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Technogym BIOSTRENGTH LINE, Service Maintenance Manual

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Technogym BIOSTRENGTH LINE Service Maintenance Manual Download Page 18

 

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1 

 

Page 1.2

 

1.3.   GENERAL RULES FOR REPAIR PROCEDURES 

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

reassembly. 

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

and maintenance than those contained in this manual. 

 
5.  Before starting the repair procedure, make sure that the recommended tools are available and in 

good condition. 

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

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

 
 

Summary of Contents for BIOSTRENGTH LINE

Page 1: ...SERVICE MAINTENANCE MANUAL REV 2 1...

Page 2: ......

Page 3: ...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 re...

Page 4: ......

Page 5: ...A wiring diagram 2 6 2 5 2 Type B wiring diagram 2 12 2 5 3 Type C wiring diagram 2 19 2 5 4 Type D wiring diagram 2 26 2 6 SEPARATED BOARD VERSION 2 34 2 6 1 Type A wiring diagram 2 34 2 6 2 Type B w...

Page 6: ...ET PROCEDURE 6 9 6 3 1 Buffer battery test 6 9 6 3 2 TGS interface test 6 9 6 3 3 FPGA test 6 9 6 3 4 Solenoid test 6 10 6 3 5 Weight stack motor test 6 10 6 3 6 Seat motor test 6 12 6 4 TEST PROCEDUR...

Page 7: ...stack plates 7 22 7 1 21 Disassembling the bars 7 23 7 1 22 Disassembling the seat guard 7 24 7 1 23 Disassembling the electrical box 7 25 7 1 24 Disassembling the electronic components of the electr...

Page 8: ...3 6 Disassembling the seat keyboard 7 89 7 3 7 Disassembling the Plexiglas weight stack guard 7 90 7 3 8 Disassembling the weight stack pulleys 7 91 7 3 9 Disassembling the weight stack cover 7 92 7 3...

Page 9: ...ectrical box 7 153 7 4 26 Disassembling the electronic components of the electrical box 7 154 7 4 27 Disassembling the bell guard 7 156 7 4 28 Disassembling the weight stack frame guard 7 157 7 4 29 D...

Page 10: ...the main keyboard 7 217 7 6 6 Disassembling the seat keyboard 7 218 7 6 7 Removing the seat 7 219 7 6 8 Disassembling the front guard 7 220 7 6 9 Disassembling the electrical box 7 221 7 6 10 Disasse...

Page 11: ...ps 7 278 7 7 23 Disassembling the cross 7 279 7 7 24 Disassembling the sinker 7 280 7 7 25 Disassembling the weight stack plates 7 281 7 7 26 Disassembling the bars 7 282 7 7 27 Disassembling the seat...

Page 12: ...ing the seat motor 7 342 7 8 40 Disassembling the power entry 7 343 7 8 41 Disassembling the starter plate and fuses 7 344 7 9 LEG PRESS 7 345 7 9 1 Disassembling the display 7 345 7 9 2 Removing the...

Page 13: ...entry 7 400 8 ADJUSTMENTS 8 1 8 1 ADJUSTING THE WEIGHT STACK PLATE SELECTION 8 1 8 1 1 OFFSET 8 1 8 1 2 Distance between plates 8 2 8 1 3 Weight stack motor inertia 8 3 8 2 ADJUSTING THE MECHANISMS PH...

Page 14: ...t stack motor test cycles 9 18 9 5 3 Number of relay switching cycles to move the weight stack motor upward 9 18 9 5 4 Number of relay switching cycles to move the weight stack motor downward 9 18 9 5...

Page 15: ...0 4 10 3 7 Check the mechanisms 10 4 10 3 8 Check the gas springs 10 4 10 3 9 Check the pulleys 10 4 10 3 10 Check the cam group 10 4 10 3 11 Check the primary and secondary shaft connection chain 10...

Page 16: ...BIOSTRENGTH LINE Service Maintenance manual rev 2 1 Page xii Page intentionally left blank...

Page 17: ...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...

Page 18: ...the recommended brands 3 Use special tools where specified 4 Consult the technical circulars which may contain more up to date information on adjustments and maintenance than those contained in this m...

Page 19: ...RISTICS The sizes quoted in the following figures must be considered as minimum dimensions easily reachable disassembling some parts of the machines such as seat footboard and casing or display holder...

Page 20: ...BIOSTRENGTH LINE Service Maintenance manual rev 2 1 Page 2 2 2 1 3 LEG EXTENSION 2 1 4 LEG CURL 2 1 5 VERTICAL TRACTION...

Page 21: ...BIOSTRENGTH LINE Service Maintenance manual rev 2 1 Page 2 3 2 1 6 SHOULDER PRESS 2 1 7 CHEST PRESS 2 1 8 ROWING TORSO...

Page 22: ...2670 1020 1600 2 2 ELECTRICAL CHARACTERISTICS MACHINE Mains voltage Frequency Consumption Fuses Abdominal Crunch 115 230 Vac 50 60 Hz 100 VA 5x20 1 6 A slow blow Lower Back 115 230 Vac 50 60 Hz 100 V...

Page 23: ...conforms to the following directives Europe USA EMI EN 60601 1 2 Safety EN 60601 1 EN 957 1 Directive 73 23 CEE 93 68 CEE 89 336 CEE UL 2601 1 Moreover Machines do not produce electromagnetic disturba...

Page 24: ...BIOSTRENGTH LINE Service Maintenance manual rev 2 1 Page 2 6 2 5 UNIFIED BOARD VERSION 2 5 1 TYPE A WIRING DIAGRAM This diagram is for Abdominal Crunch and Lower Back...

Page 25: ...0 220 Vac line phase neutral earth Voltage selector board labeled GF990505 order code 0WQ123 Name Type of connector Connection CN1 3 pin female AMP MNL 110 220 Vac line phase neutral CN2 3 pin termina...

Page 26: ...device input Patch cords Name Type of connector Connection CN21 6 pin open male AMP MINIFIT 24 Vdc weight stack motor with reed CN23 6 pin open male AMP MODU II Encoder signals CN24 4 pin open male AM...

Page 27: ...witch CN1 Slot Ground Yellow 1 4 Faston Neutral Blue 2 6 Faston Phase Black 1 BS 7 L Low voltage power cable Power supply Bio Driver Board Power supply CN2 CN7 Signal Color Bio driver board CN9 1 12 V...

Page 28: ...en 15 17 Solenoid enable White 13 3 Tx from FPGA to CPU White yellow 12 6 Reset to FPGA Yellow red 18 3 zero sensor White black 17 BS 00 Zero sensor extension cable Bio Driver Board Patch Bio Driver B...

Page 29: ...4 Ground Green 4 5 solenoid Orange 4 6 Solenoid ground Blue 3 BS 10 Solenoid extension cord Patch Patch Patch CN25 Signal Color Open CN26 3 solenoid Blue 3 4 Solenoid ground Red 4 BS 232 Serial outpu...

Page 30: ...BIOSTRENGTH LINE Service Maintenance manual rev 2 1 Page 2 12 2 5 2 TYPE B WIRING DIAGRAM This diagram is for Leg Curl Vertical Traction Shoulder Press Chest Press and Rowing Torso...

Page 31: ...10 220 Vac line phase neutral earth Voltage selector board labeled GF990505 order code 0WQ123 Name Type of connector Connection CN1 3 pin female AMP MNL 110 220 Vac line phase neutral CN2 3 pin termin...

Page 32: ...vice input Patch cords Name Type of connector Connection CN21 6 pin open male AMP MINIFIT 24 Vdc weight stack motor with reed CN22 6 pin open male AMP MINIFIT 24 Vdc seat adjustment motor with reed CN...

Page 33: ...switch CN1 Slot Ground Yellow 1 4 Faston Neutral Blue 2 6 Faston Phase Black 1 BS 7 L Low voltage power cable Power supply Bio Driver Board Power supply CN2 CN7 Signal Color Bio driver board CN9 1 12...

Page 34: ...stack motor pulses White green 9 10 Seat motor Pulses Red 10 15 Solenoid status Green 15 17 Solenoid enable White 13 3 Tx from FPGA to CPU White yellow 12 6 Reset to FPGA Yellow red 18 3 zero sensor...

Page 35: ...le could be divided into two parts BS 2 2S Seat motor cable Bio Driver Board Patch cord Bio Driver Board CN2 Signal Color Open CN22 1 motor White 1 2 motor Blue 2 5 Pulses Red 5 6 Ground Black 6 CAUTI...

Page 36: ...enoid Blue 3 4 Solenoid ground Red 4 BS 232 Serial output cable CPU Board Serial connector CPU Board K15 Signal Color Serial connector 2 ground Black 5 3 Tx to PC Yellow 2 4 Rx from PC Green 3 BS TLCB...

Page 37: ...BIOSTRENGTH LINE Service Maintenance manual rev 2 1 Page 2 19 2 5 3 TYPE C WIRING DIAGRAM This diagram is for Leg Extension...

Page 38: ...10 220 Vac line phase neutral earth Voltage selector board labeled GF990505 order code 0WQ123 Name Type of connector Connection CN1 3 pin female AMP MNL 110 220 Vac line phase neutral CN2 3 pin termin...

Page 39: ...ype of connector Connection CN1 2 pin open male AMP MINIFIT Safety sensor input signal CN2 4 pin male AMP MODU II Safety sensor input signal to driver board CN3 2 pin male AMP MODU II Reset Patch cord...

Page 40: ...h Yellow green Faston Slot BS 14 S High voltage power cable Filter Power supply 110 230 Selector switch Filter CN18 Signal Color Power supply CN1 Selector switch CN1 Slot Ground Yellow 1 4 Faston Neut...

Page 41: ...Purple 2 3 Weight stack motor up Blue 3 4 Seat motor up Brown 4 5 Weight stack motor down Black 5 6 Seat motor down Yellow 6 7 Weight stack motor alarm White red 7 8 Seat motor Alarm Pink 8 9 Weight...

Page 42: ...olor Open CN21 1 motor Black 1 2 motor Red 2 4 12 Vdc White 4 5 Pulses Green 5 6 Ground Orange 6 BS 2S Seat motor cable Bio Driver Board Motor Bio Driver Board CN2 Signal Color Motor 1 motor White 1 2...

