact cable



BS-2: Weight stack motor cable Weight stack motor interface board – Patch cord

WSMI board CN3


1 + motor Red 1 2 - motor Black 2 4 + 12 Vdc White 4 5 Pulses Brown 5 6 Ground Green 6

BS-P: Weight stack motor cable Weight stack motor – Patch

Motor Signal Color Open CN21

+ motor Brown 1 - motor Green 2 + 12 Vdc Black 4 Pulses White 5

Output

Ground Red 6

BS-9: Weight stack cable FPGA Board – Solenoid interface board – Patch cord

Open FPGA board CN1

SI board CN2

Signal Color

CN23 CN26

1 - Channel A Green 1 - 2 - Channel B White 2 - 3 - +12 Vdc Red 3 - 4 - Ground Black 4 - - 1 + solenoid Brown - 3 - 2 Solenoid ground Gray - 4


Page 2.40

BS-E: Encoder cable Encoder – Patch

Encoder Signal Color Open CN23

Channel A Green 1 Channel B White 2 +12 Vdc Red 3 Output

Ground Black 4


Patch CN26



BS-M: Solenoid cable Solenoid – Patch

Solenoid Signal Color Open CN27

+ solenoid White 3 Output Solenoid ground White 4


CPU Board K15




CPU Board K6

Signal Color TLCBR



Page 2.41

2.6.2. TYPE B WIRING DIAGRAM This diagram is for Leg Extension not provided with safety device, Leg Curl, Vertical Traction, Shoulder Press, Chest Press and Rowing Torso.


Page 2.42



• Power switch


• Fuse


• Filter


• Selector switch







Page 2.43





• Seat motor interface board (labeled GF970305 - order code 0WQ081)




• Patch cords


supply CN22 6-pin open male AMP MNLI Seat and reed motor power supply CN23 6-pin open male AMP MODU II Encoder signals CN24 2-pin open male AMP MODU II Zero sensor signal CN25 2-pin open male AMP MODU II Zero sensor signal CN26 4-pin open male AMP MODU II Solenoid power supply CN27 4-pin open male AMP MODU II Solenoid power supply


Page 2.44

2.6.2.2. Cables


Power socket CN11


PE



Power switch CN14




Fuses CN16


PE


- Earth Yellow–green Faston Slot


Filter CN18





Page 2.45

BS-7/L: Low-voltage power cable

Power supply – FPGA Board Power supply CN2 CN7





FPGA board CN4




Page 2.46

BS-6: Signal cable

CPU Board – Low Kit Solenoid signal cable

CPU Board K4

Signal Color SI board CN1

17 Enable White 2 15 Status Green 3 12 Ground Gray 4




Seat motor signal cable CPU Board

K4 Signal Color SAMI board

CN1 4 Motor up Brown 2 6 Motor down Yellow 3 8 Alarm Orange 4

10 Pulses Red 5 2 Ground Purple 6







CAUTION: On the Chest Press only, the BS-4 and BS-6 cables are divided into two

parts - BS-4B and BS-4A, BS-6B and BS-6A - as for the Leg Press. See paragraph 2.6.4.2 for a description of these cables.


Page 2.47

BS-00: Zero sensor extension cable








WSMI board CN3






Output

Ground Red 6


Page 2.48

BS-2S: Seat motor cable

Seat motor interface board – Patch cord SAMI board

CN3 Signal Color Open

CN22 1 + motor Red 1 2 - motor Black 2 5 Pulses Brown 5 6 Ground Green 6

This cable is used only on Vertical Traction, Shoulder Press and Rowing Torso. On Leg Extension, Leg Curl and Chest Press, the connector CN21 of the motor cable connects directly to connector CN3 on the seat motor interface board.

BS-S: Seat motor cable Seat motor – Patch


+ motor White 1 - motor Blue 2 Pulses Red 5 Output

Ground Black 6

BS-9: Weight stack cable FPGA Board – Solenoid interface board – Patch cord

Open FPGA board CN1

SI board CN2

Signal Color

CN23 CN26



Page 2.49

BS-E: Encoder cable

Encoder – Patch Encoder Signal Color Open

CN23 Channel A Green 1 Channel B White 2 +12 Vdc Red 3 Output

Ground Black 4


Patch CN26







CPU Board K15




CPU Board K6

Signal Color TLCBR



Page 2.50

2.6.3. TYPE C WIRING DIAGRAM This diagram is for Leg Extension provided with safety device.


Page 2.51



• Power switch


• Fuse


• Filter


• Selector switch







Page 2.52





• Seat motor interface board (labeled GF991206 - order code 0WQ00011)

Name Type of connector Connection CN1 6-pin male AMP MODU II Signals: CPU connection CN2 2-pin terminal board 18 Vac 5A power supply CN3 6-pin female AMP MNL 24 Vdc motor with reed CS1 2-pin open male AMP MINIFIT Safety sensor input signal CS2 2-pin male AMP MODU II Reset



• Patch cords


supply CN23 6-pin open male AMP MODU II Encoder signals CN24 2-pin open male AMP MODU II Zero sensor signal CN25 2-pin open male AMP MODU II Zero sensor signal CN26 4-pin open male AMP MODU II Solenoid power supply CN27 4-pin open male AMP MODU II Solenoid power supply CN28 2-pin open female AMP MINIFIT Safety sensor signal CN29 2-pin open male AMP MINIFIT Safety sensor signal


Page 2.53

2.6.3.2. Cables


Power socket CN11


PE



Power switch CN14




Fuses CN16


PE



Faston Slot


Filter CN18





Page 2.54

BS-7/L: Low-voltage power cable

Power supply – FPGA Board Power supply CN2 CN7





FPGA board CN4




Page 2.55

BS-6: Signal cable

CPU Board – Low Kit Solenoid signal cable

CPU Board K4






Seat motor signal cable CPU Board

K4 Signal Color SAMI board

CN1 4 Motor up Brown 2 6 Motor down Yellow 3 8 Alarm Orange 4








BS-00: Zero sensor extension cable Patch – Patch

Patch CN24




Page 2.56

BS-0: Zero sensor cable




WSMI board CN3






Output

Ground Red 6

BS-S: Seat motor cable Seat motor – Seat motor interface board

Motor Signal Color SAMI board CN3

+ motor White 1 - motor Blue 2 Pulses Red 5 Output

Ground Black 6


Page 2.57

BS-9: Weight stack cable

FPGA Board – Solenoid interface board – Patch cord Open FPGA

board CN1

SI board CN2

Signal Color

CN23 CN26





Ground Black 4


Patch CN26







Page 2.58

BS-232: Serial output cable

CPU Board – Serial connector CPU Board

K15 Signal Color Serial connector



CPU Board K6

Signal Color TLCBR


BS-30: Signal sensor cable Seat motor interface board – Sensor interface Board

SAMI board CS1 CN2



BS-31: Sensor cable Sensor Interface Board – Sensor



1 + Signal White 1 2 - Signal Black 2


Page 2.59

2.6.4. TYPE D WIRING DIAGRAM This diagram is for Leg Press.


Page 2.60



• Power switch


• Fuse


• Filter


• Selector switch

Name Type of connector Connection CN19 Contacts to be soldered 110/220 Vac line: phase, neutral CN12 Contacts to be soldered 110/220 Vac line: phase, neutral




Name Type of connector Connection K1 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground K3 6-pin male AMP MODU II Serial: RS-232 K4 9x2-pin male AMP MODU II Signals: I/O connection K5 4x2-pin male AMP MODU II Signals: I/O connection K6 4-pin male AMP MODU II TLCBR K15 6-pin male AMP MODU II External serial port


Page 2.61





• LP seat motor interface board (labeled GF971127 - order code 0WQ084)

Name Type of connector Connection CN1 9-pin female AMP MNL 48 Vdc motor, reed and microswitch CN2 2-pin terminal board 48 Vdc, 6A power supply CN3 6-pin male AMP MODU II Signals: CPU connection


Name Type of connector Connection CN1 8-pin male AMP MODU II Signals: connection with encoder CN2 6-pin male AMP MODU II RS-232 serial CN3 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground CN4 4-pin male AMP MODU I Low voltage: +12 Vdc, +5 Vdc, ground

• Patch cords


supply CN23 6-pin open male AMP MODU II Encoder signals CN25 2-pin open male AMP MODU II Zero sensor signal CN26 4-pin open male AMP MODU II Solenoid power supply CN27 4-pin open male AMP MODU II Solenoid power supply CN28 4-pin open male AMP MODU II Photocell signals CN29 4-pin open male AMP MODU II Seat limit switch signals CN30 4-pin open male AMP MODU II Seat limit switch signals CN31 Male faston 4.8x0.5 Front seat limit switch signals CN32 Male faston 4.8x0.5 Back seat limit switch signals CN33 Male faston 6.3x0.8 LP transformer power supply CN34 6-pin open AMP MODU II connector LP seat control signals


Page 2.62

Name Type of connector Connection CN35 4-pin open male AMP MODU II Photocell signals CN36 8x2-pin open male AMP MODU II Signals from CPU to low kit CN37 6-pin open male AMP MODU II Signals from low kit to encoder and

solenoid CN38 4-pin open MOLEX MINIFIT Low-voltage FPGA-CPU power supply CN39 2-pin open AMP MNL LP seat motor power supply

2.6.4.2. Cables


Power socket CN11


PE



Power switch CN14




Fuses CN16


PE



Faston Slot


Page 2.63

BS-14/LPO: High-voltage power cable

Filter – Power supply – 110/230 Selector switch – Patch cord Filter CN18



Open CN33

Slot Ground Yellow 1 - - 4 - - - 1 - Faston Neutral Blue - - Faston 6 - - - 4 - Faston Phase Black - - Faston

BS-15/LPO: High-voltage power cable Patch – 110/230 Selector switch

Patch CN33

Signal Color Selector switch CN12

Faston Neutral Blue 4 Faston Phase Black 1

BS-7/L: Low-voltage power cable Power supply – FPGA Board





BS-4A: Low voltage cable FPGA Board– Patch cord

FPGA board CN4




Page 2.64

BS-4B: Low voltage cable Patch cord – CPU Board

Patch CN38



BS-6B: Signal cable CPU Board – Patch cord

CPU Board K4


Solenoid signal cable 17 Enable White 12 15 Status Green 10 12 Ground Gray 8

Weight stack motor signal cable 3 Motor up Blue 11 5 Motor down Black 13 7 Alarm Gray–pink 15 9 Pulses White–green 16 1 Ground White–yellow 14

Seat motor signal cable 4 Motor up Brown 1 6 Motor down Yellow 3 8 Alarm Orange 5



K3 Signal Color Open






Page 2.65

BS-6A: Signal cable Patch cord – Low kit Solenoid signal cable

Patch CN36



Weight stack motor signal cable Patch CN36

Signal Color WSMI board CN1

11 Motor up Blue 2 13 Motor down Black 3 15 Alarm Gray–pink 4 16 Pulses White–green 5 14 Ground White–yellow 6

Seat motor signal cable Patch CN36


1 Motor up Brown 2 3 Motor down Yellow 3 5 Alarm Orange 4 7 Pulses Red 5 9 Ground Purple 6

FPGA signal cable Patch CN36


4 Tx to CPU White–Blue 4 2 Reset White–brown 5 6 Ground Shield 2





Page 2.66

BS-2: Weight stack motor cable

Weight stack motor interface board – Patch cord WSMI board


CN21 1 + motor Red 1 2 - motor Black 2 4 + 12 Vdc White 4 5 Pulses Brown 5 6 Ground Green 6




Output

Ground Red 6

BS-9A: Weight stack cable FPGA Board – Solenoid interface board – Patch cord

FPGA board CN1

SI board CN2


1 - Channel A Green 1 2 - Channel B White 2 3 - +12 Vdc Red 3 4 - Ground Black 4 - 1 + solenoid Brown 5 - 2 Solenoid ground Gray 6


Page 2.67

BS-9B: Weight stack cable

Patch cord – Patch cord Open Patch

CN37 Signal Color

CN23 CN26

1 Channel A Green 1 - 2 Channel B White 2 - 3 +12 Vdc Red 3 - 4 Ground Black 4 - 5 + solenoid Brown - 3 6 Solenoid ground Gray - 4




Ground Black 4


Patch CN26







Page 2.68

BS-25/LPO: LP seat motor cable

LP SAMI Board – Patch cord LP SAMI Board


CN34 2 Motor up Brown 2 3 Motor down Yellow 3 4 Alarm Orange 4 5 Pulses Red 5 6 Ground Purple 6

BS-20/LPO: LP seat motor extension cable LP SAMI Board – Patch cord

Open LP SAMI Board CN1

Signal Color

CN28 CN29 CN39

1 + motor Brown - - 1 2 - motor Blue - - 2 4 +5 Vdc White 2 - - 5 Pulses Blue 3 - - 6 Ground Red 4 - - 7 Rear limit switch Orange - 2 - 8 Front limit switch Yellow - 3 - 9 Ground Black - 4 -

BS-10/LPO: LP seat motor limit switch extension cable Patch – Patch

Patch CN29


2 Rear limit switch White 2 3 Front limit switch Blue 3 4 Ground Red 4

BS-21/LPO: LP seat motor limit switch cable Patch cord – Photocell – Limit switch

Patch CN30

Signal Color Front limit switch CN31

Rear limit switch CN32

2 Rear limit switch Orange - Faston 3 Front limit switch Yellow Faston - 4 Ground Black Faston Faston


Page 2.69

BS-22/LPO: LP seat motor photocell extension cable Patch – Patch

Patch CN28


2 + 5 Vdc White 1 3 Pulses Blue 2 4 Ground Red 4

BS-S/LPO: LP seat motor cable LP seat motor – Patch


+ motor Brown 1 Output - motor Blue 2

BS-F/LPO: LP seat motor photocell cable LP seat motor photocell – Patch


+ 5 Vdc White 1 Pulses Blue 2 Output Ground Red 4


CPU Board K15




CPU Board K6

Signal Color TLCBR



Page 2.70



Page 3.1

3. OPERATING PRINCIPLE

3.1. BLOCK DIAGRAM

The figure below shows the block diagram for the machine:


Page 3.2

3.1.1. POWER ENTRY This is the entry socket for the machine power supply. It has both an input and output so that up to a maximum of 3-4 machines may be connected in series. It is located under the floor panels of the machine, which must be removed to access the power entry.

3.1.2. POWER SWITCH This is a 2-position (ON and OFF) switch to start the machine. It is housed on a plate together with the fuse holders, located: • On Abdominal Crunch, Lower Back, Leg Extension and Leg Curl, under the seat at the back of

the machine; • On Vertical Traction, Shoulder Press, Chest Press and Rowing Torso, under the seat on the

right-hand side of the machine; • On Leg Press, next to the weight stack inside the machine.

3.1.3. FUSES Two fuses are installed to protect both the phase and neutral. Their size depends on the type of machine, as described in paragraph 2.2. . They are housed on a plate together with the power switch.

3.1.4. FILTER This is used to reduce conducted disturbance on the line. The filter used is model FN 660, manufactured by SCHAFFNER. It is attached to the outside of the low kit electrical box.

3.1.5. VOLTAGE SELECTOR BOARD This is a board which, when used together with a transformer having 2 primary 110-Vac circuits, ensures the correct power supply to the transformer when powered at either 110 Vac or 230 Vac. It is able to automatically detect the line voltage type and to switching a relay contact in order to change the connection of the 2 primary circuits on the standard transformer from serial (for 230-v power supply) to parallel (for 110-v power supply).

3.1.6. POWER SUPPLY Receives the incoming line voltage and outputs the direct current (+5 V and +12 V) to power the display, Bio servo board and encoder. It has a built-in line power supply sensor that allows it to configure itself to the measured level. It is located inside the low kit electrical box.

3.1.7. TRANSFORMER Different types of transformers are installed on the machine depending on the type of electrical diagram: • Type D diagram with unified board (Leg Press): mounts a transformer with 2 110-Vac

primary circuits and 2 secondary circuits: one at 18Vac/5A and the other at 38Vac/6A. This transformer powers the Bio Servo board via the 18Vac/5A output, and the LP driver board via the 38Vac/6A output.

• Other diagrams with unified board: mount a transformer with 2 110-Vac primary circuits, and 1 secondary circuit at 18 Vac/10A. This transformer powers the Bio Servo board via the 18Vac/10A output.


Page 3.3

3.1.8. DISPLAY This is the “brain” of the machine, and manages all functions according to the instructions received from the program recorded in the EPROM. The TGS interface (TLCBR and key reader) is built-in to read exercise data and write exercise feedback on a TGS key, via RS 232 serial port. It controls all external devices (encoder, weight stack motor, solenoid for the additional weight and, where it is available, the seat motor) using the Bio servo board to set up the machine as request and shows the exercise data (weight lifted, speed and power).Upon choosing the exercise, it receives information from the user via keyboard or via TGS. If the machine is not used for a time interval specified by the user, it carries out a reset procedure, during which it tests the efficiency of the external devices connected and sets the motors to their default values. This reset procedure is also the first to take place each time the machine is switched on. It comes complete with buffer battery to provide constant power to a memory containing the machine configuration data.

3.1.9. BIO SERVO BOARD It is the board that interfaces the CPU boards to the electronic components. The board receives continuous power from the power supply, and sends it to the display and encoder. A green SMD LED, situated in the FPGA section, lights when the board is receiving power correctly. The board also receives, as input, the 18Vac/10A secondary power from the transformer, which stabilizes at 24 Vdc for the solenoid, the weight stack and, where available, the seat motor and 12 Vdc for the internal logic. It is equipped with a 12A fuse to protect it from any short-circuits on the input voltage. It has 4 independent sections and each of those manages the electronic components. The 4 sections are easy identifiable from the position of the connectors to which the electronic components will be connected:

3.1.9.1. FPGA section This is the section that receives the encoder signals and processes them. The processed data, that represents the top plate position, are sent to the CPU via a RS-232 serial connection.

3.1.9.2. Solenoid interface section This is the section that manages the interface between the CPU board and solenoid. It receives the solenoid command signal from the CPU board, and based on this signal either supplies or cuts off working voltage to the solenoid. It generates a status signal as feedback for the command received.

3.1.9.3. Weight stack motor section This is the section that manages the interface between the CPU board and weight stack motor. It receives the motor command signal from the CPU board, and based on this signal either supplies or cuts off working voltage to the motor. It generates an alarm signal if any problems occur on the motor (overcurrent). It receives the motor encoder signal, which it filters, squares and sends to the CPU board. The board uses to power the motor 2 16A relays mounted on a socket.


Page 3.4

3.1.9.4. Seat motor section This is the section that manages the interface between the CPU board and seat motor. It receives the motor command signal from the CPU board, and based on this signal either supplies or cuts off working voltage to the motor. It generates an alarm signal if any problems occur on the motor (overcurrent). It receives the motor encoder signal, which it filters, squares and sends to the CPU board. This section is missing on the Abdominal Crunch, Lower Back and Leg Press. On the Leg Extension it interfaces the safety device signal. In normal condition the safety device is a NC contact, white it is NA in emergency condition. On the other machines, it is a jumper. The board uses to power the motor 2 10A relays.

3.1.10. LP DRIVER BOARD This is the board that manages on the Leg Press the interface between the CPU board, the Bio servo board and the seat motor. It receives the motor command signal from the CPU board, and based on this signal either supplies or cuts off working voltage to the motor. It generates an alarm signal if any problems occur on the motor: • surge current; • short-circuit; • blocked rotor. It receives the motor encoder signal, which it filters, squares and sends to the CPU board. It handles the limit switches in order to prevent that the motor will move in the direction of a pressed limit switch. The board is equipped with a programmable chip containing the operating logic, and may be configured by means of the jumpers: • Jumper J1

Handles the encoder power supply voltage: if it is in position 1-2, there are 12 Vdc on pin 1 of connector CN12, while if it is in position 2-3 there are 5 Vdc.

CAUTION: Keep the jumper in position 2-3. • Jumper J2

To enable limit switch management: management is enabled if open, disabled if closed.

CAUTION: Keep the jumper open at all times. • Jumper J3

To motor current ripple management: management is enabled if open, disabled if closed.

CAUTION: Keep the jumper open at all times.


Page 3.5

It is powered by receiving, as input, a 38Vac/6A secondary power from the specific LP transformer, which stabilizes (via a 20-A external jumper) at 48 Vdc for the motor and 5 and 12 Vdc for the internal logic. There are 3 LEDs on the board:

LED Description DL1 with the limit switches enabled, it is ON if the front

microswitch is resting, or OFF if the microswitch is pressed DL2 with the limit switches enabled, it is ON if the rear

microswitch is resting, or OFF if the microswitch is pressed DL3 It is ON when the board microswitch is properly “functional”

The board uses to power the motor 2 10A relays.

3.1.11. WIRE ENCODER The wire encoder is located inside the weight stack, attached to a later column, with the wire fastened to the first plate in the weight stack to measure its position. Moving the weight stack shortens or lengthens the wire, and the encoder outputs a number of pulses to the Bio servo board in proportion to the linear movement of the wire. In order to function properly, it must be powered at 12 Vdc, with a current of at least 100 mA.

3.1.12. SOLENOID The solenoid is located on the first plate in the weight stack. A pin may be shifted inside it, used to select the additional weight of 2.5 Kg on all machines, except for the Leg Press, where it is 5 Kg. When the solenoid is energized, the pin is inside and does not select the additional weight; when it is not energized, the pin is pushed out by a spring to select the additional weight. In order to function properly, it must be powered at 24 Vdc that it receives form the Bio servo board.

3.1.13. WEIGHT STACK MOTOR The weight stack motor moves the chain, connected to the slide that selects the desired weight. This is a 24-V, 5-A DC motor complete with: • an internal reducer (1:79); • a Hall sensor to measure the rpm (encoder) and supply a square-wave output signal with a duty

cycle of 50%. In order to function properly, it must be powered at 24 Vdc that it receives form the Bio servo board.

3.1.14. SEAT MOTOR This is a linear actuator equipped with:


Page 3.6

• 24-V, 5-A DC motor; • a stem that moves a maximum of 250 mm; • a reed sensor to measure the rpm (encoder) and supply a square-wave output signal. Through its stem, the seat motor moves the machine mechanisms that adjust the seat position: • Forward and back on Leg Extension and Leg Curl; • Up and down on Vertical Traction, Shoulder Press, Chest Press and Rowing Torso. This motor is not present on Leg Press, Abdominal Crunch and Lower Back. In order to function properly, it must be powered at 24 Vdc that it receives form the Bio servo board.

3.1.15. LP SEAT MOTOR On Leg Press, the motor and mechanism are different from the other machines: the motor has an output reducer that powers a gear, which in turn moves the rack and connected seat. The motor is 48Vdc/6A, equipped with dual output shaft, to which the following are connected: • irreversible 1:100 reducer; • encoder disc that turns within a photocell, to supply the CPU board with the signal to check the

motor position. In order to function properly, it must be powered at 48 Vdc that it receives form the LP driver board.

3.1.16. ZERO SENSOR This is a reed contact that acts as a zero sensor for the weight stack selection system. A magnet is present on the upper brush of the weight stack selection slide; when it is near this reed, the magnet causes it to switch status. This makes it possible to define a precise position for the slide, for use as a reference measure in selecting the plates properly.

3.1.17. SAFETY DEVICE This device is available on: • Leg Extension: to prevent the risk of the user’s thigh being crushed between the fixed and

moving parts of the machine seat, an embedded sensor has been installed on the fixed part of the seat.

• Leg Press: to prevent the risk of the user’s feet being crushed between the machine seat and the bars, an embedded sensor has been installed on the seat and in series to that an emergency button has been placed in the column closer to the user.

This sensor consists of a rubber tube containing two conducting strips which make contact when the tube is pressed. Pressing the tube thus locks the seat and inhibits the seat movement function. The sensor is connected to the electronics of the machine by means of a sensor interface board. There are 4 LEDs on this board:


Page 3.7

• L1 – red LED: if ON indicates an alarm condition; • L2 – yellow LED: if ON indicates that the sensor is defective or its connector is open-circuited; • L3 – green LED: if ON indicates that the circuit board is operating correctly; • L4 – orange LED: if ON indicates that the sensor is pressed. During normal operation LED L3 is on. In the case of the following events: • pressing of the sensor; • malfunction of the sensor; • damage to the cable connecting the sensor to the sensor interface board; • the user presses the emergency button. the circuit board sends an alarm signal to the Bio servo/LP driver and CPU boards and illuminates LEDs L1 and L2 or L4. In this condition the seat movement is inhibited until the circuit board is reset. In order to reset the circuit board: • turn the machine off and power it back up after a delay of at least 5 seconds. • short circuit the pins of connector CN3.

WARNING: If the sensor remains pressed, the circuit board will continue to generate the alarm signal, and the only way to force a recovery from this anomalous condition is to disconnect cable BS-30 from connector CE1 of the Bio driver board, and then to short circuit its pins.


Page 3.8

3.2. SOLENOID MANAGEMENT

3.2.1. MECHANICS The additional weight is selected by using a mechanism such as the one schematically illustrated in the figure below.

Figure 3.2.1

Figure 3.2.2

The solenoid a is located on the first plate in the weight stack. Inside, it contains a pin b that moves freely in and out, and which is: • pushed outside the solenoid by the spring c to select the additional weight d when the solenoid

is de-energized (Figure 3.2.1); • drawn into the solenoid by the magnetic field produced, to deselect the additional weight d,

when the solenoid is energized (Figure 3.2.2).

3.2.2. CONTROLS To change the selection of the additional weight, the CPU board sends the enable signal to the Bio servo board. This powers the solenoid properly, which in turn generates an internal field that draws the pin inside, to avoid selecting the additional weight.


Page 3.9

The Bio servo board can check whether the solenoid is absorbing current (meaning that it is energized, and thus the pin does not select the additional weight) and send this information to the CPU board to notify that the check has been successful.

3.2.3. THE SIGNALS INVOLVED The machine controls selection of the additional weight via the CPU board, the Bio servo board and the solenoid as shown in the figure below:

The following signals come into play: • Enable signal

This is the signal generated by the CPU (pin 17-1 on connector K4) to enable the solenoid. This signal enters the Bio servo board (pins 13-1 on connector CN7), and is processed by the latter to pilot the solenoid with the proper supply voltage. The control logic states that when the enable signal is high (~ 4 V) the solenoid is powered (24 Vdc) and the pin does not select the additional weight, while when the signal is low (~ 0 V) the solenoid is not powered (0 Vdc) and the pin selects the additional weight. The figure below shows the switching of the enable signal to select the additional weight:

Bio servo board

Enable

CPU board

Status

S

Solenoid

17-1/K4 15-1/K4

13-1/CN7 15-1/CN7

5-6/CN3


Page 3.10

Figure 3.2.3

• Status signal This is the signal generated by the Bio servo board (pins 15-1 on connector CN7) to notify the CPU board (pins 15-1 on connector K4) of the solenoid status: if this signal is high (~ 5 V), no current is circulating in the solenoid; if it is low (~ 0 V), current is circulating in the solenoid. The figure below shows the switching of the status signal caused by selection of the additional weight:

Figure 3.2.4

• Voltage on solenoid This is the signal for the solenoid generated by the solenoid interface board (pins 5-6 on connector CN3): when it is 24 Vdc the solenoid is powered; when it is 0 Vdc, the solenoid is not powered. The figure below shows the switching of the power supply signal caused by selection of the additional weight:


Page 3.11

Figure 3.2.5


Page 3.12

3.3. WEIGHT STACK MOTOR MANAGEMENT

3.3.1. MECHANICS Each plate a of the weight stack is fitted with a pin b that is pushed out by a small spring c: • when the pin is in its external position, the plate hooks onto the cross d (Figure 3.3.1); • when the pin is in its internal position, the plates are released from the cross d (Figure 3.3.2).

Figure 3.3.1

Figure 3.3.2

By adjusting the position of the selector switches appropriately, it is possible to select the desired plates, and thus the weight with which to perform the exercise. The additional weight is selected by using a mechanism such as the one schematically illustrated in the figure below:


Page 3.13

Figure 3.3.3

To adjust the position of the pin b on each plate a, a motor c turns a gear d which in turn moves a chain e. Selector switches f are connected to the chain to press against the plate pin. The first selector is slanted to make it easier to press the pin spring, When the selectors f press the pins b inward, the plates are released from the cross g, while if the pin's spring pushes it outward, the plate hooks onto the cross g. The figure above shows the free plates shaded in gray, and selected plates in white.

3.3.2. CONTROLS To adjust the selected weight, the CPU board sends the motor up signal (to increase the weight) or motor down signal (to decrease the weight) to the Bio servo board. This powers the motor properly, which in turn moves. Due to the movement of the motor, the Hall sensor, integrated into the motor as encoder, produces the pulses that the Bio servo board sends to the CPU board. The CPU board counts the pulses received. As soon as the number of pulses corresponds to the desired position, it disables the motor command signal. If the current absorbed by the motor after the starting point is too high, and above a set threshold value, the Bio servo board sends an alarm signal to the CPU board to disable the motor. The pre-set value may be adjusted using trimmer PT1.

CAUTION: do not adjust this trimmer unless strictly necessary. In any case, always check the cause of the increased current in play (increased friction, mechanical parts interfering with movement, electrical problems on the motor) before adjusting the trimmer.

CAUTION: every time the trimmer is adjusted to raise the level of current absorbed by the motor, make sure it is not greater than 5A, the maximum value allowed by the motor.


Page 3.14

During the initial reset procedure of the machine, the weight stack motor moves until the zero sensor reed detects the passage of the magnet connected to the first weight stack pin selection brush. This position corresponds to the home reference (zero) of the weight stack motor position, and all other positions will be gauged based on it.

WARNING: on some machines a resistor 0.5Ohm/25W is mounted in series to the motor in order to reduce the peak current at the starting point.

3.3.3. THE SIGNALS INVOLVED The machine controls weight selection via the CPU board, the Bio servo board and the weight stack motor as shown in the figure below: The following signals come into play: • Motor up signal on (↑↑↑↑)

This is the signal generated by the CPU (pin 3-1 on connector K4) to enable the weight stack motor to move counter-clockwise, to select a higher weight. This signal enters the Bio servo board (pins 3-1 on connector CN7), and is processed by the latter to pilot the weight stack motor with the proper supply voltage. The control logic states that when the motor up signal is low (~ 0 V) the motor is stopped and thus not powered (0 Vdc), while when the signal is high (~ 4 V) the motor moves because it is

Pulses

Bio servo board

↓

CPU board

Hall sensor

↑ Alarm

Motor

Zero switch

3-1/K4 5-1/K4 7-1/K4 9-1/K4

3-1/CN7 5-1/CN7 7-1/CN7 9-1/CN7

1-2/CN1 PT1 4-5-6/CN1

Pulses

3/K5-1/K4

Zero switch

17-1/CN7

1-2/CN4


Page 3.15

powered (24 Vdc). Thus the motor turns counter-clockwise as long as the motor up signal is high. The motor stops as soon as the signal returns to being low. The figure below shows the switching of the motor up signal to turn the motor counter-clockwise:

Figure 3.3.4

• Motor down signal on (↓↓↓↓) This is the signal generated by the CPU (pin 5-1 on connector K4) to enable the weight stack motor to move clockwise, to select a lower weight. This signal enters the Bio servo board (pins 5-1 on connector CN7), and is processed by the latter to pilot the weight stack motor with the proper supply voltage. The control logic states that when the motor down signal is low (~ 0 V) the motor is stopped and thus not powered (0 Vdc), while when the signal is high (~ 4 V) the motor moves because it is powered (-24 Vdc). Thus the motor turns clockwise as long as the motor up signal is high. The motor stops as soon as the signal returns to being low. The figure below shows the switching of the motor signal to turn the motor clockwise:

Figure 3.3.5

• Alarm signal This is the signal generated by the Bio servo board (pins 7-1 on connector CN7) when a surge current is detected on the motor. This signal is sent to the CPU board (pin 7-1 on connector K4).


Page 3.16

The CPU board disables the motor up or motor down command that generated the alarm signal as soon as it is received, to protect the motor from the consequences of use during a current surge. The control logic states that when the alarm signal is high (~ 5 V), the Bio servo board can freely pilot the motor. As soon as this signal becomes low (~ 0 V), the CPU board sets the previously sent motor up or motor down signal low, thus the Bio servo board resets the alarm signal, which then returns high. All of this takes place in the space of a few msec. The figure below shows the alarm signal:

Figure 3.3.6

• Pulses This is the signal generated by the Hall-effect sensor built into the motor to measure the rpm of the motor (encoder). This is a square-wave signal with a duty cycle of 50% that provides the machine with feedback on the motor position. This signal enters the Bio servo board (pin 5-6 on connector CN1), and here it is filtered, squared and sent (pin 9-1 on connector CN7) to the CPU board (pin 9-1 on connector K4). The figure below shows the encoder signal output from the motor:

Figure 3.3.7

The figure below shows the encoder signal output from the Bio servo board:


Page 3.17

Figure 3.3.8

CAUTION: the encoder signal output from the motor is dirtier and varies between approximately 3 – 12 V, while the signal output from the board is cleaner and varies between 0 – 5 V.

• Motor voltage

This is the power supply signal for the weight stack motor produced by the Bio servo board (pin 1-2 on connector CN1): when it is: → 0 Vdc the motor is stopped; → +24 Vdc the motor runs counter-clockwise; → +24 Vdc the motor runs clockwise. The figure below shows the switching of the power supply signal upon receiving a motor up command, followed after a brief interval by a motor down command:

Figure 3.3.9

• Zero switch This is the signal of a reed that normally open (5 V) and closes (0 V) if approached by the magnet connected to the weight stack pin selection brush. This signal enters the Bio servo board (pin 1-2 on connector CN4) and sent (pin 17-1 on connector CN7) to the CPU board (pin 3 on connector K5 - pin 1 on connector K4).


Page 3.18

3.4. SEAT MOTOR MANAGEMENT

3.4.1. MECHANICS On a few machines, the position of the seat on the machine may be adjusted (not present on Abdominal Crunch and Lower Back). On some machines this is done by adjusting the horizontal position (Leg Extension and Leg Curl), while on others it is vertical (Vertical Traction, Shoulder Press, Chest Press and Rowing Torso). On Leg Press, the motor and control electronics are different, and will thus be discussed in paragraph 3.5. “Seat motor management for Leg Press”. Regardless of the machine, the position is adjusted by using a mechanism such as the one schematically illustrated in the figure below.

