Technogym Personal Selection TÜV Service Maintenance Manual
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Technogym Personal Selection TÜV Service Maintenance Manual

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MAINTENANCE MANUAL
Rev. 1.0

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Summary of Contents for Technogym Personal Selection TÜV

  • Page 1 & ERVICE MAINTENANCE MANUAL Rev. 1.0...
  • Page 3 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.

  • Page 5: Table Of Contents

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 Contents 1. GENERAL NOTICES............................1.1 1.1. I ..............................1.1 NTRODUCTION 1.2. R ............................1.1 ECOMMENDATIONS 1.3. G ......................1.2 ENERAL RULES FOR REPAIR PROCEDURES 2. TECHNICAL CHARACTERISTICS........................2.1 2.1. P ..........................
  • Page 6 Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 6.9. D ..............6.16 ISASSEMBLING UNLOCKING LEVER ON BDUCTOR DDUCTOR 7. SPECIAL OPERATIONS............................. 7.1 7.1. L ...................... 7.1 OCKING DOWN THE CABLE FIXING DOWELS 7.2. L ..........................7.2 OCKING DOWN THE PULLEYS 8.

  • Page 7: General Notices

    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.

  • Page 8: 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.

  • Page 9: Technical Characteristics

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 2. TECHNICAL CHARACTERISTICS The Personal Selection TÜV machine code is a sequence of alphanumeric characters arranged as follows: 2.1. PRODUCT CODE: MACHINES PERSONAL SELECTION TÜV Characters description key to values 1,2,3 Personal Selection TÜV D69 = machine...
  • Page 10 Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 For example, a possible product code would be: D69510-ALR0CGGK which is interpreted as follows: D69 51 0 - AL R0 C GG K Unit of measurement, Kg Plastic parts colour RAL 7024 Gray casing colour Brillant green upholstery colour Silver frame colour...

  • Page 11: Equipments: Mechanical Characteristics

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 2.3. EQUIPMENTS: MECHANICAL CHARACTERISTICS 2.3.1. D6946 – U PPER D6946 – Upper Back stand by max during exercise Dimensions 119 x 114 x 148.5 cm 119 x 142 x 148.5 cm 47 x 45 x 58 in 47 x 56 x 58 in Overall weight...

  • Page 12: D6951 - Leg Press

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 2.3.3. D6951 – L RESS D6951 – Leg Press stand by max during exercise Dimensions 207 x120 x 180 cm 207 x120 x 180 cm 81 x 47 x 71 in 81 x 47 x 71 in Overall weight 572 Kg –...

  • Page 13: D6958 - Lower Back

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 2.3.5. D6958 – L OWER D6958 – Lower Back stand by max during exercise Dimensions 121 x 103 x 148.5 cm 140 x 103 x 148.5 cm 48 x 40 x 58 in 55 x 40 x 58 in Overall weight 212 Kg –...

  • Page 14: D6980 - Low Row

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 2.3.7. D6980 – L D6980 – Low Row stand by max during exercise Dimensions 113.5 x 120.5 x 148 cm 113.5 x 120.5 x 148 cm 44.5 x 47.5 x 58.5 in 44.5 x 47.5 x 58.5 in Overall weight 268 Kg –...

  • Page 15: D6991 - Leg Extension

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 2.3.9. D6991 – L XTENSION D6991 – Leg Extension stand by max during exercise Dimensions 130 x 105 x 148.5 cm 152 x 105 x 148.5 cm 51 x 41 x 58 in 60 x 41 x 58 in Overall weight 257 Kg –...

  • Page 16: Bench: Mechanical Characteristics

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 2.4. BENCH: MECHANICAL CHARACTERISTICS 2.4.1. D6P915 – C RUNCH ENCH D6P915 – Crunch Bench Standard configuration max in usage Dimensions 144 x 66 x 115 cm 155 x 66 x 115 cm 52 x 26 x 46 in 61 x 26 x 46 in Overall weight...

  • Page 17: Ambient Specifications

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 Be aware: • The dimensions are “length x width x height” related to the user in exercise position. • The stand by dimensions are the minimum machine dimensions without any disassembling.
  • Page 18 Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 Page intentionally left blank Page 2.10...