Page 43: ...to PC Yellow 2 4 Rx from PC Green 3 BS TLCBR TGS connector cable CPU Board TLCBR CPU Board K6 Signal Color TLCBR 1 12 V Red 8 2 ground Black 6 3 Tx to TGS Yellow 2 4 Rx from TGS Green 1 BS 30 Signal...

Page 44: ...BIOSTRENGTH LINE Service Maintenance manual rev 2 1 Page 2 26 2 5 4 TYPE D WIRING DIAGRAM This diagram is for Leg Press...

Page 45: ...10 220 Vac line phase neutral earth Voltage selector board labeled GF990505 order code 0WQ123 Name Type of connector Connection CN1 3 pin female AMP MNL 110 220 Vac line phase neutral CN2 3 pin termin...

Page 46: ...at motor CN2 2 pin terminal board 38 Vac 6A power supply CN3 6 pin male AMP MODU II Signals servo board CN4 4x2 pin male AMP MODU II Encoder and microswitches CE1 2 pin male AMP MODU II Signals safety...

Page 47: ...cable Power switch Fuses Power switch CN14 Signal Color Fuses CN15 Faston Neutral Black Faston Faston Phase Black Faston BS 13 High voltage power cable Fuses Filter Earth node Fuses CN16 Signal Color...

Page 48: ...driver board CN8 Signal Color CPU Board K1 1 12 Vdc Black 1 2 Ground Red 2 3 Ground White 3 4 5 Vdc Green 4 BS 6 2 Signal cable CPU Board Bio Driver Board CPU Board K4 K3 K5 Signal Color Bio Driver Bo...

Page 49: ...olor Open CN27 Signal White 1 Output Ground Black 2 BS 2 2R Weight stack motor cable Bio Driver Board Patch cord Bio Driver Board CN1 Signal Color Open CN21 1 motor Black 1 2 motor Red 2 4 12 Vdc Whit...

Page 50: ...ALP LP seat motor cable LP Driver Board Patch cord LP Driver Board CN1 Signal Color Open 1 motor Black 1 2 motor Black 2 BS 28 2ALP LP seat motor component cable LP Driver Board Patch cord LP Driver B...

Page 51: ...ck 6 3 Tx to TGS Yellow 2 4 Rx from TGS Green 1 BS 30 Signal sensor cable LP Driver Board Sensor interface Board LP Driver Board CE1 CN2 Signal Color Sensor interface Board CN2 1 12 Vdc Red 1 2 Alarm...

Page 52: ...BIOSTRENGTH LINE Service Maintenance manual rev 2 1 Page 2 34 2 6 SEPARATED BOARD VERSION 2 6 1 TYPE A WIRING DIAGRAM This diagram is for Abdominal Crunch and Lower Back...

Page 53: ...e neutral earth CN18 2 male Faston M5 screw slot 110 220 Vac line phase neutral earth Selector switch Name Type of connector Connection CN19 Contacts to be soldered 110 220 Vac line phase neutral Powe...

Page 54: ...1 8 pin male AMP MODU II Signals connection with encoder CN2 6 pin male AMP MODU II RS 232 serial to CPU CN3 4 pin male AMP MODU I Low voltage 12 Vdc 5 Vdc ground CN4 4 pin male AMP MODU I Low voltage...

Page 55: ...n Earth Yellow green Faston Slot BS 14 High voltage power cable Filter Power supply 110 230 Selector switch Filter CN18 Signal Color Power supply CN1 Selector switch CN19 Slot Ground Yellow 1 4 Faston...

Page 56: ...und Gray 4 Weight stack motor signal cable CPU Board K4 Signal Color WSMI board CN1 3 Motor up Blue 2 5 Motor down Black 3 7 Alarm Gray pink 4 9 Pulses White green 5 1 Ground White yellow 6 FPGA signa...

Page 57: ...1 1 motor Red 1 2 motor Black 2 4 12 Vdc White 4 5 Pulses Brown 5 6 Ground Green 6 BS P Weight stack motor cable Weight stack motor Patch Motor Signal Color Open CN21 motor Brown 1 motor Green 2 12 Vd...

Page 58: ...CN27 3 solenoid Blue 3 4 Solenoid ground Red 4 BS M Solenoid cable Solenoid Patch Solenoid Signal Color Open CN27 solenoid White 3 Output Solenoid ground White 4 BS 232 Serial output cable CPU Board S...

Page 59: ...INE Service Maintenance manual rev 2 1 Page 2 41 2 6 2 TYPE B WIRING DIAGRAM This diagram is for Leg Extension not provided with safety device Leg Curl Vertical Traction Shoulder Press Chest Press and...

Page 60: ...e neutral earth CN18 2 male Faston M5 screw slot 110 220 Vac line phase neutral earth Selector switch Name Type of connector Connection CN19 Contacts to be soldered 110 220 Vac line phase neutral Powe...

Page 61: ...gnals CPU connection CN2 2 pin terminal board 18 Vac 5A power supply CN3 6 pin female AMP MNL 24 Vdc motor with reed FPGA Board labeled GF970601 order code 0WQ069 Name Type of connector Connection CN1...

Page 62: ...cable Power switch Fuses Power switch CN14 Signal Color Fuses CN15 Faston Neutral Blue Faston Faston Phase Black Faston BS 13 High voltage power cable Fuses Filter Earth node Fuses CN16 Signal Color...

Page 63: ...N3 1 12 V Red 1 3 5 V Orange 4 4 Ground Gray 3 5 Faston Earth Black 2 The connection between connector CN7 and pin 5 on connector CN2 both on the power supply serves to ground the low voltage groundin...

Page 64: ...t motor signal cable CPU Board K4 Signal Color SAMI board CN1 4 Motor up Brown 2 6 Motor down Yellow 3 8 Alarm Orange 4 10 Pulses Red 5 2 Ground Purple 6 FPGA signal cable CPU Board K3 Signal Color FP...

Page 65: ...ensor Signal Color Open CN25 Signal White 1 Output Ground Black 2 BS 2 Weight stack motor cable Weight stack motor interface board Patch cord WSMI board CN3 Signal Color Open CN21 1 motor Red 1 2 moto...

Page 66: ...ension Leg Curl and Chest Press the connector CN21 of the motor cable connects directly to connector CN3 on the seat motor interface board BS S Seat motor cable Seat motor Patch Motor Signal Color Ope...

Page 67: ...CN27 3 solenoid Blue 3 4 Solenoid ground Red 4 BS M Solenoid cable Solenoid Patch Solenoid Signal Color Open CN27 solenoid White 3 Output Solenoid ground White 4 BS 232 Serial output cable CPU Board S...

Page 68: ...BIOSTRENGTH LINE Service Maintenance manual rev 2 1 Page 2 50 2 6 3 TYPE C WIRING DIAGRAM This diagram is for Leg Extension provided with safety device...

Page 69: ...e neutral earth CN18 2 male Faston M5 screw slot 110 220 Vac line phase neutral earth Selector switch Name Type of connector Connection CN19 Contacts to be soldered 110 220 Vac line phase neutral Powe...

Page 70: ...CN3 6 pin female AMP MNL 24 Vdc motor with reed CS1 2 pin open male AMP MINIFIT Safety sensor input signal CS2 2 pin male AMP MODU II Reset FPGA Board labeled GF970601 order code 0WQ069 Name Type of...

Page 71: ...cable Power switch Fuses Power switch CN14 Signal Color Fuses CN15 Faston Neutral Blue Faston Faston Phase Black Faston BS 13 High voltage power cable Fuses Filter Earth node Fuses CN16 Signal Color...

Page 72: ...N3 1 12 V Red 1 3 5 V Orange 4 4 Ground Gray 3 5 Faston Earth Black 2 The connection between connector CN7 and pin 5 on connector CN2 both on the power supply serves to ground the low voltage groundin...

Page 73: ...hite green 5 1 Ground White yellow 6 Seat motor signal cable CPU Board K4 Signal Color SAMI board CN1 4 Motor up Brown 2 6 Motor down Yellow 3 8 Alarm Orange 4 10 Pulses Red 5 2 Ground Purple 6 FPGA s...

Page 74: ...h cord WSMI board CN3 Signal Color Open CN21 1 motor Red 1 2 motor Black 2 4 12 Vdc White 4 5 Pulses Brown 5 6 Ground Green 6 BS P Weight stack motor cable Weight stack motor Patch Motor Signal Color...

Page 75: ...c Red 3 4 Ground Black 4 1 solenoid Brown 3 2 Solenoid ground Gray 4 BS E Encoder cable Encoder Patch Encoder Signal Color Open CN23 Channel A Green 1 Channel B White 2 12 Vdc Red 3 Output Ground Blac...

Page 76: ...able CPU Board TLCBR CPU Board K6 Signal Color TLCBR 1 12 V Red 8 2 ground Black 6 3 Tx to TGS Yellow 2 4 Rx from TGS Green 1 BS 30 Signal sensor cable Seat motor interface board Sensor interface Boar...

Page 77: ...BIOSTRENGTH LINE Service Maintenance manual rev 2 1 Page 2 59 2 6 4 TYPE D WIRING DIAGRAM This diagram is for Leg Press...

Page 78: ...e Faston M5 screw slot 110 220 Vac line phase neutral earth Selector switch Name Type of connector Connection CN19 Contacts to be soldered 110 220 Vac line phase neutral CN12 Contacts to be soldered 1...

Page 79: ...beled GF970601 order code 0WQ069 Name Type of connector Connection CN1 8 pin male AMP MODU II Signals connection with encoder CN2 6 pin male AMP MODU II RS 232 serial CN3 4 pin male AMP MODU I Low vol...

Page 80: ...MNL LP seat motor power supply 2 6 4 2 Cables BS 11 High voltage power cable Power socket Power switch Earth node Power socket CN11 Signal Color Power switch CN13 PE Faston Earth Yellow green Slot Fas...

Page 81: ...tor switch Patch CN33 Signal Color Selector switch CN12 Faston Neutral Blue 4 Faston Phase Black 1 BS 7 L Low voltage power cable Power supply FPGA Board Power supply CN2 CN7 Signal Color FPGA Board C...