Figure 3.4.1

To adjust the seat, a linear actuator a, while its internal motor moves, moves the stem b forward and back until the front limit c and rear limit d are reached. The actuator a is fastened to the machine frame e by means of the fitting f, while the stem b is fasted to the seat g: thus moving the stem forward and back also moves the seat.

3.4.2. CONTROLS To adjust the seat position, the CPU board sends the motor up signal (to move the seat forwards or back) or the motor down signal (to move the seat up and down) to the Bio servo board. This powers the motor properly, which in turn moves. Due to the movement of the motor, the reed sensor produces the pulses that the Bio servo board sends to the CPU board. The CPU board counts the pulses received. As soon as the number of pulses corresponds to the desired position, it disables the motor command signal. If the current absorbed by the motor after the starting point is too high, and above a set threshold value, the Bio servo board sends an alarm signal to the CPU board to disable the motor. The pre-set value may be adjusted using trimmer PT2.


Page 3.19

CAUTION: do not adjust this trimmer unless strictly necessary. In any case, always

check the cause of the increased current in play (increased friction, mechanical parts interfering with movement, electrical problems on the motor) before adjusting the trimmer.

CAUTION: every time the trimmer is adjusted to raise the level of current absorbed by the motor, make sure it is not greater than 5A, the maximum value allowed by the motor.

When the motor reaches the front or back limit, its inability to continue causes an increase in the current absorbed by the motor, and thus the Bio servo board generates an alarm signal to the CPU board. During the reset procedure when the machine is switched on, this alarm signal is used to determine the limits of the motor: the motor moves forward (up) and then back (down) a few cm, until the board sends an alarm signal. This position corresponds to the home reference (zero) of the seat motor position, and all other positions will be gauged based on it.


Page 3.20

3.4.3. THE SIGNALS INVOLVED The machine controls the seat position via the CPU board, the Bio servo board and the seat motor as shown in the figure below:

The following signals come into play: • Motor up signal on (↑↑↑↑)

This is the signal generated by the CPU (pin 4-2 on connector K4) to enable the seat motor to move the seat forward (up). This signal enters the Bio servo board (pin 4-2 on connector CN7), and is processed by the latter to pilot the seat motor with the proper supply voltage. The control logic states that when the motor up signal is low (~ 0 V) the motor is stopped and thus not powered (0 Vdc), while when the signal is high (~ 4 V) the motor moves because it is powered (24 Vdc). Thus the motor moves the seat forward (up) as long as the motor up signal is high. The motor stops as soon as the signal returns to being low. The figure below shows the switching of the motor up signal to move the seat:

Bio servo board

↓

CPU board

Reed sensor

↑ Alarm Pulses

Motor

4-2/K4 6-2/K4 8-2/K4 10-2/K4

4-2/CN7 6-2/CN7 8-2/CN7 10-2/CN7

1-2/CN2 PT2 5-6/CN2

Pulses


Page 3.21

Figure 3.4.2

• Motor down signal on (↓↓↓↓) This is the signal generated by the CPU (pin 6-2 on connector K4) to enable the seat motor to move the seat back (down). This signal enters the Bio servo board (pin 6-2 on connector CN7), and is processed by the latter to pilot the seat motor with the proper supply voltage. The control logic states that when the motor down signal is low (~ 0 V) the motor is stopped and thus not powered (0 Vdc), while when the signal is high (~ 4 V) the motor moves because it is powered (-24 Vdc). Thus the motor moves the seat back (down) as long as the motor up signal is high. The motor stops as soon as the signal returns to being low. The figure below shows the switching of the motor signal to move the seat:

Figure 3.4.3

• Alarm signal This is the signal generated by the Bio servo board (pin 8-2 on connector CN7) when a surge current is detected on the motor.

CAUTION: the board produces this signal when the motor reaches its stroke limits. This signal is sent to the CPU board (pin 8-2 on connector K4). The CPU board disables the motor up or motor down command that generated the alarm signal as soon as it is received, to protect the motor from the consequences of use during a current surge.


Page 3.22

The control logic states that when the alarm signal is high (~ 5 V), the Bio servo board can freely pilot the motor. As soon as this signal becomes low (~ 0 V), the CPU board sets the previously sent motor up or motor down signal low, thus the Bio servo board resets the alarm signal, which then returns high. All of this takes place in the space of a few msec. The figure below shows the alarm signal:

Figure 3.4.4

• Pulses This is the signal generated by the reed sensor built into the motor to measure the rpm of the motor (encoder). This is a square-wave signal that provides the machine with feedback on the motor position. This signal enters the Bio servo board (pins 5-6 on connector CN2), and here it is filtered, squared and sent (pins 10-2 on connector CN7) to the CPU board (pins 10-2 on connector K4). The figure below shows the encoder signal output from the motor:

Figure 3.4.5

The figure below shows the encoder signal output from the Bio servo board seat:


Page 3.23

Figure 3.4.6

CAUTION: the encoder signal output from the motor is dirtier and varies between approximately 8.7 – 11 V, while the signal output from the board is cleaner and varies between 0 – 5 V.

• Motor voltage

This is the power supply signal for the seat motor produced by the Bio servo board (pins 1-2 on connector CN2): when it is: → 0 Vdc the motor is stopped; → +24 Vdc the motor turns to move the stem outward; → –24 Vdc the motor turns to move the stem inward. The figure below shows the switching of the power supply signal upon receiving a motor up command, followed after a brief interval by a motor down command:

Figure 3.4.7


Page 3.24

3.5. SEAT MOTOR MANAGEMENT FOR LEG PRESS

3.5.1. MECHANICS The seat position on the Leg Press is selected using a mechanism such as the one schematically illustrated in the figure below.

Figure 3.5.1

To adjust the seat position, the entire seat a moves freely along two bars b by means of plastic wheels c. The seat is connected to the motor d, which has an output reducer e that drives a gear f on a rack g, connected to the machine frame h. When the motor moves, the gear turns on the fixed rack, thereby moving the motor and the entire seating unit. A photocell-based encoder h is connected to the motor. On the rack are two plugs i, which activate the two normally-closed limit switches l at the ends of the motor stroke.

3.5.2. CONTROLS To adjust the seat position, the CPU board sends the motor up signal (to move the seat forward) or the motor down signal (to move the seat back) to the LP driver board through Bio servo board. The LP servo board powers the motor properly, which in turn moves. Due to the movement of the motor, the photocell produces the pulses that enter the LP driver board through Bio servo board. This cleans and filters the signal received, and sends it to the CPU board. The CPU board counts the pulses received. As soon as the number of pulses corresponds to the desired position, it disables the motor command signal. The board is equipped with a microprocessor (ST6) that also contains the operating program for the board. This board makes it possible to check the following working conditions of the motor:


Page 3.25

• Surge current, after the starting point when the motor is turned on; • short-circuit; • blocked rotor. In these circumstances, the LP driver board sends an alarm signal to the CPU board through Bio servo board to disable the motor. When the motor reaches the front or back limit, the corresponding microswitch opens and disables movement by the motor in that direction. When the board receives a signal that the limit switch is open, it generates the alarm signal to the CPU board to disable movement.

CAUTION: if a limit switch is defective, damaged, or disconnected, the board detects its open signal and prevents the seat from moving in that direction.

The board also has a few LEDs, two of which (DL1 and DL2) have to do with the microswitches: when either is lit, the corresponding microswitch contact is closed; when off, the contact is open. During the reset procedure when the machine is switched on, the rear limit switch is used to determine the home position of the seat: the motor moves forward and then back a few cm, until the limit switch opens and the board sends an alarm signal. This position corresponds to the home reference (zero) of the seat motor position, and all other positions will be gauged based on it.


Page 3.26

3.5.3. THE SIGNALS INVOLVED The machine controls the seat position via the CPU board, the Bio servo board, the LP driver board and the seat motor as shown in the figure below: The following signals come into play: • Motor up signal on (↑↑↑↑)

This is the signal generated by the CPU (pin 4-2 on connector K4) to enable the seat motor to move the seat forward (up). This signal enters the LP driver board (pins 2-6 on connector CN3), and is processed by the latter to pilot the seat motor with the proper supply voltage. The control logic states that when the motor up signal is low (~ 0 V) the motor is stopped and thus not powered (0 Vdc), while when the signal is high (~ 4 V) the motor moves because it is

LP driver board

↓

Bio servo board

Photocell

↑ Alarm Pulses

Motor

2-6/CN6 3-6/CN6 4-6/CN6 5-6/CN6

2-6/CN3 3-6/CN3 4-6/CN3 5-6/CN3

1-2/CN1 1-3-5/CN4

Pulses

Limit switch

2-4-6/CN4

↓

CPU board

↑ Alarm Pulses

4-2/K4 6-2/K4 8-2/K4 10-2/K4

4-2/CN7 6-2/CN7 8-2/CN7 10-2/CN7


Page 3.27

powered (-48 Vdc). Thus the motor moves the seat forward as long as the motor up signal is high. The motor stops as soon as the signal returns to being low. The figure below shows the switching of the motor up signal to move the motor:

Figure 3.5.2

• Motor down signal on (↓↓↓↓) This is the signal generated by the CPU (pins 6-2 on connector K4) to enable the seat motor to move the seat back. This signal enters the LP driver board (pins 3-6 on connector CN3), and is processed by the latter to pilot the seat motor with the proper supply voltage. The control logic states that when the motor down signal is low (~ 0 V) the motor is stopped and thus not powered (0 Vdc), while when the signal is high (~ 4 V) the motor moves because it is powered (48 Vdc). Thus the motor moves the seat back as long as the motor up signal is high. The motor stops as soon as the signal returns to being low. The figure below shows the switching of the motor signal to move the seat:

Figure 3.5.3

• Alarm signal This is the signal generated by the LP driver board (pins 4-6 on connector CN3) when a hazardous situation (surge current, short-circuit or blocked rotor) is detected on the motor, or when a limit switch contact is open. This signal is sent to the CPU board (pin 8-2 on connector K4). The CPU board disables the motor up or motor down command that generated the alarm


Page 3.28

signal as soon as it is received, to protect the motor from the consequences of use during a current surge, or to prevent it from surpassing the limits set by the microswitches. The control logic states that when the alarm signal is high (~ 5 V), the LP driver board can freely pilot the motor. As soon as this signal becomes low (~ 0 V), the CPU board sets the previously sent motor up or motor down signal low, thus the LP driver board resets the alarm signal, which then returns high. All of this takes place in the space of a few msec. The figure below shows the alarm signal:

Figure 3.5.4

• Pulses This is the signal generated by the photocell that reads the teeth of the encoder disc aligned with the motor, to measure the number of motor RPM. The photocell is powered via pin 1 (+5 Vdc) on connector CN4 and produces a square-wave signal that provides the machine with feedback on the motor position. This signal enters the LP driver board (pins 3-5 on connector CN4), and here it is filtered, squared and sent (pins 5-6 on connector CN3) to the CPU board (pins 10-2 on connector K4). The figure below shows the encoder signal output from the motor:

Figure 3.5.5

The figure below shows the encoder signal output from the LP driver board:


Page 3.29

Figure 3.5.6

CAUTION: in both cases the encoder signal varies from 0 – 5 V, but it is dirtier at the motor output and cleaner at the board output.

• Motor voltage

This is the power supply signal for the LP seat motor produced by the LP driver board (pins 1-2 on connector CN1): when it is: → 0 Vdc the motor is stopped; → + 48 Vdc the motor moves to shift the seat back; → – 48 Vdc the motor moves to shift the seat forwards. The figure below shows the switching of the power supply signal upon receiving a motor up command, followed after a brief interval by a motor down command:

Figure 3.5.7

• Limit switch The limit switches are normally closed, opening if the motor moves the seat to one end. Thus, when the machine seat is in a middle position, the microswitch contact must be closed; when the microswitch is tripped, the contact must open.


Page 3.30

3.6. WIRE ENCODER MANAGEMENT

3.6.1. MECHANICS The wire encoder is located inside the weight stack, attached to a later column, with the wire fastened to the first plate in the weight stack to measure its position.

Figure 3.6.1-1

Moving the weight stack shortens or lengthens the wire, and the encoder outputs a number of pulses to the Bio servo board in proportion to the linear movement of the wire.

3.6.2. CONTROLS The pulses produced by the encoder are read by the Bio servo board and this, using the FPGA, converts them into a RS232 serial signal that is sent to the CPU board. The CPU board uses this serial signals to detect the top plate position and hence to show the ROM, reps, sets and power of the exercise in progress. The section has a 4-position dip-switch, used to select (in binary mode) the number of pulses the encoder produces for each mm the wire is moved.

CAUTION: Keep these dip-switches set to position 0100, which corresponds to 2 pulses/mm.

Each time the power supply is switched on, the CPU board sends a reset signal to the Bio servo board to reset the initial value of top plate position counter.

3.6.3. THE SIGNALS INVOLVED The machine controls the top plate position via the CPU board, the Bio servo board and the encoder as shown in the figure below:


Page 3.31

The following signals come into play: • Encoder signals (A channel e B channel)

These are the 2 square wave signals produced by the encoder when the encoder pulley is moved. These signals enter the Bio servo board (pins 1-4 and pins 2-4 on connector CN3) and here used to define the top plate position.

• Serial signal (Tx) This is the RS232 serial signal generated by the Bio servo board (pins 12-1 on connector CN7) to define the top plate position. This signal enters the CPU board (pin 3 on connector K3 - pin 1 on connector K4). The communication protocol continuously sends 4 bytes from the FPGA board to the CPU board, containing: • Byte 1: the communication synchrony byte. This is “0111 1111”, or 127 in decimal form.

Any other figure means that the communication is incorrect. • Bytes 2-3: the high and low first plate position bytes, respectively. The value converted to

decimal mode is twice the position in mm. For instance, if the figures are “0000 0001” and “0010 1100”, in decimal form that is 300, which means a shift of 150 mm.

• Byte 4: always 0: has no meaning.

Bio driver board

CPU board

Tx (RS 232)

Wire Encoder

3/K3-1/K4

12-1/CN7

1-4/CN3

B channel

2-4/CN3

A channel

Reset

6/K3-1/K4

18-1/CN7


Page 3.32

• Reset signal

This is the signal generated by the CPU (pin 6 on connector K3 - pin 1 on connector K4) each time the power supply is switched on to reset the top plate position. This signal enters the Bio servo board (pins 18-1 on connector CN7). The control logic states that when the reset signal is normally high (~ 5 V), while at the power on the signal goes low (~ 0 V) for about 100 µsec e and then it goes back to high.


Page 4.1

4. ACCESSORIES The equipment has no accessories.


Page 4.2



Page 5.1

5. INSTALLATION INSTRUCTIONS

5.1. SPECIFICATIONS AND REQUIREMENTS

For proper installation of the equipment, make sure that: 1. The equipment is installed on a level, vibration-free surface with a sufficient capacity to support

its weight plus that of the user. 2. The area is not dusty or sandy. 3. The operating temperature and humidity requirements indicated in paragraph 2.3. are observed. 4. The equipment is not placed near sources of heat, sources of electromagnetic disturbance

(television sets, electric motors, antennas, high-voltage power lines, appliances, etc.…) or medical equipment.

5. The mains voltage is the same as indicated on the equipment’s rating plate. 6. The electrical system is properly grounded. 7. The electrical socket is used solely by the equipment, and supplies enough power to run the

machine. See paragraph 2.1.1. for power consumption rates of individual machines. 8. The machine makes the connection available to other machines in cascade. The recommended

maximum number of machines to be connected in cascade is limited by the maximum capacity of 10 A of the power socket of the machine connected to the power supply mains. In this case, make sure that the power socket supplies at least 10 A.

9. The equipment power cord is placed in such a way that people will not trip over it. We recommend that you use the raceways supplied with the equipment for this purpose.

5.2. INSTALLATION

For proper installation of the equipment, follow the machine assembly procedure described in the “Biostrength line – installation manual” provided with each machine. Once the machine is installed in the proper position: 1. Connect the power supply cable to the equipment. 2. Set the start button to 0. 3. Connect the power supply cable to the power socket.

5.3. FIRST POWER-ON

Once installation is complete, the machine is ready to be turned on. To power-on the machine, simply switch the start button from position 0 to position 1. When switched on, the machine performs a start-up procedure that: • sounds the buzzer; • turns on all LEDs;


Page 5.2

• checks the efficiency of all components as described in paragraph 6.2. “Automatic components test”.

When finished, the machine sets itself in stand-by mode to await a command from the keyboard. To make sure the machine is working properly: • Make sure the components test does not identify and display any errors. • Perform the automatic procedure to configure the machine as described in paragraphs 9.2.

“Configuring the technical parameters” and 9.3. “Configuring the user parameters”. • Get on the machine. • Press the “+” and “−” keys on the keyboard to adjust the selected weight, and make sure that the

machine changes the selection appropriately, with no error signals. Make sure to select a weight that requires using the additional weight.

• Press the “←” and “→” or “↑” and “↓” keys on the keyboard to adjust the seat position; make sure that the machine changes the selection appropriately, with no error signals.

• Begin the exercise, and make sure the ROM, reps and power displays change.


Page 6.1

6. TROUBLESHOOTING The troubleshooting procedures are shown in the form of flow charts. In order to facilitate consultation, the following standard box shapes are used.

This type of box is the START point of the troubleshooting procedure. It typically contains a description of the problem or malfunction.

This type of box represents a decision point in the troubleshooting procedure. It typically contains a description of the CHECK to be made, with an outcome that can be either a positive (YES) or negative (NO) response.

This type of box is a step in the troubleshooting procedure where an ACTION must be carried out. It typically contains a description of the ACTION necessary to resolve the problem. Therefore, after executing the specified ACTION: 1. Check whether the problem has been resolved; 2. If the problem persists, it is recommended to resume the troubleshooting

procedure from the point before the action was carried out.

A circled number (such as that shown on the left) next to a box of the troubleshooting procedure indicates that detailed instructions for performing that particular check or action are provided below the flowchart.

A circled letter (such as that shown on the left) is used to highlight a point in the procedure. Typically, this indicator is used in page changes.


Page 6.2

6.1. MANUAL COMPONENTS TEST

To carry out the manual components test, shut off the machine, switch it back on and press “Enter” when the machine sounds the buzzer. The machine will not carry out the normal initialization procedure, but will ask you to enter the password that protects against unauthorized access:

P A S S W O R D = *

After typing the password “2501” and pressing the “Enter” key to continue, the machine will light all LEDs on the display, and the following messages will appear on the LCD:

W U 0 D 0 E 0 F 0 M 0 S U 0 D 0 E 0 F 0 A 0 R 0

In this environment you can check the operation of the: • Weight stack motor; • Seat motor; • Solenoid; • Zero sensor. by monitoring the status of the command and control signals exchanged between the CPU board and the Bio servo board to manage the function. When complete, press the “Clear” key to exit the procedure and continue with machine initialization. Four segments are present on the LCD:

Weight stack motor Zero sensor W U 0 D 0 E 0 F 0 M 0 S U 0 D 0 E 0 F 0 A 0 R 0

Seat motor Solenoid The following pages describe in detail the meaning of what appears on the LCD.

6.1.1. WEIGHT STACK MOTOR The part regarding the weight stack motor, marked by the letter W, allows you to monitor the status of the signals exchanged between the CPU board and the Bio servo board. The LCD displays: • U0/1: the status of the motor up signal produced by the CPU board and sent to the Bio servo

board to select a higher weight. When the letter U is followed by 0, this means there is no movement command; when the value is 1, the CPU board is ordering movement.


Page 6.3

To change this signal, press the “+” key on the machine display.

• D0/1: the status of the motor down signal produced by the CPU board and sent to the Bio servo board to select a lower weight. When the letter D is followed by 0, this means there is no movement command; when the value is 1, the CPU board is ordering movement. To change this signal, press the “−−−−” key on the machine display.

• EXXX: indicates the number of pulses produced by the weight stack motor encoder and received by the CPU board. This value must increase when the motor moves to select a higher weight, and decrease when the motor moves to select a lower weight. This value may be either positive or negative.

• F0/1: the status of the alarm signal produced by the Bio servo board and sent to the CPU board

to disable movement. When the letter F is followed by 0, this means there is no alarm; when the reading is 1, an alarm signal has arrived. Movement stops in this condition. The alarm status will reset to 0 as soon as the button enabling the movement that caused the alarm is released.

Using this procedure, it is possible to identify various situations, some of which are listed below: Problem Cause Solution

Replace the CPU board. The status of the U and/or D signals does not change when the “+” and/or “-” keys are pressed, and the motor does not move.

The CPU board does not produce the command signals. Replace the keyboard.

Connector cable between the CPU board and Bio servo board is defective.

Replace the cable.

Bio servo board defective. Replace the Bio servo board. Motor defective. Replace the motor.

Pressing the “+” and/or “-” keys changes the status of the U and/or D signals, and the motor does not move.

Power supply defective. Check the motor power supply. Connector cable between the CPU board and Bio servo board is defective.

Replace the cable. The motor moves but the encoder signal status does not change. Encoder defective. Replace the motor.

Mechanical problem. Check the weight stack selection system. The motor moves, then stops

immediately because an alarm signal arrives. Low current limit setting on the

Bio servo board. Check the current limit setting.

6.1.2. ZERO SENSOR STATUS The part regarding the zero sensor, marked by the letter M, allows you to monitor the status of the of the zero sensor signal. The LCD displays:


Page 6.4

• M0/1: When the letter M is followed by 0, this means that the zero sensor contact is open; when the value is 1, the contact is closed. As the weight stack motor moves, when the magnet on the selection brush passes in front of the zero sensor, it produces a beep an M changes from 0 to 1.

Using this procedure, it is possible to identify various situations, some of which are listed below: Problem Cause Solution

The sensor and magnet are too far apart. Adjust the distance.

Sensor defective. Replace the zero sensor. Connector cable between the zero sensor and CPU board is defective.

Replace the cable.

The signal does not switch when the magnet passes in front of the sensor.

CPU board defective. Replace the CPU board.

6.1.3. SEAT MOTOR

This section is not active on the Abdominal Crunch and Lower Back machines. The part regarding the seat motor, marked by the letter S, allows you to monitor the status of the signals exchanged between the CPU board and the Bio servo board. The LCD displays: • U0/1: the status of the motor up signal produced by the CPU board and sent to the Bio servo

board to move the seat forward or up. When the letter U is followed by 0, this means there is no movement command; when the value is 1, the CPU board is ordering movement.

To change this signal, press the “↑↑↑↑” or “→→→→” key on the machine display.

• D0/1: the status of the motor down signal produced by the CPU board and sent to the Bio servo board to move the seat back or down. When the letter D is followed by 0, this means there is no movement command; when the value is 1, the CPU board is ordering movement.

To change this signal, press the “↓↓↓↓” or “←←←←” keys on the machine display.

• EXXX: indicates the number of pulses produced by the seat motor encoder and received by the CPU board. This value must increase when the motor moves to move the seat forward or up, and decrease when the motor moves to move the seat back or down. This value may be either positive or negative.

• F0/1: the status of the alarm signal produced by the Bio servo board and sent to the CPU board

to disable movement. When the letter F is followed by 0, this means there is no alarm; when the reading is 1, an alarm signal has arrived. Movement stops in this condition. The alarm status will reset to 0 as soon as the button enabling the movement that caused the alarm is released.

Using this procedure, it is possible to identify various situations, some of which are listed below:


Page 6.5

Problem Cause Solution

Replace the CPU board. The status of the U and/or D signals does not change when the “+” and/or “-” keys are pressed, and the motor does not move.

The CPU board does not produce the command signals. Replace the keyboard.

Connector cable between the CPU board and Bio servo board (LP Bio servo) is defective.

Replace the cable.

Bio servo board (LP Bio servo) defective.

Replace the Bio servo board (LP Bio servo).

Motor defective. Replace the motor.

Pressing the “+” and/or “-” keys changes the status of the U and/or D signals, and the motor does not move.

Power supply defective. Check the motor power supply. Connector cable between the CPU board and Bio servo board (LP Bio servo) is defective.

Replace the cable. The motor moves but the encoder signal status does not change. Encoder defective. Replace the motor.

Mechanical problem. Check the weight stack selection system. The motor moves, then stops

immediately because an alarm signal arrives, although it is far from one end.

Low current limit setting on the Bio servo board (LP Bio servo ).

Check the current limit setting.

6.1.4. SOLENOID The part regarding the solenoid allows you to monitor the status of the signals exchanged between the CPU board and the Bio servo board. The LCD displays: • A0/1: the status of the motor up signal produced by the CPU board and sent to the Bio servo

board to activate the solenoid. When the letter A is followed by 0, this means that there is no enable command; when the value is 1, the CPU board is sending the enable command to select the additional weight.

To change this signal, press the “Enter” key on the machine display.

• R0/1: the status of the solenoid signal produced by the Bio servo board and sent to the CPU board to monitor whether it is selected. When the letter R is followed by 0, this means that the solenoid is not enabled; when it is 1, the solenoid is enabled. Under normal operating conditions, the values of A and R must be equal: A0R0 and A1R1. In fault conditions you will see A1R0.

Using this procedure, it is possible to identify various situations, some of which are listed below:


Page 6.6

Problem Cause Solution

Replace the CPU board. Pressing the “Enter” key does not switch the status of the A signals, and the motor solenoid is not enabled.

The CPU board does not produce the command signal.

Replace the keyboard.

Connector cable between the CPU board and solenoid is defective.

Replace the cable.

Bio servo board defective. Replace the Bio servo board.

The solenoid does not change status, even after receiving the enable command.

Solenoid defective. Replace the solenoid.


Page 6.7

6.2. AUTOMATIC COMPONENTS TEST

The automatic components test procedure may be activated while the machine is in stand by, by pressing the keys “1”, “3” and “4” simultaneously. To access this procedure, you must enter the password that protects against unauthorized access.

P A S S W O R D = *

After typing the password “2512” and pressing the “Enter” key to continue, the machine will display:

E L E C T R I C A L T E S T = 1 M E C H A N I C A L T E S T = 2

Select the desired option: • Electrical test

This test automatically runs the motors intermittently, subjecting the electronic components of the machine to a more intensive test, since they are required to start and stop the motors every few seconds.

• Mechanical test

This test automatically runs the motors continuously, subjecting the mechanical components of the machine to a more intensive test, since they are required to move continuously between the available limits.

In both cases the machine will alternate the LCD display, every 10 seconds, between monitoring communication between the Bio servo board and the CPU board and displaying the cycle counter. When complete, press the “Clear” key to exit the procedure and continue with machine initialization. The following pages describe in detail the meaning of what appears on the LCD.

6.2.1. MONITORING COMMUNICATION BETWEEN THE BIO SERVO BOARD AND THE CPU BOARD

The LCD will read:

F P G A : 1 = 1 2 7 2 = x x x 3 = x x 4 = 0 m m = x x X x

As described in paragraph 3.1. , the CPU board and Bio servo board are connected via a RS 232 serial communication protocol that continuously sends 4 bytes from the Bio servo board to the CPU board. The LCD shows the numerical value of 5 measurements, representing the numerical values of the 4 communication bytes between the Bio servo board and CPU and the position in mm of the weight stack cross, derived from bytes 2 and 3 of the communication.


Page 6.8

By monitoring the values shown, you can analyze the communication status. • Communication active

If the communication is active, the procedure shows the data; otherwise, nothing appears. The communication is also correct if measurement “1” always has a value of 127, meaning that the synchrony byte of the communication has been identified.

• Weight stack shift

The value of measurements “2” and “3” provide information on the movement of the weight stack. This value is shown in millimeters “mm”. By moving the weight stack between two predefined positions whose distance is known and taking the difference between the value in “mm” when the weight stack is in the 2 positions, the result is the distance value in mm measured by the encoder, which must match the same measurement taken by a normal ruler.

If the movement takes place while the machine is moving the weight stack motor, the machine disables its movement to prevent the plates from falling. However, we recommend that you make sure in advance that the selected weight can be lifted.

6.2.2. COUNTER DISPLAY The LCD reads:

S E A T : x W E I G H T : x

The LCD displays the number of complete cycles carried out by the machine during this automatic test procedure of the seat motor and weight stack motor.


Page 6.9

6.3. RESET PROCEDURE

When the machine is switched on, and after each time the technical and user parameters are configured, the machine will carry out a reset procedure, during which it tests all components in the order listed below:

6.3.1. BUFFER BATTERY TEST The machine checks the data stored in the battery-powered RAM of the buffer battery. If it finds meaningless data, it aborts the reset procedure and displays the following message on the LCD:

H W F A U L T : C H E C K B A T T E R Y

To exit this error condition, carry out the checks described in paragraph 6.5. “The LCD displays the message “HW fault: check battery””.

This is a BLOCKING error, meaning that it prevents the machine from being used.

6.3.2. TGS INTERFACE TEST The machine checks whether the TGS interface is functioning properly by sending a status request. This test makes it possible to check only the functioning status of the TLCBR board. If it receives no response, or an incorrect response, it aborts the reset procedure and displays the following message on the LCD:

H W F A U L T : C H E C K T G S R E A D E R / W R I T E R

To exit this error condition, carry out the checks described in paragraph 6.6. “The LCD displays the message “HW fault: check TGS””.


6.3.3. FPGA TEST The machine checks whether the serial communication with the Bio servo board is correct. If not, it aborts the reset procedure and displays the following message on the LCD:

H W F A U L T : C H E C K F P G A R E A D E R

To exit this error condition, carry out the checks described in paragraph 6.7. “The LCD displays the message “HW fault: check FPGA””.



Page 6.10

6.3.4. SOLENOID TEST The machine checks whether it is possible to command and control the solenoid by sending an enable signal and checking the status signal it receives from the Bio servo board. If it is not correct, it interrupts the reset procedure, beeps and displays the following message on the LCD for 5 seconds:

A D D - O N W G H T . P R O B L E M = M A G N E T

To exit this error condition, carry out the checks described in paragraph 6.8. “The LCD displays the message “Add-on weight problem = magnet””.

This error does NOT prevent using the machine, but only disables using the additional weight, in that the added weight would always appear to be selected, and the selected weight may be increased and decreased by 5 Kg (10 lbs) and not 2.5 Kg (5 lbs).

6.3.5. WEIGHT STACK MOTOR TEST The machine checks whether it is possible to command and control the weight stack motor by sending a movement signal, and checking the encoder and alarm signals it receives from the Bio servo board. Under normal conditions, the test takes place as follows: • the machine moves the weight stack motor; • this moves the selection system; • when the magnet inserted in the selection brush passes in front of the zero sensor, the latter

changes status: this is the zero position of the weight stack selection system; • the machine moves the weight stack motor to select 5 Kg. based on the configuration

parameters; • the test is complete.

CAUTION: under normal conditions, the Bio servo board should not produce any alarm signal.

Reasons that may cause the test to fail include: 1. Mechanical problem

If, during movement, the CPU board receives the alarm signal 3 consecutive times in three attempts carried out within an interval of approximately 10 seconds, this means that there is something preventing movement. In this case, the machine aborts the reset procedure and displays the following message on the LCD:

W G H T . S T A C K P R O B L E M = F A I L

To exit this error condition, carry out the checks described in paragraph 6.9. “The LCD displays the message “Weight stack problem = fail””.


Page 6.11

2. Motor problem

If, during movement, the CPU board receives no encoder signal and the signal from the zero sensor does not change for approximately 60 seconds, this means there is no movement due to a probable motor fault, In this case, the machine aborts the reset procedure and displays the following message on the LCD:

W G H T . S T A C K P R O B L E M = M O T O R

To exit this error condition, carry out the checks described in paragraph 6.10. “The LCD displays the message “Weight stack problem = motor””.

3. Encoder problem If, during movement, the CPU board receives no encoder signal but the zero sensor signal changes, this means there is movement but no encoder signal due to a probable fault on the encoder itself. In this case, the machine aborts the reset procedure and displays the following message on the LCD:

W G H T . S T A C K P R O B L E M = E N C O D E R

To exit this error condition, carry out the checks described in paragraph 6.11. “The LCD displays the message “Weight stack problem = encoder””.

4. Zero sensor problem If, during movement, the CPU board receives the encoder signal but does not detect a change in the zero sensor signal, this means there is movement but the zero sensor status cannot change due to a probable fault in the zero sensor itself. In this case, the machine aborts the reset procedure and displays the following message on the LCD:

W G H T . S T A C K P R O B L E M = S W I T C H S T O P

To exit this error condition, carry out the checks described in paragraph 6.12. “The LCD displays the message “Weight stack problem = limit switch sensor””.

Each specific error message alternates every 10 seconds with the following message, inviting you to call technical service to solve the problem.

C A L L F O R A S S I S T A N C E

All of these are BLOCKING errors, meaning that they prevent the machine from being used.


Page 6.12

6.3.6. SEAT MOTOR TEST The machine checks whether it is possible to command and control the seat motor by sending a movement signal and checking the encoder and alarm signals it receives from the Bio servo board (LP Bio servo). Under normal conditions, the test takes place as follows: • the machine moves the seat motor; • it waits for it to reach one end; • when it arrives, the Bio servo board (LP Bio servo) produces an alarm signal that it sends to the

CPU board; • the machine considers this to be the reference value, and moves the seat motor (based on the

configuration parameters) until the default position is selected; • the test is complete.

CAUTION: under normal conditions, the Bio servo board (LP Bio servo) should not produce any alarm signal after the first, considered normal.

Reasons that may cause the test to fail include: 1. Mechanical problem

If, during movement and after receiving the normal alarm signal, the CPU board receives 3 more out of 3 consecutive movement attempts carried out approximately 10 seconds apart, this means that there is something preventing movement. In this case, the machine aborts the reset procedure and displays the following message on the LCD:

S E A T P R O B L E M = F A I L

To exit this error condition, carry out the checks described in paragraph 6.13. “The LCD displays the message “Seat problem = fail””.

2. Motor problem

If, during movement, the CPU board receives no encoder or alarm signal for approximately 60 seconds, this means there is no movement due to a probable motor fault, In this case, the machine aborts the reset procedure and displays the following message on the LCD:

S E A T P R O B L E M = M O T O R

To exit this error condition, carry out the checks described in paragraph 6.15. “The LCD displays the message “Seat problem = motor””.

3. Encoder problem

If, during movement, the CPU board receives no encoder signal for approximately 60 seconds, this means there is movement but no encoder due to a probable fault on the encoder itself. In this case, the machine aborts the reset procedure and displays the following message on the LCD:


Page 6.13

S E A T P R O B L E M = E N C O D E R

To exit this error condition, carry out the checks described in paragraph 6.16. “The LCD displays the message “Seat problem = encoder””.

