Technogym KINESIS ONE Service Maintenance Manual
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Technogym KINESIS ONE Service Maintenance Manual

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S
&
ERVICE
MAINTENANCE MANUAL
R
. 2.1
EV

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Summary of Contents for Technogym KINESIS ONE

  • Page 1 & ERVICE MAINTENANCE MANUAL . 2.1...
  • 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

    KINESIS ONE: Service & Maintenance Manual rev. 2.1 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 ..............................2.1 RODUCT CODES 2.2.
  • Page 6 KINESIS ONE: Service & Maintenance Manual rev. 2.1 8.2.1. Check the pulleys............................ 8.4 8.2.2. Check the weight stack rod stops......................8.4 8.2.3. Replacing the cables..........................8.4 8.2.4. Screw and bolt check..........................8.4 8.2.5. Checking for mechanism play ........................ 8.4 8.2.6. Checking cross alignment ........................8.4 9.

  • 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 adjusts and maintenance than those contained in this manual.

  • Page 9: Technical Characteristics

    KINESIS ONE: Service & Maintenance Manual rev. 2.1 2. TECHNICAL CHARACTERISTICS 2.1. PRODUCT CODES The coding of machine takes into account of all possible variants and options available for the products. The code of the machine, which don’t has the Serial Number, is composed of 16...

  • Page 10: Mechanical Caratteristics

    KINESIS ONE: Service & Maintenance Manual rev. 2.1 2.2. MECHANICAL CARATTERISTICS KINESIS ONE Width A 1405mm – 55” Length B 1650mm – 65” Height C 2120mm – 83” Machine weight 361 Kg – 797 lb Weight stack weight 2x79 Kg - 2x175 lb 2.3.

  • Page 11: Conformity To Regulations

    KINESIS ONE: Service & Maintenance Manual rev. 2.1 2.4. CONFORMITY TO REGULATIONS The machine conforms to the following directives: EUROPA EN 957-1 (2005) Security EN 957-2 (2003) 93/42/CE Directive Page 2.3...
  • Page 12 KINESIS ONE: Service & Maintenance Manual rev. 2.1 Page intentionally left blank Page 2.4...

  • Page 13: Cables Passage

    KINESIS ONE: Service & Maintenance Manual rev. 2.1 3. CABLES PASSAGE KINESIS ONE Rif. Cable code Length (mm) 0R000106AA 2300 0R000182AB (CRIMPED) 14300 The two modules of the machine and then the routing of the cables are perfectly symmetrical, on the two sides.
  • Page 14 KINESIS ONE: Service & Maintenance Manual rev. 2.1 Page intentionally left blank Page 3.2...

  • Page 15: Accessories

    KINESIS ONE: Service & Maintenance Manual rev. 2.1 4. ACCESSORIES 4.1. GENERIC ACCESSORIES The accessories supplied are detailed in the User Manual of the machine with the relevant particulars of use. Page 4.1...
  • Page 16 KINESIS ONE: Service & Maintenance Manual rev. 2.1 Page intentionally left blank Page 4.2...

  • Page 17: Installation And Handling Machines

    KINESIS ONE: Service & Maintenance Manual rev. 2.1 5. INSTALLATION HANDLING MACHINES 5.1. SPECIFICATIONS AND REQUIREMENTS For correct machine installation, make sure that: • The machine is installed on a level surface that is free of vibrations and has sufficient carrying capacity for the combined weight of the machine and user.
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  • Page 19: Disassembly Part

    KINESIS ONE: Service & Maintenance Manual rev. 2.1 6. DISASSEMBLY PART To correctly carry out the procedures detailed below, please take care of the following picture to identify the LEFT and the RIGHT side, of the machine. Page 6.1...

  • Page 20: Rear Panel Disassembly

    KINESIS ONE: Service & Maintenance Manual rev. 2.1 6.1. REAR PANEL DISASSEMBLY 1. Unscrew the 2 screws (a), backing off first of all the lower one and then the higher, using a 6mm hexagonal wrench. 2. Remove the panel. Figure 6.1-1...

  • Page 21: Fornt Panel Disassembly

    KINESIS ONE: Service & Maintenance Manual rev. 2.1 6.2. FORNT PANEL DISASSEMBLY Figure 6.2-1 1. Back off the 4 screws and their washers (a). Remove first of all the lower screws and then the higher ones, using a 6mm hexagonal wrench.

  • Page 22: Rear Cable Disassembly

    KINESIS ONE: Service & Maintenance Manual rev. 2.1 6.3. REAR CABLE DISASSEMBLY 6.3.1. EAR CABLE DISASSEMBLY Carry operations described paragraphs: 6.1. “Rear panel disassembly”. 1. Lift up the first plate (a) of the weight stack to loosen the tension of the cable, as shown in figure.

  • Page 23: Rear Cable Reassembly

    KINESIS ONE: Service & Maintenance Manual rev. 2.1 2. Back off the two grub screws of the cable- retainer shown in figure and pull the cable off. To reassemble the rear cable, follow the instructions in the following paragraph. Figure 6.3-2 6.3.2.
  • Page 24 KINESIS ONE: Service & Maintenance Manual rev. 2.1 4. Pass the cable on the pulley (c) of the spring group, routing it inside the anti-slip off device system (d). Figure 6.3-4 5. Lower the spring group pulley down, 800mm far from the frame board plate (see figure at side).

