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Issue date Edition Doc No. JOHNSON Revision Edition time Page date G7-S77-02 CALF EXTENSION SERVICE MANUAL Approval Review Editor Allen Sun Allen Sun Hans Kong...
CONTENTS CHAPTER 1:SERIAL NUMBER LOCATION................... 1 CHAPTER 2:MAINTENANCE & SAFETY....................2 CHAPTER 3:ASSEMBLY INSTRUCTION....................4 CHAPTER 4:TROUBLESHOOTING......................6 4.1 The Repetition Display Is Blank Or Is Not Counting Movements..........6 4.2 Incremental Weight Pin Is Loose Or Feels Sloppy..............8 4.3 Weight Stack Pin Will Not Go Into Some Or All Weight Plates..........9 4.4 The Weight Stack Cable Is Falling Off A Pulley Or Cam............10 4.5 Repetition Magnet Has Fallen Off Or Is Missing................11 4.6 Rom Plunger Or Pull Pins Does Not Move Easily..............12...
CHAPTER 2:MAINTENANCE & SAFETY IMPORTANT SAFETY INFORMATION It is the sole responsibility of the purchaser of MATRIX products to instruct all individuals, whether they are the end user or supervising personnel on proper usage of the equipment. It is recommended that all users of MATRIX exercise equipment be informed of the following information prior to its use.
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CHAPTER 2:MAINTENANCE & SAFETY PROPER USAGE 1. Do not exceed weight limits of the exercise device. 2. If applicable, set safety stops to appropriate height. 3. If applicable, adjust seat pads, leg pads, foot pads, range of motion adjustment, or any other type of adjustment mechanisms to a comfortable start position.
CHAPTER 4:TROUBLESHOOTING 4.1 THE REPETITION DISPLAY IS BLANK OR IS NOT COUNTING MOVEMENTS. Possible Causes 1) The rep counter battery is dead or disconnected. 2) The rep counter is unplugged from the repetition sensors. 3) The magnet is missing or positioned incorrectly. 4) The repetition sensors are faulty or positioned incorrectly.
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CHAPTER 4:TROUBLESHOOTING 4.1 THE REPETITION IS BLANK OR IS NOT COUNTING MOVEMENTS.
CHAPTER 4:TROUBLESHOOTING 4.2 INCREMENTAL WEIGHT PIN IS LOOSE OR FEELS SLOPPY Possible causes 1) The snap ring holding the incremental weight pin in position is damaged or missing. 2) The incremental weight pin is damaged. Solution 1) Remove the weight stack covers. a.
CHAPTER 4:TROUBLESHOOTING 4.3 WEIGHT STACK PIN WILL NOT GO INTO SOME OR ALL WEIGHT PLATES Possible Causes 1) The weight stack pin is bent. 2) The cable is attached too loosely or too tightly. 3) The weight plates are not seated correctly at the bottom of the guide rods. 4) The top weight plate bushings are damaged.
CHAPTER 4:TROUBLESHOOTING 4.4 THE WEIGHT STACK CABLE IS FALLING OFF A PULLEY OR CAM Possible Causes 1) The cable is too loose or too tight. 2) The cable is routed incorrectly. Solution 1) Check the tightness of the cable. Make sure that it is tensioned properly. 2) Check the routing of the cable through the weight stack.
CHAPTER 4:TROUBLESHOOTING 4.5 REPETITION MAGNET HAS FALLEN OFF OR IS MISSING Possible Causes 1) The repetition counter magnet was not secured tightly enough to the repetition counter bracket. Solution 1) Remove side covers and the 2 screws fixing the magnet frame (Figure A). 2) Install a zip tie to securely attach the magnet to the bracket (Figure B).