Each specific error message alternates every 10 seconds with the following message, inviting you to call technical service to solve the problem.

C A L L F O R A S S I S T A N C E

These errors do NOT prevent the machine from being used, but produce a beep, displaying the message on the LCD for 10 seconds, then allow you to use the machine but without moving the seat.


Page 6.14

6.4. TEST PROCEDURE DURING USE

During normal machine operation, the machine checks the components to detect any malfunctions. The following problems may be detected:

6.4.1. WEIGHT STACK MOTOR FAILURE If the machine detects a failure on the weight stack motor, it may be caused by: 1. Mechanical problem

If the CPU board detects an alarm signal 3 consecutive times out of 3 attempts carried out approximately 10 seconds apart, this means that there is something preventing movement. In this case, the machine displays the following message on the LCD:

W G H T . S T A C K P R O B L E M = F A I L

To exit this error condition, carry out the checks described in paragraph 6.9. “The LCD displays the message “Weight stack problem = fail””.


2. Motor – encoder problem If the CPU board receives no encoder signal during movement, this means there is no movement due to a probable motor fault, or that there is movement but it is not detected by a defective encoder. In this case, the machine displays the following message on the LCD:

W G H T . S T A C K P R O B L E M = G E N E R I C

To exit this error condition, shut off the machine, switch it back on and see which error appears on the LCD display. Carry out the checks described in paragraphs 6.10. “The LCD displays the message “Weight stack problem = motor”” or 6.11. “The LCD displays the message “Weight stack problem = encoder””.


6.4.2. SEAT MOTOR TEST If the machine detects a failure on the weight stack motor, this may be caused by: 1. Mechanical problem

If, during movement and after receiving the normal alarm message, the CPU board receives 3 more in 3 movement attempts carried out approximately 10 seconds apart, this means there is something preventing movement. In this case, the machine displays the following message on the LCD:


Page 6.15

S E A T P R O B L E M = F A I L

To exit this error condition, carry out the checks described in paragraph 6.13. “The LCD displays the message “Seat problem = fail””.

This error does NOT prevent the machine from being used, but produces a beep, displaying the message on the LCD for 5 seconds, then allows you to use the machine but without moving the seat.

2. Motor – encoder problem

If, during movement, the CPU board receives no encoder signal for approximately 60 seconds, this means there is no movement due to a probable motor fault, or that there is movement but it is not detected by a defective encoder. In this case, the machine displays the following message on the LCD:

S E A T P R O B L E M = G E N E R I C

To exit this error condition, shut off the machine, switch it back on and see which error appears on the LCD display. Carry out the checks described in paragraphs 6.15. “The LCD displays the message “Seat problem = motor”” and 6.16. “The LCD displays the message “Seat problem = encoder””.

This error does NOT prevent the machine from being used, but produces a beep, displaying the message on the LCD for 5 seconds, then allows you to use the machine but without moving the seat.

This test procedure does not allow you to detect problems on the TGS interface, FPGA or zero sensor. In addition, the checks carried out are less sensitive than those performed during the reset procedure. Thus whenever the machine shows an error message during operation, we recommend that you shut it off, switch it back on and check the error messages displayed by the reset procedure as described in paragraph 6.3. .


Page 6.16

6.5. THE LCD DISPLAYS THE MESSAGE “HW FAULT: CHECK BATTERY”

This error message appears when the machine finds incorrect data saved in the battery-powered RAM of the buffer battery.

HW FAULT: CHECK BATTERY

YES Check whether the buffer battery is

chargedReplace the buffer battery

NOReplace the CPU board

1

Follow the step-by-step guide to properly diagnose the error. Pay special attention to those tests indicated in numbered boxes, and described in detail here below: (1) Remove the buffer battery from the CPU board, and use a multimeter to measure the voltage

at its ends. It should read 3.6 Vdc.

The battery is recharged by the CPU board when powered. If the recharging part of the board is not working, the battery will tend to run low over time.

After restoring the defective component, carry out the steps described in paragraphs 9.1. “Configuring parameter defaults”, 9.2. “Configuring the technical parameters” and 9.3. “Configuring the user parameters”.


Page 6.17

6.6. THE LCD DISPLAYS THE MESSAGE “HW FAULT: CHECK TGS”

This error message appears when the machine receives an incorrect response, or no response, when requesting the status of the TGS system.

HW FAULT: CHECK TGS

YESIs the green LED on the key reader

lit?

NO

NO

Check whether the supply output voltage from the CPU board is

correct

4

YESCheck and/or replace the

BS-TLCBR cable


Check whether the supply input voltage to the TLCBR is correct

3

YESReplace the TLCBR

Check whether the supply output voltage from the TLCBR is

correct

2

YESReplace the flat cable

NO

Check whether the supply input voltage to the key reader is

correct

1

YESReplace the key reader

NO

A


Page 6.18

YESCheck whether the machine works if the TLCBR is replaced with a

functional one

NO

Replace the CPU board Check whether the BS-TLCBR cable is intact

5

YESReplace the BS-TLCBR

cable

NO

A

Replace the TLCBR

Follow the step-by-step guide to properly diagnose the error. Pay special attention to those tests indicated in numbered boxes, and described in detail here below: (1) Disconnect the flat cable connector from the key reader. Insert the tester probes between pins

4 and 7 (ground) on the same connector. The table below shows the numbering in a flat cable connector:

1 3 5 7 9 2 4 6 8 10

You should get a reading of approximately 12 Vdc.

(2) Disconnect the flat cable connector from the TLCBR. Insert the tester probes between pins 4

and 7 (ground) on the same connector. You should get a reading of approximately 12 Vdc. (3) Disconnect the AMP MODU II 8-pin connector from TLCBR. Insert the tester probes

between pins 1 and 3 (ground) on the same connector. You should get a reading of approximately 12 Vdc.

(4) Disconnect the K6 connector from the CPU board. Insert the tester probes between pins 1 and

2 (ground) on the same connector. You should get a reading of approximately 12 Vdc. (5) Check the continuity of the cable wires, following the diagram in paragraphs 2.6. and 2.5. .


Page 6.19

6.7. THE LCD DISPLAYS THE MESSAGE “HW FAULT: CHECK FPGA”

This error message appears when the CPU board receives no signal from the Bio servo board, or receives an incorrect signal.

HW FAULT: CHECK FPGA

Replace the CPU board

Replace the Bio servo board

Check whether the Bio servo board sends signals to the

serial cable connected to the CPU board

YES

NO

1

2

Check whether the CPU board receives signals on the serial cable connected to the Bio

servo board

Replace the BS-6/2 cable

Check whether the error signal still appears on the LCD if the

CPU board is replacedReplace the Bio servo

board

YES

NO

NOYES

Follow the step-by-step guide to properly diagnose the error. Pay special attention to those tests indicated in numbered boxes, and described in detail here below: (1) Insert the oscilloscope probes between pins 12 and 1 of the CN7 connector on the Bio servo

board. With the time scale in 100 µsec, you should see the signal change from high to low. (2) Insert the oscilloscope probes between pins 3 of the K3 connector and pin 1 of the K4

connector on the CPU board. With the time scale in 100 µsec, you should see the signal change from high to low.

On Chest Press and Leg Press, the BS-6/2 cable is divided into 2 parts through the

connector CN36. Carry out the test on this connector and, if necessary, replace only the defective section of the BS-6/2 cable.


Page 6.20

6.8. THE LCD DISPLAYS THE MESSAGE “ADD-ON WEIGHT PROBLEM = MAGNET”

This error message appears when the CPU board sends the solenoid enable command, and receives a solenoid status signal from the Bio servo board as though the solenoid were disabled.

ADD-ON WEIGHT PROBLEM = MAGNET



Check whether the solenoid enable output signal from the

CPU board is correct

NO

Check whether the solenoid enable input signal to the Bio

servo board is correct

YES

2

3

Check whether the solenoid enable output signal from the Bio


NO

4


NO

YES

A

YES

Check whether the input voltage to the Bio servo board is correct

NO

1

YES

B


Page 6.21



Check whether the solenoid status output signal from the Bio


NO

Check whether the solenoid status input signal to the CPU

board is correct

YES

7

8


NO

A

YES

Check whether the solenoid is enabled

NOReplace the solenoid

YES

Check whether the solenoid enable signal at the connector

CN26 is correct

NO

6

Replace the BS-10 cable

YES

Check whether the solenoid enable signal at the connector

CN24 is correct

NO

5


YES


Page 6.22

YESReplace the selector

switch

B

Check whether the input power supply to the transf ormer is

correct

NO Replace the transf ormer and/or the

rectif ier bridge

9

Follow the step-by-step guide to properly diagnose the error. Pay special attention to those tests indicated in numbered boxes, and described in detail here below: (1) Insert the multimeter probes between pins 1 (signal) and 2 of the CN10 connector on the Bio

servo board. You should get a reading of approximately 24 Vdc. (2) Insert the multimeter probes between pins 17 (signal) and 1 of the K4 connector on the CPU

board. With the solenoid enabled (additional weight not selected) you should get a reading of approximately 4 Vdc, while with the solenoid disabled (additional weight selected) you should get a reading of approximately 0 Vdc.

(3) Insert the multimeter probes between pins 13 (signal) and 1 of the CN7 connector on the Bio

servo board. With the solenoid enabled (additional weight not selected) you should get a reading of approximately 4 Vdc, while with the solenoid disabled (additional weight selected) you should get a reading of approximately 0 Vdc.




servo board. With the solenoid enabled (additional weight not selected) you should get a reading of approximately 24 Vdc, while with the solenoid disabled (additional weight selected) you should get a reading of approximately 0 Vdc.

(5) Insert the multimeter probes between pins 3 (signal) and 4 of the CN24 patch cord. With the

solenoid enabled (additional weight not selected) you should get a reading of approximately 24 Vdc, while with the solenoid disabled (additional weight selected) you should get a reading of approximately 0 Vdc.

(6) Insert the multimeter probes between pins 3 (signal) and 4 of the CN26 patch cord. With the

solenoid enabled (additional weight not selected) you should get a reading of approximately 24 Vdc, while with the solenoid disabled (additional weight selected) you should get a reading of approximately 0 Vdc.


Page 6.23

(7) Insert the multimeter probes between pins 15 (signal) and 1 of the CN7 connector on the Bio servo board. With the solenoid enabled (additional weight not selected) you should get a reading of approximately 0 Vdc, while with the solenoid disabled (additional weight selected) you should get a reading of approximately 5 Vdc.

(8) Insert the multimeter probes between pins 15 (signal) and 1 of the K4 connector on the CPU

board. With the solenoid enabled (additional weight not selected) you should get a reading of approximately 0 Vdc, while with the solenoid disabled (additional weight selected) you should get a reading of approximately 5 Vdc.



(9) Insert the multimeter probes between pins 110 or 220 (signal) and 0 of the CN2 connector of

the selector switch. You should get a reading of approximately 220 Vac or 110 Vac, depending on the line voltage.


Page 6.24

6.9. THE LCD DISPLAYS THE MESSAGE “WEIGHT STACK PROBLEM = FAIL”

This error message appears when the CPU board receives an alarm signal from the Bio servo board after enabling movement of the weight stack motor in one direction. This signal means that the absorbed current of the motor is greater than a value preset on the board by means of the setting described in paragraph 8.14., due to: • Low current limit setting; • Insufficient lubrication of the weight stack selection system; • Damaged weight stack selection system chain; • Damaged selection brush; • Weight stack plates with defective springs; • Damaged motor. Check these parts; when you find the defective one, replace it to restore machine operation.


Page 6.25

6.10. THE LCD DISPLAYS THE MESSAGE “WEIGHT STACK PROBLEM = MOTOR”

This error message appears during the initial machine reset, when the CPU board does not receive the encoder signal from the Bio servo board, and the zero sensor signal does not change for approximately 60 seconds, after enabling movement of the weight stack motor in one direction. This means there is no movement.

WEIGHT STACK PROBLEM = MOTOR



Check whether the weight stack motor enable output signal from

the CPU board is correct

NO

Check whether the weight stack motor enable input signal to the

Bio servo board is correct

YES

2

3

Check whether the weight stack motor enable output signal from

the Bio servo board is correct

NO

4


NO

YES

YES

Check whether the power supply to the Bio servo board is correct

NO

1

YES

B

A


Page 6.26

A

Check whether the motor runsNO

Replace the motor

YESReplace the BS-2/2R

cable


switch

B

Check whether the supply voltage to the transformer is correct

NOReplace the

transformer and/or the rectifier bridge

5


servo board. You should get a reading of approximately 24 Vdc. (2) Insert the multimeter probes between pins 3 (motor up signal) and 1 or between pins 5 (motor

down signal) and 1 of the K4 connector on the CPU board. With the motor enabled you should get a reading of approximately 4 Vdc, while with the motor stopped you should get a reading of approximately 0 Vdc.

(3) Insert the multimeter probes between pins 3 (motor up signal) and 1 or between pins 5 (motor

down signal) and 1 of the CN7 connector on the Bio servo board. With the motor enabled you should get a reading of approximately 4 Vdc, while with the motor stopped you should get a reading of approximately 0 Vdc.




servo board. With the motor enabled you should get a reading of approximately 24 Vdc if running counter-clockwise and -24 Vdc if running clockwise, while with the motor stopped you should get a reading of approximately 0 Vdc.


Page 6.27

(5) Insert the multimeter probes between pins 110 or 220 (signal) and 0 of the CN2 connector of the selector switch. You should get a reading of approximately 220 Vac or 110 Vac depending on the line voltage.


Page 6.28

6.11. THE LCD DISPLAYS THE MESSAGE “WEIGHT STACK PROBLEM = ENCODER”

This error message appears during the initial machine reset, when the CPU board does not receive the encoder signal from the Bio servo board, while noting a change in the zero sensor signal, after enabling movement of the weight stack motor in one direction. This means there is movement but no encoder signal.

WEIGHT STACK PROBLEM = ENCODER

Replace the weight stack motor

Replace the BS-2/2R cable

Check whether the weight stack motor encoder output signal from the weight stack motor is correct

NO

Check whether the weight stack motor encoder input signal to the


YES

1

2

Check whether the weight stack motor encoder output signal to the Bio servo board is correct

NO

3


NO

Check whether the weight stack motor encoder input signal to the


NOReplace the BS-6/2

cable

YES

YES

YES


4

Follow the step-by-step guide to properly diagnose the error. Pay special attention to those tests indicated in numbered boxes, and described in detail here below:


Page 6.29

(1) Insert the oscilloscope probes between pins 5 (signal) and 6 of the CN21 patch cord. With the motor enabled you should see a square wave signal ranging from approximately 3.5 Vdc to 11.2 Vdc.

(2) Insert the oscilloscope probes between pins 5 (signal) and 6 on the CN1 connector on the Bio

servo board. With the motor enabled you should see a square wave signal ranging from approximately 3.5 Vdc to 11.2 Vdc.

(3) Insert the oscilloscope probes between pins 9 (signal) and 1 of the CN7 connector on the Bio

servo board. With the motor enabled you should see a square wave signal ranging from approximately 0 Vdc to 5 Vdc.



(4) Insert the oscilloscope probes between pins 9 (signal) and 1 of the K4 connector on the CPU

board. With the motor enabled you should see a square wave signal ranging from approximately 0 Vdc to 5 Vdc.


Page 6.30

6.12. THE LCD DISPLAYS THE MESSAGE “WEIGHT STACK PROBLEM = LIMIT SWITCH SENSOR”

This error message appears during the initial machine reset, when the CPU board receives the encoder signal from the Bio servo board, but does not detect a change in the zero sensor signal, after enabling movement of the weight stack motor in one direction. This means there is movement but no zero signal.

Carry out the tests shown in the diagram below by passing the selection brush, with magnet inserted, in front of the sensor.

WEIGHT STACK PROBLEM = LIMIT SWITCH SENSOR

Adjust the position of zero sensor and/or

replace the zero sensor


Check whether the zero sensor signal on the connector CN27 is

correct

NO

Check whether the zero sensor input signal to the Bio servo

board is correct

1

2

NO

YES


Check whether the zero sensor input signal to the CPU board is

correct

YES

4


YES


Check whether the zero sensor output signal at the Bio servo

board is correct

3

NO

YES


Page 6.31

Follow the step-by-step guide to properly diagnose the error. Pay special attention to those tests indicated in numbered boxes, and described in detail here below: (1) Insert the multimeter probes between pins 1 (signal) and 2 on the CN27 patch cord. With the

brush far from the sensor you should get a reading of approximately 5 Vdc while with the brush close to the sensor you should get a reading of approximately 0 Vdc.

(2) Insert the multimeter probes between pins 1 (signal) and 2 on the CN4 connector on the Bio

servo board. With the brush far from the sensor you should get a reading of approximately 5 Vdc while with the brush close to the sensor you should get a reading of approximately 0 Vdc.

(3) Insert the multimeter probes between pins 17 (signal) and 1 on the CN7 connector on the Bio

servo board. With the brush far from the sensor you should get a reading of approximately 5 Vdc while with the brush close to the sensor you should get a reading of approximately 0 Vdc.

(4) Insert the multimeter probes between pins 3 (signal) of the K5 and 1 of the K4 connector on

the CPU board. With the brush far from the sensor you should get a reading of approximately 5 Vdc while with the brush close to the sensor you should get a reading of approximately 0 Vdc.




Page 6.32

6.13. THE LCD DISPLAYS THE MESSAGE “SEAT PROBLEM = FAIL”

This error message appears when the CPU board receives an alarm signal from the Bio servo board (LP Bio servo), in addition to the first considered to be normal, after enabling movement of the seat motor in one direction. This signal means that the absorbed current of the motor is greater than a value preset on the board by means of the setting described in paragraph 8.16., due to: • Low current limit setting; • Insufficient lubrication of the seat adjustment system; • Damaged motor. Check these parts; when you find the defective one, replace it to restore machine operation.


Page 6.33

6.14. THE LCD DISPLAYS THE MESSAGE “EMERGENCY ACTIVATED”

This message appears only on the Leg Press and the Leg Extension when the CPU receives an alarm signal from the Bio servo board and the seat movement is disabled because: • the emergency sensor has been pressed; • the emergency button as been pressed (only on Leg Press); • the Bio servo board is continuously sending an alarm signal.

EMERGENCY ACTIVATED

Replace the sensor

Replace the cable BS-31

Check whether the sensor is correct

NO

Check whether the sensor input signal to the sensor interface

board is correct

YES

1

2

Check whether the emergency output signal at the sensor interface board is correct

NO

3

Replace the sensor interface board

NO

Check whether the emergency input signal to the sensor interface board is correct

NOReplace the cable

BS-30

YES

YES

YES

Execute the troubleshooting procedure

"The LCD displays the message "Seat problem =

fail""

4


Page 6.34

Follow the step-by-step guide to properly diagnose the error. Pay special attention to those tests indicated in numbered boxes, and described in detail here below: (1) Insert the multimeter probes between pins 1 (signal) and 2 of the patch connector CN28. You

should get a reading approximately between 1200 and 2300 Ohm. (2) Insert the multimeter probes between pins 1 (signal) and 2 of the connector CN1 on the Sensor

interface board. You should get a reading between 1200 and 2300 Ohm. (3) Insert the multimeter probes between pins 1 (signal) and 2 of the connector CN2 on the Sensor

interface board. You should get a close contact when the sensor is not pressed and an open contact if the sensor has been pressed.

(4) Insert the multimeter probes between pins 1 (signal) and 2 of the connector CE1 on the LP

board. You should get a close contact when the sensor is not pressed and an open contact if the sensor has been pressed.


Page 6.35

6.15. THE LCD DISPLAYS THE MESSAGE “SEAT PROBLEM = MOTOR”

This error message appears during the initial machine reset when the CPU board does not receive the encoder signal from the Bio servo board (LP Bio servo), and does not detect the alarm signal for approximately 60 seconds, after enabling movement of the seat motor in one direction. This means there is no movement.

6.15.1. FOR LEG PRESS

SEAT PROBLEM = MOTOR



Check whether the seat motor enable output signal from the


NO

Check whether the seat motor enable input signal at the Bio servo

board is correct

YES

2

3

NO

YES


Check whether the seat motor enable output signal from the Bio


YES

4

NO

A

Check whether the supply voltage to the LP driver board is correct

1

NOB


Page 6.36

A


Replace the motor

YESReplace the cables between the LP driver board and the motor

Check whether the seat motor enable output signal to the LP

driver board is correct

6

NOReplace the LP driver

board

YES

Check whether the seat motor enable input signal to the LP driver

board is correct

5

YES

NOReplace the BS-25/2LP

cable


switch

B

Check whether the supply voltage to the LP transformer is correct

NOReplace the LP


7

Follow the step-by-step guide to properly diagnose the error. Pay special attention to those tests indicated in numbered boxes, and described in detail here below: (1) Insert the multimeter probes between pins 1 (signal) and 2 of the CN2 connector on the LP

driver board. You should get a reading of approximately 48 Vdc. (2) Insert the multimeter probes between pins 4 (motor up signal) and 2 or between pins 6 (motor

down signal) and 2 of the K4 connector on the CPU board. With the motor enabled you


Page 6.37

should get a reading of approximately 4 Vdc, while with the motor stopped you should get a reading of approximately 0 Vdc.


down signal) and 2 of the connector CN7 on the Bio servo board. With the motor enabled you should get a reading of approximately 4 Vdc, while with the motor stopped you should get a reading of approximately 0 Vdc.


down signal) and 6 of the connector CN6 on the Bio servo board. With the motor enabled you should get a reading of approximately 4 Vdc, while with the motor stopped you should get a reading of approximately 0 Vdc.


down signal) and 6 of the CN3 connector on the LP driver board. With the motor enabled you should get a reading of approximately 4 Vdc, while with the motor stopped you should get a reading of approximately 0 Vdc.

(6) Insert the multimeter probes between pins 1 (signal) and 2 of the CN1 connector on the LP

driver board. With the motor enabled you should get a reading of approximately 48 Vdc if running counter-clockwise and -48 Vdc if running clockwise, while with the motor stopped you should get a reading of approximately 0 Vdc.


the selector switch. You should get a reading of approximately 220 Vac or 110 Vac depending on the line voltage.


Page 6.38

6.15.2. FOR LEG EXTENSION, LEG CURL, VERTICAL TRACTION, SHOULDER PRESS, CHEST PRESS AND ROWING TORSO

SEAT PROBLEM = MOTOR



Check whether the seat motor enable output signal from the


NO

Check whether the seat motor enable input signal to the Bio


YES

2

3

Check whether the seat motor enable output signal from the Bio


NO

4


NO


Replace the motor

YES

YES

YES

Replace the BS-2S cable

Check whether the supply voltage to the Bio servo board is correct

1

NOA

YES


Page 6.39


switch

A

Check whether the supply voltage to the transformer is correct

NOReplace the


5


servo board. You should get a reading of approximately 24 Vdc. (2) Insert the multimeter probes between pins 4 (motor up signal) and 2 or between pins 6 (motor

down signal) and 2 of the K4 connector on the CPU board. With the motor enabled you should get a reading of approximately 4 Vdc, while with the motor stopped you should get a reading of approximately 0 Vdc.


down signal) and 2 of the CN7 connector on the Bio servo board. With the motor enabled you should get a reading of approximately 4 Vdc, while with the motor stopped you should get a reading of approximately 0 Vdc.

On the Chest Press, the BS-6/2 cable is divided into 2 parts through the connector CN36.

Carry out the test on this connector and, if necessary, replace only the defective section of the BS-6/2 cable.


servo board. With the motor enabled you should get a reading of approximately 24 Vdc if running counter-clockwise and -24 Vdc if running clockwise, while with the motor stopped you should get a reading of approximately 0 Vdc.


the selector switch. You should get a reading of approximately 220 Vac or 110 Vac depending on the line voltage.


Page 6.40

6.16. THE LCD DISPLAYS THE MESSAGE “SEAT PROBLEM = ENCODER”

This error message appears during the initial machine reset, when the CPU board does not receive the encoder signal from the Bio servo board once it has detected a change in the alarm signal, after enabling movement of the seat motor in one direction. This means that there is movement, but no encoder signal.

6.16.1. FOR LEG PRESS

SEAT PROBLEM = ENCODER

Replace the photocellCheck whether the seat motor encoder output signal from the

photocell is correct

NO

2

YES

Check whether the photocell board is powered

1

YES

BNO

A

YES

Check whether the seat motor encoder output signal from the LP


NO

4

Replace the LP driver board

YES

Check whether the seat motor encoder input signal to the LP


3

NO Replace the cables between the motor and

the LP driver board


Page 6.41

Check whether the seat motor encoder input signal to the CPU

board is correct


cable

YESReplace the CPU board

7

A

Check whether the seat motor encoder input signal at the Bio


NO

5

Replace the BS-25/2LP cable

YES

Check whether the seat motor encoder output signal from the


NO

6


YES

B

Check whether the seat motor encoder power supply at the LP

driver board output is correct

8

Replace the cables between the motor and

the LP driver board

YESReplace the LP driver

board

NO

Follow the step-by-step guide to properly diagnose the error. Pay special attention to those tests indicated in numbered boxes, and described in detail here below: (1) Insert the multimeter probes between pins 1 (signal) 4 of the connector on the photocell board.

You should get a reading of approximately 5 Vdc. (2) Insert the oscilloscope probes between pins 2 (signal) and 4 of the connector on the photocell



Page 6.42

(3) Insert the oscilloscope probes between pins 3 (signal) and 5 of the CN4 connector on the LP

driver board. With the motor enabled you should see a square wave signal ranging from approximately 0 Vdc to 5 Vdc.

(4) Insert the oscilloscope probes between pins 5 (signal) and 6 of the CN3 connector on the LP

driver board. With the motor enabled you should see a square wave signal ranging from approximately 0 Vdc to 5 Vdc.

(5) Insert the oscilloscope probes between pins 5 (signal) and 6 of the connector CN6 on the Bio


(6) Insert the oscilloscope probes between pins 10 (signal) and 2 of the connector CN7 on the Bio



board. With the motor enabled you should see a square wave signal ranging from approximately 0 Vdc to 5 Vdc circa.

(8) Insert the multimeter probes between pins 1 (signal) and 5 of the CN4 connector on the LP

driver board. You should get a reading of approximately 5 Vdc.


Page 6.43

6.16.2. FOR LEG EXTENSION, LEG CURL, VERTICAL TRACTION, SHOULDER PRESS, CHEST PRESS AND ROWING TORSO

SEAT PROBLEM = ENCODER

Replace the seat motorCheck whether the seat motor encoder input signal to the Bio


YES

1

Check whether the seat motor encoder output signal from the


NO

2


NO

Check whether the seat motor encoder input signal to the CPU

board is correct


cable

YES

YESReplace the CPU board

3

Follow the step-by-step guide to properly diagnose the error. Pay special attention to those tests indicated in numbered boxes, and described in detail here below: (1) Insert the oscilloscope probes between pins 5 (signal) and 6 of the CN2 connector on the Bio

servo board. With the motor enabled you should see a square wave signal ranging from approximately 3.5 Vdc to 11.2 Vdc.

(2) Insert the oscilloscope probes between pins 10 (signal) and 2 of the CN2 connector on the Bio





Page 6.44

On the Chest Press, the BS-6/2 cable is divided into 2 parts through the connector CN36. Carry out the test on this connector and, if necessary, replace only the defective section of the BS-6/2 cable.


Page 6.45

6.17. THE DISPLAY DOES NOT TURN ON

This problem appears when the display does not receive enough supply voltage to initialize the CPU board and manage the machine components. This is caused by a problem on the power supply line regarding the following components: power cord, power entry, start button, fuses, filter, power supply, Bio servo board, CPU board and the cables connecting them.

Check whether the fuses are intact

Check whether the power cord is intact

Check whether the power socket of the fitness center where the

machine is installed supplies the correct voltage

Replace the blown fuses

Replace the power cord

Connect the machine to another working socket

THE DISPLAY DOES NOT TURN

ON

Check whether the line voltage leaving the power entry is

correct

NO

YES

NO

YES

NO

YES

NO

YES

1

A

Replace the power entry


Page 6.46

NO

Check whether the line voltage output from the start switch is

correct

Check whether the line voltage to the fuse holders is correct

Check whether the line voltage from the fuse holders is correct

Replace the start switch


Replace the damaged fuse holder

YES

NO

NO

YES

NO

YES

3

4

5

Check whether the line voltage input to the start switch is

correct

2


YES

A

Check whether the line voltage to the filter is correct

6


NO

B


Page 6.47

NO

Check whether the line voltage input to the power supply is

correct

Check whether the direct current output from the power supply is

correct

Check whether the direct current input to the Bio servo board is

correct

Replace the BS-14/S cable

Replace the power supply

Replace the BS-7/L cable

YES

NO

NO

YES

NO

YES

8

9

10

Check whether line voltage is output from the filter

7

Replace the filter

YES

B

Check whether the direct current output from the Bio


11


NO

C


Page 6.48

NOCheck whether the direct voltage input to the CPU board is correct

12


YES

C


Follow the step-by-step guide to properly diagnose the error. Pay special attention to those tests indicated in numbered boxes, and described in detail here below:

CAUTION: carry out these checks with the machine powered and the start switch set to ON.

(1) Insert the multimeter probes between pins of the CN11 connector on the power entry (between

the blue and black cables). You should get a reading of approximately 220 Vac or 110 Vac depending on the line voltage.

(2) Insert the multimeter probes between pins of the CN13 input connector on the start switch

(between the blue and black cables). You should get a reading of approximately 220 Vac or 110 Vac depending on the line voltage.

(3) Insert the multimeter probes between pins of the CN14 output connector on the start switch


(4) Insert the multimeter probes between pins of the CN15 input connector on the fuse holders


(5) Insert the multimeter probes between pins of the CN16 output connector on the fuse holders


(6) Insert the multimeter probes between pins of the CN17 input connector on the filter (between


(7) Insert the multimeter probes between pins of the CN18 output connector on the filter (between



Page 6.49

(8) Insert the multimeter probes between pins 4 (signal) and 6 of the CN1 connector on the power supply. You should get a reading of approximately 220 Vac or 110 Vac depending on the line voltage.

(9) Insert the multimeter probes between pins 1 (signal) and 4 of the CN2 connector on the power

supply. You should get a reading of approximately 12 Vdc. Insert the multimeter probes between pins 3 and 4 of the CN2 connector on the power supply. You should get a reading of approximately 5 Vdc.


servo board. You should get a reading of approximately 12 Vdc. Insert the multimeter probes between pins 4 (signal) and 3 of the CN9 connector on the Bio servo board. You should get a reading of approximately 5 Vdc.


servo board. You should get a reading of approximately 12 Vdc. Insert the multimeter probes between pins 4 (signal) and 2 of the CN4 connector on the Bio servo board. You should get a reading of approximately 5 Vdc.

On Chest Press and Leg Press, the BS-4 cable is divided into 2 parts through the

connector CN38. Before checking the voltages on the CPU board, check whether they are correct on this connector and, if necessary, replace only the defective section of the BS-4 cable.

(12) Insert the multimeter probes between pins 1 (signal) and 2 of the K1 connector on the CPU

board. You should get a reading of approximately 12 Vdc. Insert the multimeter probes between pins 4 (signal) and 2 of the K1 connector on the CPU board. You should get a reading of approximately 5 Vdc.


Page 6.50

6.18. THE MACHINE DOES NOT READ THE TGS: THE RED LED ON THE KEY READER IS NOT LIT

This problem occurs when the display does not recognize that a TGS has been inserted in the key reader, or is unable to access the TGS. This is caused by a problem with the TGS interface components (TLCBR and key reader and the corresponding connector cables) or by a defective TGS. It should not concern problems with the CPU, since the initial test checks communication, and in any case no error message means that the serial communication line between the CPU board and TLCBR is working properly.

Perform these tests using a TGS known to work properly.

Check whether the BS-TLCBR cable is intact

Replace the BS-TLCBR cable

THE MACHINE DOES NOT READ

THE TGS

NO

YES

Check whether the TGS is read if the key reader is replaced with

another that works

Check whether the TGS is read if the TLCBR is replaced with

another that works

Replace the key reader

Replace the TLCBRCheck or replace the flat cable

NO

YES

NO YES


Page 7.1

7. DISASSEMBLY OF COMPONENTS

7.1. ABDOMINAL CRUNCH

7.1.1. DISASSEMBLING THE DISPLAY

Figure 7.1.1-1

1. Shut off the equipment and unplug the power cord from the wall socket.

2. Unscrew the 4 self-tapping screws a holding

the DISPLAY, using a medium-sized Philips screwdriver.

Hold the DISPLAY up before unscrewing the last screw.

Figure 7.1.1-2

3. Open the DISPLAY. To remove the DISPLAY: 1. Disconnect the connectors b. 2. Remove the DISPLAY. To re-mount the DISPLAY, follow the above steps in reverse order.


Page 7.2

7.1.2. REMOVING THE ELECTRONIC DISPLAY BOARDS

Figure 7.1.2-1

Follow the steps described in paragraph 7.1.1. “Disassembling the display”. With the display resting on a bench: To remove the CPU a and LED b BOARDS: 1. Disconnect the connector c from the

keyboard. 2. Disconnect the connector d from the

TLCBR. 3. Disconnect the connectors e from the LCD. 4. Use a small Philips screwdriver to unscrew

the 5 screws f. 5. Remove the CPU and LED BOARDS. 6. To separate the CPU and LED boards,

disconnect the 2 connectors and the 4 coupling elements.

When finished, configure the machine parameters as described in paragraphs 9.2. and 9.3. .

To disassemble the TLCBR g: 1. Disconnect the 2 connectors h. 2. Use a medium-sized straight screwdriver to

unscrew the 3 holding screws i. 3. Remove the board. To disassemble the KEY READER l: 1. Disconnect the connector m. 2. Use a medium-sized Philips screwdriver to

unscrew the 2 screws n. 3. Remove the connector block o. 4. Remove the KEY READER.

Continued on next page →


Page 7.3

To disassemble the LCD, located under the LED board: 1. Remove the CPU and LED BOARDS. 2. Disconnect the 2 connectors. 3. Unscrew the 4 screws holding the board to

the shell, using a small Philips screwdriver. 4. Remove the LCD. To re-mount the ELECTRONIC DISPLAY CARDS, follow the above steps in reverse order.


Page 7.4

7.1.3. REMOVING THE EPROM

Figure 7.1.3-1

Follow the steps described in paragraph 7.1.1. “Disassembling the display”. With the display resting on a bench: 1. Remove the EPROM a from their seat, using

an integrated circuit extractor.

