SERVICE MAINTENANCE MANUAL - Technogym · 2. Use original Technogym spare parts and lubricants of the recommended brands. 3. Use special tools where specified. 4. Consult the Technical

SERVICE & MAINTENANCE MANUAL

Rev. 1.1

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 or use of this manual. This document contains proprietary information that is protected by copyright. All rights reserved. No part of this document may be photocopied, reproduced or translated into another language without the prior written consent of Technogym. The Technogym® trademark is property of Technogym S.p.A. The Unica Evolution™ trademark is property of Technogym S.p.A.

UNICA EVOLUTION: Service & Maintenance Manual - rev. 1.1

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

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

2. TECHNICAL CHARACTERISTICS.................................................................................................................. 2.1 2.1. PRODUCT VERSIONS ......................................................................................................................................... 2.1 2.2. PRODUCT CODE ................................................................................................................................................ 2.1 2.3. MECHANICAL CHARACTERISTICS ..................................................................................................................... 2.2 2.4. AMBIENT SPECIFICATIONS ................................................................................................................................ 2.2 2.5. CONFORMITY TO REGULATIONS........................................................................................................................ 2.2

3. INSTALLING AND MOVING THE MACHINES ............................................................................................ 3.1 3.1. SPECIFICATIONS AND REQUIREMENTS .............................................................................................................. 3.1 3.2. INSTALLATION.................................................................................................................................................. 3.1 3.3. MOVING ........................................................................................................................................................... 3.2

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

5. WHAT IF …........................................................................................................................................................... 5.1 5.1. THE WEIGHT STACK DOES NOT SLIDE SMOOTHLY ............................................................................................. 5.1 5.2. THE WEIGHT STACK CABLE IS NOT TAUT........................................................................................................... 5.2

6. HOW TO DISASSEMBLE THE …..................................................................................................................... 6.1 6.1. SEAT GAS SPRING ............................................................................................................................................. 6.1 6.2. PECTORAL ARM ................................................................................................................................................ 6.3 6.3. WEIGHT STACK................................................................................................................................................. 6.4

7. SPECIAL OPERATIONS..................................................................................................................................... 7.1 7.1. LOCKING DOWN THE CABLE FIXING DOWELS .................................................................................................... 7.1

8. MAINTENANCE................................................................................................................................................... 8.1 8.1. CLEANING ........................................................................................................................................................ 8.1

8.1.1. Cleaning the frame and painted parts.................................................................................................. 8.1 8.1.2. Cleaning the chrome-plated parts........................................................................................................ 8.1 8.1.3. Cleaning upholstery ............................................................................................................................. 8.1

8.2. ROUTINE MAINTENANCE................................................................................................................................... 8.3 8.2.1. Check the cross, bars and weight stack plates ..................................................................................... 8.3 8.2.2. Check the cables................................................................................................................................... 8.3 8.2.3. Check the pulleys.................................................................................................................................. 8.3 8.2.4. Check the mechanisms ......................................................................................................................... 8.3 8.2.5. Check the gas spring ............................................................................................................................ 8.4 8.2.6. Check the lever limit switch buffers...................................................................................................... 8.4 8.2.7. Check the cross limit switch ................................................................................................................. 8.4 8.2.8. Checking the upholstery ....................................................................................................................... 8.4 8.2.9. Checking various rubber parts............................................................................................................. 8.4

8.3. SPECIAL MAINTENANCE.................................................................................................................................... 8.5 8.3.1. Replacing the cables............................................................................................................................. 8.5 8.3.2. Screw and bolt check............................................................................................................................ 8.5 8.3.3. Checking for mechanism play .............................................................................................................. 8.5 8.3.4. Checking cross alignment .................................................................................................................... 8.5

9. RECOMMENDED SPARE PARTS .................................................................................................................... 9.1

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9.1. CABLES ............................................................................................................................................................ 9.1 9.2. UPHOLSTERY.................................................................................................................................................... 9.1 9.3. SPARE PARTS .................................................................................................................................................... 9.2

10. WELLNESS MATE CONFIGURATION......................................................................................................... 10.1 10.1. USER: MACHINE CONFIGURATION................................................................................................................... 10.2

10.1.1. Language............................................................................................................................................ 10.2 10.1.2. Units of measurement......................................................................................................................... 10.2 10.1.3. Pacer display...................................................................................................................................... 10.3 10.1.4. Pacer speed ........................................................................................................................................ 10.3 10.1.5. Pacer return speed ............................................................................................................................. 10.3 10.1.6. Display icons during the exercise ...................................................................................................... 10.4 10.1.7. Value of additional weight ................................................................................................................. 10.4 10.1.8. Enabling the TGS key......................................................................................................................... 10.4 10.1.9. Enable function keys........................................................................................................................... 10.5 10.1.10. Display exercise duration................................................................................................................ 10.5 10.1.11. Display power.................................................................................................................................. 10.5 10.1.12. Repetition number used for ROM acquisition ................................................................................. 10.6 10.1.13. Inactive time before reset ................................................................................................................ 10.6 10.1.14. Default number of repetitions.......................................................................................................... 10.6 10.1.15. Default number of sets..................................................................................................................... 10.7 10.1.16. Default recovery time during the exercise....................................................................................... 10.7 10.1.17. Default recovery time during the test .............................................................................................. 10.7 10.1.18. Clock setting: hours......................................................................................................................... 10.8 10.1.19. Clock setting: minutes ..................................................................................................................... 10.8 10.1.20. Inactive time before end of set......................................................................................................... 10.8