  • Page 19: Installing And Moving The Machines

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 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.
  • Page 20 Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 3. Remove the carton and the nylon bag, and leave the machine secured to the pallet with the fixing straps. 4. Position the machine in the place of installation using a pallet truck, a wheeled platform (dolly) or by fitting the wheels as described in paragraph 3.2.2.

  • Page 21: Moving

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 3.2. MOVING For proper movement of the machines, proceed as follows: 3.2.1. OVING WITHOUT WHEELS When lifting or moving the machine press only against the frame. 1. Adequately protect the parts of the frame that will be in contact with the means of transportation: pallet changer or lift truck.
  • Page 22 Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 Photo 3.2-2 2. Tip the machine from the weight stack side and insert 1 or 2 steering wheels under the user side hoists, as illustrated in the following photo: Photo 3.2-3 Depending on the wheel model used, it could be necessary to back off the screw fixing the foot, inserter the wheel and secure it using the screw previously removed.

  • Page 23: Accessories

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 4. ACCESSORIES There are no accessories available with this product line. Page 4.1...
  • Page 24 Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 Page intentionally left blank Page 4.2...

  • Page 25: What If

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

  • Page 26: The Weight Stack Cable Is Not Taut

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 5.2. THE WEIGHT STACK CABLE IS NOT TAUT This problem is due to lengthening of the weight stack cable. Therefore, to solve the problem you must use the cable tension adjustment system. If the cable is new, before adjusting its tension, it is necessary to do a few reps at maximum load to “stretch”...
  • Page 27 Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 1. Set the minimum weight: the only selected weight will be the cross. 2. Loosen the screw a using a 8-gauge hexagonal T-wrench, holding the nut b in place with a 17-gauge wrench. 3.

  • Page 28: The Machine Is Not Flat

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 5.3. THE MACHINE IS NOT FLAT To level the machine, you may adjust the height of the levelling foot as illustrated below: We recommend that 2 people carry out this operation. 1.

  • Page 29: The Levers Of Dual-Axis Machines Are Not Aligned

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 5.4. THE LEVERS OF DUAL-AXIS MACHINES ARE NOT ALIGNED This operation applies to Low Row, Upper Back and Vertical Traction. To align the levers of dual-axis machines, you may adjust the position of the stop buffers against which the machine levers rest, as illustrated below: 1.

  • Page 30: The Sliding Bars Of The Leg Press Seat Are Not Aligned

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 5.5. THE SLIDING BARS OF THE LEG PRESS SEAT ARE NOT ALIGNED To align the sliding bars of the seat, you may adjust the position as illustrated below: 1. Remove the seat as described in paragraph 6.5.

  • Page 31: The Tube Start To Wabble

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 5.6. THE TUBE START TO WABBLE This operation applies to Upper Back, Low Row, Crunch bench. 1. Act on the 2 screws a to adjust the amount of play between the inner and outer tube and improve their sliding movement.
  • Page 32 Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 Page intentionally left blank Page 5.8...

  • Page 33: How To Disassemble The

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 6. HOW TO DISASSEMBLE THE … 6.1. FRONT WEIGHT STACK CASING 1. Back off the 4 screws a which are fixing the front casing to the encoder support bracket, using a 4-mm hex wrench. Photo 6.1-1 2.

  • Page 34: Top

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 6.2. TOP 1. Back off the 4 screws a, using a medium Phillips screwdriver. 2. Back of the self threading screws b on both internal side of the top and remove the plates 3.

  • Page 35: Seat On Low Machines

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 6.3. SEAT ON LOW MACHINES This operation applies to Leg Curl, Leg Extension. 1. Move the seat into position 1 (all the way forward) so that the gas spring is as fully extended as possible.
  • Page 36 Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 Place a cloth between the frame and the seat carriage, to avoid to scratch the frame. 7. Back off the screw f and remove the guide g sliding it out from behind. 8.

  • Page 37: Seat On Tall Machines

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 6.4. SEAT ON TALL MACHINES This operation applies to Low Row, Upper Back e Vertical Traction. 1. Move the seat into position 1 (all the way down) so that the gas spring is as fully extended as possible.
  • Page 38 Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 6. Unscrew the 2 screws d using an 8-gauge hexagonal T-wrench. 7. Lift the machine on the weight stack side and unscrew the screw e of the foot using an 8- gauge hexagonal T-wrench;...