Figure 7.1.3-2

To replace each EPROM: 1. Insert the EPROM A into the left-hand seat,

and EPROM B into the right-hand seat. 2. Insert the EPROM pins in the seats, starting

from the bottom, so that the holes in the top seat remain free.

3. Make sure the reference notch b on the EPROM is aligned with the reference notch c on its seat.

4. Make sure the feet of the EPROM are positioned above the holes in the seat.

5. Push the feet into the seat.

Each EPROM may be irreparably damaged if its reference notch is not aligned with the one on the seat, or if its pins are bent.


Page 7.5

7.1.4. DISASSEMBLING THE TLCBR CHIP

Figure 7.1.4-1

Follow the steps described in paragraph 7.1.1. “Disassembling the display”. With the display resting on a bench: 1. Remove the CHIP a from its seat, using an

integrated circuit extractor.

Figure 7.1.4-2

To re-mount the CHIP: 1. Make sure the reference notch b on the CHIP

is aligned with the reference notch c on its seat.

2. Make sure the feet of the CHIP are positioned above the holes in the seat.


The CHIP can be irreparably damaged if the CHIP reference notch is not aligned with the one on the seat, or if the feet are bent.


Page 7.6

7.1.5. DISASSEMBLING THE MAIN KEYBOARD

Figure 7.1.5-1

Follow the steps described in paragraph 7.1.1. “Disassembling the display”. 1. Disconnect the connector a from the

KEYBOARD.

Figure 7.1.5-2

With the display resting on a bench: 2. Using a fine-tipped tool, raise one edge of the

KEYBOARD and remove it. To replace the new KEYBOARD, with the display resting on a bench: 1. Remove the film protecting the adhesive. 2. Begin attaching the adhesive part starting

from left to right, without bending the KEYBOARD.

3. Insert the connector in the slot provided on the display and connect it to the CPU board.

4. Remove the protective film.

When reassembling the keyboard, make sure that the keys do not bend and do not remain pressed.

The KEYBOARD may be assembled only once, since the tracks and keys will be damaged during disassembly.


Page 7.7

7.1.6. DISASSEMBLING THE PLEXIGLAS WEIGHT STACK GUARD

Figure 7.1.6-1


For each side of the weight stack: 2. Unscrew the 2 screws a using a 3-gauge

hexagonal T-wrench. 3. Remove the Plexiglas cover.

Figure 7.1.6-2

4. Pull the PLEXIGLAS upward, taking care with the rubber gasket.

To reassemble the PLEXIGLAS, follow the above steps in reverse order.


Page 7.8

7.1.7. DISASSEMBLING THE WEIGHT STACK PULLEYS

Figure 7.1.7-1

Follow the steps described in paragraph 7.1.6. “Disassembling the plexiglas weight stack guard”. For each of the 2 PULLEYS: 1. Unscrew the screw a and the nut b using 2

17-gauge wrenches. 2. Remove the PULLEY. To reassemble the PULLEYS, follow the above steps in reverse order.

For easier disassembly and reassembly of the PULLEYS, it may be necessary to loosen the cable tension.

When the operation is complete, adjust the cable tension as described in paragraph 8.4. .


Page 7.9

7.1.8. DISASSEMBLING THE WEIGHT STACK COVER

Figure 7.1.8-1

Follow the steps described in paragraph 7.1.6. “Disassembling the plexiglas weight stack guard”. 1. Cut the clamp a.

Figure 7.1.8-2

2. Cut the clamp b. 3. Disconnect the patch cord c from the

solenoid cable.



Page 7.10

Figure 7.1.8-3

4. Using 2 22-gauge wrenches, loosen the counter-nut d then unscrew the screw e from the cable terminal until the cable is free.

5. Disconnect the connector f from the solenoid cable.

6. Remove the spiral cable g and its guide h from the hook i.

Figure 7.1.8-4

7. Use a 6-gauge hexagonal T-wrench to unscrew the 8 screws l.

8. Pull the WEIGHT STACK COVER upward and rest it on the seat, being careful not to damage the cable.

To reassemble the WEIGHT STACK COVER, follow the above steps in reverse order.



Page 7.11

7.1.9. DISASSEMBLING THE ADDITIONAL WEIGHT

Figure 7.1.9-1

Follow the steps described in paragraph 7.1.8. “Disassembling the weight stack cover”. 1. Remove the ADDITIONAL WEIGHT a by

sliding it upward.

Press the solenoid pin inward so that it does not interfere with the additional weight.

To reassemble the ADDITIONAL WEIGHT, follow the above steps in reverse order.


Page 7.12

7.1.10. DISASSEMBLING THE ENCODER

Figure 7.1.10-1

Follow the steps described in paragraph 7.1.6. “Disassembling the plexiglas weight stack guard” limited solely to the external part. 1. Release the slot a of the ENCODER wire

from the hook.

Figure 7.1.10-2

2. Disconnect the connector b of the ENCODER cable.

3. Use a 4-gauge hexagonal T-wrench to unscrew the 3 screws c.

4. Remove the ENCODER.

Hold the ENCODER up before unscrewing the last screw.

To replace the ENCODER, follow the above steps in reverse order.


Page 7.13

7.1.11. DISASSEMBLING THE SOLENOID

Figure 7.1.11-1

Follow the steps described in paragraph 7.1.6. “Disassembling the plexiglas weight stack guard” limited solely to the external part. 1. Disconnect the connector a from the

SOLENOID cable. 2. Unscrew the 2 screws b using a 5-gauge

hexagonal T-wrench. 3. Remove the SOLENOID by lifting the

additional weight. To reassemble the SOLENOID, follow the above steps in reverse order.


Page 7.14

7.1.12. DISASSEMBLING THE SELECTOR BRUSH

Figure 7.1.12-1

Follow the steps described in paragraph 7.1.6. “Disassembling the plexiglas weight stack guard” limited solely to the internal part. 1. Switch the machine on. 2. Follow the steps described in paragraph 9.2

“Configuring the technical parameters” until the final procedure that moves the brush into position as shown in the figure alongside.

3. Use a 5.5-gauge wrench to unscrew the 2

screws a. 4. Remove the SELECTION BRUSH. 5. You may also replace the solenoid b by

removing it with pliers. To reassemble the SELECTION BRUSH, follow the above steps in reverse order


Page 7.15

7.1.13. DISASSEMBLING THE ZERO SENSOR

Figure 7.1.13-1

Follow the steps described in paragraph 7.1.6. “Disassembling the plexiglas weight stack guard” limited solely to the internal part. 1. Loosen the counter-nut a using a 13-gauge

wrench. 2. Disconnect the connector b from the cable. 3. Remove the ZERO SENSOR. To reassemble the ZERO SENSOR, follow the above steps in reverse order.

When the operation is complete, adjust the position of the SENSOR as described in paragraph 8.8. .


Page 7.16

7.1.14. DISASSEMBLING THE WEIGHT STACK SELECTION SYSTEM

Figure 7.1.14-1

Follow the steps described in paragraphs 7.1.6. “Disassembling the plexiglas weight stack guard” and 7.1.13. “Disassembling the zero sensor”. Working on the inner part of the weight stack: 1. Unscrew the screw a using a 4-gauge

hexagonal T-wrench. 2. Remove the transverse support plate b by

turning it counter-clockwise. 3. Disconnect the zero sensor cable.

Figure 7.1.14-2

Working on the outer part of the weight stack: 4. Cut the clamp c and disconnect the connector

d of the weight stack motor cable. 5. Loosen the 4 nuts e using a jointed 4-gauge

wrench. 6. Remove the WEIGHT STACK SELECTION

SYSTEM frame by shifting it towards the inside of the machine, then lifting it up.

To reassemble the WEIGHT STACK SELECTION SYSTEM, follow the above steps in reverse order.

When the operation is complete, adjust the position of the WEIGHT STACK SELECTION and plate selection system as described in paragraphs 8.1. and 8.9. .


Page 7.17

7.1.15. DISASSEMBLING THE WEIGHT STACK SELECTION CHAIN

Figure 7.1.15-1

Follow the steps described in paragraph 7.1.14. “Disassembling the weight stack selection system”. 1. Move the weight stack selection system onto

a bench or flat surface. 2. Loosen the nut a using an 8-gauge wrench. 3. Unscrew the screw b using a jointed 5-gauge

hexagonal wrench, until the CHAIN is removed from the upper guide.

If this is not possible, unscrew the screw c using a 3-gauge hexagonal T-wrench to disassemble the upper guide.

4. Remove the CHAIN from the lower pinion. 5. Remove the CHAIN. To reassemble the CHAIN, follow the above steps in reverse order.

When the operation is complete, adjust the tension of the WEIGHT STACK SELECTION CHAIN, the position of the weight stack and plate selection system as described in paragraphs 8.1. , 8.10. and 8.9. .


Page 7.18

7.1.16. DISASSEMBLING THE WEIGHT STACK MOTOR

Figure 7.1.16-1

Follow the steps described in paragraphs 7.1.14. “Disassembling the weight stack selection system” and 7.1.15. “Disassembling the weight stack selection chain”. 1. Loosen the dowel a using a 2.5-gauge

hexagonal T-wrench. 2. Slide the pinion b from the motor shaft. 3. Unscrew the 3 screws c, using a 4-gauge

hexagonal T-wrench. 4. Remove the MOTOR. To reassemble the MOTOR, follow the above steps in reverse order.

When the operation is complete, adjust the tension of the weight stack selection chain, the position of the weight stack and plate selection system as described in paragraphs 8.1. , 8.10. and 8.9. .


Page 7.19

7.1.17. DISASSEMBLING THE CROSS STOPS

Figure 7.1.17-1

Follow the steps described in paragraph 7.1.8. “Disassembling the weight stack cover”. For each CROSS STOP: 1. Unscrew the 2 dowels a, using a 4-gauge

hexagonal T-wrench. 2. Remove the CROSS STOP by sliding it

upward. To reassemble the CROSS STOPS, follow the above steps in reverse order

When the operation is complete, adjust the position of the CROSS STOPS as described in paragraph 8.3. .


Page 7.20

7.1.18. DISASSEMBLING THE CROSS

Figure 7.1.18-1

Follow the steps described in paragraphs 7.1.8. “Disassembling the weight stack cover”, 7.1.9. “Disassembling the additional weight”, 7.1.10. “Disassembling the encoder”, 7.1.14. “Disassembling the weight stack selection system” and 7.1.17. “Disassembling the cross stops”. 1. Use a special tool a to compress all of the

weight stack plate springs. 2. Remove the CROSS by sliding it upward. To reassemble the CROSS, follow the above steps in reverse order.

To reassemble the CROSS, it is not necessary to compress the plate springs; simply press it down.


Page 7.21

7.1.19. DISASSEMBLING THE SINKER

Figure 7.1.19-1

Follow the steps described in paragraph 7.1.18. “Disassembling the cross”. 1. Place the cross on a bench or flat surface. 2. Unscrew the 2 screws a using an 8-gauge

hexagonal T-wrench. 3. Remove the cable connector flange b. 4. Use a 30-gauge Allen wrench to unscrew the

ring-nut c. 5. Remove the SINKER. To reassemble the SINKER, follow the above steps in reverse order.


Page 7.22

7.1.20. DISASSEMBLING THE WEIGHT STACK PLATES

Figure 7.1.20-1

Follow the steps described in paragraphs 7.1.8. “Disassembling the weight stack cover”, 7.1.10. “Disassembling the encoder” and 7.1.18. “Disassembling the cross”. 1. Remove the WEIGHT STACK PLATES by

sliding them upward. To reassemble the WEIGHT STACK PLATES, follow the above steps in reverse order.


Page 7.23

7.1.21. DISASSEMBLING THE BARS

Figure 7.1.21-1

Follow the steps described in paragraph 7.1.8. “Disassembling the weight stack cover”. For each of the 2 counter-weight vibration bars: 1. Unscrew the 2 dowels a, using a 4-gauge

hexagonal T-wrench.

Hold the BAR up before unscrewing the last screw .

2. Remove the BAR by sliding it upward. To reassemble the BARS, follow the above steps in reverse order


Page 7.24

7.1.22. DISASSEMBLING THE SEAT GUARD

Figure 7.1.22-1


2. Use a medium-sized Philips screwdriver to

unscrew the 4 screws a. 3. Remove the REAR SEAT GUARD.

Figure 7.1.22-2

4. Loosen the 2 screws b using a medium-sized Philips screwdriver.

5. Release the FRONT SEAT GUARD from the loose 2 screws by first pushing it back, then upward.

6. Spread the sides slightly and slide out the FRONT SEAT GUARD .

To reassemble the SEAT GUARDS, follow the above steps in reverse order


Page 7.25

7.1.23. DISASSEMBLING THE ELECTRICAL BOX

Figure 7.1.23-1

Follow the steps described in paragraph 7.1.22. “Disassembling the seat guard”. 1. Unscrew the screw a using a 4-gauge

hexagonal T-wrench. 2. Open the cover of the ELECTRICAL BOX.

Figure 7.1.23-2

3. Disconnect the cable connectors c. 4. Unscrew the 3 nuts b using a 10-gauge tube

wrench. 5. Remove the ELECTRICAL BOX. To reassemble the ELECTRICAL BOX, follow the above steps in reverse order.


Page 7.26

7.1.24. DISASSEMBLING THE ELECTRONIC COMPONENTS OF THE ELECTRICAL BOX

Figure 7.1.24-1

Follow the steps described in paragraph 7.1.23. “Disassembling the electrical box”. With the electrical box resting on a bench: To disassemble the POWER SUPPLY a: 1. Disconnect the 2 connectors. 2. Disconnect the 4 plastic coupling elements. 3. Remove the card. To disassemble the FPGA BOARD b: 1. Disconnect the 4 connectors. 2. Disconnect the 4 plastic coupling elements. 3. Remove the card. To disassemble the IMP BOARD c: 1. Lift the board. 2. Disconnect the 2 connectors. 3. Disconnect the 4 plastic coupling elements. 4. Remove the card. To disassemble the IEM BOARD d: 1. Lift the board. 2. Disconnect the 2 connectors. 3. Disconnect the 4 plastic coupling elements. 4. Remove the card. To disassemble the TRANSFORMER e: 1. Disconnect the secondary cables from the

board connectors. 2. Unweld the primary cables from the selector

switch. 3. Unscrew the holding screw a using an 8-

gauge wrench. 4. Remove the transformer.



Page 7.27

To disassemble the 110/220 SELECTOR SWITCH f: 1. Unweld the cables. 2. Unscrew the holding nut. 3. Remove the selector switch. To disassemble the FILTER g: 1. Disconnect the connectors. 2. Unscrew the 2 holding nuts. To reassemble the ELECTRONIC COMPONENTS OF THE ELECTRICAL BOX, follow the above steps in reverse order.


Page 7.28

7.1.25. DISASSEMBLING THE BELL GUARD

Figure 7.1.25-1


2. Unscrew the 2 screws a using a 3-gauge

hexagonal T-wrench. 3. Slide the BELL GUARD upwards. To replace the BELL GUARD, follow the above steps in reverse order.


Page 7.29

7.1.26. DISASSEMBLING THE WEIGHT STACK FRAME GUARD

Figure 7.1.26-1

Carry out the operation described in paragraph 7.1.25. “Disassembling the bell guard”. 1. Use a medium-sized Philips screwdriver to

unscrew the screw a. 2. Remove the UPPER GUARD.

Figure 7.1.26-2

3. Unscrew the 2 screws b using a 2.5-gauge hexagonal T-wrench.

4. Remove the cross-piece c. 5. Remove the 4 caps d (2 on each side of the

GUARD) using a small flat screwdriver. 6. Use a medium-sized Philips screwdriver to

unscrew the 4 screws under the 4 caps d. 7. Widening the sides slightly, remove the

WEIGHT STACK FRAME GUARD by sliding it down and then up.

To reassemble the WEIGHT STACK FRAME GUARD, follow the above steps in reverse order.


Page 7.30

7.1.27. DISASSEMBLING THE WEIGHT STACK CABLE

Figure 7.1.27-1

Follow the steps described in paragraphs 7.1.6. “Disassembling the plexiglas weight stack guard” for just one part and 7.1.26. “Disassembling the weight stack frame guard”. 1. Using 2 22-gauge wrenches, loosen the

counter-nut a then unscrew the screw b from the WEIGHT STACK CABLE terminal until it is free from the cross.

Figure 7.1.27-2

2. Unscrew the 2 dowels c using a 4-gauge hexagonal T-wrench.

3. Remove the cable with the aid of a pair of pliers.

To reassemble the WEIGHT STACK CABLE, follow the above steps in reverse order.

When the operation is complete, adjust the tension of the WEIGHT STACK CABLE, and the phasing of the cam and lever mechanism, as described in paragraphs 8.4. and 8.2. .


Page 7.31

7.1.28. DISASSEMBLING THE BELL

Figure 7.1.28-1

Follow the steps described in paragraph 7.1.25. “Disassembling the bell guard”. 1. Unscrew the screw a using a 6-gauge

hexagonal T-wrench. 2. Remove the BELL. To reassemble the BELL, follow the above steps in reverse order.

During reassembly, make sure that the BELL pin is inserted in the hole provided in the round part connected to the primary shaft.


Page 7.32

7.1.29. DISASSEMBLING THE PRIMARY SHAFT - SECONDARY SHAFT CHAIN

Figure 7.1.29-1

Follow the steps described in paragraph 7.1.28. “Disassembling the bell”. 1. Move the CHAIN until the coupling link a is

placed on the primary shaft crown b. 2. Release the spring clamp c of the coupling

link using the pliers provided. 3. Remove the coupling plate d. 4. Remove the coupling link. 5. Remove the CHAIN. To reassemble the CHAIN, follow the above steps in reverse order.

To position the CHAIN correctly, adjust the cam phasing and lever mechanism as described in paragraph 8.2. .

When the operation is complete, adjust the alignment and tension of the PRIMARY SHAFT-SECONDARY SHAFT CHAIN as described in paragraphs 8.11. and 8.12. .


Page 7.33

7.1.30. DISASSEMBLING THE PRIMARY SHAFT

Figure 7.1.30-1

Follow the steps described in paragraphs 7.1.26. “Disassembling the weight stack frame guard”, 7.1.28. “Disassembling the bell” and 7.1.29. “Disassembling the primary shaft - secondary shaft chain”. 1. Unscrew the 4 screws a using a 17-gauge

wrench. 2. Remove the PRIMARY SHAFT. To disassemble the components of the PRIMARY SHAFT, place it on a bench or flat surface. Then: To disassemble the bearing b: 1. Unscrew the two dowels using a 2-gauge

hexagonal T-wrench. 2. Remove the bearing. To disassemble the stop c: 1. Remove the bearing b. 2. Use a 4-gauge hexagonal T-wrench to

unscrew the dowel d. 3. Remove the stop. To disassemble the pinion e: 1. Remove the bearing b, and the stop c. 2. Use a 4-gauge hexagonal T-wrench to

unscrew the dowel f. 3. Remove the pinion. To disassemble the bearing g: 1. Remove the bearing b, the stop c, and the

pinion e. 2. Use a 2-gauge T-wrench to unscrew the 3

dowels h. 3. Remove the bearing.



Page 7.34

To replace the PRIMARY SHAFT and its components, follow the above steps in reverse order.



Page 7.35

7.1.31. DISASSEMBLING THE SECONDARY SHAFT

Figure 7.1.31-1

Follow the steps described in paragraphs 7.1.26. “Disassembling the weight stack frame guard”, 7.1.27. “Disassembling the weight stack cable” and 7.1.29. “Disassembling the primary shaft - secondary shaft chain”. 1. Loosen the 2 counter-nuts a and tighten the 2

setting screws b of the SECONDARY SHAFT using a 17-gauge wrench.

2. Use a 4-gauge wrench to unscrew the 17 screws c.

3. Remove the SECONDARY SHAFT. To disassemble the components of the SECONDARY SHAFT, place it on a bench or flat surface. Then: To remove the bearings d and e: 1. Use a 2-gauge T-wrench to unscrew the 3

dowels f of the bearings. 2. Remove the bearings.

Figure 7.1.31-2

To disassemble the cam g: 1. Remove the bearing d. 2. Unscrew the screw h fastening the cable

holder, using an 8-gauge hexagonal T-wrench.

3. Unscrew the screw i fastening the cam hub, using an 8-gauge hexagonal T-wrench.

4. Remove the cam.

For easier removal of the cam, we recommend unscrewing the 3 screws I fastening the cam to the pinion, using a 6-gauge hexagonal T-wrench.

To disassemble the pinion m:



Page 7.36

1. Remove the bearing e. 2. Use a 3-gauge hexagonal T-wrench to

unscrew the 6 screws l. 3. Remove the pinion. To replace the SECONDARY SHAFT and its components, follow the above steps in reverse order.

To reassemble the components of the SECONDARY SHAFT, align the punch on a tooth of the pinion with the hole in the cam.



Page 7.37

7.1.32. DISASSEMBLING THE WEIGHT STACK FRAME PULLEY

Figure 7.1.32-1

Follow the steps described in paragraph 7.1.26. “Disassembling the weight stack frame guard”. 1. Use the special pliers provided to remove the

snap ring a. 2. Use a pushing tool to push the b inside. 3. Remove the PULLEY, being careful with the

2 plastic spacers.

The cable holder is fastened to the frame by the dowel d, which may be removed using a 3-gauge hexagonal T-wrench.

To replace the PULLEY, follow the above steps in reverse order.

For easier reassembly of the PULLEY, it may be necessary to loosen the cable tension.



Page 7.38

7.1.33. DISASSEMBLING THE MAT

Figure 7.1.33-1


2. Use a large, flat screwdriver to release the 4

pressure fasteners A holding the MAT against the frame.

3. Remove the MAT by pulling it upward until the remaining fastener B is released.

To reassemble the MAT, rest it on the frame and press down at the 5 fastening points.


Page 7.39

7.1.34. DISASSEMBLING THE POWER ENTRY

Figure 7.1.34-1

Follow the steps described in paragraph 7.1.33. “Disassembling the mat”. 1. Unscrew the screw a using a 4-gauge

hexagonal T-wrench. 2. Remove the Plexiglas guard b.

The screw a remains inside the Plexiglas guard.

3. Disconnect the 3 connector fastons c. 4. Remove the POWER ENTRY by pressing a

medium-sized straight screwdriver against its plastic springs.

To reassemble the POWER ENTRY, follow the above steps in reverse order


Page 7.40

7.1.35. DISASSEMBLING THE STARTER PLATE AND FUSES

Figure 7.1.35-1

Follow the steps described in paragraph 7.1.22. “Disassembling the seat guard”. 1. Loosen the 2 screws a using a 5-gauge

hexagonal T-wrench. 2. Remove the STARTING PLATE AND

FUSES, being careful not to tear the cables. 3. The PLATE is thus available for any

necessary operations. To replace the STARTING PLATE AND FUSES, follow the above steps in reverse order.


Page 7.41

7.2. LOWER BACK


Figure 7.2.1-1


2. Use a medium Philips screwdriver to

unscrew the 4 self-tapping screws a holding the DISPLAY.


Figure 7.2.1-2

3. Open the DISPLAY. To remove the DISPLAY: 1. Disconnect the connectors b. 2. Remove the DISPLAY. To re-mount the display, follow the above steps in reverse order.


Page 7.42


Figure 7.2.2-1





disconnect the 2 connectors and 4 coupling elements.







Page 7.43


the shell, using a small Philips screwdriver. 4. Remove the LCD. To re-mount the ELECTRONIC DISPLAY BOARDS, follow the above steps in reverse order.


Page 7.44


Figure 7.2.3-1



Figure 7.2.3-2









Page 7.45


Figure 7.2.4-1



Figure 7.2.4-2







Page 7.46


Figure 7.2.5-1


KEYBOARD.

Figure 7.2.5-2









Page 7.47


Figure 7.2.6-1




Figure 7.2.6-2




Page 7.48


Figure 7.2.7-1






Page 7.49


Figure 7.2.8-1


Figure 7.2.8-2


solenoid cable.



Page 7.50

Figure 7.2.8-3




Figure 7.2.8-4






Page 7.51


Figure 7.2.9-1


sliding it upward.




Page 7.52


Figure 7.2.10-1


from the hook.

Figure 7.2.10-2







Page 7.53


Figure 7.2.11-1






Page 7.54


Figure 7.2.12-1







Page 7.55


Figure 7.2.13-1





Page 7.56


Figure 7.2.14-1




Figure 7.2.14-2








Page 7.57


Figure 7.2.15-1






When the operation is complete, adjust the tension of the WEIGHT STACK SELECTION CHAIN, the position of the weight stack and plate selection system as described in paragraphs 8.1., 8.10. and 8.9. .


Page 7.58


Figure 7.2.16-1




When the operation is complete, adjust the tension of the weight stack selection chain, the position of the weight stack and plate selection system as described in paragraphs 8.1., 8.10. and 8.9. .


Page 7.59


Figure 7.2.17-1






Page 7.60


Figure 7.2.18-1





Page 7.61


Figure 7.2.19-1





Page 7.62


Figure 7.2.20-1




Page 7.63


Figure 7.2.21-1


hexagonal T-wrench.




Page 7.64


Figure 7.2.22-1




Figure 7.2.22-2






Page 7.65


Figure 7.2.23-1



Figure 7.2.23-2




Page 7.66


Figure 7.2.24-1

Follow the steps described in paragraph 7.2.23. “Disassembling the electrical box”. With the electrical box resting on a bench: To disassemble the POWER SUPPLY a: 1. Disconnect the 2 connectors. 2. Disconnect the 4 plastic coupling elements. 3. Remove the board. To disassemble the FPGA BOARD b: 1. Disconnect the 4 connectors. 2. Disconnect the 4 plastic coupling elements. 3. Remove the board. To disassemble the IMP BOARD c: 1. Lift the board. 2. Disconnect the 2 connectors. 3. Disconnect the 4 plastic coupling elements. 4. Remove the board. To disassemble the IEM BOARD d: 1. Lift the board. 2. Disconnect the 2 connectors. 3. Disconnect the 4 plastic coupling elements. 4. Remove the board. To disassemble the TRANSFORMER e: 1. Disconnect the secondary cables from the

board connectors. 2. Unsolder the primary cables from the selector





Page 7.67

To disassemble the 110/220 SELECTOR SWITCH f: 1. Unsolder the cables. 2. Unscrew the holding nut. 3. Remove the selector switch. To disassemble the FILTER g: 1. Disconnect the connectors. 2. Unscrew the 2 holding nuts. To reassemble the ELECTRONIC COMPONENTS OF THE ELECTRICAL BOX, follow the above steps in reverse order.


Page 7.68


Figure 7.2.25-1



hexagonal T-wrench. 3. Remove the BELL GUARD. To replace the BELL GUARD, follow the above steps in reverse order.


Page 7.69


Figure 7.2.26-1

Follow the steps described in paragraph 7.2.25. “Disassembling the bell guard”. 1. Use a medium-sized Philips screwdriver to


Figure 7.2.26-2








Page 7.70


Figure 7.2.27-1



Figure 7.2.27-2






Page 7.71

7.2.28. DISASSEMBLING THE RELEASE LEVER CABLE

Figure 7.2.28-1

1. Unscrew the setting screw of the LEVER RELEASE CABLE, using a 13-gauge wrench on the counter-nut a and screw b.

2. Remove the 2 nut covers c. 3. Use a 17-gauge wrench to unscrew the 2

screws d, located under the nut covers. 4. Remove the release handle and set it on the

floor.

Hold the release handle up before unscrewing the last screw.

5. Pull the cable from the release handle,

passing the blocking ball through the holes provided.

Figure 7.2.28-2

6. Pulling the cable outward, turn the threaded part e to create a space of 2-3 mm near the bell.

7. Align the slot in part e with the one in the screw f below.

8. Move the cable along the slot to the space created.

9. Fully unscrew part e. 10. Pull the black plastic part g outward, and

remove the cable, making the blocking ball pass through the hole provided.

Lock the part g in place, to prevent the spring from pulling it inward and making it inaccessible without disassembling the bell as described in paragraph 7.2.29. .

11. Remove the LEVER RELEASE CABLE.



Page 7.72

If you need to replace the cable because the bell blocking ball is broken, the spring pulls part g into the bell; to recover it, you must disassemble the bell as described in paragraph 7.2.29. .

To reassemble the LEVER RELEASE CABLE, follow the above steps in reverse order.

When the operation is complete, adjust the lever release cable tension as described in paragraph 8.13. .


Page 7.73


Figure 7.2.29-1

Follow the steps described in paragraphs 7.2.25. “Disassembling the bell guard” and 7.2.28. “Disassembling the release lever cable”. 1. Unscrew the screw a using a 6-gauge


During reassembly, make sure that the BELL pin is inserted in the hole provided in the round part connected to the primary shaft between the movement limitation pins.


Page 7.74


Figure 7.2.30-1







Page 7.75


Figure 7.2.31-1










Page 7.76




Page 7.77


Figure 7.2.32-1






Figure 7.2.32-2




4. Remove the cam.


To disassemble the pinion m: 1. Remove the bearing e. 2. Use a 6-gauge hexagonal T-wrench to

unscrew the 3 screws l. 3. Remove the pinion.



Page 7.78

To replace the SECONDARY SHAFT and its components, follow the above steps in reverse order.




Page 7.79


Figure 7.2.33-1



2 plastic spacers.






Page 7.80


Figure 7.2.34-1







Page 7.81


Figure 7.2.35-1








Page 7.82


Figure 7.2.36-1






Page 7.83

7.3. LEG EXTENSION


Figure 7.3.1-1





Figure 7.3.1-2



Page 7.84


Figure 7.3.2-1








unscrew the 3 holding screws i. 3. Remove the card. To disassemble the KEY READER l: 1. Disconnect the connector m. 2. Use a medium-sized Philips screwdriver to




Page 7.85

To disassemble the LCD, located under the LED board: 1. Remove the CPU and LED BOARDS. 2. Disconnect the 2 connectors. 3. Unscrew the 4 screws the board to the shell,

using a small Philips screwdriver. 4. Remove the LCD. To re-mount the ELECTRONIC DISPLAY CARDS, follow the above steps in reverse order.


Page 7.86


Figure 7.3.3-1



Figure 7.3.3-2









Page 7.87


Figure 7.3.4-1



Figure 7.3.4-2







Page 7.88


Figure 7.3.5-1


KEYBOARD.

Figure 7.3.5-2









Page 7.89

7.3.6. DISASSEMBLING THE SEAT KEYBOARD

Figure 7.3.6-1


KEYBOARD.

Figure 7.3.6-2









Page 7.90


Figure 7.3.7-1




Figure 7.3.7-2




Page 7.91


Figure 7.3.8-1

Follow the steps described in paragraph 7.3.7. “Disassembling the Plexiglas weight stack guard”. For each of the 2 PULLEYS: 1. Unscrew the screw a and the nut b using 2





Page 7.92


Figure 7.3.9-1

Follow the steps described in paragraph 7.3.7. “Disassembling the Plexiglas weight stack guard”. 1. Cut the clamp a.

Figure 7.3.9-2


solenoid cable.



Page 7.93

Figure 7.3.9-3




Figure 7.3.9-4






Page 7.94


Figure 7.3.10-1


sliding it upward.




Page 7.95


Figure 7.3.11-1

Follow the steps described in paragraph 7.3.7. “Disassembling the Plexiglas weight stack guard” limited solely to the external part. 1. Release the slot a of the ENCODER wire

from the hook.

Figure 7.3.11-2







Page 7.96


Figure 7.3.12-1

Follow the steps described in paragraph 7.3.7. “Disassembling the Plexiglas weight stack guard” limited solely to the external part. 1. Disconnect the connector a from the





Page 7.97


Figure 7.3.13-1

Follow the steps described in paragraph 7.3.7. “Disassembling the Plexiglas weight stack guard” limited solely to the internal part. 1. Switch the machine on. 2. Follow the steps described in paragraph 9.2






Page 7.98


Figure 7.3.14-1

Follow the steps described in paragraph 7.3.7. “Disassembling the Plexiglas weight stack guard” limited solely to the internal part. 1. Loosen the counter-nut a using a 13-gauge




Page 7.99


Figure 7.3.15-1

Follow the steps described in paragraphs 7.3.7. “Disassembling the Plexiglas weight stack guard” and 7.3.14. “Disassembling the zero sensor”. Working on the inner part of the weight stack: 1. Unscrew the screw a using a 4-gauge



Figure 7.3.15-2








Page 7.100


Figure 7.3.16-1








Page 7.101


Figure 7.3.17-1






Page 7.102


Figure 7.3.18-1






Page 7.103


Figure 7.3.19-1





Page 7.104


Figure 7.3.20-1





Page 7.105


Figure 7.3.21-1




Page 7.106


Figure 7.3.22-1


hexagonal T-wrench.




Page 7.107


Figure 7.3.23-1




Figure 7.3.23-2






Page 7.108

7.3.24. DISASSEMBLING THE SEAT MOTOR

Figure 7.3.24-1

Carry out these operations with the machine powered and switched on.

1. Position the seat all the way forward 0. 2. Unscrew the 2 screws b using a 4-gauge

hexagonal T-wrench for each side of the motor guard a.

3. Remove the motor guard.

Figure 7.3.24-2

4. Use a medium-sized Philips screwdriver to unscrew the 5 screws c.

5. Remove the backrest guard . 6. Unscrew the screw d and the nut e using 2

17-gauge wrenches. 7. Remove the motor from its housing. 8. Move the seat back.



Page 7.109

Figure 7.3.24-3

9. Unscrew the 4 screws holding the seat guard using a medium-sized Philips screwdriver.

10. Remove the seat guard. 11. For each seat support bar, unscrew the 2

screws f using 2 17-gauge wrenches. 12. Unscrew the 2 support bars from the frame,

taking special care with the vibration bars. 13. Remove the seat by sliding it upward.

Be careful with the motor cable, still connected.

Figure 7.3.24-4

14. Rest the seat on the support frame as shown in the figure alongside.

15. Shut the machine off. 16. Follow the steps described in paragraph

7.3.23. “Disassembling the seat guard” and disconnect the motor cable.