  • Page 25: Removing Weight Stack Cable (Handles)

    KINESIS ONE: Service & Maintenance Manual rev. 2.1 6.4. REMOVING WEIGHT STACK CABLE (HANDLES) 6.4.1. EIGHT STACK CABLE AND HANDLES DISASSEMBLY Carry operations described paragraphs: “Rear panel disassembly”. 1. Lift up the first plate (a) of the weight stack to loosen the tension of the cable, as shown in figure.

  • Page 26: Weight Stack Cable Reassembly

    KINESIS ONE: Service & Maintenance Manual rev. 2.1 6.4.2. EIGHT STACK CABLE REASSEMBLY With reference to the scheme at the beginning of this chapter, the following steps are referring to the LEFT side of the equipment. Carry out them on the RIGHT side of the equipment, considering it’s perfectly symmetrical.
  • Page 27 KINESIS ONE: Service & Maintenance Manual rev. 2.1 1. Lift up the first plate (a) of weight stack and secure with the selection pin on the front, as shown in figure. Figure 6.4-4 2. Rotate COUNTERCLOCKWISE until the spring group pulley (c) rises upward until it’s almost up to the frame.
  • Page 28 KINESIS ONE: Service & Maintenance Manual rev. 2.1 4. Pass the cable through the less deep hole on the internal side of the cam. Figure 6.4-6 5. Fix the crimped end of the cable inside the cable-retainer and house it in the cam, as shown in figure.
  • Page 29 KINESIS ONE: Service & Maintenance Manual rev. 2.1 6. Pass the cable on the external pulley (d) of the cross, routing it from the back to the front side of the pulley. Figure 6.4-8 7. Route the cable on the small pulley (e) fixed on the top side of the frame as shown in the figure.
  • Page 30 Figure 6.4-10 Mount all the handles on the cable so that the Technogym® logo, is readable by the user, in operating position. Figure 6.4-11 →...
  • Page 31 KINESIS ONE: Service & Maintenance Manual rev. 2.1 Go now on the front side of the machine: 10. Pass the cable through the rotating pulley system and its central bearing (g).Pull it out from the other side, as shown in figure.
  • Page 32 KINESIS ONE: Service & Maintenance Manual rev. 2.1 On the rear side of the machine: 15. Pass the cable on the upper pulley (l) shown in figure and get back the pulley on the cross. Figure 6.4-15 16. Route the cable on the internal pulley of the...
  • Page 33 KINESIS ONE: Service & Maintenance Manual rev. 2.1 Figure 6.4-17 17. Remove the Allen T wrench used at the point (3) of Figure 6.4-5. 18. Rotate the cam 6 times CLOCKWISE and lock again the cam. If working on the RIGHT side rotate the cam 6 time COUNTERCLOCKWISE.

  • Page 34: Arms Disassembly

    KINESIS ONE: Service & Maintenance Manual rev. 2.1 6.5. ARMS DISASSEMBLY 6.5.1. OWER ARMS Figure 6.5-1 Carry out the operations described in paragraphs: 6.1. “Rear panel disassembly”. 1. Back off the 8 screws (a), using a 17mm wrench. 2. Remove the arms from the front side.

  • Page 35: Upper Arms

    KINESIS ONE: Service & Maintenance Manual rev. 2.1 6.5.2. PPER ARMS Carry operations described paragraphs: 6.1. “Rear panel disassembly”. 1. Back off the 2 screws (a) using a 5mm hexagonal wrench. 2. Remove the top panel. Figure 6.5-2 Figure 6.5-3 3.

  • Page 36: Pulley Disassembly

    KINESIS ONE: Service & Maintenance Manual rev. 2.1 6.6. PULLEY DISASSEMBLY Carry operations described paragraphs: 6.1. “Rear panel disassembly”. 1. Back off the central screw (a) using a 17mm wrench, locking the nut on the opposite side with another 17mm wrench, as shown in the figure at the side.

  • Page 37: Cam Disassembly

    KINESIS ONE: Service & Maintenance Manual rev. 2.1 6.7. CAM DISASSEMBLY Carry operations described paragraphs: 6.1. “Rear panel disassembly”. 1. Disconnect the cables connected to the cam as described at paragraphs 6.3. “Rear cable disassembly” 6.4. “Removing ”. 2. Back off the central screw (a) using a 17mm wrench.

  • Page 38: Rotating Pulley System Disassembly

    KINESIS ONE: Service & Maintenance Manual rev. 2.1 6.8. ROTATING PULLEY SYSTEM DISASSEMBLY 1. Pull the cable out as described in paragraphs: 6.4. “Removing Weight stack cable (handles)”. 2. Back off the screws (a) using a 5mm hexagonal wrench, on the both sides.
  • Page 39 KINESIS ONE: Service & Maintenance Manual rev. 2.1 5. Remove the 2 seeger (f) and (g). Figure 6.8-4 6. Use a T wrench and a rubber hammer, to slightly hit the pulleys support (h) and remove it from the opposite side, as shown in figure.