Page 82: ...atus Green 10 12 Ground Gray 8 Weight stack motor signal cable 3 Motor up Blue 11 5 Motor down Black 13 7 Alarm Gray pink 15 9 Pulses White green 16 1 Ground White yellow 14 Seat motor signal cable 4...

Page 83: ...or up Blue 2 13 Motor down Black 3 15 Alarm Gray pink 4 16 Pulses White green 5 14 Ground White yellow 6 Seat motor signal cable Patch CN36 Signal Color Open CN34 1 Motor up Brown 2 3 Motor down Yello...

Page 84: ...es Brown 5 6 Ground Green 6 BS P Weight stack motor cable Weight stack motor Patch Motor Signal Color Open CN21 motor Brown 1 motor Green 2 12 Vdc Black 4 Pulses White 5 Output Ground Red 6 BS 9A Weig...

Page 85: ...k 4 5 solenoid Brown 3 6 Solenoid ground Gray 4 BS E Encoder cable Encoder Patch Encoder Signal Color Open CN23 Channel A Green 1 Channel B White 2 12 Vdc Red 3 Output Ground Black 4 BS 10 Solenoid ex...

Page 86: ...motor Brown 1 2 motor Blue 2 4 5 Vdc White 2 5 Pulses Blue 3 6 Ground Red 4 7 Rear limit switch Orange 2 8 Front limit switch Yellow 3 9 Ground Black 4 BS 10 LPO LP seat motor limit switch extension c...

Page 87: ...otor Brown 1 Output motor Blue 2 BS F LPO LP seat motor photocell cable LP seat motor photocell Patch Motor Signal Color Open CN35 5 Vdc White 1 Pulses Blue 2 Output Ground Red 4 BS 232 Serial output...

Page 88: ...BIOSTRENGTH LINE Service Maintenance manual rev 2 1 Page 2 70 Page intentionally left blank...

Page 89: ...BIOSTRENGTH LINE Service Maintenance manual rev 2 1 Page 3 1 3 OPERATING PRINCIPLE 3 1 BLOCK DIAGRAM The figure below shows the block diagram for the machine...

Page 90: ...OLTAGE SELECTOR BOARD This is a board which when used together with a transformer having 2 primary 110 Vac circuits ensures the correct power supply to the transformer when powered at either 110 Vac o...

Page 91: ...board is receiving power correctly The board also receives as input the 18Vac 10A secondary power from the transformer which stabilizes at 24 Vdc for the solenoid the weight stack and where available...

Page 92: ...the Bio servo board and the seat motor It receives the motor command signal from the CPU board and based on this signal either supplies or cuts off working voltage to the motor It generates an alarm s...

Page 93: ...er of pulses to the Bio servo board in proportion to the linear movement of the wire In order to function properly it must be powered at 12 Vdc with a current of at least 100 mA 3 1 12 SOLENOID The so...

Page 94: ...st be powered at 48 Vdc that it receives form the LP driver board 3 1 16 ZERO SENSOR This is a reed contact that acts as a zero sensor for the weight stack selection system A magnet is present on the...

Page 95: ...to the sensor interface board the user presses the emergency button the circuit board sends an alarm signal to the Bio servo LP driver and CPU boards and illuminates LEDs L1 and L2 or L4 In this cond...

Page 96: ...in and out and which is pushed outside the solenoid by the spring c to select the additional weight d when the solenoid is de energized Figure 3 2 1 drawn into the solenoid by the magnetic field prod...

Page 97: ...into play Enable signal This is the signal generated by the CPU pin 17 1 on connector K4 to enable the solenoid This signal enters the Bio servo board pins 13 1 on connector CN7 and is processed by th...

Page 98: ...solenoid if it is low 0 V current is circulating in the solenoid The figure below shows the switching of the status signal caused by selection of the additional weight Figure 3 2 4 Voltage on solenoid...

Page 99: ...BIOSTRENGTH LINE Service Maintenance manual rev 2 1 Page 3 11 Figure 3 2 5...

Page 100: ...the plate hooks onto the cross d Figure 3 3 1 when the pin is in its internal position the plates are released from the cross d Figure 3 3 2 Figure 3 3 1 Figure 3 3 2 By adjusting the position of the...

Page 101: ...y which in turn moves Due to the movement of the motor the Hall sensor integrated into the motor as encoder produces the pulses that the Bio servo board sends to the CPU board The CPU board counts the...

Page 102: ...d the Bio servo board and the weight stack motor as shown in the figure below The following signals come into play Motor up signal on This is the signal generated by the CPU pin 3 1 on connector K4 to...

Page 103: ...on connector CN7 and is processed by the latter to pilot the weight stack motor with the proper supply voltage The control logic states that when the motor down signal is low 0 V the motor is stopped...

Page 104: ...the alarm signal which then returns high All of this takes place in the space of a few msec The figure below shows the alarm signal Figure 3 3 6 Pulses This is the signal generated by the Hall effect...

Page 105: ...is 0 Vdc the motor is stopped 24 Vdc the motor runs counter clockwise 24 Vdc the motor runs clockwise The figure below shows the switching of the power supply signal upon receiving a motor up command...

Page 106: ...rward and back until the front limit c and rear limit d are reached The actuator a is fastened to the machine frame e by means of the fitting f while the stem b is fasted to the seat g thus moving the...

Page 107: ...ure it is not greater than 5A the maximum value allowed by the motor When the motor reaches the front or back limit its inability to continue causes an increase in the current absorbed by the motor an...

Page 108: ...CN7 and is processed by the latter to pilot the seat motor with the proper supply voltage The control logic states that when the motor up signal is low 0 V the motor is stopped and thus not powered 0...

Page 109: ...ves because it is powered 24 Vdc Thus the motor moves the seat back down as long as the motor up signal is high The motor stops as soon as the signal returns to being low The figure below shows the sw...

Page 110: ...few msec The figure below shows the alarm signal Figure 3 4 4 Pulses This is the signal generated by the reed sensor built into the motor to measure the rpm of the motor encoder This is a square wave...

Page 111: ...between 0 5 V Motor voltage This is the power supply signal for the seat motor produced by the Bio servo board pins 1 2 on connector CN2 when it is 0 Vdc the motor is stopped 24 Vdc the motor turns t...

Page 112: ...which activate the two normally closed limit switches l at the ends of the motor stroke 3 5 2 CONTROLS To adjust the seat position the CPU board sends the motor up signal to move the seat forward or...

Page 113: ...to disable movement CAUTION if a limit switch is defective damaged or disconnected the board detects its open signal and prevents the seat from moving in that direction The board also has a few LEDs...

Page 114: ...orward up This signal enters the LP driver board pins 2 6 on connector CN3 and is processed by the latter to pilot the seat motor with the proper supply voltage The control logic states that when the...

Page 115: ...The control logic states that when the motor down signal is low 0 V the motor is stopped and thus not powered 0 Vdc while when the signal is high 4 V the motor moves because it is powered 48 Vdc Thus...

Page 116: ...ll of this takes place in the space of a few msec The figure below shows the alarm signal Figure 3 5 4 Pulses This is the signal generated by the photocell that reads the teeth of the encoder disc ali...

Page 117: ...is 0 Vdc the motor is stopped 48 Vdc the motor moves to shift the seat back 48 Vdc the motor moves to shift the seat forwards The figure below shows the switching of the power supply signal upon rece...

Page 118: ...GA converts them into a RS232 serial signal that is sent to the CPU board The CPU board uses this serial signals to detect the top plate position and hence to show the ROM reps sets and power of the e...

Page 119: ...nters the CPU board pin 3 on connector K3 pin 1 on connector K4 The communication protocol continuously sends 4 bytes from the FPGA board to the CPU board containing Byte 1 the communication synchrony...

Page 120: ...K3 pin 1 on connector K4 each time the power supply is switched on to reset the top plate position This signal enters the Bio servo board pins 18 1 on connector CN7 The control logic states that when...

Page 121: ...BIOSTRENGTH LINE Service Maintenance manual rev 2 1 Page 4 1 4 ACCESSORIES The equipment has no accessories...

Page 122: ...BIOSTRENGTH LINE Service Maintenance manual rev 2 1 Page 4 2 Page intentionally left blank...

Page 123: ...8 The machine makes the connection available to other machines in cascade The recommended maximum number of machines to be connected in cascade is limited by the maximum capacity of 10 A of the power...

Page 124: ...configure the machine as described in paragraphs 9 2 Configuring the technical parameters and 9 3 Configuring the user parameters Get on the machine Press the and keys on the keyboard to adjust the se...

Page 125: ...sponse This type of box is a step in the troubleshooting procedure where an ACTION must be carried out It typically contains a description of the ACTION necessary to resolve the problem Therefore afte...

Page 126: ...nitoring the status of the command and control signals exchanged between the CPU board and the Bio servo board to manage the function When complete press the Clear key to exit the procedure and contin...

Page 127: ...t that caused the alarm is released Using this procedure it is possible to identify various situations some of which are listed below Problem Cause Solution Replace the CPU board The status of the U a...

Page 128: ...o servo board to move the seat forward or up When the letter U is followed by 0 this means there is no movement command when the value is 1 the CPU board is ordering movement To change this signal pre...

Page 129: ...because an alarm signal arrives although it is far from one end Low current limit setting on the Bio servo board LP Bio servo Check the current limit setting 6 1 4 SOLENOID The part regarding the sol...

Page 130: ...gnals and the motor solenoid is not enabled The CPU board does not produce the command signal Replace the keyboard Connector cable between the CPU board and solenoid is defective Replace the cable Bio...

Page 131: ...machine to a more intensive test since they are required to move continuously between the available limits In both cases the machine will alternate the LCD display every 10 seconds between monitoring...

Page 132: ...g the weight stack between two predefined positions whose distance is known and taking the difference between the value in mm when the weight stack is in the 2 positions the result is the distance val...

Page 133: ...hecks whether the TGS interface is functioning properly by sending a status request This test makes it possible to check only the functioning status of the TLCBR board If it receives no response or an...