17. Unscrew the screw g and the nut h using 2 17-gauge wrenches.

18. Remove the MOTOR SEAT. To reassemble the SEAT MOTOR, follow the above steps in reverse order.


Page 7.110


Figure 7.3.25-1



Figure 7.3.25-2




Page 7.111


Figure 7.3.26-1

Follow the steps described in paragraph 7.3.25. “Disassembling the electrical box”. With the electrical box resting on a bench: To disassemble the POWER SUPPLY a: 1. Disconnect the 2 connectors. 2. Disconnect the 4 plastic coupling elements. 3. Remove the card. To disassemble the FPGA BOARD b: 1. Disconnect the 4 connectors. 2. Disconnect the 4 plastic coupling elements. 3. Remove the card. To disassemble the IMP BOARD c: 1. Lift the board. 2. Disconnect the 2 connectors. 3. Disconnect the 4 plastic coupling elements. 4. Remove the card. To disassemble the IMS BOARD d: 1. Lift the board. 2. Disconnect the 2 connectors. 3. Disconnect the 4 plastic coupling elements. 4. Remove the card. To disassemble the IEM BOARD e: 1. Lift the board. 2. Disconnect the 2 connectors. 3. Disconnect the 4 plastic coupling elements. 4. Remove the card.



Page 7.112

To disassemble the TRANSFORMER f: 1. Disconnect the secondary cables from the



gauge wrench. 4. Remove the transformer. To disassemble the 110/220 SELECTOR SWITCH g: 1. Unsolder the cables. 2. Unscrew the holding nut. 3. Remove the selector switch. To disassemble the FILTER h: 1. Disconnect the connectors. 2. Unscrew the 2 holding nuts. To reassemble the ELECTRONIC COMPONENTS OF THE ELECTRICAL BOX, follow the above steps in reverse order.


Page 7.113


Figure 7.3.27-1





Page 7.114


Figure 7.3.28-1



Figure 7.3.28-2








Page 7.115


Figure 7.3.29-1

Follow the steps described in paragraphs 7.3.7. “Disassembling the Plexiglas weight stack guard” for just one part and 7.3.28. “Disassembling the weight stack frame guard”. 1. Using 2 22-gauge wrenches, loosen the


Figure 7.3.29-2






Page 7.116


Figure 7.3.30-1

Follow the steps described in paragraph 7.3.27. “Disassembling the bell guard”. 1. Unscrew the screw a using a 6-gauge


During reassembly, make sure that the BELL pin is inserted in the hole provided in the weight stack frame.


Page 7.117


Figure 7.3.31-1







Page 7.118


Figure 7.3.32-1










Page 7.119




Page 7.120


Figure 7.3.33-1






Figure 7.3.33-2




4. Remove the cam.





Page 7.121






Page 7.122


Figure 7.3.34-1



2 plastic spacers.






Page 7.123


Figure 7.3.35-1







Page 7.124


Figure 7.3.36-1








Page 7.125


Figure 7.3.37-1






Page 7.126

7.4. LEG CURL


Figure 7.4.1-1





Figure 7.4.1-2



Page 7.127


Figure 7.4.2-1












Page 7.128




Page 7.129


Figure 7.4.3-1



Figure 7.4.3-2









Page 7.130


Figure 7.4.4-1



Figure 7.4.4-2







Page 7.131


Figure 7.4.5-1


KEYBOARD.

Figure 7.4.5-2









Page 7.132


Figure 7.4.6-1


KEYBOARD.

Figure 7.4.6-2









Page 7.133


Figure 7.4.7-1




Figure 7.4.7-2




Page 7.134


Figure 7.4.8-1






Page 7.135


Figure 7.4.9-1


Figure 7.4.9-2


solenoid cable.



Page 7.136

Figure 7.4.9-3




Figure 7.4.9-4






Page 7.137


Figure 7.4.10-1


sliding it upward.




Page 7.138


Figure 7.4.11-1


from the hook.

Figure 7.4.11-2







Page 7.139


Figure 7.4.12-1






Page 7.140


Figure 7.4.13-1







Page 7.141


Figure 7.4.14-1





Page 7.142


Figure 7.4.15-1




Figure 7.4.15-2








Page 7.143


Figure 7.4.16-1








Page 7.144


Figure 7.4.17-1






Page 7.145


Figure 7.4.18-1






Page 7.146


Figure 7.4.19-1

Follow the steps described in paragraphs 7.4.9. “Disassembling the weight stack cover”, 7.4.10. “Disassembling the additional weight”, 7.4.11. “Disassembling the encoder”, 7.4.15. “Disassembling the weight stack selection system” and 7.4.18. “Disassembling the cross stops”. 1. Loosen the 2 screws a using a 4-gauge

hexagonal T-wrench. 2. Remove the 2 counter-weights

Figure 7.4.19-2

3. Use a special tool c to compress all of the weight stack plate springs.

4. Remove the CROSS by sliding it upward. To reassemble the CROSS, follow the above steps in reverse order.



Page 7.147


Figure 7.4.20-1





Page 7.148


Figure 7.4.21-1




Page 7.149


Figure 7.4.22-1


hexagonal T-wrench.




Page 7.150


Figure 7.4.23-1




Figure 7.4.23-2






Page 7.151


Figure 7.4.24-1

Carry out these operations with the machine powered and switched on.

1. Position the seat all the way forward 0. 2. Unscrew the 2 screws b using a 4-gauge

hexagonal T-wrench for each side of the motor guard a.

3. Remove the motor guard.

Figure 7.4.24-2

4. Use a medium-sized Philips screwdriver to unscrew the 5 screws c.

5. Remove the backrest guard . 6. Unscrew the screw d and the nut e using 2

17-gauge wrenches. 7. Remove the motor from its housing. 8. Move the seat back.



Page 7.152

Figure 7.4.24-3

9. Unscrew the 4 screws holding the seat guard using a medium-sized Philips screwdriver.

10. Remove the seat guard. 11. For each seat support bar, unscrew the 2

screws g using 2 17-gauge wrenches. 12. Unscrew the 2 support bars from the frame,

taking special care with the vibration bars. 13. Remove the seat by sliding it upward.

Be careful with the motor cable, still connected.

Figure 7.4.24-4

14. Rest the seat on the support frame as shown in the figure alongside.

15. Shut the machine off. 16. Follow the steps described in paragraph

7.4.23. “Disassembling the seat guard” and disconnect the motor cable.

17. Unscrew the screw g and the nut h using 2 17-gauge wrenches.

18. Remove the MOTOR SEAT. To reassemble the SEAT MOTOR, follow the above steps in reverse order.


Page 7.153


Figure 7.4.25-1



Figure 7.4.25-2




Page 7.154


Figure 7.4.26-1

Follow the steps described in paragraph 7.4.25. “Disassembling the electrical box”. With the electrical box resting on a bench: To disassemble the POWER SUPPLY a: 1. Disconnect the 2 connectors. 2. Disconnect the 4 plastic coupling elements. 3. Remove the board. To disassemble the FPGA BOARD b: 1. Disconnect the 4 connectors. 2. Disconnect the 4 plastic coupling elements. 3. Remove the board. To disassemble the IMP BOARD c: 1. Lift the board. 2. Disconnect the 2 connectors. 3. Disconnect the 4 plastic coupling elements. 4. Remove the board. To disassemble the IMS BOARD d: 1. Lift the board. 2. Disconnect the 2 connectors. 3. Disconnect the 4 plastic coupling elements. 4. Remove the board. To disassemble the IEM BOARD e: 1. Lift the board. 2. Disconnect the 2 connectors. 3. Disconnect the 4 plastic coupling elements. 4. Remove the board.



Page 7.155






Page 7.156


Figure 7.4.27-1





Page 7.157


Figure 7.4.28-1



Figure 7.4.28-2








Page 7.158


Figure 7.4.29-1



Figure 7.4.29-2






Page 7.159


Figure 7.4.30-1

Follow the steps described in paragraphs 7.4.27. “Disassembling the bell guard”. 1. Unscrew the screw a using a 6-gauge


During reassembly, make sure that the BELL pin is inserted in the hole provided in the weight stack frame.


Page 7.160


Figure 7.4.31-1







Page 7.161


Figure 7.4.32-1










Page 7.162




Page 7.163


Figure 7.4.33-1






Figure 7.4.33-2




4. Remove the cam.





Page 7.164






Page 7.165


Figure 7.4.34-1



2 plastic spacers.






Page 7.166


Figure 7.4.35-1







Page 7.167


Figure 7.4.36-1








Page 7.168


Figure 7.4.37-1






Page 7.169

7.5. VERTICAL TRACTION


Figure 7.5.1-1





Figure 7.5.1-2

3. Open the DISPLAY. To remove the DISPLAY: 1. Disconnect the connectors b. 2. Remove the DISPLAY. To reassemble the display, follow the above steps in reverse order.


Page 7.170


Figure 7.5.2-1












Page 7.171




Page 7.172


Figure 7.5.3-1



Figure 7.5.3-2









Page 7.173


Figure 7.5.4-1



Figure 7.5.4-2







Page 7.174


Figure 7.5.5-1


KEYBOARD.

Figure 7.5.5-2









Page 7.175


Figure 7.5.6-1


KEYBOARD.

Figure 7.5.6-2









Page 7.176

7.5.7. REMOVING THE SEAT

Figure 7.5.7-1


2. Use a 4-gauge wrench to unscrew the 17

screws a. 3. Remove the SEAT. To replace the SEAT, follow the above steps in reverse order.


Page 7.177

7.5.8. DISASSEMBLING THE FRONT GUARD

Figure 7.5.8-1

1. Move the seat to position 0 so that the easy

start lever is down. 2. Shut off the equipment and unplug the power

cord from the wall socket. For each side: 3. Remove the cap a of the GUARD using a

small flat screwdriver. 4. Unscrew the screw under the cap a using a

medium-sized Philips screwdriver. 5. Spread the sides slightly and slide out the

FRONT GUARD. To reassemble the FRONT GUARDS, follow the above steps in reverse order.

Reassemble the FRONT GUARD, snapping it into the front locks provided.


Page 7.178


Figure 7.5.9-1

Follow the steps described in paragraph 7.5.8. “Disassembling the front guard”. 1. Unscrew the screw a using a 4-gauge

hexagonal T-wrench. 2. Open the cover of the ELECTRICAL BOX. 3. Disconnect the cable connectors c. 4. Unscrew the 4 nuts b (2 on each side) using a

10-gauge tube wrench. 5. Remove the ELECTRICAL BOX. To reassemble the ELECTRICAL BOX, follow the above steps in reverse order.


Page 7.179


Figure 7.5.10-1




Page 7.180






Page 7.181

7.5.11. DISASSEMBLING THE UPRIGHT GUARD

Figure 7.5.11-1

Follow the steps described in paragraphs 7.5.7. “Removing the seat” and 7.5.8. “Disassembling the front guard”. For each side: 1. Remove the 2 caps a of the GUARD using a

small flat screwdriver. 2. Unscrew the 2 screws under the 2 caps a

using a medium-sized Philips screwdriver. 3. Widening the sides slightly, remove the

UPRIGHT GUARD by sliding it upward. To reassemble the UPRIGHT GUARD, follow the above steps in reverse order.


Page 7.182


Figure 7.5.12-1

Follow the steps described in paragraphs 7.5.7. “Removing the seat”, 7.5.8. “Disassembling the front guard” and 7.5.11. “Disassembling the upright guard”. 1. Disconnect the connector from the motor

cable. 2. Unscrew the screw a and its nut using 2 17-

gauge wrenches. 3. Unscrew the screw b and its nut using 2 17-

gauge wrenches. 4. Remove the MOTOR SEAT. To reassemble the SEAT MOTOR, follow the above steps in reverse order.


Page 7.183

7.5.13. DISASSEMBLING THE PRESTART CABLE

Figure 7.5.13-1

Follow the steps described in paragraphs 7.5.7. “Removing the seat”, 7.5.8. “Disassembling the front guard” and 7.5.11. “Disassembling the upright guard”. 1. Unscrew the 2 screws a using a 5-gauge

hexagonal T-wrench for each side. 2. Remove the guard b.

Figure 7.5.13-2

3. Loosen the nut c to loosen the tension of the PRESTART CABLE.



Page 7.184

Figure 7.5.13-3

4. Unscrew the 3 dowels d using a 4-gauge

hexagonal T-wrench. 5. Remove the MAIN PRESTART CABLE

with the aid of a pair of pliers. 6. Slide the MAIN PRESTART CABLE out the

front of the machine. For each part of the SECONDARY PRESTART CABLE: 7. Unscrew the 3 dowels e, using a 4-gauge

hexagonal T-wrench. 8. Remove the SECONDARY PRESTART

CABLE with the aid of a pair of pliers. 9. Remove the SECONDARY PRESTART

CABLE by sliding it out of the coupling element.

To reassemble the PRESTART CABLE, follow the above steps in reverse order.

When the operation is complete, adjust the PRESTART CABLE tension as described in paragraphs 8.5..


Page 7.185

7.5.14. DISASSEMBLING THE REAR GUARD

Figure 7.5.14-1


For each side of the weight stack: 2. Remove the 2 caps a of the GUARD using a



REAR GUARD by raising it slightly, then sliding it down.

To reassemble the REAR GUARDS, follow the above steps in reverse order.


Page 7.186


Figure 7.5.15-1

Follow the steps described in paragraph 7.5.11. “Disassembling the upright guard” or 7.5.14. “Disassembling the rear guard”. 1. Disconnect the connector a from the solenoid

cable. 2. Unscrew the 2 screws b using a 5-gauge




Page 7.187


Figure 7.5.16-1

Follow the steps described in paragraph 7.5.11. “Disassembling the upright guard” or 7.5.14. “Disassembling the rear guard”. 1. Switch the machine on. 2. Follow the steps described in paragraph 9.2






Page 7.188


Figure 7.5.17-1

Follow the steps described in paragraph 7.5.14. “Disassembling the rear guard”. 1. Using 2 22-gauge wrenches, loosen the

counter-nut a, then unscrew the screw b of the WEIGHT STACK CABLE terminal until it is free of the cross.

Figure 7.5.17-2






Page 7.189

7.5.18. DISASSEMBLING THE PULLEYS

Figure 7.5.18-1

Follow the steps described in paragraph 7.5.14. “Disassembling the rear guard”. For each PULLEY: 1. Unscrew the screw a and the nut b using 2





Page 7.190


Figure 7.5.19-1

Follow the steps described in paragraphs 7.5.14. “Disassembling the rear guard” and 7.5.18. “Disassembling the pulleys”. 1. Loosen the counter-nut a using a 13-gauge




Page 7.191


Figure 7.5.20-1

Follow the steps described in paragraphs 7.5.11. “Disassembling the upright guard” and 7.5.14. “Disassembling the rear guard”. 1. Use a 17-gauge wrench to unscrew the 2

screws a. 2. Lift the rear pulley group.

Figure 7.5.20-2

3. Unscrew the 2 screws b using a 17-gauge wrench.

4. Unscrew the screw c using a 4-gauge

hexagonal T-wrench. 5. Remove the transverse support plate d. 6. Disconnect the zero sensor cable.



Page 7.192

Figure 7.5.20-3

Working on the inner part of the weight stack: 7. Cut the clamp e and disconnect the connector

f of the weight stack motor cable. 8. Loosen the 4 nuts g using a 4-gauge universal






Page 7.193


Figure 7.5.21-1








Page 7.194


Figure 7.5.22-1






Page 7.195

7.5.23. DISASSEMBLING THE REAR LEVER GUARD

Figure 7.5.23-1


For each side of the weight stack: 2. Remove the cap a of the GUARD using a

small flat screwdriver. 3. Unscrew the 5 screws b, one of which is

under the cap a, using a medium-sized Philips screwdriver.

4. Slide the REAR LEVER GUARD out. To reassemble the REAR LEVER GUARDS, follow the above steps in reverse order.


Page 7.196

7.5.24. DISASSEMBLING THE LEVER CABLE

Figure 7.5.24-1

Follow the steps described in paragraphs 7.5.14. “Disassembling the rear guard” and 7.5.23. “Disassembling the rear lever guard”. For each lever group: 1. Loosen the 2 dowels a, using a 4-gauge

hexagonal T-wrench. 2. Remove the LEVER CABLE with the aid of

a pair of pliers. 3. Remove the LEVER CABLE by sliding it out

of the pulleys. To reassemble the LEVER CABLE, follow the above steps in reverse order.

When the operation is complete, adjust the tension of the LEVER CABLE and the lever position as described in paragraphs 8.6. and 8.5. .


Page 7.197

7.5.25. DISASSEMBLING THE CAM GROUP

Figure 7.5.25-1

Follow the steps described in paragraphs 7.5.14. “Disassembling the rear guard”, 7.5.23. “Disassembling the rear lever guard” and 7.5.24. “Disassembling the lever cable”. For each CAM GROUP: 1. Unscrew the 3 nuts a using a 13-gauge tube

wrench. 2. Remove the counter-weight.

Hold the counter-weight up before unscrewing the last nut.

3. Loosen the screw b using a 6-gauge

hexagonal T-wrench. 4. Use a 30-gauge Allen wrench to unscrew the

ring-nut c. 5. Remove the CAM GROUP. 6. To separate the cam from the hub, unscrew

the 3 screws d using a 6-gauge hexagonal T-wrench.

To reassemble the LEVER CABLE, follow the above steps in reverse order.

When the operation is complete, adjust the position of the levers as described in paragraph 8.2. .


Page 7.198

7.5.26. DISASSEMBLING THE LEVERS

Figure 7.5.26-1


Working first on the LEFT LEVER and then on the RIGHT LEVER: 2. Unscrew the cap a using a 6-gauge hexagonal

T-wrench.

Figure 7.5.26-2

3. Unscrew the screw b using a 17-gauge tube wrench.

4. Remove the washer. 5. Use the extractor provided in the machine

service box to remove the LEVER, tightening the extractor screw using a 24-gauge wrench.

To reassemble the LEVERS, working first on the RIGHT LEVER and then on the LEFT LEVER: 1. Insert the lever on the shaft, making sure that

the key is inserted in the slot provided on the LEVER.

2. Push the LEVER all the way down with a rubber hammer.

3. Insert and tighten the screws removed previously.



Page 7.199

7.5.27. DISASSEMBLING THE FRONT LEVER GUARD

Figure 7.5.27-1

Follow the steps described in paragraphs 7.5.23. “Disassembling the rear lever guard” and 7.5.26. “Disassembling the levers”. For each side of the weight stack: 1. Remove the cap a of the GUARD using a



3. Slide the FRONT LEVER GUARD out. To reassemble the FRONT LEVER GUARD, follow the above steps in reverse order.


Page 7.200


Figure 7.5.28-1


2. Use a 3-gauge hexagonal T-wrench to

unscrew the 2 screws a on both the front and back.

3. Remove the Plexiglas cover.

Figure 7.5.28-2

4. Unscrew the 6 screws a using an 8-gauge hexagonal T-wrench.

5. Remove the WEIGHT STACK COVER by sliding it upwards.



Page 7.201

7.5.29. DISASSEMBLING THE COLUMN EXTENSION

Figure 7.5.29-1

Follow the steps described in paragraphs 7.5.23. “Disassembling the rear lever guard”, 7.5.26. 7.5.27. Disassembling the front lever guard” and 7.5.28. “Disassembling the weight stack cover”. For each side of the weight stack: 1. Use a 6-gauge T-wrench to unscrew the 2

screws a. 2. Remove the COLUMN EXTENSION. To reassemble COLUMN EXTENSION, follow the above steps in reverse order.


Page 7.202

7.5.30. DISASSEMBLING THE COLUMNS

Figure 7.5.30-1

Follow the steps described in paragraphs 7.5.23. “Disassembling the rear lever guard”, 7.5.26. 7.5.27. Disassembling the front lever guard”, 7.5.28. “Disassembling the weight stack cover” and 7.5.29. “Disassembling the column extension.” For each column: 1. Use an 8-gauge T-wrench to unscrew the 2

screws a. 2. Remove the COLUMN by bending it down.

When removing the first column, make sure that the additional weight does not tip over, since it is held in place by the two columns.

To reassemble the COLUMN, follow the above steps in reverse order.

To reassemble the column, make sure that the dowels on its base are inserted in the holes provided on the frame base.


Page 7.203


Figure 7.5.31-1

Follow the steps described in paragraph 7.5.30. “Disassembling the columns” limited solely to the right-hand column. 1. Remove the ADDITIONAL WEIGHT a by

sliding it out from the side.



To reassemble the additional weight, make sure that it locks into the grooves provided in the columns.


Page 7.204


Figure 7.5.32-1

Follow the steps described in paragraph 7.5.30. “Disassembling the columns” limited solely to the right-hand column. 1. Release the slot a of the ENCODER wire

from the hook.

Figure 7.5.32-2


3. Cut the clamp c. 4. Disconnect the connector d from the encoder

cable. 5. Unscrew the 3 screws e using a 3-gauge

hexagonal T-wrench. 6. Remove the ENCODER.




Page 7.205


Figure 7.5.33-1

Follow the steps described in paragraphs 7.5.23. “Disassembling the rear lever guard”, 7.5.26. 7.5.27. Disassembling the front lever guard”, 7.5.28. “Disassembling the weight stack cover” and 7.5.29. “Disassembling the column extension.”. For each of the 2 counter-weight vibration bars: 1. Unscrew the 2 dowels a, using a 4-gauge

hexagonal T-wrench.


2. Rest the BAR on the floor. 3. Remove the rubber holding the BAR in

place. 4. Remove the BAR by sliding it upward.

To remove the bar, it may be necessary to bend the encoder support slat.

To reassemble the BARS, follow the above steps in reverse order


Page 7.206

7.5.34. DISASSEMBLING THE CROSS AND WEIGHT STACK PLATES

Figure 7.5.34-1

Follow the steps described in paragraph 7.5.30. “Disassembling the columns” limited solely to the right-hand column. 1. Select the minimum weight (5 Kg or 10 lbs.). For each bar: 2. Loosen the dowel a using a 4-gauge

hexagonal T-wrench. 3. Remove the counter-weight. 4. Disconnect the solenoid cable connector. 5. Unhook the encoder cable.

Figure 7.5.34-2

6. Raise the CROSS until the cross sinker is released from the WEIGHT STACK PLATES, and lock in this position.

Follow the steps described in paragraph 7.5.33. “Disassembling the bars”. 7. Remove the CROSS and WEIGHT STACK

PLATES by sliding them out from the side.

Make sure the stack of PLATES does not tip over.

To reassemble the CROSS and WEIGHT STACK PLATES, follow the above steps in reverse order.


Page 7.207


Figure 7.5.35-1

Follow the steps described in paragraph 7.5.34. “Disassembling the cross and weight stack plates”. 1. Place the cross on a bench or flat surface. 2. Unscrew the 2 screws a using an 8-gauge




Page 7.208

7.5.36. DISASSEMBLING THE MATS

Figure 7.5.36-1

1. Shut off the equipment and unplug the power

cord from the wall socket. For each side: 2. Use a large, flat screwdriver to release the 3

pressure fasteners A holding the LARGE MAT against the frame.

3. Remove the LARGE MAT by pulling it upward.


pressure fasteners B holding the CORNER MAT against the frame.

5. Remove the CORNER MAT by pulling it upward.

To reassemble the MATS, rest them on the frame and press down at the fastening points.


Page 7.209

7.5.37. DISASSEMBLING THE DISPLAY SUPPORT

Figure 7.5.37-1

Follow the steps described in paragraph 7.5.36. “Disassembling the mats” only for the large right-hand mat. 1. Disconnect the connectors a. 2. Unscrew the 4 screws b using a 6-gauge

hexagonal T-wrench. 3. Remove the DISPLAY SUPPORT; be

careful with the previously disconnected cables.

To reassemble the DISPLAY SUPPORT, follow the above steps in reverse order.


Page 7.210


Figure 7.5.38-1

Follow the steps described in paragraph 7.5.36. “Disassembling the mats”. 1. Unscrew the screw a using a 4-gauge







Page 7.211


Figure 7.5.39-1

Follow the steps described in paragraphs 7.5.7. “Removing the seat”, 7.5.8. “Disassembling the front guard” and 7.5.11. “Disassembling the upright guard”. 1. Loosen the 2 screws a using a 5-gauge





Page 7.212

7.6. SHOULDER PRESS


Figure 7.6.1-1





Figure 7.6.1-2

3. Open the DISPLAY. To remove the DISPLAY: 1. Disconnect the connectors b. 2. Remove the DISPLAY. To reassemble the display, follow the above steps in reverse order.


Page 7.213


Figure 7.6.2-1












Page 7.214




Page 7.215


Figure 7.6.3-1



Figure 7.6.3-2









Page 7.216


Figure 7.6.4-1



Figure 7.6.4-2







Page 7.217


Figure 7.6.5-1


KEYBOARD.

Figure 7.6.5-2









Page 7.218


Figure 7.6.6-1


KEYBOARD.

Figure 7.6.6-2









Page 7.219


Figure 7.6.7-1





Page 7.220


Figure 7.6.8-1









Page 7.221


Figure 7.6.9-1

Follow the steps described in paragraph 7.6.8. “Disassembling the front guard”. 1. Unscrew the screw a using a 4-gauge

hexagonal T-wrench. 2. Open the cover of the ELECTRICAL BOX. 3. Disconnect the cable connectors c. 4. Unscrew the 4 nuts b (2 on each side) using a



Page 7.222


Figure 7.6.10-1




Page 7.223






Page 7.224


Figure 7.6.11-1

Follow the steps described in paragraphs 7.6.7. “Removing the seat” and 7.6.8. “Disassembling the front guard”. For each side: 1. Remove the 2 caps a of the GUARD using a





Page 7.225


Figure 7.6.12-1

Follow the steps described in paragraphs 7.6.7. “Removing the seat”, 7.6.8. “Disassembling the front guard” and 7.6.11. “Disassembling the upright guard”. 1. Disconnect the connector from the motor





Page 7.226


Figure 7.6.13-1

Follow the steps described in paragraphs 7.6.7. “Removing the seat”, 7.6.8. “Disassembling the front guard” and 7.6.11. “Disassembling the upright guard”. 1. Unscrew the 2 screws a using a 5-gauge


Figure 7.6.13-2




Page 7.227

Figure 7.6.13-3


hexagonal T-wrench. 5. Remove the MAIN PRESTART CABLE

with the aid of a pair of pliers. 6. Slide the MAIN PRESTART CABLE out the

front of the machine. For each part of the SECONDARY PRESTART CABLE: 7. Unscrew the 3 dowels e, using a 4-gauge

hexagonal T-wrench. 8. Remove the SECONDARY PRESTART

CABLE with the aid of a pair of pliers. 9. Remove the SECONDARY PRESTART

CABLE by sliding it out of the coupling element.

To reassemble the PRESTART CABLE, follow the above steps in reverse order.

When the operation is complete, adjust the PRESTART CABLE tension as described in paragraphs 8.5..


Page 7.228


Figure 7.6.14-1


For each side of the weight stack: 2. Remove the 2 caps a of the GUARD using a



REAR GUARD by raising it slightly, then sliding it down.

To reassemble the REAR GUARDS, follow the above steps in reverse order.


Page 7.229


Figure 7.6.15-1

Follow the steps described in paragraph 7.6.11. “Disassembling the upright guard” or 7.6.14. “Disassembling the rear guard”. 1. Disconnect the connector a from the solenoid





Page 7.230


Figure 7.6.16-1

Follow the steps described in paragraph 7.6.11. “Disassembling the upright guard” or 7.6.14. “Disassembling the rear guard”. 1. Switch the machine on. 2. Follow the steps described in paragraph 9.2






Page 7.231


Figure 7.6.17-1

Follow the steps described in paragraph 7.6.14. “Disassembling the rear guard”. 1. Using 2 22-gauge wrenches, loosen the


Figure 7.6.17-2






Page 7.232


Figure 7.6.18-1

Follow the steps described in paragraph 7.6.14. “Disassembling the rear guard”. For each PULLEY: 1. Unscrew the screw a and the nut b using 2





Page 7.233


Figure 7.6.19-1

Follow the steps described in paragraphs 7.6.14. “Disassembling the rear guard” and 7.6.18. “Disassembling the pulleys”. 1. Loosen the counter-nut a using a 13-gauge




Page 7.234


Figure 7.6.20-1

Follow the steps described in paragraphs 7.6.11. “Disassembling the upright guard” and 7.6.14. “Disassembling the rear guard”. 1. Use a 17-gauge wrench to unscrew the 2

screws a. 2. Lift the rear pulley group.

Figure 7.6.20-2


4. Unscrew the screw c using a 4-gauge

hexagonal T-wrench. 5. Remove the transverse support plate d. 6. Disconnect the zero sensor cable.



Page 7.235

Figure 7.6.20-3

Working on the inner part of the weight stack: 7. Cut the clamp e and disconnect the connector

f of the weight stack motor cable. 8. Loosen the 4 nuts g using a 4-gauge universal






Page 7.236


Figure 7.6.21-1








Page 7.237


Figure 7.6.22-1






Page 7.238

7.6.23. DISASSEMBLING THE REAR LEVER GUARD

Figure 7.6.23-1


For each side of the weight stack: 2. Remove the cap a of the GUARD using a



4. Slide the REAR LEVER GUARD out. To reassemble the REAR LEVER GUARDS, follow the above steps in reverse order.


Page 7.239


Figure 7.6.24-1

Follow the steps described in paragraphs 7.6.14. “Disassembling the rear guard” and 7.6.23. “Disassembling the rear lever guard”. For each lever group: 1. Loosen the 2 dowels a, using a 4-gauge




When the operation is complete, adjust the tension of the LEVER CABLE and the lever position as described in paragraphs 8.6. and 8.2. .


Page 7.240


Figure 7.6.25-1

Follow the steps described in paragraphs 7.6.14. “Disassembling the rear guard”, 7.6.23. “Disassembling the rear lever guard” and 7.6.24. “Disassembling the lever cable”. For each CAM GROUP: 1. Unscrew the 3 nuts a using a 13-gauge tube

wrench. 2. Remove the counter-weight.

Hold the counter-weight up before unscrewing the last nut.

3. Loosen the screw b using a 6-gauge

hexagonal T-wrench. 4. Use a 30-gauge Allen wrench to unscrew the

ring-nut c. 5. Remove the CAM GROUP. 6. To separate the cam from the hub, unscrew

the 3 screws d using a 6-gauge hexagonal T-wrench.

To reassemble the LEVER CABLE, follow the above steps in reverse order.



Page 7.241


Figure 7.6.26-1


Working first on the LEFT LEVER and then on the RIGHT LEVER: 2. Unscrew the cap a using a 6-gauge hexagonal

T-wrench.

Figure 7.6.26-2










Page 7.242

7.6.27. DISASSEMBLING THE FRONT LEVER GUARD

Figure 7.6.27-1

Follow the steps described in paragraphs 7.6.23. “Disassembling the rear lever guard” and 7.6.26. “Disassembling the levers”. For each side of the weight stack: 1. Remove the cap a of the GUARD using a



3. Slide the FRONT LEVER GUARD out. To reassemble the FRONT LEVER GUARD, follow the above steps in reverse order.


Page 7.243


Figure 7.6.28-1


2. Use a 3-gauge hexagonal T-wrench to

unscrew the 2 screws a on both the front and back.

3. Remove the Plexiglas cover.

Figure 7.6.28-2

4. Unscrew the 8 screws a using a 6-gauge hexagonal T-wrench.

5. Remove the WEIGHT STACK COVER by sliding it upwards.



Page 7.244

7.6.29. DISASSEMBLING THE COLUMN EXTENSION

Figure 7.6.29-1

Follow the steps described in paragraphs 7.6.23. “Disassembling the rear lever guard”, 7.6.26. “Disassembling the levers”, 7.6.27. “Disassembling the front lever guard” and 7.6.28. “Disassembling the weight stack cover”. For each side of the weight stack: 1. Use a 6-gauge T-wrench to unscrew the 2

screws a. 2. Remove the COLUMN EXTENSION. To reassemble COLUMN EXTENSION, follow the above steps in reverse order.


Page 7.245

7.6.30. DISASSEMBLING THE COLUMNS

Figure 7.6.30-1

Follow the steps described in paragraphs 7.6.23. “Disassembling the rear lever guard”, 7.6.26. “Disassembling the levers”, 7.6.27. “Disassembling the front lever guard”, 7.6.28. “Disassembling the weight stack cover” and 7.6.29. “Disassembling the column extension”. For each column: 1. Use an 8-gauge T-wrench to unscrew the 2

screws a. 2. Remove the COLUMN by bending it down.

When removing the first column, make sure that the additional weight does not tip over, since it is held in place by the two columns.

To reassemble the COLUMN, follow the above steps in reverse order.

To reassemble the column, make sure that the dowels on its base are inserted in the holes provided on the frame base.


Page 7.246


Figure 7.6.31-1

Follow the steps described in paragraph 7.6.30. “Disassembling the columns” limited solely to the right-hand column. 1. Remove the ADDITIONAL WEIGHT a by

sliding it out from the side.



To reassemble the additional weight, make sure that it locks into the grooves provided in the columns.


Page 7.247


Figure 7.6.32-1

Follow the steps described in paragraph 7.6.30. “Disassembling the columns” limited solely to the right-hand column. 1. Release the slot a of the ENCODER wire

from the hook.

Figure 7.6.32-2


3. Cut the clamp c. 4. Disconnect the connector d from the encoder

cable. 5. Unscrew the 3 screws e using a 3-gauge

hexagonal T-wrench. 6. Remove the ENCODER.




Page 7.248


Figure 7.6.33-1

Follow the steps described in paragraphs 7.6.23. “Disassembling the rear lever guard”, 7.6.26. “Disassembling the levers”, 7.6.27. “Disassembling the front lever guard”, 7.6.28. “Disassembling the weight stack cover” and 7.6.29. “Disassembling the column extension”. For each of the 2 counter-weight vibration bars: 1. Unscrew the 2 dowels a, using a 4-gauge

hexagonal T-wrench.


2. Rest the BAR on the floor. 3. Remove the rubber holding the BAR in

place. 4. Remove the BAR by sliding it upward.

To remove the bar, it may be necessary to bend the encoder support slat.

To reassemble the BARS, follow the above steps in reverse order


Page 7.249

7.6.34. DISASSEMBLING THE CROSS AND WEIGHT STACK PLATES

Figure 7.6.34-1

Follow the steps described in paragraph 7.6.30. “Disassembling the columns” limited solely to the right-hand column. 1. Select the minimum weight (5 Kg or 10 lbs.). For each bar: 2. Disconnect the solenoid cable connector. 3. Unhook the encoder cable. 4. 5. Raise the CROSS until the cross sinker is

released from the WEIGHT STACK PLATES, and lock in this position.

Follow the steps described in paragraph 7.6.33. “Disassembling the bars”. 6. Remove the CROSS and WEIGHT STACK

PLATES by sliding them out from the side.