10.2. USER: ROM CONFIGURATION ........................................................................................................................ 10.9 10.3. SERVICE: MACHINE CONFIGURATION............................................................................................................ 10.10

10.3.1. Machine code ................................................................................................................................... 10.10 10.3.2. Minimum ROM length...................................................................................................................... 10.11 10.3.3. Default ROM start............................................................................................................................ 10.11 10.3.4. Default ROM length ......................................................................................................................... 10.11 10.3.5. %ROM first rep ................................................................................................................................ 10.11 10.3.6. Type of encoder used........................................................................................................................ 10.12 10.3.7. Enable display adjustments .............................................................................................................. 10.12 10.3.8. Configure type of reader for Wellness System ................................................................................. 10.13 10.3.9. Configuration of the weight stack .................................................................................................... 10.13

10.4. SERVICE: WEIGHT STACK CONFIGURATION................................................................................................... 10.15 10.4.1. Complete procedure ......................................................................................................................... 10.15 10.4.2. Fast procedure ................................................................................................................................. 10.16

10.5. SERVICE: PERIPHERALS CHECK PANEL.......................................................................................................... 10.18 10.6. SERVICE: CHECK/SET COUNTERS .................................................................................................................. 10.20

10.6.1. Neon lamp on-time ........................................................................................................................... 10.20 10.6.2. Machine on-time............................................................................................................................... 10.20 10.6.3. Number of repetitions....................................................................................................................... 10.20 10.6.4. Total weight lifted............................................................................................................................. 10.21

10.7. CONFIGURATION: CALIBRATION................................................................................................................... 10.22 10.8. RESET PROCEDURE ....................................................................................................................................... 10.23

11. APPENDIX........................................................................................................................................................... 11.1 11.1. TOOLS TO USE ................................................................................................................................................ 11.1


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 drawings which illustrate the procedure being described. This manual contains notices and symbols which have a specific meaning:

WARNING: non observance may result in accident or injury.

ATTENTION: non observance may cause damage to the machine.

Information about the operation in progress.

OBSERVE: observation about the operation in progress.

1.2. RECOMMENDATIONS

Technogym recommends the following steps for planning repair procedures: • Carefully evaluate the customer’s description of the machine malfunction and ask all the

necessary questions to clarify the symptoms of the problem. • Clearly diagnose the causes of the problem. This manual provides the fundamental theoretical

basis, which must then be integrated by personal experience and attendance at the training courses periodically offered by Technogym.

• Rationally plan the repair procedure so as to minimize the downtime necessary for procuring

spare parts, preparing tools, etc. • Access the component to be repaired, avoiding any unnecessary operations. In this regard it will

be useful to refer to the disassembly sequence described in this manual.

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1.3. GENERAL RULES FOR REPAIR PROCEDURES

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

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

adjustments and maintenance than those contained in this manual. 5. Before starting the repair procedure, make sure that the recommended tools are available and in

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

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


2. TECHNICAL CHARACTERISTICS

2.1. PRODUCT VERSIONS

Evolution Unica is available in 2 different versions, either with or without the Wellness Mate. The version equipped with Wellness Mate is named Unica Evolution Trainer:

Code Description Wellness mate M310 Unica Evolution NO M311 Unica Evolution Trainer YES

This manual is referred specifically to the M310 “Unica Evolution” machine version, however the M311 “Unica Evolution Trainer” differs only in the presence of the Wellness Mate, and information about this unit is provided in the separate manual: “Wellness Mate: Service & Maintenance Manual”

2.2. PRODUCT CODE

The following variations have been defined: • Language:

Code Description ITA Italian ING English FRA French SPA Spanish TED German

• Frame color:

Code Color AL Silver NB Black

• Upholstery color:

Code Color M Bordeaux L Black X Cream I Tobacco

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• Packing type:

Code Packing E Abroad I Italy

Thus the machine code will be:

M310 - ITA - ALL - E Packing

Frame and upholstery color

Language Machine code

2.3. MECHANICAL CHARACTERISTICS

Width (minimum) 120 cm 47 inch Width (during exercise) 160 cm 63 inch Length 184 cm 72 inch Height 207 cm 82 inch Weight of the machine 150 Kg 331 lb Weights pack 90 Kg 198 lb

2.4. AMBIENT SPECIFICATIONS

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

2.5. CONFORMITY TO REGULATIONS

The machine conforms to the following directives:

Directive Europe USA Machinery Safety Directive 89/392/EEC 89/392/EEC


3. INSTALLING AND MOVING THE MACHINES

3.1. 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. You have observed the temperature and humidity operating requirements indicated in paragraph

2.4. “Ambient specifications”.

3.2. INSTALLATION

The machine is supplied partially disassembled, packed in three boxes which are tied together and fixed to a wooden pallet having the dimensions given in the following drawing.

The machine installation and assembly procedures are illustrated in a CD-ROM with video clips and photographs.

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3.3. MOVING

Once the machine has been assembled, it can be moved over short distances using the two wheels supplied with the machine.

Figure 3.3-1

1. Screw the two wheels of Figure 3.3-1 into the special holes on the sides of the weight stack column using a 17 mm Box wrench.

Figure 3.3-2

2. Insert the ring provided a into the footrest and the bottom hook into the Leg Extension lever as shown in the figures Figure 3.3-2.