4.6 ADJUSTABLE HANDLE DOES NOT MOVE EASILY Possible causes 1) The pins are rubbing on the frame creating friction. Solution 1) Remove the affected pin, add grease (Matrix recommends Super Lube brand grease with PTFE) and then re-install the pin.(1000401290)
CHAPTER 5:PARTS REPLACEMENT 5.1 TESTING THE UNIT Once the unit or replacement part is fully installed and assembled and properly placed on the floor, use the following instructions to test the machine: NOTE: Not all of the replacement instructions will apply to every model. 1) Check that the weight stack pin will slide freely into the weight stack at all positions.
CHAPTER 5:PARTS REPLACEMENT 5.3 REPETITION COUNTER 1) Remove the 4 screws going through the aluminum wing into the top cover of the weight stack (Figure A). 2) Disconnect the repetition counter wire and remove the aluminum wing and top cover from the weight stack (Figure B).
CHAPTER 5:PARTS REPLACEMENT 5.4 SIDE COVER 1) Remove the 4 screws going through the aluminum wing into the top cover of the weight stack (Figure A). 2) Disconnect the repetition counter wire and remove the aluminum wing and top cover from the weight stack (Figure B).
CHAPTER 5:PARTS REPLACEMENT 5.5 REPETITION SENSOR 1) Remove the 4 screws going through the aluminum wing into the top cover of the weight stack (Figure A). 2) Disconnect the repetition counter wire and remove the aluminum wing and top cover from the weight stack (Figure B).
CHAPTER 5:PARTS REPLACEMENT 5.6 INCREMENTAL WEIGHT PIN 1) Remove the side covers as outlined in Section 5.4. 2) Remove the 4 screws holding on the clear plastic cover over the incremental weight pin and remove it (Figures A & B). 3) Remove the 2 screws holding on the reaction block and remove it (Figures C &...
CHAPTER 5:PARTS REPLACEMENT 5.7 WEIGHT PLATE 1) Remove the outside cover as outlined in Section 5.2&5.4. 2) Remove the 4 screws holding on the clear plastic cover over the incremental weight pin and remove it (Figures A & B). 3) Remove the 2 screws holding on the reaction block and remove it (Figures C & D). 4) Move the rubber cover on the cable by pulling up on it (Figure E).
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CHAPTER 5:PARTS REPLACEMENT 5.7 WEIGHT PLATE FIGURE H FIGURE I FIGURE J...
CHAPTER 5:PARTS REPLACEMENT 5.8 WEIGHT STACK PULLEY 1) Remove the side covers as outlined in Section 5.4. 2) Remove the 4 screws holding on the clear plastic cover over the incremental weight pin and remove it (see Section 5.6 for pictures). 3) Move the rubber cover on the cable by pulling up on it (Figure A).
CHAPTER 5:PARTS REPLACEMENT 5.9 BACK & SEAT PAD 1) Remove the 2 screws to replace the back pad (Figure A). 2) Remove 4 screws under the seat pad on both sides to replace the pad (Figure B). FIGURE A FIGURE B...
CHAPTER 5:PARTS REPLACEMENT 5.10 ADJUSTABLE HANDLE 1) Remove the chain fixing handle (Figure A). 2) Remove the fixing screw and the handle (Figure B). 3) Remove the stopper ring (Figure C). 4) Add grease on the pull pin and reserve step 1-3 to replace(Figure D).(1000401290) FIGURE A FIGURE B FIGURE C...
CHAPTER 6:PARTS LIST Part List SAP No. SAP Description Control board 1000096514 Control Board;Matrix;;H102;S1.60;;GM40; Sensor 1000096531 Sensor;;;;;24AWG;1200mm;OKIx3+XHS-5Y; Adjustable pin 1000398254 Adjustment Pin Assembly;Assembly;;weight Snap ring 1000102910 Snap Ring;External C-Shaped;S-12;;BED; Adjustable rod 1000398482 Incremental Adjustable Rod-Exreawork;Inc Fixing axle 1000408503 Fixing Axle;Steel Rope Head;Short;45#;Ch...