Make sure the stack of PLATES does not tip over.

To reassemble the CROSS and WEIGHT STACK PLATES, follow the above steps in reverse order.


Page 7.250


Figure 7.6.35-1

Follow the steps described in paragraph 7.6.34. “Disassembling the cross and weight stack plates”. 1. Place the cross on a bench or flat surface. 2. Unscrew the 2 screws a using an 8-gauge




Page 7.251


Figure 7.6.36-1


cord from the wall socket. For each side: 2. Use a large, flat screwdriver to release the 3

pressure fasteners A holding the LARGE MAT against the frame.

3. Remove the LARGE MAT by pulling it upward.


pressure fasteners B holding the CORNER MAT against the frame.

5. Remove the CORNER MAT by pulling it upward.

To reassemble the MATS, rest them on the frame and press down at the fastening points.


Page 7.252


Figure 7.6.37-1

Follow the steps described in paragraph 7.6.36. “Disassembling the mats” only for the large right-hand mat. 1. Disconnect the connectors a. 2. Unscrew the 4 screws b using a 6-gauge





Page 7.253


Figure 7.6.38-1

Follow the steps described in paragraph 7.6.36. “Disassembling the mats”. 1. Unscrew the screw a using a 4-gauge







Page 7.254


Figure 7.6.39-1

Follow the steps described in paragraphs 7.6.7. “Removing the seat”, 7.6.8. “Disassembling the front guard” and 7.6.11. “Disassembling the upright guard”. 1. Loosen the 2 screws a using a 5-gauge





Page 7.255

7.7. CHEST PRESS


Figure 7.7.1-1





Figure 7.7.1-2



Page 7.256


Figure 7.7.2-1












Page 7.257




Page 7.258


Figure 7.7.3-1



Figure 7.7.3-2









Page 7.259


Figure 7.7.4-1



Figure 7.7.4-2







Page 7.260


Figure 7.7.5-1


KEYBOARD.

Figure 7.7.5-2









Page 7.261


Figure 7.7.6-1


KEYBOARD.

Figure 7.7.6-2









Page 7.262

7.7.7. DISASSEMBLING THE REAR PLEXIGLAS WEIGHT STACK GUARD

Figure 7.7.7-1




Figure 7.7.7-2




Page 7.263

7.7.8. DISASSEMBLING THE FRONT PLEXIGLAS WEIGHT STACK GUARD

Figure 7.7.8-1




Figure 7.7.8-2




Page 7.264

7.7.9. DISASSEMBLING THE WEIGHT STACK PULLEY

Figure 7.7.9-1

Follow the steps described in paragraph 7.7.7. “Disassembling the rear Plexiglas weight stack guard”. 1. Unscrew the screw a and the nut b using 2

17-gauge wrenches. 2. Remove the PULLEY. To replace the PULLEY, follow the above steps in reverse order.

For easier disassembly and reassembly of the PULLEY, it may be necessary to loosen the cable tension.



Page 7.265


Figure 7.7.10-1

Follow the steps described in paragraphs 7.7.7. “Disassembling the rear Plexiglas weight stack guard” and 7.7.8. “Disassembling the front plexiglas weight stack guard”. 1. Cut the clamp a.

Figure 7.7.10-2


solenoid cable.



Page 7.266

Figure 7.7.10-3




Figure 7.7.10-4






Page 7.267


Figure 7.7.11-1


sliding it upward.




Page 7.268


Figure 7.7.12-1

Follow the steps described in paragraph 7.7.7. “Disassembling the rear Plexiglas weight stack guard”. 1. Release the slot a of the ENCODER wire

from the hook.

Figure 7.7.12-2







Page 7.269


Figure 7.7.13-1

Follow the steps described in paragraph 7.7.7. “Disassembling the rear Plexiglas weight stack guard”. 1. Disconnect the connector a from the





Page 7.270


Figure 7.7.14-1

Follow the steps described in paragraph 7.7.7. “Disassembling the rear Plexiglas weight stack guard”. 1. Switch the machine on. 2. Follow the steps described in paragraph 9.2






Page 7.271


Figure 7.7.15-1

Follow the steps described in paragraph 7.7.7. “Disassembling the rear Plexiglas weight stack guard”. 1. Loosen the counter-nut a using a 13-gauge




Page 7.272


Figure 7.7.16-1





Page 7.273


Figure 7.7.17-1

Follow the steps described in paragraph 7.7.16. “Removing the seat”. For each side: 1. Remove the 3 caps a of the GUARD using a





Page 7.274

7.7.18. DISASSEMBLING THE CLOSING PANELS

Figure 7.7.18-1

Follow the steps described in paragraph 7.7.17. “Disassembling the upright guard”. For each side: 1. Use a medium-sized Philips screwdriver to

unscrew the 3 screws a. 2. Remove the CLOSING PANEL. To reassemble the CLOSING PANEL, follow the above steps in reverse order.


Page 7.275


Figure 7.7.19-1

Follow the steps described in paragraphs 7.7.7. “Disassembling the rear Plexiglas weight stack guard”, 7.7.15. “Disassembling the zero sensor” and 7.7.17. “Disassembling the upright guard”. Working on the outer part of the weight stack: 1. Unscrew the screw a using a 4-gauge



Figure 7.7.19-2

Working on the inner part of the weight stack: 4. Cut the clamp c and disconnect the connector







Page 7.276


Figure 7.7.20-1








Page 7.277


Figure 7.7.21-1






Page 7.278


Figure 7.7.22-1






Page 7.279


Figure 7.7.23-1





Page 7.280


Figure 7.7.24-1





Page 7.281


Figure 7.7.25-1




Page 7.282


Figure 7.7.26-1


hexagonal T-wrench.




Page 7.283


Figure 7.7.27-1

Follow the steps described in paragraph 7.7.17. “Disassembling the upright guard”. 1. Disconnect the connector from the motor





Page 7.284


Figure 7.7.28-1

Follow the steps described in paragraph 7.7.17. “Disassembling the upright guard”. 1. Unscrew the screw a using a 4-gauge

hexagonal T-wrench. 2. Open the cover of the ELECTRICAL BOX. 3. Disconnect the cable connectors b. 4. For each side, unscrew the 2 nuts c using a



Page 7.285


Figure 7.7.29-1

Follow the steps described in paragraph 7.7.28. “Disassembling the electrical box”. With the electrical box resting on a bench: To disassemble the POWER SUPPLY a: 1. Disconnect the 2 connectors. 2. Disconnect the 4 plastic coupling elements. 3. Remove the card. To disassemble the FPGA BOARD b: 1. Disconnect the 4 connectors. 2. Disconnect the 4 plastic coupling elements. 3. Remove the card. To disassemble the IMP BOARD c: 1. Lift the board. 2. Disconnect the 2 connectors. 3. Disconnect the 4 plastic coupling elements. 4. Remove the card. To disassemble the IMS BOARD d: 1. Lift the board. 2. Disconnect the 2 connectors. 3. Disconnect the 4 plastic coupling elements. 4. Remove the card. To disassemble the IEM BOARD e: 1. Lift the board. 2. Disconnect the 2 connectors. 3. Disconnect the 4 plastic coupling elements. 4. Remove the card.



Page 7.286






Page 7.287


Figure 7.7.30-1

Follow the steps described in paragraph 7.7.17. “Disassembling the upright guard”. For type A pulleys: 1. Unscrew the screw a and the nut using 2 17-

gauge wrenches. 2. Remove the pulley. For type B pulleys: 3. Unscrew the screw b using an 8-gauge

hexagonal T-wrench. 4. Remove the washer and cable lock. 5. Remove the pulley. To reassemble the PULLEYS, follow the above steps in reverse order.


Page 7.288


Figure 7.7.31-1

Follow the steps described in paragraphs 7.7.7. “Disassembling the rear Plexiglas weight stack guard” and 7.7.17. “Disassembling the upright guard”. 1. Using 2 22-gauge wrenches, loosen the


Figure 7.7.31-2






Page 7.289


Figure 7.7.32-1

Follow the steps described in paragraphs 7.7.17. “Disassembling the upright guard” and 7.7.30. “Disassembling the pulleys” limited only to the pulleys on which the cable runs. 1. For each arm, unscrew the screw a using a

17-gauge wrench. 2. Remove the LEVER CABLE. To reassemble the LEVER CABLE, follow the above steps in reverse order.

When the operation is complete, adjust the LEVER CABLE tension as described in paragraph 8.6. .


Page 7.290

7.7.33. DISASSEMBLING THE DOUBLING CABLE

Figure 7.7.33-1

Follow the steps described in paragraph 7.7.17. “Disassembling the upright guard” and 7.7.30. “Disassembling the pulleys” limited only for the pulley whose support is connected to the DOUBLING CABLE. 1. Unscrew the 2 dowels a, using a 4-gauge

hexagonal T-wrench. 2. Remove the DOUBLING CABLE with the

aid of a pair of pliers. 3. Slide the DOUBLING CABLE from the

pulley support. To reassemble the DOUBLING CABLE, follow the above steps in reverse order.

When the operation is complete, adjust the DOUBLING CABLE tension as described in paragraph 8.7. .


Page 7.291


Figure 7.7.34-1

Follow the steps described in paragraphs 7.7.17. “Disassembling the upright guard”, 7.7.31. “Disassembling the weight stack cable” and 7.7.33. “Disassembling the doubling cable”. For each side: 1. Turn the cam until you can see the 2 dowels

a, which must be loosened using a 3-gauge hexagonal T-wrench.


3. Remove the bearing c. 4. Remove the CAM GROUP and place it on a

bench.

Figure 7.7.34-2

With the CAM GROUP on the bench: 5. Unscrew the screw d fastening the hub to the

shaft, using an 8-gauge hexagonal T-wrench. 6. Unscrew the 3 screws e using a 6-gauge

hexagonal T-wrench. 7. Separate the components. To reassemble the CONNECTOR CABLE, follow the above steps in reverse order.

When the operation is complete, adjust the tension of the weight stack cable, and the phasing of the cam and lever mechanism, as described in paragraphs 8.4. and 8.2. .


Page 7.292


Figure 7.7.35-1









Page 7.293


Figure 7.7.36-1

Follow the steps described in paragraph 7.7.35. “Disassembling the front guard”. 1. Unscrew the 2 screws a using a 5-gauge


Figure 7.7.36-2




Page 7.294

Figure 7.7.36-3


hexagonal T-wrench. 5. Remove the PRESTART CABLE with the

aid of a pair of pliers. 6. Slide the PRESTART CABLE out the front

of the machine. To reassemble the PRESTART CABLE, follow the above steps in reverse order.

When the operation is complete, adjust the PRESTART CABLE tension as described in paragraph 8.5. .


Page 7.295


Figure 7.7.37-1

Follow the steps described in paragraph 7.7.35. “Disassembling the front guard”. 1. Select the minimum weight. 2. Shut off the equipment and unplug the power

cord from the wall socket. For each LEVER: 3. Raise the LEVER slightly and unscrew the

screw a using a 17-gauge wrench.

Figure 7.7.37-2

4. Unscrew the screw b using a 17-gauge wrench.


6. Remove the 2 clamps d blocking the LEVER.

7. Remove the LEVER. 8. With the LEVER resting on the bench, you

may also work on the 2 oblique bearings. To reassemble the LEVERS, follow the above steps in reverse order



Page 7.296


Figure 7.7.38-1


cord from the wall socket. For each MAT: 2. Use a large, flat screwdriver to release the 3


3. Remove the MAT by pulling it upward. To reassemble the MATS, rest them on the frame and press down at the 3 fastening points.


Page 7.297


Figure 7.7.39-1

Follow the steps described in paragraph 7.7.38. “Disassembling the mats” only for the right-hand mat. 1. Disconnect the connectors a. 2. Unscrew the 4 screws b using a 6-gauge





Page 7.298


Figure 7.7.40-1

1. Select the minimum weight. 2. Shut off the equipment and unplug the power

cord from the wall socket. Follow the steps described in paragraph 7.7.38. “Disassembling the mats” only for the right-hand mat. 3. Raise the right lever slightly. 4. Unscrew the screw a using a 4-gauge







Page 7.299


Figure 7.7.41-1

Follow the steps described in paragraph 7.7.17. “Disassembling the upright guard”. 1. Loosen the 2 screws a using a 5-gauge





Page 7.300

7.8. ROWING TORSO


Figure 7.8.1-1





Figure 7.8.1-2



Page 7.301


Figure 7.8.2-1












Page 7.302




Page 7.303


Figure 7.8.3-1



Figure 7.8.3-2









Page 7.304


Figure 7.8.4-1



Figure 7.8.4-2







Page 7.305


Figure 7.8.5-1


KEYBOARD.

Figure 7.8.5-2









Page 7.306


Figure 7.8.6-1


KEYBOARD.

Figure 7.8.6-2









Page 7.307

7.8.7. DISASSEMBLING THE REAR PLEXIGLAS WEIGHT STACK GUARD

Figure 7.8.7-1




Figure 7.8.7-2




Page 7.308

7.8.8. DISASSEMBLING THE FRONT PLEXIGLAS WEIGHT STACK GUARD

Figure 7.8.8-1




Figure 7.8.8-2




Page 7.309

7.8.9. DISASSEMBLING THE WEIGHT STACK PULLEY

Figure 7.8.9-1

Follow the steps described in paragraph 7.8.7. “Disassembling the rear plexiglas weight stack guard”. 1. Unscrew the screw a and the nut b using 2

17-gauge wrenches. 2. Remove the PULLEY. To replace the PULLEY, follow the above steps in reverse order.

For easier disassembly and reassembly of the PULLEY, it may be necessary to loosen the cable tension.



Page 7.310


Figure 7.8.10-1

Follow the steps described in paragraphs 7.8.7. “Disassembling the rear plexiglas weight stack guard” and 7.8.8. “Disassembling the front plexiglas weight stack guard”. 1. Cut the clamp a.

Figure 7.8.10-2


solenoid cable.



Page 7.311

Figure 7.8.10-3




Figure 7.8.10-4






Page 7.312


Figure 7.8.11-1


sliding it upward.




Page 7.313


Figure 7.8.12-1

Follow the steps described in paragraph 7.8.7. “Disassembling the rear plexiglas weight stack guard”. 1. Release the slot a of the ENCODER wire

from the hook.

Figure 7.8.12-2







Page 7.314


Figure 7.8.13-1

Follow the steps described in paragraph 7.8.7. “Disassembling the rear plexiglas weight stack guard”. 1. Disconnect the connector a from the solenoid





Page 7.315


Figure 7.8.14-1

Follow the steps described in paragraph 7.8.7. “Disassembling the rear plexiglas weight stack guard”. 1. Switch the machine on. 2. Follow the steps described in paragraph 9.2






Page 7.316


Figure 7.8.15-1

Follow the steps described in paragraph 7.8.7. “Disassembling the rear plexiglas weight stack guard”. 1. Loosen the counter-nut a using a 13-gauge




Page 7.317


Figure 7.8.16-1


cord from the wall socket. For each MAT: 2. Use a large, flat screwdriver to release the 3


3. Remove the MAT by pulling it upward. To reassemble the MATS, rest them on the frame and press down at the 3 fastening points.


Page 7.318

7.8.17. DISASSEMBLING THE PRESTART LEVERS

Figure 7.8.17-1


cord from the wall socket. For each side of the machine: 2. Unscrew the screw a using a 10-gauge

hexagonal T-wrench. 3. Remove the PRESTART LEVER, holding

the metal panel b in place to keep it from falling.

Remove the metal panel from the slot on the vertical guard or, after removing the back of the vertical guard, from the open part.

To reassemble the PRESTART LEVERS, follow the above steps in reverse order


Page 7.319


Figure 7.8.18-1

Follow the steps described in paragraphs 7.8.8. “Disassembling the front plexiglas weight stack guard”, 7.8.16. “Disassembling the mats” and 7.8.17. “Disassembling the prestart levers”. 1. Select the minimum weight (5 Kg or 10 lbs.).2. Move the levers and block them in the

forward position. 3. Use a medium-sized Philips screwdriver to

unscrew the 2 screws a. 4. Remove the guard b.

Figure 7.8.18-2

5. Move the block c so that you can rotate the display upwards.



Page 7.320

Figure 7.8.18-3


unscrew the 6 screws d. 7. Remove the front portion of the UPRIGHT

GUARD. 8. Remove the 4 caps e (2 on each side) from

the GUARD using a small flat screwdriver. 9. Unscrew the 4 screws under the 4 caps e


UPRIGHT GUARD by sliding it upward and then to the right.

To reassemble the UPRIGHT GUARD, follow the above steps in reverse order.


Page 7.321


Figure 7.8.19-1

Follow the steps described in paragraph 7.8.7. “Disassembling the rear plexiglas weight stack guard”, 7.8.15. “Disassembling the zero sensor” and 7.8.18. “Disassembling the upright guard”. Working on the outer part of the weight stack: 1. Unscrew the screw a using a 4-gauge



Figure 7.8.19-2

Working on the inner part of the weight stack: 4. Cut the clamp c and disconnect the connector







Page 7.322


Figure 7.8.20-1








Page 7.323


Figure 7.8.21-1






Page 7.324


Figure 7.8.22-1






Page 7.325


Figure 7.8.23-1





Page 7.326


Figure 7.8.24-1





Page 7.327


Figure 7.8.25-1

Follow the steps described in paragraphs 7.8.23. “Disassembling the cross” and 7.8.24. “Disassembling the sinker”. 1. Remove the WEIGHT STACK PLATES by



Page 7.328


Figure 7.8.26-1


hexagonal T-wrench.

Hold the BAR up before unscrewing the last screw.



Page 7.329


Figure 7.8.27-1

Follow the steps described in paragraph 7.8.18. “Disassembling the upright guard”. 1. Unscrew the screw a using a 4-gauge

hexagonal T-wrench. 2. Open the cover of the ELECTRICAL BOX. 3. Disconnect the cable connectors c. 4. For each side, unscrew the 2 screws b using a



Page 7.330


Figure 7.8.28-1




Page 7.331






Page 7.332


Figure 7.8.29-1

Follow the steps described in paragraph 7.8.18. “Disassembling the upright guard”. For type A pulleys: 1. Unscrew the screw a and the nut using 2 17-

gauge wrenches. 2. Remove the pulley. For type B pulleys: 3. Unscrew the screw b using an 8-gauge

hexagonal T-wrench. 4. Remove the washer and cable lock. 5. Remove the pulley. To reassemble the PULLEYS, follow the above steps in reverse order.


Page 7.333


Figure 7.8.30-1

Follow the steps described in paragraphs 7.8.7. “Disassembling the rear plexiglas weight stack guard” and 7.8.18. Disassembling the upright guard”. 1. Using 2 22-gauge wrenches, loosen the


Figure 7.8.30-2






Page 7.334


Figure 7.8.31-1

Follow the steps described in paragraph 7.8.18. “Disassembling the upright guard”. 1. Unscrew the 2 dowels a, using a 4-gauge

hexagonal T-wrench. 2. Remove the DOUBLING CABLE with the

aid of a pair of pliers. 3. Unscrew the screw b, and the nut c using 2

22-gauge wrenches. 4. Remove the DOUBLING CABLE by sliding

it out of the pulleys. To disassemble the joint: 1. Unscrew the screw d using a 17-gauge

wrench. 2. Remove the joint. To reassemble the DOUBLING CABLE, follow the above steps in reverse order.



Page 7.335


Figure 7.8.32-1

Follow the steps described in paragraph 7.8.18. “Disassembling the upright guard”, 7.8.30. “Disassembling the weight stack cable”, 7.8.31. “Disassembling the doubling cable” and 7.8.33. “Disassembling the levers”. 1. Unscrew the 4 screws a (2 on each side)

using a 17-gauge wrench. 2. Remove the CAM GROUP. To disassemble the components of the CAM GROUP, place it on a bench or flat surface. Then: To disassemble the bearings b: 1. Turn the shaft until you can see the 2 dowels

c, which must be loosened using a 3-gauge hexagonal T-wrench.

2. Remove the bearing. To disassemble the hub and cam d: 1. Remove the bearings b. 2. Unscrew the screw e using a 4-gauge

hexagonal T-wrench. 3. Remove the hub and cam. To separate the cam and hub: 1. Unscrew the 3 screws e using a 6-gauge

hexagonal T-wrench. 2. Separate the components. To replace the CAM GROUP and its components, follow the above steps in reverse order.


Page 7.336


Figure 7.8.33-1


Working first on the RIGHT LEVER and then on the LEFT LEVER: 2. Unscrew the cap a using a 6-gauge hexagonal

T-wrench.

Figure 7.8.33-2









Page 7.337

7.8.34. DISASSEMBLING THE CHEST REST RELEASE KNOB

Figure 7.8.34-1


cord from the wall socket. 2. Remove the peg a with a peg remover tool. 3. Turn the mobile part of the knob until you

see the 2 dowels under the 2 holes b. 4. Use a 2-gauge hexagonal T-wrench to

unscrew the 2 dowels. 5. Remove the CHEST REST RELEASE

KNOB by sliding it upward. To reassemble the CHEST REST RELEASE KNOB, follow the above steps in reverse order.


Page 7.338

7.8.35. DISASSEMBLING THE LEVER GUARD

Figure 7.8.35-1

Follow the steps described in paragraph 7.8.18. “Disassembling the upright guard” limited solely to the rear part, 7.8.33. “Disassembling the levers” and 7.8.34. “Disassembling the chest rest release knob”. 1. Use a medium-sized Philips screwdriver to

unscrew the 2 screws a. 2. Remove the lower portion of the LEVER

GUARD.

Figure 7.8.35-2

3. Use a medium-sized Philips screwdriver to unscrew the 2 screws b.

4. Remove the upper portion of the LEVER GUARD.

To reassemble the LEVER GUARD, follow the above steps in reverse order.

During reassembly, correctly position the rectangular bushing of the chest rest between the parts of the LEVER GUARD.


Page 7.339


Figure 7.8.36-1

Follow the steps described in paragraph 7.8.18. “Disassembling the upright guard” and 7.8.35. “Disassembling the lever guard”. For each lever: 1. Unscrew the 2 dowels a, using a 4-gauge






Page 7.340

7.8.37. DISASSEMBLING THE LEVER SHAFT

Figure 7.8.37-1

Follow the steps described in paragraphs 7.8.33. “Disassembling the levers”, 7.8.34. “Disassembling the chest rest release knob” and 7.8.35. “Disassembling the lever guard”. For each lever: 1. Use a 30-gauge Allen wrench to unscrew the

ring-nut a. 2. Remove pulley b. 3. Slide the LEVER SHAFT out from above. To reassemble the LEVER SHAFT, follow the above steps in reverse order.


Page 7.341


Figure 7.8.38-1

Follow the steps described in paragraph 7.8.16. “Disassembling the mats”. 1. Use a medium-sized Philips screwdriver to

unscrew the 4 screws a. 2. Remove the rear portion of the SEAT

GUARD.

Figure 7.8.38-2

3. Unscrew the 2 screws b using a 4-gauge hexagonal T-wrench.

4. Remove the front part of the SEAT GUARD, spreading the side panels slightly.

To replace the SEAT GUARD, follow the above steps in reverse order.


Page 7.342


Figure 7.8.39-1

Follow the steps described in paragraph 7.8.38. “Disassembling the seat guard”. 1. Disconnect the connector from the motor

cable. 2. Unscrew the screw a and the nut b using 2

17-gauge wrenches. 3. Unscrew the screw c and the nut d using 2

17-gauge wrenches. 4. Remove the MOTOR SEAT. To reassemble the SEAT MOTOR, follow the above steps in reverse order.


Page 7.343


Figure 7.8.40-1


cord from the wall socket. Follow the steps described in paragraph 7.8.16. “Disassembling the mats” only for the left-hand mat. 2. Unscrew the screw a using a 4-gauge







Page 7.344


Figure 7.8.41-1

Follow the steps described in paragraph 7.8.18. “Disassembling the upright guard”. 1. Loosen the 2 screws a using a 5-gauge





Page 7.345

7.9. LEG PRESS


Figure 7.9.1-1



unscrew the screw a.

Hold the DISPLAY up before unscrewing the screw.

3. Turn the display downward.

Figure 7.9.1-2

4. Use a medium-sized Philips screwdriver to unscrew the 4 screws b.




Page 7.346

Figure 7.9.1-3

5. Open the DISPLAY. To remove the DISPLAY: 1. Disconnect the connectors c. 2. Remove the DISPLAY. To re-mount the display, follow the above steps in reverse order.


Page 7.347


Figure 7.9.2-1












Page 7.348




Page 7.349


Figure 7.9.3-1



Figure 7.9.3-2









Page 7.350


Figure 7.9.4-1



Figure 7.9.4-2







Page 7.351


Figure 7.9.5-1


KEYBOARD.

Figure 7.9.5-2









Page 7.352


Figure 7.9.6-1


KEYBOARD.

Figure 7.9.6-2









Page 7.353


Figure 7.9.7-1



unscrew the screw a.

Hold the DISPLAY up before unscrewing the screw.

3. Turn the display downward.

Figure 7.9.7-2

4. Unscrew the 2 screws a using a 3-gauge hexagonal T-wrench for each side of the weight stack.

5. Remove the WEIGHT STACK COVER. To reassemble the WEIGHT STACK COVER, follow the above steps in reverse order.


Page 7.354


Figure 7.9.8-1

Follow the steps described in paragraph 7.9.7. “Disassembling the weight stack cover”. 1. Pull the PLEXIGLAS upward, taking care

with the rubber gasket. To reassemble the PLEXIGLAS, follow the above steps in reverse order.


Page 7.355


Figure 7.9.9-1

Follow the steps described in paragraph 7.9.8. “Disassembling the plexiglas weight stack guard”. For each of the 2 CENTRAL PULLEYS : 1. Unscrew the screw a using an 8-gauge

hexagonal T-wrench. 2. Remove the PULLEY. For each of the 2 SIDE PULLEYS: 3. Unscrew the screw b and its nut using 2 17-

gauge wrenches. 4. Remove the PULLEY. To reassemble the PULLEYS, follow the above steps in reverse order.




Page 7.356


Figure 7.9.10-1

Follow the steps described in paragraphs 7.9.7. “Disassembling the weight stack cover” and 7.9.8. “Disassembling the plexiglas weight stack guard”. 1. Release the slot a of the ENCODER wire

from the hook.

Figure 7.9.10-2







Page 7.357

7.9.11. DISASSEMBLING THE WEIGHT STACK COVER FRAME

Figure 7.9.11-1

Follow the steps described in paragraphs 7.9.8. “Disassembling the plexiglas weight stack guard”, 7.9.9. “Disassembling the weight stack pulleys” and 7.9.10. “Disassembling the encoder”. 1. Disconnect the connector a from the solenoid

cable. 2. Remove the spiral cable b and its guide c

from the hook d.

Figure 7.9.11-2

3. Cut the clamp e. 4. Cut the clamp f. 5. Disconnect the patch cord g of the solenoid

cable. 6. Unscrew the 6 screws h using a 8-gauge

hexagonal T-wrench. 7. Pull the 2 column extensions and the

WEIGHT STACK COVER FRAME upward. To reassemble the WEIGHT STACK COVER FRAME, follow the above steps in reverse order.



Page 7.358


Figure 7.9.12-1

Follow the steps described in paragraphs 7.9.7. “Disassembling the weight stack cover”, 7.9.8. “Disassembling the plexiglas weight stack guard” limited solely to the external part and 7.9.11. “Disassembling the weight stack cover frame”. 1. Remove the ADDITIONAL WEIGHT a by

sliding it upward.




Page 7.359


Figure 7.9.13-1

Follow the steps described in paragraphs 7.9.8. “Disassembling the plexiglas weight stack guard” limited solely to the external part. 1. Disconnect the connector a from the





Page 7.360


Figure 7.9.14-1







Page 7.361


Figure 7.9.15-1





Page 7.362


Figure 7.9.16-1




Figure 7.9.16-2








Page 7.363


Figure 7.9.17-1








Page 7.364


Figure 7.9.18-1






Page 7.365


Figure 7.9.19-1

Follow the steps described in paragraph 7.9.11. “Disassembling the weight stack cover frame”. For each CROSS STOP: 1. Unscrew the 2 dowels a, using a 4-gauge





Page 7.366


Figure 7.9.20-1

Follow the steps described in paragraphs 7.9.11. “Disassembling the weight stack cover frame”, 7.9.12. “Disassembling the additional weight” and 7.9.19. “Disassembling the cross stops”. 1. Loosen the 2 screws a using a 4-gauge

hexagonal T-wrench. 2. Remove the 2 counter-weights b.

Figure 7.9.20-2

3. Use a special tool c to compress all of the weight stack plate springs.

4. Remove the CROSS by sliding it upward. To reassemble the CROSS, follow the above steps in reverse order.



Page 7.367


Figure 7.9.21-1





Page 7.368


Figure 7.9.22-1

Follow the steps described in paragraphs 7.9.10. “Disassembling the encoder”, 7.9.11. “Disassembling the weight stack cover frame” and 7.9.20. “Disassembling the cross”. 1. Remove the WEIGHT STACK PLATES by



Page 7.369


Figure 7.9.23-1

Follow the steps described in paragraph 7.9.11. “Disassembling the weight stack cover frame”. For each of the 2 counter-weight vibration bars: 1. Unscrew the 2 dowels a, using a 4-gauge

hexagonal T-wrench.

Hold the BAR up before unscrewing the last screw.



Page 7.370


Figure 7.9.24-1


cord from the wall socket. 2. Unscrew the 2 screws a using a 5-gauge

hexagonal T-wrench. 3. Remove the guard b. 4. Use a medium-sized Philips screwdriver to

unscrew the 4 screws c. 5. Slide the front portion of the REAR GUARD

forward. 6. Remove the 2 caps d (1 on each side of the


unscrew the 2 screws under the 2 caps d. 8. Slide the rear portion of the REAR GUARD

back. To replace the REAR GUARD, follow the above steps in reverse order.


Page 7.371

7.9.25. DISASSEMBLING THE CENTRAL GUARD

Figure 7.9.25-1

Follow the steps described in paragraph 7.9.24. “Disassembling the rear guard”. 1. Use a medium-sized Philips screwdriver to

unscrew the 3 screws a. 2. Slide the 2 parts of the CENTRAL GUARD

out from the side. To replace the CENTRAL GUARD, follow the above steps in reverse order.


Page 7.372

7.9.26. DISASSEMBLING THE MAIN ELECTRICAL BOX This box contains the power supply and the components to manage the encoder, solenoid and weight stack motor.

Figure 7.9.26-1

Follow the steps described in paragraphs 7.9.24. “Disassembling the rear guard” and 7.9.25. “Disassembling the central guard”. 1. Unscrew the screw a using a 4-gauge


Figure 7.9.26-2




Page 7.373

7.9.27. DISASSEMBLING THE ELECTRONIC COMPONENTS OF THE MAIN ELECTRICAL BOX

Figure 7.9.27-1

Follow the steps described in paragraph 7.9.26. “Disassembling the main electrical box”. With the electrical box resting on a bench: To disassemble the POWER SUPPLY a: 1. Disconnect the 2 connectors. 2. Disconnect the 4 plastic coupling elements. 3. Remove the card. To disassemble the FPGA BOARD b: 1. Disconnect the 4 connectors. 2. Disconnect the 4 plastic coupling elements. 3. Remove the card. To disassemble the IMP BOARD c: 1. Lift the board. 2. Disconnect the 2 connectors. 3. Disconnect the 4 plastic coupling elements. 4. Remove the card. To disassemble the IEM BOARD d: 1. Lift the board. 2. Disconnect the 2 connectors. 3. Disconnect the 4 plastic coupling elements. 4. Remove the card. To disassemble the TRANSFORMER e: 1. Disconnect the secondary cables from the






Page 7.374

To disassemble the 110/220 SELECTOR SWITCH f: 1. Unsolder the cables. 2. Unscrew the holding nut. 3. Remove the selector switch. To disassemble the FILTER g: 1. Disconnect the connectors. 2. Unscrew the 2 holding nuts. To reassemble the ELECTRONIC COMPONENTS OF THE ELECTRICAL BOX, follow the above steps in reverse order.


Page 7.375

7.9.28. DISASSEMBLING THE SECONDARY ELECTRICAL BOX This box contains the components to manage the seat motor.

Figure 7.9.28-1

Follow the steps described in paragraphs 7.9.24. “Disassembling the rear guard” and 7.9.25. “Disassembling the central guard”. 1. Unscrew the screw a using a 4-gauge


Figure 7.9.28-2




Page 7.376

7.9.29. DISASSEMBLING THE ELECTRONIC COMPONENTS OF THE SECONDARY ELECTRICAL BOX

Figure 7.9.29-1

Follow the steps described in paragraph 7.9.28. “Disassembling the secondary electrical box”. With the electrical box resting on a bench: To disassemble the IMS LPO BOARD a: 1. Lift the board. 2. Disconnect the 3 connectors. 3. Disconnect the 4 plastic coupling elements. 4. Remove the card. To disassemble the TRANSFORMER b: 1. Disconnect the secondary cables from the



gauge wrench. 4. Remove the transformer. To disassemble the 110/220 SELECTOR SWITCH c: 1. Unsolder the cables. 2. Unscrew the holding nut. 3. Remove the selector switch. To disassemble the RECTIFIER d: 1. Disconnect the cables. 2. Unscrew the holding nut. 3. Remove the rectifier. To reassemble the ELECTRONIC COMPONENTS OF THE SECONDARY ELECTRICAL BOX, follow the above steps in reverse order.


Page 7.377

7.9.30. DISASSEMBLING THE SEAT MOTOR PHOTOCELL

Figure 7.9.30-1


2. Unscrew the screw a using a 3-gauge T-

wrench. 3. Remove the protective photocell cover b.

Figure 7.9.30-2

4. Disconnect the connector c. 5. Use a small straight screwdriver to unscrew

the 2 screws d: 6. Remove the photocell board e.

When reassembling the photocell cover, make sure the slot is aligned with the cable passage.

To reassemble the SEAT MOTOR PHOTOCELL, follow the above steps in reverse order.


Page 7.378

7.9.31. DISASSEMBLING THE SEAT MOTOR BRUSHES

Figure 7.9.31-1


2. Manually loosen the protective cover a of the

brush. 3. Remove the brush. To reassemble the SEAT MOTOR BRUSHES, follow the above steps in reverse order.