Continued on following page →


Figure 3.3-3

3. Lift the machine on the rear wheels, using the anatomical handgrips of the Arm Curl lever and move the equipment with great caution, due to the risk of it tipping over.

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4. ACCESSORIES The equipment is supplied with the following accessories: • lifting ring; • handle; • pulley handle; • ankle strap; • floor exercise mat; • set of tools for assembly and adjustments; • oil for lubrication; • User’s manual; • wheels for moving the equipment; • screws for assembly.

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5. WHAT IF …

5.1. THE WEIGHT STACK DOES NOT SLIDE SMOOTHLY

This problem is due to insufficient lubrication of the bars or grime build-up from a mixture of dust and oil. Clean and lubricate as illustrated below:

Photo 5.1-1

1. Use a paper towel slightly dampened with ethyl alcohol to clean the weight stack bars of the machine, removing dust and grime.

2. Reassemble the cross and add a few drops of the oil found in the service box to the cross bushings as shown in the photo below.

3. Move the cross up and down, making sure to

distribute the oil evenly along the full length of the bars.

4. Dry excess oil from the bushings with a dry cloth.

Do not use too much oil, and dry all excess thoroughly since too much oil could cause more dust to build up.

When the bars and bushings are especially dirty, and only when the cross alone or at most the cross and one plate are selected, it may not return to rest on the other plates but stick a few centimeters above. Clean and lubricate the bars thoroughly, as well as inside the bushings where the bars slide, using a paper towel moistened with ethyl alcohol.

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5.2. THE WEIGHT STACK CABLE IS NOT TAUT

This problem is caused by the elongation of the weight stack cable, especially during the initial period of use. To correct the problem it is therefore necessary to adjust the cable tension.

If the cable is new, perform a few repetitions at maximum load before adjusting its tension, in order to “pull” the cable.

Figure 5.2-1

1. Select the minimum weight load: the only weight selected will be that of the cross.

2. Back off the lock nut a using a 17mm gauge

wrench. 3. Turn the adjusting screw b using a 17mm

gauge wrench and tighten the lock nut

Check the cable tension by performing a few repetitions with the minimum weight load and slowly resting the cross on the weight stack. The cross should stay properly rested on the weight stack, with the cable slightly taut.


6. HOW TO DISASSEMBLE THE …

6.1. SEAT GAS SPRING

Figure 6.1-1

1. Using the special pliers, remove the snap ring a and pull out the pin b from the lower part of the seat gas piston.

Figure 6.1-2

2. Remove the plastic cap from the hole on the frame which allows access to the parts indicated by the letters in the figure.

3. Remove the snap ring c and pull out the pin d

from the upper part of the seat gas piston.

Continued on following page →

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Page 6.2

Figure 6.1-3

4. After releasing the entire seat gas piston group from the frame, if only the gas piston is damaged proceed as follows: • back off the nut e securing it to the fork,

using a 13-mm wrench; • back off the lock-nut f using a 13-mm

wrench and unscrew the component g which is connected to the cable of the seat adjustment system.

5. To reassemble the gas piston, follow the

disassembly instructions in reverse order.


6.2. PECTORAL ARM

Figure 6.2-1

1. Remove the pin a from the upper part of the Pectoral arm using a 6-mm pointed tool.

Figure 6.2-2

2. Remove component b from the top.

Figure 6.2-3

3. Using a ringnut spanner, back off the nut c, taking care with the arm which can now be pulled out from the bottom.

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6.3. WEIGHT STACK

If it is necessary to disassemble the weight stack from the machine, proceed as follows: 1. Overturn the machine on its rear side; 2. Separate the weight stack column from the rest of the frame; 3. Back off the guide rod fixing screws and the bolts securing the weight stack to the base of the

column; 4. Remove the guide rods from the upper part of the weight stack column and pull out the plates

which are now free to come out.

The detailed procedure for disassembling the weight stack column is described in the installation CD Rom.


7. SPECIAL OPERATIONS The term special operations refers to those procedures whose correct execution is fundamental for the safe and reliable operation of the machine.

7.1. LOCKING DOWN THE CABLE FIXING DOWELS

The machine cables are fixed to ratchets by means of the grub screws indicated in the figure below. The fixing dowels must be carefully locked down to prevent them from working loose and allowing the cable to come out, causing problems to the user.

Figure 7.1-1

Use a torque wrench to ensure that the dowels are locked down with the prescribed torque of 16 Nm / 11.8 ft.lbs..

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8. MAINTENANCE Periodic scheduled maintenance operations are necessary to keep the machines in perfect working order and prevent problems. There are essentially 3 types of maintenance operations: • Cleaning operations; • Routine maintenance operations; • Special maintenance operations. These should be carried out at different intervals, and by technical personnel with different skill sets. The paragraphs below illustrate the recommended operations.

8.1. 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 cleaning:

8.1.1. CLEANING THE FRAME AND PAINTED PARTS 1. Clean the frame and painted parts of the machine using a cloth moistened with neutral (non-

acid) soap.

CAUTION: do not use alcohol, benzene, or chemical products in general.

8.1.2. CLEANING THE CHROME-PLATED PARTS

Do not carry out this test on the sliding bars of the weight stack. 1. Use a paper towel slightly dampened with ethyl alcohol to clean the chrome-plated parts of the

machine, removing dust and grime.