  • Page 39: Leg Press Seat

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 6.5. LEG PRESS SEAT 1. Loosen the 4 dowels a, using a 4-gauge hexagonal T-wrench. 2. Remove the cable b. Photo 6.5-1 3. Unscrew the 2 screws c, using a 4-gauge hexagonal T-wrench, locking down the nuts on the opposite side, using an 8-mm wrench.
  • Page 40 Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 6. Unscrew the 2 screws e, using a 4-gauge hexagonal T-wrench, locking down the nuts on the opposite side, using an 8-mm wrench. 7. Remove the sheet metal f by pulling it forward.

  • Page 41: Easy Start For Tall Machines

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 6.6. EASY START FOR TALL MACHINES This operation applies to Vertical Traction. 1. Use an 8-gauge hexagonal T-wrench to unscrew the 3 screws a and remove the easy start group b by sliding it forward. Photo 6.6-1 2.
  • Page 42 Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 9. Adjust the previously inserted peg remover tool to stretch the spring taut and move the tie-rod until you can see the dowel g. 10. Loosen the dowel g using a 4-gauge hexagonal T-wrench.

  • Page 43: Release Lever

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 6.7. RELEASE LEVER This operation applies to Leg Curl, Leg Extension Lower Back. 1. Unscrew the screw a using a 5-gauge hexagonal T-wrench and remove the plastic guard b, sliding it upward. Photo 6.7-1 2.
  • Page 44 Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 The version at present in production is composed by the following pieces: Ref. Code Description 0D000766-* Housing 0G000117-# ROM button 0M022 Return spring 0N447 Adjustment shaft 0P000661AB Threaded pin 0P6176 Link pin 0P6216AA Selector pin...

  • Page 45: Selector Switch For Additional Weight

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 6.8. SELECTOR SWITCH FOR ADDITIONAL WEIGHT This operation does not apply to Leg Press, Low Row. The selector switch for additional weight is hooked onto the cross. Since there are only 2 mechanical solutions available: •...

  • Page 46: Machines With Cross With Doubling Pulley

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 6.8.2. ACHINES WITH CROSS WITH DOUBLING PULLEY This operation applies to Rotary Torso, Upper Back and Vertical Traction. For machines with doubling pulley: 1. Loosen the cable tension and lock the levers. 2.
  • Page 47 Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 For all equipment: 6. Unscrew the screw e using a 17-gauge sector wrench. 7. Remove the selector switch. Photo 6.8-4 8. Unscrew the bolt f using a 4-gauge wrench. 9. Remove the blade g and ball bearing h allowing the 2 selector switch positions to be selected.

  • Page 48: Disassembling Unlocking Lever On Abductor - Adductor

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 6.9. DISASSEMBLING UNLOCKING LEVER ON ABDUCTOR - ADDUCTOR 1. Back off the 4 screws a using a medium Phillips screwdriver and remove the upper plastic housing. 2. Back off the 2 screws b using a 5-mm hex wrench and remove the lower plastic housing.

  • Page 49: Special Operations

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 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 At least one end of the weight stack cable is fixed to the wheel or to a stop by means of the dowel screws highlighted in grey and circled in the figures below.

  • Page 50: Locking Down The Pulleys

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 Figure 7.1-3 Use a torque wrench to ensure that the dowels are locked down with the prescribed torque of 16.5 Nm / 12.2 ft.lbs.. 7.2. LOCKING DOWN THE PULLEYS The screws of the pulleys, highlighted in grey and circled in the figure below, must be carefully locked down to prevent them from working loose and causing problems to the user.

  • Page 51: Weight Stack Cable

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 8. WEIGHT STACK CABLE 8.1. LENGTH OF THE WEIGHT STACK CABLE Code Machine Standard weight stack Enhanced weight stack code length (cm) code length (cm) D6946 Upper Back 0V634 0V634 D6950 Rotary Torso 0R000059...

  • Page 52: Routing Of The Weight Stack Cable

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 8.2. ROUTING OF THE WEIGHT STACK CABLE The following pages illustrate the routing of the weight stack cables through the pulleys for each machine, for use as reference when replacing the machine cables. 8.2.1.

  • Page 53: D6951 - Leg Press

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 8.2.3. D6951 – L RESS D6951 – LEG PRESS 8.2.4. D6957 – A BDOMINAL RUNCH D6957 – ABDOMINAL CRUNCH Page 8.3...