Page 7.379

7.9.32. DISASSEMBLING THE SEAT MOVEMENT LIMITATION MICROSWITCH

Figure 7.9.32-1


For each MICROSWITCH: 2. Disconnect the cable connectors a. 3. Unscrew the 2 screws b using a 3-gauge

hexagonal T-wrench. 4. Remove the MICROSWITCH. To remount the MICROSWITCHES, follow the above steps in reverse order.


Page 7.380

7.9.33. DISASSEMBLING THE SEAT MOTOR UNIT

Figure 7.9.33-1

Follow the steps described in paragraph 7.9.24. “Disassembling the rear guard” and 7.9.25. “Disassembling the central guard”. 1. Cut the clamps a. 2. Disconnect the cable connectors b. 3. Unscrew the screw c using a 6-gauge

hexagonal T-wrench.

Figure 7.9.33-2

4. Disconnect the cable connectors of the 2 microswitches.

5. Use a 4-gauge wrench to unscrew the 17 screws d.

Hold the MOTOR UNIT up before unscrewing the screw. Use caution, as it weighs 22 Kg.

Figure 7.9.33-3

Place the MOTOR UNIT on a bench: 6. Loosen the counter-nuts d using an 8-gauge

wrench. 7. Unscrew the dowels e, using a 2.5-gauge

hexagonal T-wrench. 8. Remove the pin f. 9. Remove the winch g. 10. Remove the rack h.



Page 7.381

Figure 7.9.33-4

11. Unscrew the 4 screws i using a 5-gauge hexagonal T-wrench.

12. Remove the MOTOR. To reassemble the SEAT MOTOR UNIT, follow the above steps in reverse order.

When reassembling the winch, adjust the dowels and counter-nuts so that it turns on the rack without friction.


Page 7.382


Figure 7.9.34-1


cord from the wall socket. For each side: 2. Unscrew the screw a using a 6-gauge

hexagonal T-wrench, holding the nut in place with a 17-gauge wrench.

3. Remove the pulley b. 4. Remove the SEAT.

Including the motor, the SEAT weighs approximately 90 Kg. To lighten the load, you may first disassemble the seat motor as described in paragraph 7.9.33.

To replace the SEAT, follow the above steps in reverse order.


Page 7.383

7.9.35. DISASSEMBLING THE SEAT SLIDING BARS

Figure 7.9.35-1

Follow the steps described in paragraph 7.9.34. “Removing the seat”. For the front and back end guards of the SLIDING BARS: 1. For each BAR, unscrew the screw c using a

14-gauge hexagonal T-wrench, both front and back.

2. Remove the BAR. To reassemble the BARS, follow the above steps in reverse order


Page 7.384

7.9.36. DISASSEMBLING THE SHOULDER REST GROUP RELEASE CABLE

Figure 7.9.36-1


2. Unscrew the setting screw of the LEVER

RELEASE CABLE, using a 13-gauge wrench on the counter-nut a and screw b.

3. Pull the cable from the release handle, passing the blocking ball through the holes provided.

Figure 7.9.36-2

4. Unscrew the 3 screws c, using a 2.5-gauge hexagonal T-wrench.

5. Use a 3-gauge hexagonal T-wrench to unscrew the dowel d.



Page 7.385

Figure 7.9.36-3

6. Remove the cable support.

Lock the part in place, to prevent the spring from pulling it inward and making it inaccessible without disassembling the seat as described in paragraph 7.9.34. .

7. Remove the SHOULDER REST GROUP

RELEASE CABLE.

If you need to replace the cable because the seat blocking ball, the spring pulls the part into the backrest; to recover it, you must disassemble the seat as described in paragraph 7.9.34. .

To reassemble the SHOULDER REST GROUP RELEASE CABLE, follow the above steps in reverse order.

When the operation is complete, adjust the RELEASE CABLE tension as described in paragraph 8.13. .


Page 7.386

7.9.37. DISASSEMBLING THE SHOULDER REST GROUP

Figure 7.9.37-1

1. Position the SHOULDER REST ADJUSTMENT at maximum height.

2. Follow the steps described in paragraph 7.9.36. “Disassembling the shoulder rest group release cable”.


unscrew the 6 screws a. 4. Remove the 2 backrest guards.

Figure 7.9.37-2

5. Unscrew the 2 screws b using a 3-gauge hexagonal T-wrench.

6. Remove the closing cover c. 7. Remove the cap d. 8. Use an 8-gauge T-wrench to unscrew the

screw c, holding the nut--accessible from above--in place with a 17-gauge wrench.

9. Unscrew the 6 screws a using an 8-gauge

hexagonal T-wrench.

To unscrew the 2 bottom screws, you must use a very short wrench.

10. Turn the backrest on the seat.



Page 7.387

Figure 7.9.37-3

To disassemble the gas spring: 11. Remove the nut covers f. 12. Unscrew the screw and nut underneath the

nut covers f using 2 13-gauge wrenches. 13. Unscrew the screw g and the nut h using 2

13-gauge wrenches. 14. Remove the gas spring. To disassemble the sinker: 15. Use a 3-gauge hexagonal T-wrench to

unscrew the dowel i. 16. Use a 30-gauge Allen wrench to unscrew the

ring-nut l. 17. Pull out the sinker from below, being careful

with the block. To disassemble the SHOULDER REST frame: 18. For each bar, unscrew the 2 screws m using a

17-gauge wrench. 19. Remove the bar. 20. To disassemble the SHOULDER REST

frame: To reassemble the SHOULDER REST GROUP, follow the above steps in reverse order.


Page 7.388

7.9.38. DISASSEMBLING THE TACHOGENERATOR GUARD

Figure 7.9.38-1


cord from the wall socket. 2. Use a medium-sized Philips screwdriver to

unscrew the 4 screws a. 3. Slide the CENTRAL TACHOGENERATOR

GUARD upwards. For each of the 2 SIDE TACHOGENERATOR GUARDS: 4. Use a medium-sized Philips screwdriver to

unscrew the 4 screws b (2 on each side). 5. Slide the SIDE TACHOGENERATOR

GUARD out sideways. To reassemble the TACHOGENERATOR GUARD, follow the above steps in reverse order.


Page 7.389


Figure 7.9.39-1

Follow the steps described in paragraph 7.9.38. “Disassembling the tachogenerator guard”. 1. Use a medium-sized Philips screwdriver to

unscrew the 6 screws a (3 on each side). 2. Slide the rear portion of the FRONT

GUARD back. 3. Use a medium-sized Philips screwdriver to

unscrew the 2 screws b. 4. Slide the middle portion of the FRONT

GUARD upward. 5. Remove the 2 caps c (1 on each side) using a

small flat screwdriver. 6. Unscrew the 2 screws under the 2 caps c

using a medium-sized Philips screwdriver. 7. Slide the front portion of the FRONT

GUARD forward. To reassemble the FRONT GUARDS, follow the above steps in reverse order.


Page 7.390

7.9.40. DISASSEMBLING THE LEVER MAT RUBBER

Figure 7.9.40-1


For each LEVER MAT: 2. Unscrew the 5 screws a using a 3-gauge

hexagonal T-wrench. 3. Remove the RUBBER. To reassemble the LEVER MAT RUBBER, follow the above steps in reverse order.


Page 7.391


Figure 7.9.41-1

Follow the steps described in paragraphs 7.9.38. “Disassembling the tachogenerator guard” and 7.9.39. “Disassembling the front guard”. For each LEVER: 1. Use a 2-gauge hexagonal T-wrench to

unscrew the 6 screws a, holding the screw in place from the opposite side with a 6-gauge hexagonal T-wrench.

2. Remove the lever mat.

Figure 7.9.41-2


4. Remove the LEVER counter-weight.

Hold the LEVER counter-weight up before unscrewing the last screw. Use caution, as it weighs approximately 45 Kg.

For each side of the machine and each LEVER arm: 5. Use a 30-gauge Allen wrench to unscrew the

ring-nut c, holding the screw d in place with a 6-gauge hexagonal T-wrench.

6. Remove the shaft e. 7. Remove the LEVER arms. To reassemble the LEVERS, follow the above steps in reverse order


Page 7.392


Figure 7.9.42-1

Follow the steps described in paragraphs 7.9.38. “Disassembling the tachogenerator guard” and 7.9.39. “Disassembling the front guard”. For each side: 1. Unscrew the 3 dowels a, using a 4-gauge

hexagonal T-wrench. 2. Remove the cable with the aid of a pair of

pliers. 3. Remove the cable from the pulleys. To unscrew the joints: 4. Unscrew the screw b, holding the nut c in

place with 2 17-gauge wrenches. 5. Remove the joints. To reassemble the LEVER CABLE, follow the above steps in reverse order.



Page 7.393


Figure 7.9.43-1


2. Remove the 4 caps a (2 on each side of the

GUARD) using a small flat screwdriver. 3. Unscrew the 4 screws under the 4 caps a





Page 7.394


Figure 7.9.44-1

Follow the steps described in paragraph 7.9.8. “Disassembling the plexiglas weight stack guard”. For each cam: 1. Unscrew the 2 dowels a, using a 4-gauge


pliers. 3. Remove the cable from the weight stack

pulleys. To reassemble the WEIGHT STACK CABLE, follow the above steps in reverse order.



Page 7.395


Figure 7.9.45-1

Follow the steps described in paragraphs 7.9.24. “Disassembling the rear guard”, 7.9.25. “Disassembling the central guard” and 7.9.43. “Disassembling the weight stack frame guard”. 1. Unscrew the 2 dowels a, using a 4-gauge


pliers.

Figure 7.9.45-2

3. Remove the pressed end of the DOUBLING CABLE from the slot on the doubling support.

To reassemble the DOUBLING CABLE, follow the above steps in reverse order.



Page 7.396


Figure 7.9.46-1

Follow the steps described in paragraphs 7.9.43. “Disassembling the weight stack frame guard” and 7.9.45. “Disassembling the doubling cable” limited solely to the part on the cams. 1. Unscrew the 4 screws a (2 on each side)

using a 17-gauge wrench. 2. Remove the CAM GROUP. To disassemble the components of the CAM GROUP, place it on a bench or flat surface. Then: To disassemble the bearings b: 1. Unscrew the 2 dowels c using a 3-gauge

hexagonal T-wrench. 2. Remove the bearings. To separate the cam block d: 1. Unscrew the 2 dowels e, using a 4-gauge

hexagonal T-wrench. 2. Remove the shaft f. 3. Use an 3-gauge hexagonal T-wrench to

unscrew the 8 screws, holding the nut g in place with a 17-gauge wrench.

To reassemble the CAM GROUP, follow the above steps in reverse order.

When the operation is complete, adjust the tension of the cable, and the phasing of the cam and lever mechanism, as described in paragraphs 8.4. and 8.2. .


Page 7.397

7.9.47. DISASSEMBLING THE WEIGHT STACK FRAME PULLEYS

Figure 7.9.47-1

Follow the steps described in paragraph 7.9.43. “Disassembling the weight stack frame guard”. 1. Remove the snap ring a on both sides, using

the special pliers provided. 2. Use a pushing tool to push the b inside. 3. Remove the PULLEYS, being careful with

the 2 plastic spacers.


To reassemble the PULLEYS, follow the above steps in reverse order.




Page 7.398


Figure 7.9.48-1

Follow the steps described in paragraph 7.9.43. “Disassembling the weight stack frame guard”. 1. Loosen the 2 screws a using a 5-gauge





Page 7.399


Figure 7.9.49-1




3. Remove the MAT by pulling it upward. To reassemble the MAT, rest it on the frame and press down at the 2 fastening points.


Page 7.400


Figure 7.9.50-1








Page 8.1

8. ADJUSTMENTS

8.1. ADJUSTING THE WEIGHT STACK PLATE SELECTION

The weight stack plates must be selected correctly in order for the machine to carry out the exercise without rattling caused by the plate springs which, if not correctly compressed, touch the cross sinker. The plate selection may be adjusted using a few parameters from the procedure described in paragraph 9.2. “Configuring the technical parameters”: • the OFFSET: see paragraph 9.2.2. ; • the distance between plates: see paragraph 9.2.6. ; • the weight stack motor inertia: see paragraph 9.2.4. . To understand how these parameters affect the adjustment system, we must first clarify how the machine works: during reset, the machine seeks out the zero sensor position. Once it is found, it moves the weight stack selection system by a preset number of pulses until the weight is set to 5 Kg (10 lbs). Subsequent selections of different weights are all related to forward or backward movements by the motor by a preset number of pulses.

8.1.1. OFFSET This parameter, set to 1000 by default, affects the position of the weight stack selection brush after the reset. Once it has detected the zero sensor, the machine moves the selection system by an amount equal to:

total number of weight stack pulses + (OFFSET – 1000) This tells us that: 1. The unit of measure for the OFFSET parameter is pulses of the weight stack motor encoder.

Mounting a different motor would have significant effects on this setting;

To move the brush by 1 mm, the OFFSET value must be changed by approximately 5 units.

2. Since the default setting is 1000, in ideal conditions 5 Kg. (10 lbs) are selected by moving the

weight stack selection system by a number of pulses equal to the total number of pulses of the weight stack. Obviously, in real conditions this value must be changed:

• The selection brush moves up as the OFFSET value is increased; • The selection brush moves down as the OFFSET value is reduced;


Page 8.2

The setting of the OFFSET parameter, which may be configured as described in paragraph 9.2.2. “Offset zero sensor”, must be adjusted in order to correctly select the first plate: the selection brush must be positioned so as to press against the plate pin, touching it with the beginning of the flat part as shown in the figure below:

Figure 8.1.1-1

Once you have set the OFFSET parameter, note its value on the sticker inside the display (old version equipment) or beneath the Plexiglas cover (new version equipment) so that it may be rapidly configured in case the data stored in the battery-powered RAM are lost, or if the electronic boards of the display are replaced.

The OFFSET value generally needs to be changed after any operations requiring dismantling the weight stack selection system or after the machine has been in use for some time.

8.1.2. DISTANCE BETWEEN PLATES After setting the offset parameter, we recommend increasing the weight in increments of 5 Kg (10 lbs) to check whether the selection is perfect, plate by plate. In this case the lower plate pin must be pressed as shown in the figure above, and the upper plate pin released and at least a couple of mm from the brush, as shown in the figure below:

Figure 8.1.2-1


Page 8.3

To achieve this situation, you must adjust the value of the PLATE DISTANCE parameter as described in the paragraph 9.2.6. “Distance between plates”. A specific weight is selected by moving the weight stack selection system until it receives the number of pulses equal to the configured value of the distance between plates.

8.1.3. WEIGHT STACK MOTOR INERTIA The plates are selected by moving the weight stack selection system, by switching the weight stack motor on and off. When it is shut off, the motor continues moving for a minimal amount because of inertia, although its ends are short-circuited; this distance may be identified by a limited number of pulses. To prevent this distance from losing control of the position over time, the parameter WEIGHT STACK MOTOR INERTIA, which may be configured as described in the paragraph 9.2.4. “Weight stack motor inertia”, allows you to define the advance motor shut off time so that the weight stack selection system also takes into account the motor inertia when selecting the plates.


Page 8.4

8.2. ADJUSTING THE MECHANISMS PHASING

This operation is the same for all machines.

8.2.1. ABDOMINAL CRUNCH

Figure 8.2.1-1

With the primary and secondary shaft chain and weight stack cable disconnected: 1. With the limit switch at the end of its stroke,

adjust the position of the PRIMARY SHAFT so that it respects the measurements shown in the drawing.

2. To do so, adjust the position of the limit switch by regulating the screw and nut with a 17-gauge wrench.

Figure 8.2.1-2

3. The cam and pinion of the secondary shaft must be connected so that the punch on a tooth of the pinion is aligned with the hole in the cam.



Page 8.5

Figure 8.2.1-3

4. Adjust the position of the SECONDARY SHAFT so that it respects the measurements shown in the drawing.

5. Mount the primary and secondary shaft connection chains.

6. Mount the weight stack cable.


Page 8.6

8.2.2. LOWER BACK

Figure 8.2.2-1

With the primary and secondary shaft chain and weight stack cable disconnected: 1. With the limit switch at the end of its stroke

and the lever in position 1, adjust the position of the PRIMARY SHAFT so that it respects the measurements shown in the drawing.


Figure 8.2.2-2

3. The cam and pinion of the secondary shaft must be connected so that the punch on a tooth of the pinion is aligned with the hole in the cam.



Page 8.7

Figure 8.2.2-3





Page 8.8

8.2.3. LEG EXTENSION

Figure 8.2.3-1




Figure 8.2.3-2

3. The cam and pinion of the secondary shaft must be connected so that the punch ∅ 2 on a tooth of the pinion is aligned with the hole in the cam.



Page 8.9

Figure 8.2.3-3





Page 8.10

8.2.4. LEG CURL

Figure 8.2.4-1




Figure 8.2.4-2

3. The cam and pinion of the secondary shaft must be connected so that the punch ∅ 5 on a tooth of the pinion is aligned with the hole in the cam.



Page 8.11

Figure 8.2.4-3





Page 8.12

8.2.5. VERTICAL TRACTION

Figure 8.2.5-1

1. With the seat in position 9, adjust the position of the easy start lever so that it respects the measurements shown in the drawing.

2. To do so, adjust the position of the limit switch under the easy start lever support by regulating the screw and nut with a 17-gauge wrench.

3. Connect and power all cables.

4. Adjust the starting position of the levers so that:

• They are horizontal (using the level); • The right lever does not strike the left.

5. To do so, adjust the position of the limit

switch by regulating the screw and nut with a 17-gauge wrench.

6. Adjust the ending position of the levers so that:

• They are horizontal (using the level); • They have the maximum stroke (limit

switches as tight as possible). 7. To do so, adjust the position of the limit



Page 8.13

8.2.6. SHOULDER PRESS

Figure 8.2.6-1



3. Connect and power all cables.

4. Adjust the starting position of the levers so that:

• They are horizontal (using the level); • They have the maximum stroke (limit

switches as tight as possible). 5. To do so, adjust the position of the limit


6. Adjust the ending position of the levers so that:

• They are horizontal (using the level); • The right lever does not strike the left.




Page 8.14

8.2.7. CHEST PRESS

Figure 8.2.7-1



Figure 8.2.7-2

3. The cam group must be mounted so that it respects the measurements shown in the drawing.



Page 8.15

Figure 8.2.7-3

4. Adjust the starting position of levers so that they respect the measurements shown in the drawing.

Figure 8.2.7-4

5. To adjust the starting position of the levers:

• Set the lever at 2 mm from its internal fastening point.

• Tighten the 2 screws a of the internal lever lock.

• Tighten the center screw b until the bearings are locked in place, without any play on the lever;

• Tighten the 2 screws c of the outer lever lock.

This operation must allow the spherical node and pulley to work in alignment.



Page 8.16

6. Connect and power all cables. 7. Adjust the stopping position of the levers so

that when they are both pushed and the crossed is resting against the cross limit switches, the lever limit switches are 1 mm above the lever itself.


This operation must prevent any damage to the machine by performing the exercise with a single lever.


Page 8.17

8.2.8. ROWING TORSO

Figure 8.2.8-1

1. Adjust the stopping position of the easy start lever so that it respects the measurements shown in the drawing.


switch under the easy start lever support by regulating the screw and nut with a 17-gauge wrench.

Figure 8.2.8-2




Page 8.18

Figure 8.2.8-3

4. Adjust the starting position of levers so that they respect the measurements shown in the drawing.



Figure 8.2.8-4

6. Connect and power all cables. 7. Adjust the stopping position of levers so that

they respect the measurements shown in the drawing.




Page 8.19

8.2.9. LEG PRESS

Figure 8.2.9-1


2. Adjust the starting position of the mats so that:

• They have the maximum stroke; • The block of mats may easily be moved

to perform the exercise with the mats connected or disconnected.

3. Cut the weight stack cable (5480 mm) and

the lever cable (4330 mm) to size. 4. Connect and power all cables.

Adjust the doubling cable, adapting its size, so that the cables have the proper tension.

The weight stack cable must detach from the cam at the notch on the cam itself.


Page 8.20

8.3. ADJUSTING THE POSITION OF THE CROSS LIMIT SWITCH

This operation holds for the Abdominal Crunch, Lower Back, Leg Extension, Leg Curl, Chest Press, Rowing Torso and Leg Press.

Adjusting the position of the weight stack limit switch limits the cross stroke, to avoid possible breakage of mechanical parts due to overly long strokes by the weight stack. Therefore, with d as the distance between the top of the cross and the bottom of the limit switch, as shown in the figure below:

Figure 8.3-1

This should be adjusted as shown in the table below:

Machine Distance mm

Abdominal Crunch 400 Lower Back 365 Leg Extension 470 Leg Curl 450 Vertical Traction - Shoulder Press - Chest Press 550 Rowing Torso 505 Leg Press 565


Page 8.21

8.4. ADJUSTING THE WEIGHT STACK CABLE TENSION


Figure 8.4-1

1. Set the minimum weight: the only selected

weight will be the cross. 2. Loosen the counter-nut a using a 22-gauge

wrench. 3. Tighten the screw b at the end of the CABLE

so that the cable is taut and the cross raised. 4. Slowly loosen the screw b until the cable is

still taut, but the cross is resting on the weight stack.

5. Tighten the counter-nut a using a 22-gauge wrench.

Check the tension of the cable by carrying out a couple of repetitions with the minimum weight, and then slowly resting the cross on the weight stack. The cross must rest firmly on the weight stack, and the cable must be slightly taut.

The length of the weight stack cable is shown in the table below:

Machine Length (mm)

Abdominal Crunch 2670 Lower Back 2860 Leg Extension 2730 Leg Curl 2680 Vertical Traction 2770 Shoulder Press 2770 Chest Press 2210 Rowing Torso 2340 Leg Press 5480


Page 8.22

8.5. ADJUSTING THE PRESTART CABLE TENSION

8.5.1. ADJUSTING THE PRIMARY PRESTART CABLE TENSION

This operation holds for the Vertical Traction, Shoulder Press and Chest Press.

Figure 8.5.1-1

1. Make sure that the easy start lever is properly positioned.

2. Adjust the easy start cable tension by means

of the nut a, holding the screw b in place so that the cable is taut.

The length of the primary easy start cable is shown in the table below:

Machine Length (mm)

Abdominal Crunch - Lower Back - Leg Extension - Leg Curl - Vertical Traction 2610 Shoulder Press 2520 Chest Press 1180 Rowing Torso - Leg Press -


Page 8.23

8.5.2. ADJUSTING THE SECONDARY PRESTART CABLE TENSION

This operation holds for the Vertical Traction and Shoulder Press.

Figure 8.5.2-1

1. Adjust the length of the 2 parts of the secondary easy start cables so that the easy start lever activates the 2 levers evenly.

The length of each part of the secondary weight stack cable is shown in the table below:

Machine Length (mm)

Abdominal Crunch - Lower Back - Leg Extension - Leg Curl - Vertical Traction 820 Shoulder Press 820 Chest Press - Rowing Torso - Leg Press -


Page 8.24

8.6. ADJUSTING THE LEVER CABLE

This operation holds for the Vertical Traction, Shoulder Press, Chest Press, Rowing Torso and Leg Press.

The length of the lever cable is shown in the table below:

Machine Length (mm)

Abdominal Crunch - Lower Back - Leg Extension - Leg Curl - Vertical Traction 2800 Shoulder Press 2400 Chest Press 3550 Rowing Torso 2530 Leg Press 4330

When the cable is cut to size, it must be stretched taut by adjusting the other machine cables.


Page 8.25

8.7. ADJUSTING THE DOUBLING CABLE

This operation holds for the Rowing Torso and Leg Press. The length of the doubling cable is shown in the table below:

Machine Length (mm)

Abdominal Crunch - Lower Back - Leg Extension - Leg Curl - Vertical Traction - Shoulder Press - Chest Press 820 Rowing Torso 1150 Leg Press 2160

When the cable is cut to size, it must be stretched taut by adjusting the other machine cables.


Page 8.26

8.8. ADJUSTING THE ZERO SENSOR POSITION


Figure 8.8-1

1. Carry out the procedure described in paragraph 6.1. “Manual Components Test” until the solenoid of the weight stack selection brush is in front of the zero sensor.

2. Loosen the nut a using a 22-gauge wrench. 3. Move the sensor until it is 3.5 mm from the

weight stack selection system brush.


Page 8.27

8.9. ADJUSTING THE POSITION OF THE WEIGHT STACK SELECTION SYSTEM


Figure 8.9-1

1. Set the maximum weight: all plates in the weight stack are selected.

2. Make sure that the distance between the pin on the first plate and that of the last and the white plastic sliding block of the selection system is 1÷÷÷÷2 mm.

Figure 8.9-2

3. To regulate this distance, adjust the: • Screw a using a 4-gauge hexagonal T-

wrench; • Move the motor support frame along the

slots, after first loosening the 4 nuts b.


Page 8.28

8.10. ADJUSTING THE TENSION OF THE WEIGHT STACK SELECTION CHAIN


Figure 8.10-1

1. Loosen the nut a using an 8-gauge wrench. 2. Adjust the CHAIN TENSION by turning the

screw b using a jointed 5-gauge hexagonal wrench, so that the chain does not shake while moving.

3. When the adjustment is complete, tighten the nut loosened previously.

After completing this adjustment, carry out the mechanical test of the components for at least 15 minutes as described in the paragraph 6.2. then check the chain tension again.


Page 8.29

8.11. ADJUSTING THE PRIMARY SHAFT - SECONDARY SHAFT CHAIN ALIGNMENT

This operation holds for the Abdominal Crunch, Lower Back, Leg Extension and Leg Curl.

Figure 8.11-1

1. Loosen the screw fastening the primary shaft pinion to the shaft itself.

2. Place a striker rod on the crown of the secondary shaft.

3. Align the primary shaft pinion with the

striker rod. 4. When the alignment is complete, tighten the

screw loosened previously.

To ensure proper chain alignment, move it back and forth and make sure it moves noiselessly.

When this operation is complete, check the chain tension as described in the paragraph 8.12. .


Page 8.30

8.12. ADJUSTING THE PRIMARY SHAFT - SECONDARY SHAFT CHAIN TENSION

This operation holds for the Abdominal Crunch, Lower Back, Leg Extension and Leg Curl.

Figure 8.12-1

1. Loosen the 4 screws a fastening the

secondary shaft to the frame. 2. Adjust the nut b and the screw c so that there

is a drop in the chain of approximately 1 cm in the center between the 2 shafts.

3. Test the movement value in the center for the various lever positions.

Make sure that the above adjustments keep the axes of the primary and secondary shafts in alignment.

To make sure the chain tension is correct, move it back and forth along the entire crown of the primary shaft.

When this operation is complete, check the chain alignment as described in the paragraph 8.11. .


Page 8.31

8.13. ADJUSTING THE RELEASE CABLE TENSION

This operation holds for the Lower Back and Leg Press.

Figure 8.13-1

1. Loosen the nut a. 2. Adjust the screw b so that:

• the cable is taut; • the release lever has a play of 1 mm; • the lever releases easily.

3. Tighten the nut a loosened previously.


Page 8.32

8.14. ADJUSTING THE CURRENT LIMIT ON THE WSMI AND SAMI BOARD


Figure 8.14-1

1. To adjust the current limit setting, turn the

trimmer screw P1 on the IMS and IMP board using a small flat screwdriver, until the ideal level is reached.

WARNING: do not adjust this trimmer

unless strictly necessary. In any case, always check the reason for the need to increase the current (increased friction, mechanical parts that obstruct movement, electrical problems on the motor) before adjusting the trimmer.

CAUTION: every time the trimmer is adjusted to raise the level of current absorbed by the motor, make sure it is not greater than 5 A, the maximum value allowed by the motor.


Page 8.33

8.15. LCD CONTRAST


Figure 8.15-1

1. Leave the power cord connected to the power entry.

2. Switch the machine on. 3. Looking at the LCD, turn the trimmer screw

P1 using a small flat screwdriver to adjust the contrast, until the ideal level is reached.

Perform this operation after warm-up, thus at least one hour after turning on the machine.


Page 8.34

8.16. BUZZER TONE


Figure 8.16-1

This operation should be carried out only if the trimmer P2 has been moved accidentally.

1. Leave the power cord connected to the power

entry. 1. Remove the EPROM a from the CPU Board

using a special integrated circuit extractor. 2. Switch the machine on: the buzzer will sound

continuously. 3. Turn the trimmer screw P2 using a small flat

screwdriver to adjust the tone, until the frequency of the signal between pins 4 and 6 of integrated circuit U4, read with an oscilloscope, is 3.9 KHz.


Page 9.1

9. CONFIGURING THE MACHINE

9.1. CONFIGURING PARAMETER DEFAULTS

Proceed as follows: 1. Shut the machine off. 2. Open the display and set all dip-switches to OFF. 3. Switch the machine on. 4. The machine turns on and loads the default parameters as though it were an Abdominal. To change the configuration, you may use the procedure described in paragraphs 9.2. “Configuring the technical parameters” and 9.3. “Configuring the user parameters”.

CAUTION: if the dip-switches are all OFF when the machine is turned on, the configuration parameter value is read by the EPROM (default configuration), otherwise it is read by the battery RAM (custom configuration). Thus in order to save changes to the parameters, before shutting off the machine dip-switch 1 must be set to On.

9.2. CONFIGURING THE TECHNICAL PARAMETERS

Technical parameters are those that may be changed only by an authorized technician, since they have to do with configuring the construction parameters of the equipment. The procedure for configuring technical parameters may be activated, when the machine is in stand-by, by pressing keys “1”, “3” and “4” simultaneously, and making sure that the dip-switches on the CPU Board are set to configuration 1000. To access this procedure, you must enter the password that protects against unauthorized access.

P A S S W O R D = *

After entering the password “2501” and pressing “Enter” to continue, the machine begins to offer the configurable parameters in sequence, showing the current value and possible alternatives. Press the "Enter" key to move on to the next parameter, or the “Clear” key to quit the procedure.

Pressing the “Clear” key will abort the procedure, but any changes previously made will remain in effect. However, you must reset or turn the machine off and back on again in order for the changes to affect the current program session.


Page 9.2

9.2.1. MACHINE CODE This option allows you to set up the machine:

S E L E C T M A C H I N E C O D E = X

The possible options are listed in the table below:

Machine Code Abdominal Crunch 3 Lower Back 6 Leg Extension 2 Leg Curl 5 Vertical Traction 1 Shoulder Press 7 Chest Press 0 Rowing Torso 8 Leg Press 4

Enter the code for the machine on which you are working, then press “Enter” to continue or “Clear” to abort. Once the selection is made, the machine displays the name of the tool corresponding to the selected code. For instance, if code 7 is selected--corresponding to the Shoulder Press--the following will appear on the LCD:

S E L E C T E D M A C H I N E : S H O U L D E R P R E S S B I O

The choice of the type of machine alters the procedures described in paragraphs: • 9.2. “Configuring the technical parameters”; • 9.3. “Configuring the user parameters”; • 9.5. “Displaying working parameters”; • 9.6. “Editing the working parameters”.

as it disables those options that are not pertinent to the type of machine: seat information will not appear for the Abdominal Crunch and Lower Back.

9.2.2. OFFSET ZERO SENSOR This option allows you to set the SW offset of the zero sensor position. Correct positioning of the zero sensor is essential in order to correctly select the weight stack plates as described in paragraph 8.1. “Adjusting the weight stack plate selection”:

O F F S E T > 1 0 0 0 U < 1 0 0 0 D O F F S E T = X X X X


Page 9.3

Setting a value greater than 1000 moves the sensor upward, while a value of less than 1000 moves it downward. Enter the desired value, then press “Enter” to continue or “Clear” to abort. Since incorrectly setting this parameter will cause errors in selecting the weight stack plates, any changes must be confirmed twice via the following request:

C O N F I R M O F F S E T = X X X X N = 1 Y = 2 = X

Select the desired option, then press “Enter” to continue or “Clear” to abort.

9.2.3. NUMBER OF PULSES FOR WEIGHT STACK SELECTION This operation allows you to set the number of pulses produced by the encoder associated with the weight stack motor to select all of the weight stack plates:

T O T A L W E I G H T S T A C K P U L S E S = 5 1 0

This value depends on the type of motor used and the transmission ratios of the mechanics used in order to make the selection. Thus, if not otherwise advised, maintain this value set at 510.

Enter the value, then press “Enter” to continue or “Clear” to abort.

9.2.4. WEIGHT STACK MOTOR INERTIA This option allows you to set the inertia of the motor and of the mechanical weight stack selection system, expressed in the pulses produced by the encoder associated with the weight stack motor, so that the selection system may be stopped at precisely the desired plate:

O F F S E T M O T O R W G T O F FP U L S E S = 3

Physically, this parameter is the motor stop advance.

This value depends on the type of motor used and the mechanics used to make the selection. This value is factory-set to 3, but it may be necessary to change it due to changes in the selection system conditions.

Should you observe that the relays of the weight stack motor interface board sputter when stopping the motor at the selection pin, after jumps caused by constant adjustments to the motor position, then you must increase the value of this parameter. Indeed, if the motor inertia is greater than the configured parameter, when stopping the


Page 9.4

motor goes beyond the position to be reached; the control drives it back and forth several times until it is locked in the correct position, causing the relays to sputter.


9.2.5. WEIGHT STACK MOTOR SELECTION WINDOW This option allows you to set the width of the selection window, expressed in pulses produced by the encoder associated with the weight stack motor, corresponding to secure, silent plate selection.

O F F S E T W E I G H T L I F T E D P U L S E S = 1 0

Indeed, if the user begins the exercise during weight selection, the desired result is for the weight stack selection system to stop immediately in a position where plate selection is safe and silent.

This value depends on the type of motor used and the mechanics used to make the selection. This value is factory-set to 10, but it may be necessary to change it due to changes in the selection system conditions.


9.2.6. DISTANCE BETWEEN PLATES This option allows you to set the distance, expressed in pulses produced by the encoder associated with the weight stack motor, between plates in the weight stack. Data should be entered beginning with:

P L A T E 0 - 1 D I S T A N C EP U L S E S = X X

through:

P L A T E 2 2 - 2 3 D I S T A N C EP U L S E S = X X

This value depends on the mechanics of the weight stack, in particular the presence of spacers between plates. When using the machine, these spacers--especially those of the last plates because of the weight of the entire weight stack--may vary in thickness, thereby creating problems with selecting the weight stack correctly.