CAUTION: remove any surface rust spots with a metal scrubber. 2. If you expect the machines to remain unused for an extended period of time, we recommend

protecting the chrome-plated parts with a layer of liquid petroleum jelly applied to the surface. Once you start using them again, clean the chrome-plated parts with a paper towel slightly moistened with ethyl alcohol.

8.1.3. CLEANING UPHOLSTERY 1. We recommend that you perform this operation daily.

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2. Clean the upholstery of the machine using a cloth moistened with neutral (non-acid) soap.

CAUTION: do not use alcohol, benzene, or chemical products in general. 3. We recommend drying the upholstery after cleaning.


8.2. ROUTINE MAINTENANCE

These operations may be carried out by the machine owner, and require no special expertise.

Routine maintenance operations on the machine include cleaning, lubrication, checking for wear and tuning the machine mechanisms to ensure smooth operation. We recommend that you carry out these operations at least once a month. Follow the procedure below for routine machine maintenance:

8.2.1. 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 chrome plating of the weight stack bars. Repair and/or replace any

worn parts. 3. Check the wear status of the weight stack bars and weight stack support buffers. Repair and/or

replace any worn parts. 4. Make sure the weight stack bars are firmly fastened. Repair and/or replace any worn parts. 5. Use a paper towel slightly dampened with ethyl alcohol to clean the weight stack bars of the

machine, removing dust and grime.

CAUTION: remove any surface rust spots with a metal scrubber. 6. Lubricate the bars and bushings of the plates and cross using the oil found in the service box. 7. Check the adhesive label indicating the load corresponding to the weight stack plates. Replace

any worn parts.

8.2.2. CHECK THE CABLES 1. Check the wear status of the machine cables, paying special attention to any hardened spots or

cracks in the protective plastic of the cable. Replace any worn parts. 2. Check the passage of the machine cables through cams, pulleys and/or the terminals connected

to ball joints. 3. Lubricate ball joints with the oil found in the box service. 4. Check the tension of the machine cables.

8.2.3. CHECK THE PULLEYS 1. Check the wear status of the pulley grooves. Repair and/or replace any worn parts.

8.2.4. 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. Lubricate the mechanisms using MOLYKOTE LONGTERM W 2.

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8.2.5. CHECK THE GAS SPRING 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 a dry cloth.

CAUTION: do NOT lubricate the gas spring stem for any reason.

8.2.6. 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.

8.2.7. 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.

8.2.8. CHECKING THE UPHOLSTERY 1. Check the wear status of the upholstery. Replace any worn parts.

8.2.9. CHECKING VARIOUS RUBBER PARTS

These operations apply to handles, knobs, mats, frame guards, bell covers, Selection top, feet …

1. Check the wear status of the rubber parts used on the machine. Repair and/or replace any worn

parts.


8.3. SPECIAL MAINTENANCE

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.

Special machine maintenance operations include operative checks, lubrication, wear and tension of mechanical parts, to ensure smooth, safe machine operation. We recommend that you carry out these operations at least once every 6 months. Follow the procedure below for special machine maintenance:

8.3.1. REPLACING THE CABLES 1. Replace the machine cables once a year if the machines are used intensively, every 2 years

under normal use.

8.3.2. SCREW AND BOLT CHECK 1. Make sure that the screws and bolts are firmly tightened, especially in the weight stack and seat

adjustment areas, and around moving parts in general. Tighten any that are loose.

8.3.3. CHECKING FOR MECHANISM PLAY 1. Make sure that the machine mechanisms (lever arms, shafts, starting position adjustments,

leverages) have no play. Repair and/or replace any worn parts.

8.3.4. CHECKING CROSS ALIGNMENT 1. Do not select any weight, and lift the cross. Make sure that the sinker is properly centered over

the plate hole, and that all plates in the weight stack may be selected without any strain on the selection knob. Force it to the center by hand.

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9. RECOMMENDED SPARE PARTS

9.1. CABLES

The cables used on the machine are:

Code Description Lenght (cm) 0R000021 Lat Machine cable 582 0R000024 Pulley cable 204 0R000030 Leg Extension cable 382 0R000031 Chest Press cable 140 0R000068 Chest Press doubling cable 190 0R000069 Easy start cable 597

9.2. UPHOLSTERY

The paddings used on the machine are:

Code Description Q.ty 0I000012-# Knee rest 1 0I000018-# Roller 2 0I000020-# Scott pad 1 0I000032-# Pectoral pad 2 0I000099-# Back rest 1 0I000102-# Back rest 1 0I000105-# Head rest 1 0I000107-# Seat 1

Substitute the appropriate color code for the # character.

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9.3. SPARE PARTS

Scott pad: 0I000020-(1)

Handle: 0N000035

Rught wheel: H0000655

Seat: 0I000107-(1)

Selector pin: H0000691

Left wheel: H0000656

Kneerest: 0I000012-(1)

Tracy bar: A031

Pulley footboard: H0000154

Roller: 0I000018-(1)

Stretching panel: 0C000434

CablesTraining panel: 0C000433

Backrest: 0I000102-(1)

Backrest: 0I000099-(1)

Pectoral arm: H0000188

Left chest arm: H0000180

Lat Machine bar: A053

Technogym sticker: 0E000079

Pectoral pad: 0I000032-(1)

Right chest arm: H0000181

Headrest: 0I000105-(1)

Unica sticker: 0E000080

CAUTION: (1) Enter the appropriate color code.