Page 134: ...ignal and checking the encoder and alarm signals it receives from the Bio servo board Under normal conditions the test takes place as follows the machine moves the weight stack motor this moves the se...

Page 135: ...e following message on the LCD W G H T S T A C K P R O B L E M E N C O D E R To exit this error condition carry out the checks described in paragraph 6 11 The LCD displays the message Weight stack pro...

Page 136: ...gnal the CPU board receives 3 more out of 3 consecutive movement attempts carried out approximately 10 seconds apart this means that there is something preventing movement In this case the machine abo...

Page 137: ...he message Seat problem encoder Each specific error message alternates every 10 seconds with the following message inviting you to call technical service to solve the problem C A L L F O R A S S I S T...

Page 138: ...If the CPU board receives no encoder signal during movement this means there is no movement due to a probable motor fault or that there is movement but it is not detected by a defective encoder In th...

Page 139: ...e LCD S E A T P R O B L E M G E N E R I C To exit this error condition shut off the machine switch it back on and see which error appears on the LCD display Carry out the checks described in paragraph...

Page 140: ...perly diagnose the error Pay special attention to those tests indicated in numbered boxes and described in detail here below 1 Remove the buffer battery from the CPU board and use a multimeter to meas...

Page 141: ...Is the green LED on the key reader lit NO NO Check whether the supply output voltage from the CPU board is correct 4 YES Check and or replace the BS TLCBR cable NO Replace the CPU board Check whether...

Page 142: ...ector The table below shows the numbering in a flat cable connector 1 3 5 7 9 2 4 6 8 10 You should get a reading of approximately 12 Vdc 2 Disconnect the flat cable connector from the TLCBR Insert th...

Page 143: ...board is replaced Replace the Bio servo board YES NO NO YES Follow the step by step guide to properly diagnose the error Pay special attention to those tests indicated in numbered boxes and described...

Page 144: ...he solenoid were disabled ADD ON WEIGHT PROBLEM MAGNET Replace the CPU board Replace the BS 6 2 cable Check whether the solenoid enable output signal from the CPU board is correct NO Check whether the...

Page 145: ...NO Check whether the solenoid status input signal to the CPU board is correct YES 7 8 Replace the CPU board NO A YES Check whether the solenoid is enabled NO Replace the solenoid YES Check whether th...

Page 146: ...roximately 4 Vdc while with the solenoid disabled additional weight selected you should get a reading of approximately 0 Vdc On Chest Press and Leg Press the BS 6 2 cable is divided into 2 parts throu...

Page 147: ...connector on the CPU board With the solenoid enabled additional weight not selected you should get a reading of approximately 0 Vdc while with the solenoid disabled additional weight selected you shou...

Page 148: ...direction This signal means that the absorbed current of the motor is greater than a value preset on the board by means of the setting described in paragraph 8 14 due to Low current limit setting Ins...

Page 149: ...t of the weight stack motor in one direction This means there is no movement WEIGHT STACK PROBLEM MOTOR Replace the CPU board Replace the BS 6 2 cable Check whether the weight stack motor enable outpu...

Page 150: ...the motor enabled you should get a reading of approximately 4 Vdc while with the motor stopped you should get a reading of approximately 0 Vdc 3 Insert the multimeter probes between pins 3 motor up si...

Page 151: ...ance manual rev 2 1 Page 6 27 5 Insert the multimeter probes between pins 110 or 220 signal and 0 of the CN2 connector of the selector switch You should get a reading of approximately 220 Vac or 110 V...

Page 152: ...stack motor Replace the BS 2 2R cable Check whether the weight stack motor encoder output signal from the weight stack motor is correct NO Check whether the weight stack motor encoder input signal to...

Page 153: ...ately 3 5 Vdc to 11 2 Vdc 3 Insert the oscilloscope probes between pins 9 signal and 1 of the CN7 connector on the Bio servo board With the motor enabled you should see a square wave signal ranging fr...

Page 154: ...the tests shown in the diagram below by passing the selection brush with magnet inserted in front of the sensor WEIGHT STACK PROBLEM LIMIT SWITCH SENSOR Adjust the position of zero sensor and or repla...

Page 155: ...5 Vdc while with the brush close to the sensor you should get a reading of approximately 0 Vdc 3 Insert the multimeter probes between pins 17 signal and 1 on the CN7 connector on the Bio servo board...

Page 156: ...the first considered to be normal after enabling movement of the seat motor in one direction This signal means that the absorbed current of the motor is greater than a value preset on the board by mea...

Page 157: ...e Bio servo board is continuously sending an alarm signal EMERGENCY ACTIVATED Replace the sensor Replace the cable BS 31 Check whether the sensor is correct NO Check whether the sensor input signal to...

Page 158: ...the multimeter probes between pins 1 signal and 2 of the connector CN1 on the Sensor interface board You should get a reading between 1200 and 2300 Ohm 3 Insert the multimeter probes between pins 1 si...

Page 159: ...ng movement of the seat motor in one direction This means there is no movement 6 15 1 FOR LEG PRESS SEAT PROBLEM MOTOR Replace the CPU board Replace the BS 6 2 cable Check whether the seat motor enabl...

Page 160: ...he selector switch B Check whether the supply voltage to the LP transformer is correct NO Replace the LP transformer and or the rectifier bridge 7 Follow the step by step guide to properly diagnose th...

Page 161: ...y 4 Vdc while with the motor stopped you should get a reading of approximately 0 Vdc 5 Insert the multimeter probes between pins 2 motor up signal and 6 or between pins 3 motor down signal and 6 of th...

Page 162: ...seat motor enable output signal from the CPU board is correct NO Check whether the seat motor enable input signal to the Bio servo board is correct YES 2 3 Check whether the seat motor enable output s...

Page 163: ...0 Vdc 3 Insert the multimeter probes between pins 4 motor up signal and 2 or between pins 6 motor down signal and 2 of the CN7 connector on the Bio servo board With the motor enabled you should get a...

Page 164: ...direction This means that there is movement but no encoder signal 6 16 1 FOR LEG PRESS SEAT PROBLEM ENCODER Replace the photocell Check whether the seat motor encoder output signal from the photocell...

Page 165: ...tor encoder power supply at the LP driver board output is correct 8 Replace the cables between the motor and the LP driver board YES Replace the LP driver board NO Follow the step by step guide to pro...

Page 166: ...signal and 6 of the connector CN6 on the Bio servo board With the motor enabled you should see a square wave signal ranging from approximately 0 Vdc to 5 Vdc 6 Insert the oscilloscope probes between p...

Page 167: ...ep by step guide to properly diagnose the error Pay special attention to those tests indicated in numbered boxes and described in detail here below 1 Insert the oscilloscope probes between pins 5 sign...

Page 168: ...tenance manual rev 2 1 Page 6 44 On the Chest Press the BS 6 2 cable is divided into 2 parts through the connector CN36 Carry out the test on this connector and if necessary replace only the defective...

Page 169: ...wer entry start button fuses filter power supply Bio servo board CPU board and the cables connecting them Check whether the fuses are intact Check whether the power cord is intact Check whether the po...

Page 170: ...holders is correct Check whether the line voltage from the fuse holders is correct Replace the start switch Replace the BS 12 cable Replace the damaged fuse holder YES NO NO YES NO YES 3 4 5 Check wh...

Page 171: ...supply is correct Check whether the direct current input to the Bio servo board is correct Replace the BS 14 S cable Replace the power supply Replace the BS 7 L cable YES NO NO YES NO YES 8 9 10 Chec...

Page 172: ...t the multimeter probes between pins of the CN14 output connector on the start switch between the blue and black cables You should get a reading of approximately 220 Vac or 110 Vac depending on the li...

Page 173: ...nd 3 of the CN9 connector on the Bio servo board You should get a reading of approximately 5 Vdc 11 Insert the multimeter probes between pins 1 signal and 2 of the CN4 connector on the Bio servo board...

Page 174: ...ould not concern problems with the CPU since the initial test checks communication and in any case no error message means that the serial communication line between the CPU board and TLCBR is working...

Page 175: ...pment and unplug the power cord from the wall socket 2 Unscrew the 4 self tapping screws a holding the DISPLAY using a medium sized Philips screwdriver Hold the DISPLAY up before unscrewing the last s...

Page 176: ...hilips screwdriver to unscrew the 5 screws f 5 Remove the CPU and LED BOARDS 6 To separate the CPU and LED boards disconnect the 2 connectors and the 4 coupling elements When finished configure the ma...

Page 177: ...LCD located under the LED board 1 Remove the CPU and LED BOARDS 2 Disconnect the 2 connectors 3 Unscrew the 4 screws holding the board to the shell using a small Philips screwdriver 4 Remove the LCD T...

Page 178: ...1 Insert the EPROM A into the left hand seat and EPROM B into the right hand seat 2 Insert the EPROM pins in the seats starting from the bottom so that the holes in the top seat remain free 3 Make su...

Page 179: ...the CHIP a from its seat using an integrated circuit extractor Figure 7 1 4 2 To re mount the CHIP 1 Make sure the reference notch b on the CHIP is aligned with the reference notch c on its seat 2 Mak...

Page 180: ...EYBOARD and remove it To replace the new KEYBOARD with the display resting on a bench 1 Remove the film protecting the adhesive 2 Begin attaching the adhesive part starting from left to right without...

Page 181: ...off the equipment and unplug the power cord from the wall socket For each side of the weight stack 2 Unscrew the 2 screws a using a 3 gauge hexagonal T wrench 3 Remove the Plexiglas cover Figure 7 1...

Page 182: ...exiglas weight stack guard For each of the 2 PULLEYS 1 Unscrew the screw a and the nut b using 2 17 gauge wrenches 2 Remove the PULLEY To reassemble the PULLEYS follow the above steps in reverse order...

Page 183: ...ASSEMBLING THE WEIGHT STACK COVER Figure 7 1 8 1 Follow the steps described in paragraph 7 1 6 Disassembling the plexiglas weight stack guard 1 Cut the clamp a Figure 7 1 8 2 2 Cut the clamp b 3 Disco...