These distances are factory-set as indicated in the table below:

Plates Distance 0 – 1 24 1 – 2 24 2 – 3 23 3 – 4 24


Page 9.5

4 – 5 23 5 – 6 24 6 – 7 23 7 – 8 24 8 – 9 23 9 – 10 23 10 – 11 23 11 – 12 23 12 – 13 23 13 – 14 22 14 – 15 23 15 – 16 23 16 – 17 23 17 – 18 23 18 – 19 23 19 – 20 23 20 – 21 23 21 – 22 23 22 – 23 40

Enter the value, then press “Enter” to continue or “Clear” to abort. Move on to the next parameter when all distances have been configured.

9.2.7. NUMBER OF PULSES FOR SEAT SELECTION

This parameter does not appear for Abdominal Crunch and Lower Back. This option allows you to set the number of pulses produced by the encoder associated with the seat motor to complete the entire seat stroke:

T O T A L R A N G E S E A T P U L S E S = X X X

This value depends on the type of motor used and the transmission ratios of the mechanics used in order to make the selection. Thus, if not otherwise advised, maintain the value as specified in the table below:

Machine Pulses Leg Extension 355 Leg Curl 355 Vertical Traction 355 Shoulder Press 355 Chest Press 355 Rowing Torso 355 Leg Press 430



Page 9.6

9.2.8. SEAT OFFSET POSITION 0

This parameter does not appear for Abdominal Crunch and Lower Back. This option allows you to set the distance, expressed in pulses produced by the encoder associated with the seat motor, for the 0 position of the seat from the nearest stroke end:

O F F S E T P O S . 0 S E A T P U L S E S = X X X




9.2.9. SEAT OFFSET POSITION 9

This parameter does not appear for Abdominal Crunch and Lower Back. This option allows you to set the distance, expressed in pulses produced by the encoder associated with the seat motor, for the 9 position of the seat from the nearest stroke end:

O F F S E T P O S . 9 S E A T P U L S E S = X X X





Page 9.7

9.2.10. SEAT MOTOR INERTIA

This parameter does not appear for Abdominal Crunch and Lower Back. This option allows you to set the inertia of the motor and of the mechanical seat selection system, expressed in pulses produced by the encoder associated with the seat motor, so that the seat may be stopped in the desired position:

O F F S E T M O T O R S E A T O F FP U L S E S = X

Physically, this parameter is the motor stop advance.

This value depends on the type of motor used and the mechanics used to make the selection. This value is factory-set as indicated in the table below:


It may be necessary to change it due to changes in the selection system conditions.

Should you observe that the relays of the seat motor interface board sputter when stopping the motor, after jumps caused by constant adjustments to the motor position, then you must increase the value of this parameter. Indeed, if the motor inertia is greater than the configured parameter, when stopping the motor goes beyond the position to be reached; the control drives it back and forth several times until it is locked in the correct position, causing the relays to sputter.


9.2.11. MINIMUM ROM LENGTH This option allows you to set the value in cm of the parameter “ROM minimum length”; for a description of this parameter, see paragraph 11.1. “Configuration parameters for exercise ROM acquisition”:

R O M M I N I M U M L E N G T H c m = X X



Page 9.8

Machine Cm Abdominal Crunch 3 Lower Back 5 Leg Extension 15 Leg Curl 15 Vertical Traction 15 Shoulder Press 15 Chest Press 10 Rowing Torso 15 Leg Press 8

Enter the desired value, then press “Enter” to continue or “Clear” to abort.

9.2.12. DEFAULT ROM START This option allows you to set the value in cm of the parameter “Default ROM start”; for a description of this parameter, see paragraph 11.1. “Configuration parameters for exercise ROM acquisition”:

D E F A U L T R O M S T A R T c m = X X




9.2.13. DEFAULT ROM LENGTH This option allows you to set the value in cm of the parameter “Default ROM length”; for a description of this parameter, see paragraph 11.1. “Configuration parameters for exercise ROM acquisition”:

D E F A U L T R O M L E N G T H c m = X X



Page 9.9



9.2.14. %ROM FIRST REP This option allows you to set the value in cm of the parameter “%ROM first rep” ; for a description of this parameter, see paragraph 11.1. “Configuration parameters for exercise ROM acquisition”:

% R O M F I R S T R E P % = X X


Machine % Abdominal Crunch 45 Lower Back 45 Leg Extension 45 Leg Curl 45 Vertical Traction 45 Shoulder Press 45 Chest Press 74 Rowing Torso 55 Leg Press 45

Enter the desired value, then press “Enter” to continue or “Clear” to abort. Then the procedure will end by displaying the following message:

E N D S E T U P M A C H I N E P R O C E D U R E

After 3 seconds, the machine will then move the weight stack motor until the selection brush is aligned with the top gear, to assist its replacement, and will move the seat into position 9. In this case, the following will appear on the display:

P R E S S E N T E R T O C O N T I N U E


Page 9.10

Press “Enter” to continue or “Clear” to abort. At this point the machine will perform a reset procedure, during which the following will appear on screen:

M A C H I N E R E S E T P L E A S E W A I T . . .

When finished, the machine will return to stand-by mode.


Page 9.11

9.3. CONFIGURING THE USER PARAMETERS

Before carrying out this procedure, make sure that the type of machine is correctly set as described in paragraph 9.2. “Configuring the technical parameters”.

User parameters are those that may be changed directly by the user, since they have to do with configuring the use and interface of the equipment. The procedure for configuring user parameters may be activated, when the machine is in stand-by, by pressing keys “1”, “3” and “4” simultaneously, and making sure that the dip-switches on the CPU Board are set to Position 1000. To access this procedure, you must enter the password that protects against unauthorized access.

P A S S W O R D = *

After entering the password “2406” and pressing “Enter” to continue, the machine begins to offer the configurable parameters in sequence, showing the current value and possible alternatives. Press the "Enter" key to move on to the next parameter, or the “Clear” key to quit the procedure.

Pressing the “Clear” key will abort the procedure, but any changes previously made will remain in effect. However, you must reset or turn the machine off and back on again in order for the changes to affect the current program session.

9.3.1. LANGUAGE This option allows you to set the program language:

L A N G U A G E I = 1 U S A = 2 U K = 3 D = 4 F = 5 N L = 6 X

The following options are available: • Italian = 1; • American English = 2; • British English = 3; • German = 4; • French = 5; • Dutch = 6. Select the desired option, then press “Enter” to continue or “Clear” to abort.

9.3.2. UNIT OF MEASURE This option allows you to set the unit of measure for weights used by the system:

S E L E C T M E A S U R E U N I T K G = 1 L B S = 2 X


Page 9.12

The following options are available: • kilograms = 1; • pounds = 2. Select the desired option, then press “Enter” to continue or “Clear” to abort.

9.3.3. USING THE ADDITIONAL WEIGHT This option allows you to set whether to use the additional weight:

A . W . E N A B L E N = 1 Y = 2 = X

The following options are available: • NO = 1; • YES = 2. Select the desired option, then press “Enter” to continue or “Clear” to abort.

9.3.4. USING THE FUNCTION KEYS This option allows you to set whether the function keys can be disabled:

F U N C T I O N K E Y S N = 1 Y = 2 = X

The following options are available: • NO = 1; • YES = 2. Select the desired option, then press “Enter” to continue or “Clear” to abort. If NO is selected, it will be possible to change the machine weight and seat position, if present, only using the TGS key before executing an exercise on the machine.

9.3.5. NUMBER OF WHICH REPETITION TO USE FOR ROM ACQUISITION This option allows you to set in which repetition the ROM is to be acquired:

R O M A C Q U I S I T I O N R E P N . = X

Enter the number of the desired repetition, then press “Enter” to continue or “Clear” to abort.

9.3.6. “TIME-OUT” SETTING This option allows you to set the time interval, in minutes. of non-use of the machine, after which the machine will perform an automatic reset procedure:


Page 9.13

T I M E O U T 3 - 3 0 m i n . T I M E m i n . = 1 0

This value is factory-set to the recommended default value of 10 minutes.

If this parameter is set to 0, the machine will reset every 3 minutes and will not change the seat position.


9.3.7. SETTING THE DEFAULT SEAT POSITION

This parameter does not appear for Abdominal Crunch and Lower Back. This option allows you to set the position that the seat will automatically move to at the end of the automatic reset procedure:

S T A N D B Y S E A T P O S I T I O N = X

These distances are factory-set to their recommended default value, as indicated in the table below:

Machine Position Leg Extension 5 Leg Curl 5 Vertical Traction 5 Shoulder Press 5 Chest Press 5 Rowing Torso 0 Leg Press 0


9.3.8. ENABLE PACER This option allows you to set pacer display to show the exercise completion speed:

P A C E R E N A B L E N = 1 Y = 2 = X

The following options are available: • NO = 1; • YES = 2. Select the desired option, then press “Enter” to continue or “Clear” to abort.


Page 9.14

9.3.9. PACER SPEED This option allows you to set the speed of the pacer, if present:

P A C E R S P E E D 3 0 - 8 0 0 m m / s e c = X X X

You may enter any value between 30 and 800 mm/sec. These speeds are factory-set to their recommended default value, as indicated in the table below:

Machine Speed Abdominal Crunch 50 Lower Back 100 Leg Extension 300 Leg Curl 250 Vertical Traction 210 Shoulder Press 210 Chest Press 470 Rowing Torso 300 Leg Press 220


9.3.10. TIME BEFORE LOAD This option allows you to set the timeout in seconds the machine waits, when the weight stack is in stand by position, before considering that the set is over.

T I M E B E F O R E L O A D : 1 - 3 0 S E C . = X X X

You may enter any value between 1 and 30 sec. This time is factory-set to 5 sec.

9.3.11. PERFORM AUTO-CONFIGURATION PROCEDURE This option allows you to set whether to perform the automatic procedure to configure the machine's ROM parameters: default ROM length, default ROM start, %ROM first repetition and ROM minimum length (for a description of their meaning, see paragraph 11.1. “Configuration parameters for exercise ROM acquisition”). The automatic configuration is set up so that the value of the 4 parameters listed above is deduced from performing 3 repetitions:

A U T O C O N F I G . N = 1 Y = 2 = X

The following options are available: • NO = 1; • YES = 2.


Page 9.15

Select the desired option, then press “Enter” to continue or “Clear” to abort. If the NO option is selected, the value of the parameters will be configured manually, as described in paragraph 9.2. “Configuring the technical parameters”, while if the YES option is selected, the SW will ask you to do 3 reps and, according on these reps the SW will automatically define the value of the parameters ROM minimum length, default ROM start, default ROM length e %ROM first rep. Then the procedure will end by displaying the following message:

E N D S E T U P M A C H I N E P R O C E D U R E

After 3 seconds, the machine will then perform a reset procedure, during which the following will appear on screen:

M A C H I N E R E S E T P L E A S E W A I T . . .

When finished, the machine will return to stand-by mode.


Page 9.16

9.4. TABLE OF FACTORY SETTINGS

The tables below summarize the factory settings for the machines:

9.4.1. USER PARAMETERS

Machine Pacer speed

Time out

Seat stand-by

Abdominal Crunch 50 10 - Lower Back 100 10 - Leg Extension 300 10 5 Leg Curl 250 10 5 Vertical Traction 210 10 5 Shoulder Press 210 10 5 Chest Press 470 10 5 Rowing Torso 300 10 0 Leg Press 220 10 0

9.4.2. ROM PARAMETERS

Machine Code Minimum ROM length

Default ROM start

Default ROM length

%ROM first rep

Abdominal Crunch 3 3 5 8 45 Lower Back 6 5 5 10 45 Leg Extension 2 15 5 30 45 Leg Curl 5 15 5 30 45 Vertical Traction 1 15 10 30 45 Shoulder Press 7 15 5 30 45 Chest Press 0 10 10 30 74 Rowing Torso 8 15 5 50 55 Leg Press 4 8 2 16 45

9.4.3. BOSCH WEIGHT STACK MOTOR PARAMETERS

Machine Total weight stack pulses

Offset motor WGT off pulses

Offset weight lifted pulses

Abdominal Crunch 510 3 10 Lower Back 510 3 10 Leg Extension 510 3 10 Leg Curl 510 3 10 Vertical Traction 510 3 10 Shoulder Press 510 3 10 Chest Press 510 3 10 Rowing Torso 510 3 10 Leg Press 510 3 10


Page 9.17

9.4.4. PLATE DISTANCE

Plates Distance 0 – 1 24 1 – 2 24 2 – 3 23 3 – 4 24 4 – 5 23 5 – 6 24 6 – 7 23 7 – 8 24 8 – 9 23 9 – 10 23 10 – 11 23 11 – 12 23 12 – 13 23 13 – 14 22 14 – 15 23 15 – 16 23 16 – 17 23 17 – 18 23 18 – 19 23 19 – 20 23 20 – 21 23 21 – 22 23 22 – 23 40

9.4.5. SEAT MOTOR PARAMETERS

Machine Total seat pulse range

Offset pos. 0 seat pulses

Offset pos. 9 seat pulses

Offset motor seat off

Leg Extension 355 3 46 2 Leg Curl 355 3 10 2 Vertical Traction 355 3 10 2 Shoulder Press 355 3 10 2 Chest Press 355 3 10 2 Rowing Torso 355 3 10 2 Leg Press 430 25 18 20


Page 9.18

9.5. DISPLAYING WORKING PARAMETERS

In order to check the status of the machine and perform regular maintenance, it is possible to display the working parameter values using a special procedure. This procedure may be activated, when the machine is in stand-by, by pressing keys “1”, “3” and “4” simultaneously. To access this procedure, you must enter the password that protects against unauthorized access:

P A S S W O R D = *

After entering the password “1508” and pressing “Enter” to continue, the machine begins to offer the saved parameter values in sequence. Press the "Enter" key to move on to the next parameter, or the “Clear” key to quit the procedure. The following information will be displayed on the LED matrix at this point:

9.5.1. WEIGHT STACK MOTOR RUNNING TIME This is the total number of hours for which the weight stack motor has been used.

M O T O R W E I G H T O N H O U R S X X : X X

Press ENTER to continue.

9.5.2. WEIGHT STACK MOTOR TEST CYCLES The number of cycles performed by the weight stack motor during the test procedure described in paragraph 6.2. “Automatic components test”.

M O T O R W E I G H T C Y C L E S : X X X X X


9.5.3. NUMBER OF RELAY SWITCHING CYCLES TO MOVE THE WEIGHT STACK MOTOR UPWARD

The number of times the weight stack motor interface board relays have switched in order to move the motor upward.

W E I G H T R E L A Y U P C Y C L E S : X X X X X


9.5.4. NUMBER OF RELAY SWITCHING CYCLES TO MOVE THE WEIGHT STACK MOTOR DOWNWARD

The number of times the weight stack motor interface board relays have switched in order to move the motor downward.


Page 9.19

W E I G H T R E L A Y D O W N C Y C L E S : X X X X X


9.5.5. NUMBER OF FAIL SIGNALS PRODUCED BY THE WEIGHT STACK MOTOR INTERFACE BOARD

The number of fails signals produced by the weight stack motor interface board.

T O T A L F A I L W E I G H T N : X


9.5.6. SEAT MOTOR RUNNING TIME

This parameter does not appear for Abdominal Crunch and Lower Back. This is the total number of hours for which the seat motor has been used.

M O T O R S E A T O N H O U R S X X : X X


9.5.7. SEAT MOTOR TEST CYCLES

This parameter does not appear for Abdominal Crunch and Lower Back. The number of cycles performed by the seat motor during the test procedure described in paragraph 6.2. “Automatic components test”.

M O T O R S E A T C Y C L E S : X X X X X


9.5.8. NUMBER OF RELAY SWITCHING CYCLES TO MOVE THE SEAT MOTOR UPWARD

This parameter does not appear for Abdominal Crunch and Lower Back. The number of times the seat motor interface board relays have switched in order to move the motor upward.


Page 9.20

S E A T R E L A Y U P C Y C L E S : X X X X X


9.5.9. NUMBER OF RELAY SWITCHING CYCLES TO MOVE THE SEAT MOTOR DOWNWARD

This parameter does not appear for Abdominal Crunch and Lower Back. The number of times the seat motor interface board relays have switched in order to move the motor downward.

S E A T R E L A Y D O W N C Y C L E S : X X X X X


9.5.10. NUMBER OF FAIL SIGNALS PRODUCED BY THE SEAT MOTOR INTERFACE BOARD

This parameter does not appear for Abdominal Crunch and Lower Back. The number of fails signals produced by the seat motor interface board.

T O T A L F A I L S E A T N : X


9.5.11. NUMBER OF SOLENOID RELAY SWITCHING CYCLES The number of times the solenoid interface board relays have switched in order to activate the solenoid.

S O L E N O I D R E L A Y C Y C L E S : X X X X X


9.5.12. MACHINE RUNNING TIME This is the total number of hours for which the machine has been powered.

M A C H I N E O N H O U R S X X : X X



Page 9.21

9.5.13. NUMBER OF REPETITIONS CARRIED OUT ON THE MACHINE This is the total number of repetitions carried out by users.

T O T A L R E P S C Y C L E S : X X X X X


9.5.14. TOTAL WEIGHT LIFTED USING THE MACHINE The total weight lifted by the machine, expressed in 100-kg units. This value is obtained by adding the weight lifted for each repetition.

T O T A L W E I G H T Q . l i : X X X X X

Press ENTER to continue. When finished, the machine will return to stand-by mode. The CLEAR key may be pressed at any time to abort the procedure and return to stand-by mode.


Page 9.22

9.6. EDITING THE WORKING PARAMETERS

The procedure for editing the machine's working parameters, to set the desired values (for example, after replacing the CPU board) may be activated when the machine is in stand-by mode by pressing the keys “1”, “3” and “4” simultaneously. To access this procedure, you must enter the password that protects against unauthorized access.

P A S S W O R D = *

After entering the password “2709” and pressing “Enter” to continue, the machine begins to offer the configurable parameters in sequence, showing their current value. Press the "Enter" key to move on to the next parameter; to change a value, simply type in the new value desired. Or, you may press the “Clear” key to quit the procedure.

All data are expressed in 9-digit numbers. This means that to edit an existing 4-digit number, you must first enter 5 digits to reset the value, then enter the desired value.

The following information will be displayed on the LED matrix at this point:

9.6.1. WEIGHT STACK MOTOR RUNNING TIME This is the total number of seconds for which the weight stack motor has been used.

M O T O R W E I G H T O N S E C . X X X X X X X X X

Change the value shown or press ENTER to continue.

9.6.2. WEIGHT STACK MOTOR TEST CYCLES The number of cycles performed by the seat motor during the test procedure described in paragraph 6.2. “Automatic components test”.

M O T O R W E I G H T C Y C L E S : X X X X X X X X X


9.6.3. NUMBER OF RELAY SWITCHING CYCLES TO MOVE THE WEIGHT STACK MOTOR UPWARD

The number of times the weight stack motor interface board relays have switched in order to move the motor upward.

W E I G H T R E L A Y U P C Y C L E S : X X X X X X X X X



Page 9.23

9.6.4. NUMBER OF RELAY SWITCHING CYCLES TO MOVE THE WEIGHT STACK MOTOR DOWNWARD

The number of times the weight stack motor interface board relays have switched in order to move the motor downward.

W E I G H T R E L A Y D O W N C Y C L E S : X X X X X X X X X


9.6.5. NUMBER OF FAIL SIGNALS PRODUCED BY THE WEIGHT STACK MOTOR INTERFACE BOARD

The number of alarm signals produced by the weight stack motor interface board.

T O T A L F A I L W E I G H T N : X X X X X X X X X


9.6.6. SEAT MOTOR RUNNING TIME

This parameter does not appear for Abdominal Crunch and Lower Back. This is the total number of seconds for which the seat motor has been used.

M O T O R S E A T O N S E C . X X X X X X X X X


9.6.7. SEAT MOTOR TEST CYCLES

This parameter does not appear for Abdominal Crunch and Lower Back. The number of cycles performed by the seat motor during the test procedure described in paragraph 6.2. “Automatic components test”.

M O T O R S E A T C Y C L E S : X X X X X X X X X


9.6.8. NUMBER OF RELAY SWITCHING CYCLES TO MOVE THE SEAT MOTOR UPWARD

This parameter does not appear for Abdominal Crunch and Lower Back.


Page 9.24

The number of times the seat motor interface board relays have switched in order to move the motor upward.

S E A T R E L A Y U P C Y C L E S : X X X X X X X X X


9.6.9. NUMBER OF RELAY SWITCHING CYCLES TO MOVE THE SEAT MOTOR DOWNWARD

This parameter does not appear for Abdominal Crunch and Lower Back. The number of times the seat motor interface board relays have switched in order to move the motor downward.

S E A T R E L A Y D O W N C Y C L E S : X X X X X X X X X


9.6.10. NUMBER OF FAIL SIGNALS PRODUCED BY THE SEAT MOTOR INTERFACE BOARD

This parameter does not appear for Abdominal Crunch and Lower Back. The number of fail signals produced by the seat motor interface board.

T O T A L F A I L S E A T N : X X X X X X X X X


9.6.11. NUMBER OF SOLENOID RELAY SWITCHING CYCLES The number of times the solenoid interface board relays have switched in order to activate the solenoid.

S O L E N O I D R E L A Y C Y C L E S : X X X X X X X X X


9.6.12. MACHINE RUNNING TIME This is the total number of seconds for which the machine has been powered.

M A C H I N E O N S E C . X X X X X X X X X


Page 9.25


9.6.13. NUMBER OF REPETITIONS CARRIED OUT ON THE MACHINE This is the total number of repetitions carried out by users.

T O T A L R E P S C Y C L E S : X X X X X X X X X


9.6.14. TOTAL WEIGHT LIFTED USING THE MACHINE The total weight lifted by the machine. This value is obtained by adding the weight lifted for each repetition.

T O T A L W E I G H T Q . l i : X X X X X X X X X

Change the value shown or press ENTER to continue. When finished, the machine will return to stand-by mode. The CLEAR key may be pressed at any time to abort the procedure and return to stand-by mode.


Page 9.26



Page 10.1

10. SCHEDULED MAINTENANCE Periodic scheduled maintenance operations are necessary to keep the machines in perfect working order and prevent problems. There are essentially 4 types of maintenance operations: • Internal and external cleaning; • Mechanical operations; • Electrical/electronic operations; • Software configuration These should be carried out at different intervals, and by technical personnel with different skill sets. The paragraphs below illustrate the recommended operations.

10.1. EXTERNAL CLEANING

These operations may be carried out by the machine owner, and require no special expertise.

The machines require simply external cleaning to respect normal health and hygiene standards. We recommend that you carry out these operations at least once a week. Follow the procedure below for external cleaning :

10.1.1. PREPARING WORKING CONDITIONS 1. Shut off the machine by setting the switch to 0 (OFF). 2. Unplug the power cord from the wall socket.

10.1.2. CLEANING OPERATIONS 1. Clean the entire machine using a cloth dampened with neutral, non-acid cleanser. Make sure not

to rub too hard, especially on the display keys and the Plexiglas weight stack guard.

Never spray the product directly onto the machine.

CAUTION: do not use alcohol, benzene, or chemical products in general. 2. For the Leg Press, clean the seat sliding bars with a paper towel dipped in ethyl alcohol.


Page 10.2

10.2. INTERNAL CLEANING

These operations may be carried out only by technical personnel specially trained by Technogym, since they require disassembling parts of the machine.

Internal cleaning operations involve simply cleaning the interior of the machine to prevent dust from accumulating, which could affect the smooth movement of moving parts. We recommend that you carry out these operations at least once every 6 months. Follow the procedure below for internal cleaning:

10.2.1. PREPARING WORKING CONDITIONS 1. Shut off the machine by setting the switch to 0 (OFF). 2. Unplug the power cord from the wall socket. 3. Open all housings, the Plexiglas weight stack guards and mats on the machine.

10.2.2. CLEANING OPERATIONS 1. Clean the interior with a vacuum cleaner, concentrating especially on the weight stack area, the

electronic control box and, where present, the seat mechanisms.

CAUTION: when performing these operations, take care not to damage the wiring. 2. Move the machine using the wheels provided, and clean the floor underneath with a vacuum

cleaner. 3. With the machine open, check the wear and tension of the cables, make sure the pulleys turn

smoothly and that the mechanisms have the correct play. Call an authorized Technogym Service Center for any technical needs.


Page 10.3

10.3. MECHANICAL OPERATIONS

These operations must be carried out only by a qualified technician specially trained by Technogym and authorized to perform machine settings and start-up as well as special maintenance or repairs requiring in-depth knowledge of the machine, its operation, its safety features and intervention procedures.

Mechanical operations on the machine involve setting the machine mechanisms to ensure that they will function properly. We recommend that you carry out these operations at least once every 1 month. Follow the procedure below for mechanical operations:

10.3.1. PREPARING WORKING CONDITIONS 1. Shut off the machine by setting the switch to 0 (OFF). 2. Unplug the power cord from the wall socket. 3. Open all housings, the Plexiglas weight stack guards and mats on the machine.

10.3.2. CHECK THE WEIGHT STACK SELECTION SYSTEM 1. Disassemble the weight stack selection system. 2. Check the wear status of the:

• weight stack selection system chain; • selection brush; • selection slides.

Repair and/or replace any worn parts.

3. Check the tension of the weight stack selection system chain. 4. Lubricate weight stack selection system chain using FIN FOOD LUBE.

10.3.3. CHECK THE WEIGHT STACK PLATE SPRINGS 1. Disassemble the weight stack selection system. 2. Check the wear status of the springs on each plate of the weight stack. Repair and/or replace any

worn parts.

CAUTION: do NOT lubricate the springs and/or sliding parts of the plates for any reason.

3. Clean the plates with dry compressed air.

10.3.4. CHECK THE CROSS, BARS AND WEIGHT STACK PLATES 1. Check the wear status of the cross bushings and weight stack plates. Repair and/or replace any

worn parts. 2. Check the wear status of the weight stack bars and weight stack support buffers. Repair and/or

replace any worn parts.


Page 10.4

3. Make sure the weight stack bars are firmly fastened. Repair and/or replace any worn parts. 4. Clean the bars using alcohol. 5. Lubricate the bars and bushings of the plates and cross using BP ERGOL GHL68.

10.3.5. CHECK THE ADDITIONAL WEIGHT 1. Make sure the additional weight slides smoothly. Repair and/or replace any worn parts. 2. Lubricate the sliding tracks using MOLYKOTE LONGTERM W 2.

10.3.6. CHECK THE CABLES 1. Check the wear status of the machine cables, paying special attention to any hardened spots or

discoloration in the protective plastic of the cable. 2. Make sure the machine cables are firmly fastened to cams, pulleys and/or the ends connected to

ball joints. 3. Check the tension of the machine cables.

10.3.7. CHECK THE MECHANISMS 1. Check the wear status of the machine mechanisms: lever arms, shafts, lever systems. Repair

and/or replace any worn parts. 2. Check the phasing of the machine mechanisms. 3. Lubricate the mechanisms using MOLYKOTE LONGTERM W 2.

10.3.8. CHECK THE GAS SPRINGS

Perform this check on the Vertical Traction, Shoulder Press, Chest Press, Rowing Torso and Leg Press.

1. Check the efficiency of the gas spring, making sure it sufficiently cushions the stem return to its

outward position. 2. Clean the stem using alcohol.

CAUTION: do NOT lubricate the gas spring stem for any reason.

10.3.9. CHECK THE PULLEYS 1. Check the wear status of the pulley grooves. Repair and/or replace any worn parts.

10.3.10. CHECK THE CAM GROUP 1. Check the wear status of the cam grooves. Repair and/or replace any worn parts. 2. Make sure all parts in the cam group are firmly tightened.

10.3.11. CHECK THE PRIMARY AND SECONDARY SHAFT CONNECTION CHAIN

Perform this check on the Abdominal Crunch, Lower Back, Leg Extension and Leg Curl.

1. Check the wear status of the chain. Repair and/or replace any worn parts. 2. Check the alignment and tension of the chain.


Page 10.5

3. Lubricate the chain using MOLYKOTE LONGTERM W 2.

10.3.12. CHECK THE LEVER LIMIT SWITCH BUFFERS 1. Check the wear status of the lever limit switch buffers. Repair and/or replace any worn parts. 2. Check the position of the buffers and make sure they are firmly fastened in place.

10.3.13. CHECK THE CROSS LIMIT SWITCH 1. Check the wear status of the cross limit switch. Repair and/or replace any worn parts. 2. Check the position of the cross limit switches and make sure they are firmly fastened in place.

10.3.14. CHECK THE LEG PRESS SEAT MECHANISM 1. Check the wear status of the support bars, the pinion and rack of the seat. Repair and/or replace

any worn parts. 2. Clean the seat support bars using alcohol. 3. Lubricate the pinion and rack of the seat using MOLYKOTE LONGTERM W 2.

CAUTION: do NOT lubricate the support bars for any reason.

10.3.15. CHECK THE SEAT MECHANISM FOR OTHER MACHINES 1. Check the wear status of the support bars and seat guide. Repair and/or replace any worn parts. 2. Clean the seat support guide bars using alcohol. 3. Lubricate the seat support guide bars using BP ERGOL GHL68.

10.3.16. CHECK THE LEG PRESS BACK AND SHOULDER REST 1. Lubricate the sinker of the Leg Press back and shoulder rest to mid-height, using MOLYKOTE

LONGTERM W 2. 2. Lubricate the shoulder rest carriage bars with BP ERGOL GHL68.

10.3.17. CHECK THE WIRE ENCODER 1. Check the wear status of the encoder cable. Replace the encoder if worn. 2. Check the wear status of the encoder cable return spring. Replace the encoder if worn.


Page 10.6

10.4. ELECTRICAL/ELECTRONIC OPERATIONS


Electrical/electronic operations on the machine involve setting the electrical/electronic components of the machine to ensure that they will function properly. We recommend that you carry out these operations at least once every 1 months. Follow the procedure below for electrical/electronic operations:

10.4.1. PREPARING WORKING CONDITIONS 1. Open all housings, the Plexiglas weight stack guards and mats on the machine.

CAUTION: you must work with the machine open and live.

10.4.2. CHECK THE WIRING AND CONNECTIONS 1. Check the wear status of all wiring:

• External conditions; • Any oxidation on connectors; • Continuity of the individual wires; • Insulation of the individual wires to earth.

Repair and/or replace any substandard parts.

2. Check the status of the fuses using a tester.

10.4.3. CHECK THE DISPLAY 1. Check the efficiency of all keyboard keys. 2. Check the efficiency of all LEDs, the buzzer, the back-lighting and LCD characters on the

display. 3. With the machine shut off, check the efficiency of the buffer battery: you should measure an

ideal value of 3.6 Vdc at its ends, with a minimum acceptable level of 2.5 Vdc.

10.4.4. CHECK WEAR ON COMPONENTS 1. Check the number of times the solenoid relays have switched as described in the paragraph

9.5.11. : if the value is greater than 1,000,000, replace the relays as they will soon be damaged. 2. Check the number of times the seat movement relays have switched to move the seat motor up

and down, as described in the paragraphs 9.5.8. and 9.5.9. : if the value is greater than 750,000, replace both relays as they will soon be damaged.

3. Check the number of times the weight stack movement relays have switched to move the weight stack up and down, as described in the paragraphs 9.5.3. and 9.5.4. : if the value is greater than 500,000, replace both relays as they will soon be damaged.


Page 10.7

4. Check the number of running hours for the seat motor as described in the paragraph 9.5.6. : if the value is greater than 1500, replace the motor as its brushes will soon be worn out.

This check is not necessary on the Leg Press: in this case, simply remove the brushes and check their wear status. If they are very worn, replace only the brushes.

5. Check the number of running hours for the weight stack motor as described in the paragraph

9.5.1. : if the value is greater than 1500, replace the motor as its brushes will soon be worn out. 6. Check the number of running hours for the machine as described in the paragraph 9.5.12. : if the

value is greater than 100,000, replace the LCD as its back-lighting will soon be worn out.

10.4.5. CHECK THE COMPONENT FUNCTIONS 1. Using the machine test programs, check the functioning of the various components:

• TGS interface; • FPGA board; • Encoder; • Solenoid; • Weight stack motor; • Zero sensor; • Seat motor (if present); • Limit microswitch (on Leg Press only).

Repair and/or replace any substandard parts.


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10.5. SOFTWARE CONFIGURATION


Software configuration on the machine involves adjusting the configuration parameters to ensure that the machines will function properly. We recommend that you carry out these operations at least once every 1 months. Follow the procedure below for electrical/electronic operations:

10.5.1. PREPARING WORKING CONDITIONS 1. Open Plexiglas weight stack guards on the machines.

CAUTION: you must work with the machine open and live.

10.5.2. CONFIGURATION CHECK 1. Check the configuration of the technical parameters of the machine as described in the

paragraph 9.2. . Pay special attention to the Offset parameter, plate distance and weight stack motor inertia, since they affect the weight stack plate selection. Visually make sure the selection is correct as described in the paragraph 8.1. .

2. Check the configuration of the user parameters of the machine as described in the paragraph 9.3. .


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11. APPENDIX

11.1. CONFIGURATION PARAMETERS FOR EXERCISE ROM ACQUISITION

The exercise ROM acquisition is based on an algorithm, developed by Technogym, in which the following parameters may be configured to better adapt to the customer’s needs: • ROM minimum length

This is the minimum stroke the weight stack must carry out in order to calculate the movement as a repetition.

• Default ROM start This is the length of the stroke that the weight stack must make from the resting area to enter the exercise area, due to the mechanics of the individual machine. This movement is normally carried out using the machine’s pre-start function.

• Default ROM length This is the default amplitude of the ROM before acquiring the user’s actual ROM, and is used to correctly fill the ROM LED arc on the display.

• %ROM first rep This is the percentage of ROM, defined by the parameter “default ROM length”, which is carried out using the machine’s pre-start function during the first repetition.

11.2. CALCULATING REPETITIONS

Defining a weight stack movement as a stroke between two direction reversals in succession, the program will consider the movement to be a repetition if: • Before ROM acquisition:

− it is greater than the value defined by the parameter “ROM minimum length”; − it is greater than the value defined by the following formula:

( “default ROM length” / 100 ) * “%ROM first rep”

• After ROM acquisition:

− it is greater than the value defined by the parameter “ROM minimum length”;.


Page 11.2

11.3. LOCATING THE SERIAL NUMBER

Each machine has 2 labels containing the serial number of the machine. One of these labels is accessible externally, and is located on the seat support frame, the other is accessible by disassembling the machine mats, and is located on the frame next to the machine’s power entry.

0SMM0078-ING

TECHNOGYM S.p.A. Via G. Perticari, 20

47035 Gambettola (FC) ITALIA

Tel.: +39-0547-650438 Fax: +39-0547-650150

e-mail: [email protected]

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