10. WELLNESS MATE CONFIGURATION The machine configuration procedure is accessed, with the machine in stand by mode, by simultaneously pressing the first two keys on the left hand side for a few seconds. The machine displays the CONFIGURATION menu, illustrated in the figure below:

CONFIGURATION

USER SERVICE

CALIBRATION

• USER: this is the menu for the user settings, consisting of the machine configuration (see

paragraph 10.1. “User: machine configuration”) and the ROM configuration (see paragraph 10.2. “User: ROM configuration”);

• SERVICE: this is the menu for the technical settings, consisting of the machine configuration (see paragraph 10.3. “Service: machine configuration”) ) and the weight stack configuration (see paragraph 10.4. “Service: weight stack configuration”), the monitoring of the sensor states (see paragraph 10.5. “Service: peripherals check panel”) and the function for viewing/modifying the machine usage data (see paragraph 10.6. “Service: check/set counters”);

• CALIBRATION: this is the menu for configuring the weight stack of the machine on which the system installed (see paragraph 10.7. “Configuration: calibration”).

To skip directly from one message to the next one without making any changes, or to confirm the changes made press the OK key. To cancel a change press the ↑ key (returns to the preceding message) and then OK. To exit the configuration menu at any time hold down the ← key. To exit the configuration menu without saving the changes made press the ← key repeatedly until the machine returns to stand by.

Once the configuration procedure has been accessed, if no key is pressed for a period of 1 minute, the software automatically exits the procedure, sounds the buzzer and reverts to stand by mode.

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10.1. USER: MACHINE CONFIGURATION

To access this procedure, select the USER item from the main configuration menu and enter the password “2406” which protects against unauthorized access. Use the two center keys to enter the first password digit, then press OK; repeat for the remaining digits of the password. After pressing OK to confirm the last digit, a new menu will appear:

USER

MACHINE CONFIGURATION ROM CONFIGURATION

Use the center keys to scroll down until the MACHINE CONFIGURATION item illuminates, then press OK.

10.1.1. LANGUAGE This item displays the language used by the program. The display shows:

MACHINE CONFIGURATION

LANGUAGE ENGLISH

The language setting cannot be changed. Press OK to confirm and proceed.

10.1.2. UNITS OF MEASUREMENT This item sets the units of weight measurement. The display shows:


UNIT OF MEASURE USA = 0 EUR = 1

1

The available options are: • 1 to set European units of measurement: weight in kg; • 0 to set US units of measurement: weight in pounds. Select the desired value then press OK to confirm and proceed.


10.1.3. PACER DISPLAY This item selects whether to display the pacer during the exercise. The display shows:


DISPLAY PACER NO = 0 YES = 1

1

The available options are: • 1 to enable the pacer display • 0 to disable the pacer display. Choose the desired value then press OK to confirm and proceed.

10.1.4. PACER SPEED This item sets up the speed of the pacer, if enabled. The display shows:


PACER SPEED (10-500)

420

Enter the value of pacer speed, i.e. the target speed at which the exercise should be performed, in millimeters per second; the value must be between 10 and 500. The recommended values is 420. Press OK to confirm and proceed.

10.1.5. PACER RETURN SPEED This item sets up the return speed of the pacer, if enabled. The display shows:


PACER RETURN SPEED (10-100) % OF PACER SPEED

50

Enter the desired value for the pacer return speed, expressed as a percentage of the outward pacer speed; the value must be between 10% and 100%. The recommended setting is 50%. Press OK to confirm and proceed.

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10.1.6. DISPLAY ICONS DURING THE EXERCISE This item selects whether to display the icons indicating the speed and range of motion during the exercise. The display shows:


DISPLAY IMAGES NO = 0 YES = 1

1

The possible choices are: • 1 to enable the display of the icons; • 0 to disable the display of the icons. Select the desired value then press OK to confirm and proceed.

10.1.7. VALUE OF ADDITIONAL WEIGHT This item sets up the value of the additional weight. The display shows:


ADD-ON WEIGHT KG = 2.5

Enter the value, in the unit of measure selected, of the additional weight: this is usually 2.5 kg / 5 lbs. If the additional weight is not used, enter the value 0.0 and then press OK to confirm and proceed.

10.1.8. ENABLING THE TGS KEY This item selects whether the tests and workouts programmed from the main menu using the keyboard should be saved on the TGS key. The display shows:


KEY ENABLE NO = 0 YES = 1

1

The possible settings are: • 1 to enable saving on the TGS key;


• 0 to disable use of the TGS key. Select the desired value, then press OK to confirm and proceed.

10.1.9. ENABLE FUNCTION KEYS This item enables and disables the use of the function keys on the display. In consequence, it enables or disables the TEST, MANUAL TRAINING and TRAINING PROGRAM items in the main menu; the TGS reader remains active. When a TGS key is inserted, the keys will resume their normal functions. The display shows:


KEYPAD ENABLE NO = 0 YES = 1

1

The possible settings are: • 1 to enable the function keys; • 0 to disable the function keys. Select the desired value then press OK to confirm and proceed.

10.1.10. DISPLAY EXERCISE DURATION This item selects whether to display the duration of the exercise in seconds. The display shows:


DISPLAY SECS NO = 0 YES = 1

1

The possible settings are: • 1 to enable the display of the exercise duration; • 0 to disable it. Select the desired value then press OK to confirm and proceed.