Page 184: ...or f from the solenoid cable 6 Remove the spiral cable g and its guide h from the hook i Figure 7 1 8 4 7 Use a 6 gauge hexagonal T wrench to unscrew the 8 screws l 8 Pull the WEIGHT STACK COVER upwar...

Page 185: ...e 7 1 9 1 Follow the steps described in paragraph 7 1 8 Disassembling the weight stack cover 1 Remove the ADDITIONAL WEIGHT a by sliding it upward Press the solenoid pin inward so that it does not int...

Page 186: ...iglas weight stack guard limited solely to the external part 1 Release the slot a of the ENCODER wire from the hook Figure 7 1 10 2 2 Disconnect the connector b of the ENCODER cable 3 Use a 4 gauge he...

Page 187: ...in paragraph 7 1 6 Disassembling the plexiglas weight stack guard limited solely to the external part 1 Disconnect the connector a from the SOLENOID cable 2 Unscrew the 2 screws b using a 5 gauge hex...

Page 188: ...internal part 1 Switch the machine on 2 Follow the steps described in paragraph 9 2 Configuring the technical parameters until the final procedure that moves the brush into position as shown in the fi...

Page 189: ...assembling the plexiglas weight stack guard limited solely to the internal part 1 Loosen the counter nut a using a 13 gauge wrench 2 Disconnect the connector b from the cable 3 Remove the ZERO SENSOR...

Page 190: ...turning it counter clockwise 3 Disconnect the zero sensor cable Figure 7 1 14 2 Working on the outer part of the weight stack 4 Cut the clamp c and disconnect the connector d of the weight stack moto...

Page 191: ...ch 3 Unscrew the screw b using a jointed 5 gauge hexagonal wrench until the CHAIN is removed from the upper guide If this is not possible unscrew the screw c using a 3 gauge hexagonal T wrench to disa...

Page 192: ...stack selection chain 1 Loosen the dowel a using a 2 5 gauge hexagonal T wrench 2 Slide the pinion b from the motor shaft 3 Unscrew the 3 screws c using a 4 gauge hexagonal T wrench 4 Remove the MOTOR...

Page 193: ...aragraph 7 1 8 Disassembling the weight stack cover For each CROSS STOP 1 Unscrew the 2 dowels a using a 4 gauge hexagonal T wrench 2 Remove the CROSS STOP by sliding it upward To reassemble the CROSS...

Page 194: ...dditional weight 7 1 10 Disassembling the encoder 7 1 14 Disassembling the weight stack selection system and 7 1 17 Disassembling the cross stops 1 Use a special tool a to compress all of the weight s...

Page 195: ...bed in paragraph 7 1 18 Disassembling the cross 1 Place the cross on a bench or flat surface 2 Unscrew the 2 screws a using an 8 gauge hexagonal T wrench 3 Remove the cable connector flange b 4 Use a...

Page 196: ...ES Figure 7 1 20 1 Follow the steps described in paragraphs 7 1 8 Disassembling the weight stack cover 7 1 10 Disassembling the encoder and 7 1 18 Disassembling the cross 1 Remove the WEIGHT STACK PLA...

Page 197: ...described in paragraph 7 1 8 Disassembling the weight stack cover For each of the 2 counter weight vibration bars 1 Unscrew the 2 dowels a using a 4 gauge hexagonal T wrench Hold the BAR up before un...

Page 198: ...medium sized Philips screwdriver to unscrew the 4 screws a 3 Remove the REAR SEAT GUARD Figure 7 1 22 2 4 Loosen the 2 screws b using a medium sized Philips screwdriver 5 Release the FRONT SEAT GUARD...

Page 199: ...paragraph 7 1 22 Disassembling the seat guard 1 Unscrew the screw a using a 4 gauge hexagonal T wrench 2 Open the cover of the ELECTRICAL BOX Figure 7 1 23 2 3 Disconnect the cable connectors c 4 Uns...

Page 200: ...b 1 Disconnect the 4 connectors 2 Disconnect the 4 plastic coupling elements 3 Remove the card To disassemble the IMP BOARD c 1 Lift the board 2 Disconnect the 2 connectors 3 Disconnect the 4 plastic...

Page 201: ...220 SELECTOR SWITCH f 1 Unweld the cables 2 Unscrew the holding nut 3 Remove the selector switch To disassemble the FILTER g 1 Disconnect the connectors 2 Unscrew the 2 holding nuts To reassemble the...

Page 202: ...SASSEMBLING THE BELL GUARD Figure 7 1 25 1 1 Shut off the equipment and unplug the power cord from the wall socket 2 Unscrew the 2 screws a using a 3 gauge hexagonal T wrench 3 Slide the BELL GUARD up...

Page 203: ...2 Remove the UPPER GUARD Figure 7 1 26 2 3 Unscrew the 2 screws b using a 2 5 gauge hexagonal T wrench 4 Remove the cross piece c 5 Remove the 4 caps d 2 on each side of the GUARD using a small flat s...

Page 204: ...gauge wrenches loosen the counter nut a then unscrew the screw b from the WEIGHT STACK CABLE terminal until it is free from the cross Figure 7 1 27 2 2 Unscrew the 2 dowels c using a 4 gauge hexagonal...

Page 205: ...described in paragraph 7 1 25 Disassembling the bell guard 1 Unscrew the screw a using a 6 gauge hexagonal T wrench 2 Remove the BELL To reassemble the BELL follow the above steps in reverse order Dur...

Page 206: ...ft crown b 2 Release the spring clamp c of the coupling link using the pliers provided 3 Remove the coupling plate d 4 Remove the coupling link 5 Remove the CHAIN To reassemble the CHAIN follow the ab...

Page 207: ...the PRIMARY SHAFT place it on a bench or flat surface Then To disassemble the bearing b 1 Unscrew the two dowels using a 2 gauge hexagonal T wrench 2 Remove the bearing To disassemble the stop c 1 Rem...

Page 208: ...1 Page 7 34 To replace the PRIMARY SHAFT and its components follow the above steps in reverse order When the operation is complete adjust the alignment and tension of the PRIMARY SHAFT SECONDARY SHAF...

Page 209: ...c 3 Remove the SECONDARY SHAFT To disassemble the components of the SECONDARY SHAFT place it on a bench or flat surface Then To remove the bearings d and e 1 Use a 2 gauge T wrench to unscrew the 3 d...

Page 210: ...nion To replace the SECONDARY SHAFT and its components follow the above steps in reverse order To reassemble the components of the SECONDARY SHAFT align the punch on a tooth of the pinion with the hol...

Page 211: ...the snap ring a 2 Use a pushing tool to push the b inside 3 Remove the PULLEY being careful with the 2 plastic spacers The cable holder is fastened to the frame by the dowel d which may be removed usi...

Page 212: ...quipment and unplug the power cord from the wall socket 2 Use a large flat screwdriver to release the 4 pressure fasteners A holding the MAT against the frame 3 Remove the MAT by pulling it upward unt...

Page 213: ...sassembling the mat 1 Unscrew the screw a using a 4 gauge hexagonal T wrench 2 Remove the Plexiglas guard b The screw a remains inside the Plexiglas guard 3 Disconnect the 3 connector fastons c 4 Remo...

Page 214: ...steps described in paragraph 7 1 22 Disassembling the seat guard 1 Loosen the 2 screws a using a 5 gauge hexagonal T wrench 2 Remove the STARTING PLATE AND FUSES being careful not to tear the cables 3...

Page 215: ...ug the power cord from the wall socket 2 Use a medium Philips screwdriver to unscrew the 4 self tapping screws a holding the DISPLAY Hold the DISPLAY up before unscrewing the last screw Figure 7 2 1 2...

Page 216: ...Philips screwdriver to unscrew the 5 screws f 5 Remove the CPU and LED BOARDS 6 To separate the CPU and LED boards disconnect the 2 connectors and 4 coupling elements When finished configure the mach...

Page 217: ...LCD located under the LED board 1 Remove the CPU and LED BOARDS 2 Disconnect the 2 connectors 3 Unscrew the 4 screws holding the board to the shell using a small Philips screwdriver 4 Remove the LCD T...

Page 218: ...M 1 Insert the EPROM A into the left hand seat and EPROM B into the right hand seat 2 Insert the EPROM pins in the seats starting from the bottom so that the holes in the top seat remain free 3 Make s...

Page 219: ...the CHIP a from its seat using an integrated circuit extractor Figure 7 2 4 2 To re mount the CHIP 1 Make sure the reference notch b on the CHIP is aligned with the reference notch c on its seat 2 Mak...

Page 220: ...EYBOARD and remove it To replace the new KEYBOARD with the display resting on a bench 1 Remove the film protecting the adhesive 2 Begin attaching the adhesive part starting from left to right without...

Page 221: ...t off the equipment and unplug the power cord from the wall socket For each side of the weight stack 2 Unscrew the 2 screws a using a 3 gauge hexagonal T wrench 3 Remove the Plexiglas cover Figure 7 2...

Page 222: ...exiglas weight stack guard For each of the 2 PULLEYS 1 Unscrew the screw a and the nut b using 2 17 gauge wrenches 2 Remove the PULLEY To reassemble the PULLEYS follow the above steps in reverse order...

Page 223: ...SASSEMBLING THE WEIGHT STACK COVER Figure 7 2 8 1 Follow the steps described in paragraph 7 2 6 Disassembling the plexiglas weight stack guard 1 Cut the clamp a Figure 7 2 8 2 2 Cut the clamp b 3 Disc...

Page 224: ...or f from the solenoid cable 6 Remove the spiral cable g and its guide h from the hook i Figure 7 2 8 4 7 Use a 6 gauge hexagonal T wrench to unscrew the 8 screws l 8 Pull the WEIGHT STACK COVER upwar...

Page 225: ...e 7 2 9 1 Follow the steps described in paragraph 7 2 8 Disassembling the weight stack cover 1 Remove the ADDITIONAL WEIGHT a by sliding it upward Press the solenoid pin inward so that it does not int...

Page 226: ...iglas weight stack guard limited solely to the external part 1 Release the slot a of the ENCODER wire from the hook Figure 7 2 10 2 2 Disconnect the connector b of the ENCODER cable 3 Use a 3 gauge he...