  • Page 40: Weight Stack Disassembly

    KINESIS ONE: Service & Maintenance Manual rev. 2.1 6.9. WEIGHT STACK DISASSEMBLY Carry operations described paragraphs: 6.1. “Rear panel disassembly”. 1. Loosen the 2 grub screws (a), on the weight stack stops, using a 4mm hexagonal wrench, for each bar.
  • Page 41 KINESIS ONE: Service & Maintenance Manual rev. 2.1 On each bar: 3. Remove the tube spacer (b) from the top of the bar, as shown in figure to side. 4. Back off the 2 grub screws (c) of the stops (d), using a 4mm hexagonal wrench, and remove the stops.

  • Page 42: Foot Adjustment Disassembly

    KINESIS ONE: Service & Maintenance Manual rev. 2.1 6.10. FOOT ADJUSTMENT DISASSEMBLY 1. Back off the screw (a) using a 4mm hexagonal wrench, on both sides of the foot. Figure 6.10-1 2. Remove the covering guard (b), from the bottom.
  • Page 43 KINESIS ONE: Service & Maintenance Manual rev. 2.1 3. Back off the grub screw (c) using a 3mm hexagonal wrench. 4. Remove the foot (d). Figure 6.10-3 Page 6.25...
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  • Page 45: Adjustment

    KINESIS ONE: Service & Maintenance Manual rev. 2.1 7. ADJUSTMENT 7.1. THE WEIGHT STACK IS NOT FLOWING FLUID This problem is possible for a lack lubrication of the bars or "dirty" that accumulates fox a mix of dust and oil.

  • Page 46: The Cable Of Weight Stack Is Not In Tension

    KINESIS ONE: Service & Maintenance Manual rev. 2.1 7.2. THE CABLE OF WEIGHT STACK IS NOT IN TENSION This problem has been the lengthening of the weights stack cable, especially in the first period of use. To resolve this problem is necessary to act on the cable regulating tension system.

  • Page 47: Adjusting The Front Panel Position

    KINESIS ONE: Service & Maintenance Manual rev. 2.1 7.3. ADJUSTING THE FRONT PANEL POSITION In some cases, the front guard of the equipment may be more or less opening at the back than the correct dimension required (between 1230-1260 mm).
  • Page 48 KINESIS ONE: Service & Maintenance Manual rev. 2.1 Figure 7.3-2 To augment the dimension of the opening and move the front guard closer to the frame: 1. Act on the rear nut (b), as shown in the figure and then lock down the opposite nut.

  • Page 49: The Machine Is Not Flat

    KINESIS ONE: Service & Maintenance Manual rev. 2.1 7.4. THE MACHINE IS NOT FLAT This problem may be due to the positioning of the machine on a not flat surface. To resolve this problem is necessary to act on foot adjustment.

  • Page 50: Adjustment Weight Stack Stop

    KINESIS ONE: Service & Maintenance Manual rev. 2.1 For the adjusting feet on the arms: 2. Screw or back off the grub screw (a), using a 4mm hexagonal wrench, until the foot lay correctly down on the ground. Figure 7.4-2 7.5.

  • Page 51: Scheduled Maintenance

    The EXTRAORDINARY maintenance operations have to be performed by a TG qualified technician specially trained by Technogym. They consist of the set up, the start up, all the inspections and service operations and the adjustments the machine can need to guarantee a good state of wear and the proper functioning conditions.

  • Page 52: Ordinary Maintenance Operations

    KINESIS ONE: Service & Maintenance Manual rev. 2.1 8.1. ORDINARY MAINTENANCE OPERATIONS 8.1.1. E XTERNAL CLEANING OPERATIONS 1. Using a cloth moistened with a neutral detergent (non acidic), clean the entire machine, taking care not to rub too vigorously, especially on the keys of the display.

  • Page 53: Check The Cables

    KINESIS ONE: Service & Maintenance Manual rev. 2.1 8.1.4. HECK 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.

  • Page 54: Extra-Ordinary Maintenance Operations

    KINESIS ONE: Service & Maintenance Manual rev. 2.1 8.2. EXTRA-ORDINARY MAINTENANCE OPERATIONS 8.2.1. HECK THE PULLEYS 1. Check the wear status of the pulley grooves. Repair and/or replace any worn parts. 8.2.2. HECK THE WEIGHT STACK ROD STOPS 1. Check the wear status of the weight stack rod stops. Repair and/or replace any worn parts.

  • Page 55: Appendice

    KINESIS ONE: Service & Maintenance Manual rev. 2.1 9. APPENDICE 9.1. TOOLS TO USE The following tools are necessary to carry out all disassembly, adjustment and maintenance operations on the machines: • 17mm wrench; • 19mm wrench; • 17mm retchet wrench;...
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  • Page 58 TECHNOGYM S.p.A. Via G. Perticari, 20 47035 Gambettola (FC) ITALIA Tel.: +39-0547-650638 Fax: +39-0547-650150 e-mail: service@technogym.com 0SM00550AA-UK...

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