10.1.11. DISPLAY POWER This item selects whether to display the power expended during the exercise, expressed in Watts. The display shows:

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DISPLAY WATTS NO = 0 YES = 1

1

The possible settings are: • 1 to enable the exercise power display; • 0 to disable it. Select the desired value, then press OK to confirm and proceed.

10.1.12. REPETITION NUMBER USED FOR ROM ACQUISITION This item configures which repetition is used for the acquisition of the ROM. The display shows:


SET ROM DURING REP (2-10)

2

Enter the desired value, then press OK to confirm and proceed.

10.1.13. INACTIVE TIME BEFORE RESET This item configures how many seconds must elapse, after the weight stack has returned to the rest position, before the software reverts to stand by mode. The display shows:


TIME OUT SECS

60

Enter the desired value and then press OK to confirm and proceed.

10.1.14. DEFAULT NUMBER OF REPETITIONS This item configures the default number of repetitions which the machine uses during a MANUAL TRAINING session. The display shows:



DEFAULT REPS

12

Enter the desired value and press OK to confirm and proceed.

10.1.15. DEFAULT NUMBER OF SETS This item configures the default number of sets which the machine uses during a MANUAL TRAINING session. The display shows:


DEFAULT SETS

3


10.1.16. DEFAULT RECOVERY TIME DURING THE EXERCISE This item configures the default recovery time in seconds between successive sets in a MANUAL TRAINING session. The display shows:


WORKOUT: REST TIME SECS

60


10.1.17. DEFAULT RECOVERY TIME DURING THE TEST This item configures the recovery time in seconds between the sets of a TEST. The display shows:


TEST: REST TIME SECS 120

Enter the desired value then press OK to confirm and proceed.

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10.1.18. CLOCK SETTING: HOURS This item sets the hours of the internal clock. The display shows:


SET CURRENT TIME HOURS

12

Enter the value then press OK to confirm and proceed.

10.1.19. CLOCK SETTING: MINUTES This item sets the minutes of the internal clock. The display shows:


SET CURRENT TIME MIN. 30

Enter the value then press OK to confirm and proceed.

10.1.20. INACTIVE TIME BEFORE END OF SET This item configures how many seconds must elapse, after the weight stack has returned to the weight position, before the software considers the set finished. The display shows:


TIME OUT WEIGHT STACK SECS

4

Enter the value and press OK to confirm and proceed. At this point the configuration of the Wellness Mate parameters is complete; after sounding a beep, the software reverts to stand by mode.


10.2. USER: ROM CONFIGURATION

To access this procedure, select USER from the configuration menu and enter the password “2406” which protects against unauthorized access. Use the two center keys to enter the first password digit, then press OK; repeat for the remaining digits of the password. After pressing OK to confirm the last digit, a new menu appears:

USER

MACHINE CONFIGURATION ROM CONFIGURATION

Use the center keys to scroll down until the ROM CONFIGURATION item illuminates, then press OK. The display shows:

ROM CONFIGURATION

DO 3 REPETITIONS

The user must perform the 3 repetitions as prompted. The software will uses these repetitions to calculate the user’s ROM and all the other range of motion parameters, i.e. the limits within which a repetition is considered to be valid. Clearly, the parameters computed from these three repetitions will be valid only for those exercises where the software does not already have user-specific parameters available, i.e. for workouts programmed from the menu, or for users with a TGS key on which the personal ROM has not yet been stored. After the three repetitions, the ROM configuration is complete and the software reverts to stand by mode.

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10.3. SERVICE: MACHINE CONFIGURATION

To access the procedure, select the SERVICE item from the main configuration menu and enter the password “2501” which protects against unauthorized access. Use the two center keys to enter the first digit, then press OK; proceed in the same way for the other digits of the password. After pressing OK to confirm the last digit, a new menu appears:

SERVICE

MACHINE CONFIGURATION PERIPHERALS CHECK PANEL

CHECK/SET COUNTERS

Use the center keys to scroll down until the MACHINE CONFIGURATION item illuminates, then press OK.

10.3.1. MACHINE CODE This item sets up the machine on which the Wellness Mate system is installed. The display shows:

CONFIGURATION

MACHINE CODE = 30

Enter the number 30 corresponding to the machine, then press OK to confirm and proceed. The display will then show the name of the machine corresponding to the selected code. The LCD will show:

CONFIGURATION

MACHINE UNICA EVOLUTION


10.3.2. MINIMUM ROM LENGTH This item configures the minimum displacement of the weight stack, in cm, before the movement is considered a repetition. The display shows:

CONFIGURATION

MINIMUM ROM LENGTH CM X

Insert number 10.

10.3.3. DEFAULT ROM START This item configures the distance in cm that the weight stack must move from the rest position before entering the exercise zone. This distance depends on the mechanics of the individual machine. Typically, this displacement is achieved using the machine’s easy-start lever. The display shows:

CONFIGURATION

DEFAULT ROM START CM XX

Insert number 1.

10.3.4. DEFAULT ROM LENGTH This item configures the default value of the ROM, in cm, prior to acquisition of the user’s personal ROM, and is used to correctly fill out the ROM LED band on the display. The display shows:

CONFIGURATION

DEFAULT ROM LENGTH CM XX

Insert number 34.

10.3.5. %ROM FIRST REP This item sets the percentage of the ROM, as defined in the parameter “default ROM length”, which is performed using the machine’s easy start lever during the first repetition. The display shows:

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CONFIGURATION

ROM FIRST REP XX PERCENT

Insert number 45.