Page 227: ...in paragraph 7 2 6 Disassembling the plexiglas weight stack guard limited solely to the external part 1 Disconnect the connector a from the SOLENOID cable 2 Unscrew the 2 screws b using a 5 gauge hex...

Page 228: ...internal part 1 Switch the machine on 2 Follow the steps described in paragraph 9 2 Configuring the technical parameters until the final procedure that moves the brush into position as shown in the fi...

Page 229: ...assembling the plexiglas weight stack guard limited solely to the internal part 1 Loosen the counter nut a using a 13 gauge wrench 2 Disconnect the connector b from the cable 3 Remove the ZERO SENSOR...

Page 230: ...turning it counter clockwise 3 Disconnect the zero sensor cable Figure 7 2 14 2 Working on the outer part of the weight stack 4 Cut the clamp c and disconnect the connector d of the weight stack moto...

Page 231: ...ch 3 Unscrew the screw b using a jointed 5 gauge hexagonal wrench until the CHAIN is removed from the upper guide If this is not possible unscrew the screw c using a 3 gauge hexagonal T wrench to disa...

Page 232: ...stack selection chain 1 Loosen the dowel a using a 2 5 gauge hexagonal T wrench 2 Slide the pinion b from the motor shaft 3 Unscrew the 3 screws c using a 4 gauge hexagonal T wrench 4 Remove the MOTOR...

Page 233: ...aragraph 7 2 8 Disassembling the weight stack cover For each CROSS STOP 1 Unscrew the 2 dowels a using a 4 gauge hexagonal T wrench 2 Remove the CROSS STOP by sliding it upward To reassemble the CROSS...

Page 234: ...dditional weight 7 2 10 Disassembling the encoder 7 2 14 Disassembling the weight stack selection system and 7 2 17 Disassembling the cross stops 1 Use a special tool a to compress all of the weight s...

Page 235: ...bed in paragraph 7 2 18 Disassembling the cross 1 Place the cross on a bench or flat surface 2 Unscrew the 2 screws a using an 8 gauge hexagonal T wrench 3 Remove the cable connector flange b 4 Use a...

Page 236: ...ES Figure 7 2 20 1 Follow the steps described in paragraphs 7 2 8 Disassembling the weight stack cover 7 2 10 Disassembling the encoder and 7 2 18 Disassembling the cross 1 Remove the WEIGHT STACK PLA...

Page 237: ...described in paragraph 7 2 8 Disassembling the weight stack cover For each of the 2 counter weight vibration bars 1 Unscrew the 2 dowels a using a 4 gauge hexagonal T wrench Hold the BAR up before un...

Page 238: ...medium sized Philips screwdriver to unscrew the 4 screws a 3 Remove the REAR SEAT GUARD Figure 7 2 22 2 4 Loosen the 2 screws b using a medium sized Philips screwdriver 5 Release the FRONT SEAT GUARD...

Page 239: ...paragraph 7 2 22 Disassembling the seat guard 1 Unscrew the screw a using a 4 gauge hexagonal T wrench 2 Open the cover of the ELECTRICAL BOX Figure 7 2 23 2 3 Disconnect the cable connectors c 4 Uns...

Page 240: ...1 Disconnect the 4 connectors 2 Disconnect the 4 plastic coupling elements 3 Remove the board To disassemble the IMP BOARD c 1 Lift the board 2 Disconnect the 2 connectors 3 Disconnect the 4 plastic...

Page 241: ...220 SELECTOR SWITCH f 1 Unsolder the cables 2 Unscrew the holding nut 3 Remove the selector switch To disassemble the FILTER g 1 Disconnect the connectors 2 Unscrew the 2 holding nuts To reassemble th...

Page 242: ...DISASSEMBLING THE BELL GUARD Figure 7 2 25 1 1 Shut off the equipment and unplug the power cord from the wall socket 2 Unscrew the 2 screws a using a 3 gauge hexagonal T wrench 3 Remove the BELL GUAR...

Page 243: ...emove the UPPER GUARD Figure 7 2 26 2 3 Unscrew the 2 screws b using a 2 5 gauge hexagonal T wrench 4 Remove the cross piece c 5 Remove the 4 caps d 2 on each side of the GUARD using a small flat scre...

Page 244: ...gauge wrenches loosen the counter nut a then unscrew the screw b from the WEIGHT STACK CABLE terminal until it is free from the cross Figure 7 2 27 2 2 Unscrew the 2 dowels c using a 4 gauge hexagonal...

Page 245: ...able from the release handle passing the blocking ball through the holes provided Figure 7 2 28 2 6 Pulling the cable outward turn the threaded part e to create a space of 2 3 mm near the bell 7 Align...

Page 246: ...cking ball is broken the spring pulls part g into the bell to recover it you must disassemble the bell as described in paragraph 7 2 29 To reassemble the LEVER RELEASE CABLE follow the above steps in...

Page 247: ...g the bell guard and 7 2 28 Disassembling the release lever cable 1 Unscrew the screw a using a 6 gauge hexagonal T wrench 2 Remove the BELL To reassemble the BELL follow the above steps in reverse or...

Page 248: ...ft crown b 2 Release the spring clamp c of the coupling link using the pliers provided 3 Remove the coupling plate d 4 Remove the coupling link 5 Remove the CHAIN To reassemble the CHAIN follow the ab...

Page 249: ...the PRIMARY SHAFT place it on a bench or flat surface Then To disassemble the bearing b 1 Unscrew the two dowels using a 2 gauge hexagonal T wrench 2 Remove the bearing To disassemble the stop c 1 Rem...

Page 250: ...1 Page 7 76 To replace the PRIMARY SHAFT and its components follow the above steps in reverse order When the operation is complete adjust the alignment and tension of the PRIMARY SHAFT SECONDARY SHAF...

Page 251: ...omponents of the SECONDARY SHAFT place it on a bench or flat surface Then To remove the bearings d and e 1 Use a 3 gauge T wrench to unscrew the 2 dowels f of the bearings 2 Remove the bearings Figure...

Page 252: ...ts follow the above steps in reverse order To reassemble the components of the SECONDARY SHAFT align the punch on a tooth of the pinion with the hole in the cam When the operation is complete adjust t...

Page 253: ...the snap ring a 2 Use a pushing tool to push the b inside 3 Remove the PULLEY being careful with the 2 plastic spacers The cable holder is fastened to the frame by the dowel d which may be removed usi...

Page 254: ...quipment and unplug the power cord from the wall socket 2 Use a large flat screwdriver to release the 4 pressure fasteners A holding the MAT against the frame 3 Remove the MAT by pulling it upward unt...

Page 255: ...sassembling the mat 1 Unscrew the screw a using a 4 gauge hexagonal T wrench 2 Remove the Plexiglas guard b The screw a remains inside the Plexiglas guard 3 Disconnect the 3 connector fastons c 4 Remo...

Page 256: ...steps described in paragraph 7 2 22 Disassembling the seat guard 1 Loosen the 2 screws a using a 5 gauge hexagonal T wrench 2 Remove the STARTING PLATE AND FUSES being careful not to tear the cables 3...

Page 257: ...plug the power cord from the wall socket 2 Use a medium Philips screwdriver to unscrew the 4 self tapping screws a holding the DISPLAY Hold the DISPLAY up before unscrewing the last screw Figure 7 3 1...

Page 258: ...l Philips screwdriver to unscrew the 5 screws f 5 Remove the CPU and LED BOARDS 6 To separate the CPU and LED boards disconnect the 2 connectors and 4 coupling elements When finished configure the mac...

Page 259: ...the LCD located under the LED board 1 Remove the CPU and LED BOARDS 2 Disconnect the 2 connectors 3 Unscrew the 4 screws the board to the shell using a small Philips screwdriver 4 Remove the LCD To r...

Page 260: ...M 1 Insert the EPROM A into the left hand seat and EPROM B into the right hand seat 2 Insert the EPROM pins in the seats starting from the bottom so that the holes in the top seat remain free 3 Make s...

Page 261: ...the CHIP a from its seat using an integrated circuit extractor Figure 7 3 4 2 To re mount the CHIP 1 Make sure the reference notch b on the CHIP is aligned with the reference notch c on its seat 2 Mak...

Page 262: ...EYBOARD and remove it To replace the new KEYBOARD with the display resting on a bench 1 Remove the film protecting the adhesive 2 Begin attaching the adhesive part starting from left to right without...

Page 263: ...EYBOARD and remove it To replace the new KEYBOARD with the display resting on a bench 1 Remove the film protecting the adhesive 2 Begin attaching the adhesive part starting from left to right without...

Page 264: ...t off the equipment and unplug the power cord from the wall socket For each side of the weight stack 2 Unscrew the 2 screws a using a 3 gauge hexagonal T wrench 3 Remove the Plexiglas cover Figure 7 3...

Page 265: ...exiglas weight stack guard For each of the 2 PULLEYS 1 Unscrew the screw a and the nut b using 2 17 gauge wrenches 2 Remove the PULLEY To reassemble the PULLEYS follow the above steps in reverse order...

Page 266: ...SASSEMBLING THE WEIGHT STACK COVER Figure 7 3 9 1 Follow the steps described in paragraph 7 3 7 Disassembling the Plexiglas weight stack guard 1 Cut the clamp a Figure 7 3 9 2 2 Cut the clamp b 3 Disc...

Page 267: ...or f from the solenoid cable 6 Remove the spiral cable g and its guide h from the hook i Figure 7 3 9 4 7 Use a 6 gauge hexagonal T wrench to unscrew the 8 screws l 8 Pull the WEIGHT STACK COVER upwar...

Page 268: ...e 7 3 10 1 Follow the steps described in paragraph 7 3 9 Disassembling the weight stack cover 1 Remove the ADDITIONAL WEIGHT a by sliding it upward Press the solenoid pin inward so that it does not in...

Page 269: ...iglas weight stack guard limited solely to the external part 1 Release the slot a of the ENCODER wire from the hook Figure 7 3 11 2 2 Disconnect the connector b of the ENCODER cable 3 Use a 4 gauge he...

Page 270: ...in paragraph 7 3 7 Disassembling the Plexiglas weight stack guard limited solely to the external part 1 Disconnect the connector a from the SOLENOID cable 2 Unscrew the 2 screws b using a 5 gauge hex...