  • Page 54: D6958 - Lower Back

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 8.2.5. D6958 – L OWER D6958 – LOWER BACK 8.2.6. D6971 – V ERTICAL RACTION D6971 – VERTICAL TRACTION Page 8.4...

  • Page 55: D6980 - Low Row

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 8.2.7. D6980 – L D6980 – LOW ROW 8.2.8. D6990 – L D6990 – LEG CURL Page 8.5...

  • Page 56: D6991 - Leg Extension

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 8.2.9. D6991 – L XTENSION D6991 – LEG EXTENSION Page 8.6...

  • Page 57: Maintenance

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 9. MAINTENANCE To keep the machine in perfect working order and forestall possible problems it is necessary to carry out the scheduled maintenance operations described below. The maintenance operations can essentially be classified according to the frequency with which they need to be performed: •...

  • Page 58: Weekly Maintenance Operations

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 9.2. WEEKLY MAINTENANCE OPERATIONS These operations can be carried out by the machine owner and do not require any special skills. The weekly machine maintenance operations consists of simple cleaning, lubrication and checking the emergency stop to ensure the correct and safe functioning of the machine.

  • Page 59: Monthly Maintenance Operations

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 9.3. MONTHLY MAINTENANCE OPERATIONS These operations can be carried out by the machine owner and do not require any special skills. The monthly machine maintenance operations consists of simple cleaning, lubrication and checking the state of wear to ensure the correct and safe functioning of the machine.

  • Page 60: Check The Weight Stack Stops

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 9.3.5. HECK THE WEIGHT STACK STOPS 1. Check the wear status of the stops. Repair and/or replace any worn parts. 2. Check the position of the stops and make sure they are firmly fastened in place. 9.3.6.

  • Page 61: Twice-Yearly Maintenance Operations

    9.4. TWICE-YEARLY MAINTENANCE OPERATIONS These operations can only be carried out by a qualified technician specifically trained by Technogym and authorized to carry out machine installation and adjustments, as well as special maintenance operations or repairs which require special knowledge of the machine, its operation, safety systems and working procedures.

  • Page 62: Checking For Mechanism Play

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 9.4.8. HECKING 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. 9.4.9. HECKING CROSS ALIGNMENT 1.

  • Page 63: Functional Tests

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 10. FUNCTIONAL TESTS Every time maintenance and/or repairs are performed on a machine, it is necessary to carry out a series of mechanical tests to ensure: • that the medical device is working properly; •...

  • Page 64: Seat Group Assembly Test

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 10.4. SEAT GROUP ASSEMBLY TEST Make sure the machine seat group is properly assembled, checking that has been mounted correctly, as described in the procedures in chapter 7 of this manual, ensuring that: •...

  • Page 65: Appendix

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 11. APPENDIX 11.1. WHAT TO ORDER TO AUGMENT THE WEIGHT STACK Codes Weight stack Parts to power the Assembly Machines weight stack code Powered 0F141AA-GG x 6 weight 0B178AA x 12 bushing 95 kg 125 kg A0000176AA-KG...
  • Page 66 Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 Codes Weight stack Parts to power the Assembly Machines weight stack code Powered 0F141AA-GG x 6 weight 0B178AA x 12 bushing 100 kg 130 kg A0000190AA-KG 0E000018-KG x 1 sticker D6971 0P2010 x 1 selector rod Vertical Traction...

  • Page 67: Upholstery

    Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0 11.2. UPHOLSTERY 0I000001-R Chest rest D6946 UPPER BACK 0I082AA-R Seat 0I000311AA-R Head rest 0I197-R Head rest D6951 LEG PRESS 0I080-R Seat 0I081-R Back rest 0I080-R Seat 0I000297AA-R Back rest D6950 ROTARY TORSO 0I000214-GG Knee rest...

  • Page 68: Tools To Use

    • 4-gauge hexagonal L-wrench; • Special socket wrench provided by Technogym for Ø 17 ring-nut fitting ½ (code 0Y000061); • Special socket wrench provided by Technogym for Ø 25 ring-nut fitting ½ (code 0Y000062); • 45-gauge hook wrench (only for side pin machines) (code 0Y000092);...
  • Page 70 TECHNOGYM S.p.A. Via G. Perticari, 20 47035 Gambettola (FC) ITALIA Tel.: +39 - 0547 650638 Fax: +39 - 0547 650150 e-mail: s ervice@technogym.com H T U 0SM00424AA-UK...

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