10.3.6. TYPE OF ENCODER USED This item configures the type of encoder used on the machine. The display shows:

CONFIGURATION

ENCODER TYPE 0=INFRA 1=WIRE 2=WIRE M

1

The possible settings are: • 0 for an infrared system; • 1 for the cable activated encoder that is currently installed; • 2 for a different model of cable activated encoder. Leave this setting at 1, then press OK to confirm and proceed.

10.3.7. ENABLE DISPLAY ADJUSTMENTS This item selects whether to display the icon for adjusting the LCD contrast and brightness, as described in paragraph Errore. L'origine riferimento non è stata trovata. “Errore. L'origine riferimento non è stata trovata.”, when the machine is in stand by mode. The display shows:

CONFIGURATION

ENABLE DISPLAY SETTINGS 0 = NO 1 = YES

1

The possible settings are: • 1 to enable the display of the icon; • 0 to disable it. Select the desired value then press OK to confirm and proceed.


10.3.8. CONFIGURE TYPE OF READER FOR WELLNESS SYSTEM This item configures the type of device used by the Wellness System. The display shows:

CONFIGURATION

SELECT READER 0 = TGS 1 = SMARTCARD

0

The possible settings are: • 1 to select the smartcard; • 0 to select the TGS key. Select the desired value then press OK to confirm and proceed.

10.3.9. CONFIGURATION OF THE WEIGHT STACK This item configures the weight stack. The display shows:

CONFIGURATION

WEIGHTSTACK CONFIG 0 = NO 1 = YES

1

The possible settings are: • 1 to enable the configuration. • 0 to disable it. Select the desired value then press OK to confirm and proceed. Selecting 1 causes the SW to start executing the operations described in paragraph 10.4. “Service: weight stack configuration”, otherwise, after sounding a beep the display shows a summary of the machine usage data. In this case the display shows:

VISUALISE COUNTERS MACH.ON HOURS XXX.XX NEON ON HOURS XXX.XX

T=XX.XX REPS CYCLES XXXX WEIGHT Q.LI XXXXX

For the meaning of all these values, with the exception of “T=XX.XX”, refer to paragraph 10.6. “Service: check/set counters”.

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The parameter “T=” gives the value of the temperature in degrees Celsius measured inside the display. The normal temperature range is between 25 and 40 °C. A higher temperature is a sign of possible problems with the display, and may result in incorrect contrast values, making the LCD display difficult to read. After showing the summary data for a few seconds, the software sounds a beep and reverts to stand by mode.


10.4. SERVICE: WEIGHT STACK CONFIGURATION

To access the procedure, it is necessary to select item 1 in paragraph 10.3.9. “Configuration of the weight stack”. After pressing OK, the display shows:

CONFIGURATION

SELECT WEIGHTSTACK CONFIGURATION PROCEDURE

FAST: – COMPLETE +

Here there are two possible options: + Complete procedure: Carries out the weight stack complete configuration procedure. – Fast procedure: Carries out the weight stack fast configuration procedure, which

configure the weight stack in only five steps.

10.4.1. COMPLETE PROCEDURE After pressing OK, the display shows:

CONFIGURATION

SELECT THE LAST WEIGHT STACK PLATE

Position the weight selector pin on the last plate and press OK. The display shows:

CONFIGURATION

SELECT THE FIRST WEIGHT STACK PLATE

Position the weight selector pin on the first plate and press OK. The display shows:

CONFIGURATION

PLATE LOAD KG

1 2.5

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Using the ↑ and ↓ keys, enter the weight corresponding to the specified plate and then press OK. The program will then sequentially display the weight load corresponding to each plate. Proceed as follows: 1. position the weight selector pin on the specified plate; 2. if necessary, using the ↑ and ↓ keys, enter the weight load corresponding to the specified plate; 3. press the OK key. After confirming the value of the last plate, press and hold down the OK key for a few seconds to complete the weight stack configuration procedure and return to stand by mode.

10.4.2. FAST PROCEDURE After pressing OK, the display shows:

CONFIGURATION

TOTAL NUMBER OF PLATES

XX

Enter the total number of plates which are in the weight stack and press OK. The display shows:

CONFIGURATION NUMBER OF PLATES WHICH WEIGHT AS THE LAST PLATE

XX

Enter the number of plates which weight as the last one in the weight stack and press OK. The display shows:

CONFIGURATION SET TOTAL WEIGHT

KG=

XX

Enter the maximum value in Kg, selectable on the weight stack and press OK. The display shows:


CONFIGURATION SET LAST PLATE WEIGHT

KG=

XX

Enter the last weight plate, in Kg, of the weight stack.

CONFIGURATION


Position the weight selector pin on the last plate and press OK to complete the weight stack configuration procedure and return to stand by mode.