Page 271: ...internal part 1 Switch the machine on 2 Follow the steps described in paragraph 9 2 Configuring the technical parameters until the final procedure that moves the brush into position as shown in the fi...

Page 272: ...assembling the Plexiglas weight stack guard limited solely to the internal part 1 Loosen the counter nut a using a 13 gauge wrench 2 Disconnect the connector b from the cable 3 Remove the ZERO SENSOR...

Page 273: ...turning it counter clockwise 3 Disconnect the zero sensor cable Figure 7 3 15 2 Working on the outer part of the weight stack 4 Cut the clamp c and disconnect the connector d of the weight stack moto...

Page 274: ...ch 3 Unscrew the screw b using a jointed 5 gauge hexagonal wrench until the CHAIN is removed from the upper guide If this is not possible unscrew the screw c using a 3 gauge hexagonal T wrench to disa...

Page 275: ...stack selection chain 1 Loosen the dowel a using a 2 5 gauge hexagonal T wrench 2 Slide the pinion b from the motor shaft 3 Unscrew the 3 screws c using a 4 gauge hexagonal T wrench 4 Remove the MOTOR...

Page 276: ...aragraph 7 3 9 Disassembling the weight stack cover For each CROSS STOP 1 Unscrew the 2 dowels a using a 4 gauge hexagonal T wrench 2 Remove the CROSS STOP by sliding it upward To reassemble the CROSS...

Page 277: ...additional weight 7 3 11 Disassembling the encoder 7 3 15 Disassembling the weight stack selection system and 7 3 18 Disassembling the cross stops 1 Use a special tool a to compress all of the weight...

Page 278: ...ibed in paragraph 7 3 19 Disassembling the cross 1 Place the cross on a bench or flat surface 2 Unscrew the 2 screws a using an 8 gauge hexagonal T wrench 3 Remove the cable connector flange b 4 Use a...

Page 279: ...ES Figure 7 3 21 1 Follow the steps described in paragraphs 7 3 9 Disassembling the weight stack cover 7 3 11 Disassembling the encoder and 7 3 19 Disassembling the cross 1 Remove the WEIGHT STACK PLA...

Page 280: ...described in paragraph 7 3 9 Disassembling the weight stack cover For each of the 2 counter weight vibration bars 1 Unscrew the 2 dowels a using a 4 gauge hexagonal T wrench Hold the BAR up before un...

Page 281: ...medium sized Philips screwdriver to unscrew the 4 screws a 3 Remove the REAR SEAT GUARD Figure 7 3 23 2 4 Loosen the 2 screws b using a medium sized Philips screwdriver 5 Release the FRONT SEAT GUARD...

Page 282: ...eat all the way forward 0 2 Unscrew the 2 screws b using a 4 gauge hexagonal T wrench for each side of the motor guard a 3 Remove the motor guard Figure 7 3 24 2 4 Use a medium sized Philips screwdriv...

Page 283: ...e taking special care with the vibration bars 13 Remove the seat by sliding it upward Be careful with the motor cable still connected Figure 7 3 24 4 14 Rest the seat on the support frame as shown in...

Page 284: ...paragraph 7 3 23 Disassembling the seat guard 1 Unscrew the screw a using a 4 gauge hexagonal T wrench 2 Open the cover of the ELECTRICAL BOX Figure 7 3 25 2 3 Disconnect the cable connectors c 4 Uns...

Page 285: ...move the card To disassemble the FPGA BOARD b 1 Disconnect the 4 connectors 2 Disconnect the 4 plastic coupling elements 3 Remove the card To disassemble the IMP BOARD c 1 Lift the board 2 Disconnect...

Page 286: ...ctor switch 3 Unscrew the holding screw a using an 8 gauge wrench 4 Remove the transformer To disassemble the 110 220 SELECTOR SWITCH g 1 Unsolder the cables 2 Unscrew the holding nut 3 Remove the sel...

Page 287: ...7 DISASSEMBLING THE BELL GUARD Figure 7 3 27 1 1 Shut off the equipment and unplug the power cord from the wall socket 2 Unscrew the 2 screws a using a 3 gauge hexagonal T wrench 3 Remove the BELL GUA...

Page 288: ...emove the UPPER GUARD Figure 7 3 28 2 3 Unscrew the 2 screws b using a 2 5 gauge hexagonal T wrench 4 Remove the cross piece c 5 Remove the 4 caps d 2 on each side of the GUARD using a small flat scre...

Page 289: ...gauge wrenches loosen the counter nut a then unscrew the screw b from the WEIGHT STACK CABLE terminal until it is free from the cross Figure 7 3 29 2 2 Unscrew the 2 dowels c using a 4 gauge hexagona...

Page 290: ...w the steps described in paragraph 7 3 27 Disassembling the bell guard 1 Unscrew the screw a using a 6 gauge hexagonal T wrench 2 Remove the BELL To reassemble the BELL follow the above steps in rever...

Page 291: ...aft crown b 2 Release the spring clamp c of the coupling link using the pliers provided 3 Remove the coupling plate d 4 Remove the coupling link 5 Remove the CHAIN To reassemble the CHAIN follow the a...

Page 292: ...the PRIMARY SHAFT place it on a bench or flat surface Then To disassemble the bearing b 1 Unscrew the two dowels using a 2 gauge hexagonal T wrench 2 Remove the bearing To disassemble the stop c 1 Rem...

Page 293: ...1 Page 7 119 To replace the PRIMARY SHAFT and its components follow the above steps in reverse order When the operation is complete adjust the alignment and tension of the PRIMARY SHAFT SECONDARY SHA...

Page 294: ...c 3 Remove the SECONDARY SHAFT To disassemble the components of the SECONDARY SHAFT place it on a bench or flat surface Then To remove the bearings d and e 1 Use a 2 gauge T wrench to unscrew the 3 d...

Page 295: ...inion To replace the SECONDARY SHAFT and its components follow the above steps in reverse order To reassemble the components of the SECONDARY SHAFT align the punch on a tooth of the pinion with the ho...

Page 296: ...the snap ring a 2 Use a pushing tool to push the b inside 3 Remove the PULLEY being careful with the 2 plastic spacers The cable holder is fastened to the frame by the dowel d which may be removed usi...

Page 297: ...quipment and unplug the power cord from the wall socket 2 Use a large flat screwdriver to release the 4 pressure fasteners A holding the MAT against the frame 3 Remove the MAT by pulling it upward unt...

Page 298: ...sassembling the mat 1 Unscrew the screw a using a 4 gauge hexagonal T wrench 2 Remove the Plexiglas guard b The screw a remains inside the Plexiglas guard 3 Disconnect the 3 connector fastons c 4 Remo...

Page 299: ...steps described in paragraph 7 3 23 Disassembling the seat guard 1 Loosen the 2 screws a using a 5 gauge hexagonal T wrench 2 Remove the STARTING PLATE AND FUSES being careful not to tear the cables...

Page 300: ...ug the power cord from the wall socket 2 Use a medium Philips screwdriver to unscrew the 4 self tapping screws a holding the DISPLAY Hold the DISPLAY up before unscrewing the last screw Figure 7 4 1 2...

Page 301: ...l Philips screwdriver to unscrew the 5 screws f 5 Remove the CPU and LED BOARDS 6 To separate the CPU and LED boards disconnect the 2 connectors and 4 coupling elements When finished configure the mac...

Page 302: ...LCD located under the LED board 1 Remove the CPU and LED BOARDS 2 Disconnect the 2 connectors 3 Unscrew the 4 screws holding the board to the shell using a small Philips screwdriver 4 Remove the LCD...

Page 303: ...M 1 Insert the EPROM A into the left hand seat and EPROM B into the right hand seat 2 Insert the EPROM pins in the seats starting from the bottom so that the holes in the top seat remain free 3 Make s...

Page 304: ...the CHIP a from its seat using an integrated circuit extractor Figure 7 4 4 2 To re mount the CHIP 1 Make sure the reference notch b on the CHIP is aligned with the reference notch c on its seat 2 Ma...

Page 305: ...KEYBOARD and remove it To replace the new KEYBOARD with the display resting on a bench 1 Remove the film protecting the adhesive 2 Begin attaching the adhesive part starting from left to right without...

Page 306: ...KEYBOARD and remove it To replace the new KEYBOARD with the display resting on a bench 1 Remove the film protecting the adhesive 2 Begin attaching the adhesive part starting from left to right without...

Page 307: ...t off the equipment and unplug the power cord from the wall socket For each side of the weight stack 2 Unscrew the 2 screws a using a 3 gauge hexagonal T wrench 3 Remove the Plexiglas cover Figure 7 4...

Page 308: ...lexiglas weight stack guard For each of the 2 PULLEYS 1 Unscrew the screw a and the nut b using 2 17 gauge wrenches 2 Remove the PULLEY To reassemble the PULLEYS follow the above steps in reverse orde...

Page 309: ...SASSEMBLING THE WEIGHT STACK COVER Figure 7 4 9 1 Follow the steps described in paragraph 7 4 7 Disassembling the plexiglas weight stack guard 1 Cut the clamp a Figure 7 4 9 2 2 Cut the clamp b 3 Disc...

Page 310: ...tor f from the solenoid cable 6 Remove the spiral cable g and its guide h from the hook i Figure 7 4 9 4 7 Use a 6 gauge hexagonal T wrench to unscrew the 8 screws l 8 Pull the WEIGHT STACK COVER upwa...

Page 311: ...e 7 4 10 1 Follow the steps described in paragraph 7 4 9 Disassembling the weight stack cover 1 Remove the ADDITIONAL WEIGHT a by sliding it upward Press the solenoid pin inward so that it does not in...

Page 312: ...iglas weight stack guard limited solely to the external part 1 Release the slot a of the ENCODER wire from the hook Figure 7 4 11 2 2 Disconnect the connector b of the ENCODER cable 3 Use a 3 gauge he...

Page 313: ...d in paragraph 7 4 7 Disassembling the plexiglas weight stack guard limited solely to the external part 1 Disconnect the connector a from the SOLENOID cable 2 Unscrew the 2 screws b using a 5 gauge he...