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10.5. SERVICE: PERIPHERALS CHECK PANEL

To access this procedure, select the SERVICE item from the main configuration menu and enter the password “2501” which protects against unauthorized access. Use the two center keys to enter the first password digit, then press OK; proceed in the same way for the other digits. After pressing OK to confirm the last digit, a new menu appears:

SERVICE


CHECK/SET COUNTERS

Scroll down with the center keys until the PERIPHERALS CHECK PANEL item illuminates, then press OK. The display shows:

VISUALISE DATA

FRAME 127: 56: 3:240 412 DISL 412 DISM 0 2.5 KG

PINOUT N LOAD DW Y AW Y

This view is used for monitoring the status of the sensors and the serial communications between the FPGA board and the CPU board (continuous transmission of 4 bytes from the FPGA board see paragraph Errore. L'origine riferimento non è stata trovata.). The display shows: • 1st LINE: shows the value of the 4 bytes of the communication protocol between the 2 boards,

in decimal format, separated by “:”. The last number is the selector pin position in mm, obtained from the values of the 2nd and 3rd bytes;

• 2nd LINE: shows the following 3 values:

- DISL: the selector pin position in mm, acquired during the last weight selection before running the configuration procedure;

- DISM: the relative displacement of the selector pin from its original position, in mm, acquired before running the configuration procedure;

- last selected weight before running the configuration procedure.

• 3rd LINE: readout of the machine status:

- PINOUT: with the encoder currently used this value is always N; - LOAD DW: shows the status of the weight stack: Y if the weight stack is in the

rest position, and N if the weight stack is raised. In other words, this parameter monitors the state of the weight stack sensor;


- AW: shows whether the additional weight has been selected: Y if it is in the rest

position and N if it is raised. In other words, this parameter monitors the state of the additional weight sensor;

ATTENTION: to see the change of sensor state on the display, it is necessary to raise

the weight stack.

ATTENTION: the refresh rate for these parameters is very slow – in the order of a few seconds: therefore, to see a change in the displayed values after modifying the machine status, it is necessary to hold the position and wait.

To exit this view, press the OK key: after sounding a beep, the software will return to stand by mode.

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10.6. SERVICE: CHECK/SET COUNTERS

To access the procedure, select the SERVICE item from the main configuration menu and enter the password “2501” which protects against unauthorized access. Using the two center keys, enter the value of the first digit, then press OK; repeat for the other password digits. After pressing OK to confirm the last digit, a new menu appears:

SERVICE


CHECK/SET COUNTERS

Scroll down using the center keys until the CHECK/SET COUNTERS item illuminates, then press OK.

10.6.1. NEON LAMP ON-TIME This item shows the usage data of the lamp in hours and minutes. The display shows:

NEON LAMP TIMEON

NEON ON HOURS XXX:XX

The displayed values can be modified using the + and – keys. Press OK to confirm and proceed.

10.6.2. MACHINE ON-TIME This item shows the machine usage data in hours and minutes. The display shows:

MACHINE POWER ON

MACHINE ON HOURS XXX:XX

The displayed values can be modified using the + and – keys. Press OK to confirm and proceed.

10.6.3. NUMBER OF REPETITIONS This item displays the total number of repetitions performed on the machine. The display shows:


TOTAL REPS

CYCLES: XXXXX

The displayed value can be changed using the + and – keys. Press OK to confirm and proceed.

10.6.4. TOTAL WEIGHT LIFTED This item displays the total amount of weight lifted on the machine. This value is obtained by summing the product of weight lifted and repetitions completed for each set. The units of measurement are quintals, which correspond to 100 kg. The display shows:

TOTAL LIFTED WEIGHT

TOTAL WEIGHT Q.LI: XXXXX

The displayed values can be changed using the + or – keys. Press OK to confirm and proceed: after sounding a beep, the software reverts to stand by mode.

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10.7. CONFIGURATION: CALIBRATION

This procedure calibrates the value shown on the display so that it matches the selected weight. To access the procedure select the CALIBRATION item from the main configuration menu. The display shows:

CALIBRATION


Position the selector pin on the last plate of the weight stack, as prompted by the message, then press OK: after sounding a beep, the software reverts to stand by mode. If the procedure is completed successfully, the weight value shown on the display should match that of the selected weight stack plate.

ATTENTION: calibration is necessary if the selector pin position is changed when the machine is switched off, causing the display to show a different weight value from that actually selected by the pin.


10.8. RESET PROCEDURE

This procedure resets the machine configuration parameters to their default values. The default parameter values are loaded from the program memory and overwrite those stored in the ram with backup battery. To do this, proceed as follows: 1. Turn off the machine. 2. Switch on the machine, while holding down the key furthest to the right, until the machine

sounds 3 consecutive beeps. 3. The machine performs the reset sequence and loads the default parameters, as for a Chest Press. After completing this procedure, carry out the procedures described in paragraphs 10.1. “User: machine configuration”, 10.2. “User: ROM configuration”, 10.3. “Service: machine configuration” e 10.4. “Service: weight stack configuration”.

ATTENTION: the reset procedure should be used when the data in the memory with backup battery has been corrupted, and it is not possible to configure the parameters by the standard procedures.

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11. APPENDIX

11.1. TOOLS TO USE

The following tools are necessary to carry out all disassembly, adjustment and maintenance operations on the machines: • 13-gauge wrench; • 17-gauge wrench; • 4-gauge hexagonal T-wrench; • Torque wrench; • Box wrenches; • 6-mm pointed tool; • Ring nut spanner; • Circlip pliers; • Hammer.

CAUTION: Tool measurements are expressed in mm.

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TECHNOGYM S.p.A. Via G. Perticari, 20

47035 Gambettola (FC) ITALIA

Tel.: +39 - 0547 650438 Fax: +39 - 0547 650150

e-mail: [email protected]

0SM00146-ING

mailto:[email protected]

Documents

SERVICE MAINTENANCE MANUAL - Technogym · 2. Use original Technogym spare parts and lubricants of the recommended brands. 3. Use special tools where specified. 4. Consult the Technical