Page 314: ...internal part 1 Switch the machine on 2 Follow the steps described in paragraph 9 2 Configuring the technical parameters until the final procedure that moves the brush into position as shown in the fi...

Page 315: ...assembling the plexiglas weight stack guard limited solely to the internal part 1 Loosen the counter nut a using a 13 gauge wrench 2 Disconnect the connector b from the cable 3 Remove the ZERO SENSOR...

Page 316: ...y turning it counter clockwise 3 Disconnect the zero sensor cable Figure 7 4 15 2 Working on the outer part of the weight stack 4 Cut the clamp c and disconnect the connector d of the weight stack mot...

Page 317: ...ch 3 Unscrew the screw b using a jointed 5 gauge hexagonal wrench until the CHAIN is removed from the upper guide If this is not possible unscrew the screw c using a 3 gauge hexagonal T wrench to disa...

Page 318: ...stack selection chain 1 Loosen the dowel a using a 2 5 gauge hexagonal T wrench 2 Slide the pinion b from the motor shaft 3 Unscrew the 3 screws c using a 4 gauge hexagonal T wrench 4 Remove the MOTOR...

Page 319: ...aragraph 7 4 9 Disassembling the weight stack cover For each CROSS STOP 1 Unscrew the 2 dowels a using a 4 gauge hexagonal T wrench 2 Remove the CROSS STOP by sliding it upward To reassemble the CROSS...

Page 320: ...4 15 Disassembling the weight stack selection system and 7 4 18 Disassembling the cross stops 1 Loosen the 2 screws a using a 4 gauge hexagonal T wrench 2 Remove the 2 counter weights Figure 7 4 19 2...

Page 321: ...ibed in paragraph 7 4 19 Disassembling the cross 1 Place the cross on a bench or flat surface 2 Unscrew the 2 screws a using an 8 gauge hexagonal T wrench 3 Remove the cable connector flange b 4 Use a...

Page 322: ...ES Figure 7 4 21 1 Follow the steps described in paragraphs 7 4 9 Disassembling the weight stack cover 7 4 11 Disassembling the encoder and 7 4 19 Disassembling the cross 1 Remove the WEIGHT STACK PLA...

Page 323: ...described in paragraph 7 4 9 Disassembling the weight stack cover For each of the 2 counter weight vibration bars 1 Unscrew the 2 dowels a using a 4 gauge hexagonal T wrench Hold the BAR up before un...

Page 324: ...medium sized Philips screwdriver to unscrew the 4 screws a 3 Remove the REAR SEAT GUARD Figure 7 4 23 2 4 Loosen the 2 screws b using a medium sized Philips screwdriver 5 Release the FRONT SEAT GUARD...

Page 325: ...eat all the way forward 0 2 Unscrew the 2 screws b using a 4 gauge hexagonal T wrench for each side of the motor guard a 3 Remove the motor guard Figure 7 4 24 2 4 Use a medium sized Philips screwdriv...

Page 326: ...e taking special care with the vibration bars 13 Remove the seat by sliding it upward Be careful with the motor cable still connected Figure 7 4 24 4 14 Rest the seat on the support frame as shown in...

Page 327: ...paragraph 7 4 23 Disassembling the seat guard 1 Unscrew the screw a using a 4 gauge hexagonal T wrench 2 Open the cover of the ELECTRICAL BOX Figure 7 4 25 2 3 Disconnect the cable connectors c 4 Uns...

Page 328: ...e the board To disassemble the FPGA BOARD b 1 Disconnect the 4 connectors 2 Disconnect the 4 plastic coupling elements 3 Remove the board To disassemble the IMP BOARD c 1 Lift the board 2 Disconnect t...

Page 329: ...ctor switch 3 Unscrew the holding screw a using an 8 gauge wrench 4 Remove the transformer To disassemble the 110 220 SELECTOR SWITCH g 1 Unsolder the cables 2 Unscrew the holding nut 3 Remove the sel...

Page 330: ...7 DISASSEMBLING THE BELL GUARD Figure 7 4 27 1 1 Shut off the equipment and unplug the power cord from the wall socket 2 Unscrew the 2 screws a using a 3 gauge hexagonal T wrench 3 Remove the BELL GUA...

Page 331: ...emove the UPPER GUARD Figure 7 4 28 2 3 Unscrew the 2 screws b using a 2 5 gauge hexagonal T wrench 4 Remove the cross piece c 5 Remove the 4 caps d 2 on each side of the GUARD using a small flat scre...

Page 332: ...gauge wrenches loosen the counter nut a then unscrew the screw b from the WEIGHT STACK CABLE terminal until it is free from the cross Figure 7 4 29 2 2 Unscrew the 2 dowels c using a 4 gauge hexagona...

Page 333: ...w the steps described in paragraphs 7 4 27 Disassembling the bell guard 1 Unscrew the screw a using a 6 gauge hexagonal T wrench 2 Remove the BELL To reassemble the BELL follow the above steps in reve...

Page 334: ...aft crown b 2 Release the spring clamp c of the coupling link using the pliers provided 3 Remove the coupling plate d 4 Remove the coupling link 5 Remove the CHAIN To reassemble the CHAIN follow the a...

Page 335: ...the PRIMARY SHAFT place it on a bench or flat surface Then To disassemble the bearing b 1 Unscrew the two dowels using a 2 gauge hexagonal T wrench 2 Remove the bearing To disassemble the stop c 1 Rem...

Page 336: ...1 Page 7 162 To replace the PRIMARY SHAFT and its components follow the above steps in reverse order When the operation is complete adjust the alignment and tension of the PRIMARY SHAFT SECONDARY SHA...

Page 337: ...c 3 Remove the SECONDARY SHAFT To disassemble the components of the SECONDARY SHAFT place it on a bench or flat surface Then To remove the bearings d and e 1 Use a 3 gauge T wrench to unscrew the 2 d...

Page 338: ...inion To replace the SECONDARY SHAFT and its components follow the above steps in reverse order To reassemble the components of the SECONDARY SHAFT align the punch on a tooth of the pinion with the ho...

Page 339: ...the snap ring a 2 Use a pushing tool to push the b inside 3 Remove the PULLEY being careful with the 2 plastic spacers The cable holder is fastened to the frame by the dowel d which may be removed usi...

Page 340: ...quipment and unplug the power cord from the wall socket 2 Use a large flat screwdriver to release the 4 pressure fasteners A holding the MAT against the frame 3 Remove the MAT by pulling it upward unt...

Page 341: ...sassembling the mat 1 Unscrew the screw a using a 4 gauge hexagonal T wrench 2 Remove the Plexiglas guard b The screw a remains inside the Plexiglas guard 3 Disconnect the 3 connector fastons c 4 Remo...

Page 342: ...steps described in paragraph 7 4 23 Disassembling the seat guard 1 Loosen the 2 screws a using a 5 gauge hexagonal T wrench 2 Remove the STARTING PLATE AND FUSES being careful not to tear the cables...

Page 343: ...nplug the power cord from the wall socket 2 Use a medium Philips screwdriver to unscrew the 4 self tapping screws a holding the DISPLAY Hold the DISPLAY up before unscrewing the last screw Figure 7 5...

Page 344: ...l Philips screwdriver to unscrew the 5 screws f 5 Remove the CPU and LED BOARDS 6 To separate the CPU and LED boards disconnect the 2 connectors and 4 coupling elements When finished configure the mac...

Page 345: ...LCD located under the LED board 1 Remove the CPU and LED BOARDS 2 Disconnect the 2 connectors 3 Unscrew the 4 screws holding the board to the shell using a small Philips screwdriver 4 Remove the LCD...

Page 346: ...M 1 Insert the EPROM A into the left hand seat and EPROM B into the right hand seat 2 Insert the EPROM pins in the seats starting from the bottom so that the holes in the top seat remain free 3 Make s...

Page 347: ...the CHIP a from its seat using an integrated circuit extractor Figure 7 5 4 2 To re mount the CHIP 1 Make sure the reference notch b on the CHIP is aligned with the reference notch c on its seat 2 Ma...

Page 348: ...KEYBOARD and remove it To replace the new KEYBOARD with the display resting on a bench 1 Remove the film protecting the adhesive 2 Begin attaching the adhesive part starting from left to right without...

Page 349: ...KEYBOARD and remove it To replace the new KEYBOARD with the display resting on a bench 1 Remove the film protecting the adhesive 2 Begin attaching the adhesive part starting from left to right without...

Page 350: ...Page 7 176 7 5 7 REMOVING THE SEAT Figure 7 5 7 1 1 Shut off the equipment and unplug the power cord from the wall socket 2 Use a 4 gauge wrench to unscrew the 17 screws a 3 Remove the SEAT To replac...

Page 351: ...ent and unplug the power cord from the wall socket For each side 3 Remove the cap a of the GUARD using a small flat screwdriver 4 Unscrew the screw under the cap a using a medium sized Philips screwdr...

Page 352: ...paragraph 7 5 8 Disassembling the front guard 1 Unscrew the screw a using a 4 gauge hexagonal T wrench 2 Open the cover of the ELECTRICAL BOX 3 Disconnect the cable connectors c 4 Unscrew the 4 nuts...

Page 353: ...e the board To disassemble the FPGA BOARD b 1 Disconnect the 4 connectors 2 Disconnect the 4 plastic coupling elements 3 Remove the board To disassemble the IMP BOARD c 1 Lift the board 2 Disconnect t...

Page 354: ...ctor switch 3 Unscrew the holding screw a using an 8 gauge wrench 4 Remove the transformer To disassemble the 110 220 SELECTOR SWITCH g 1 Unsolder the cables 2 Unscrew the holding nut 3 Remove the sel...

Page 355: ...moving the seat and 7 5 8 Disassembling the front guard For each side 1 Remove the 2 caps a of the GUARD using a small flat screwdriver 2 Unscrew the 2 screws under the 2 caps a using a medium sized P...

Page 356: ...7 Removing the seat 7 5 8 Disassembling the front guard and 7 5 11 Disassembling the upright guard 1 Disconnect the connector from the motor cable 2 Unscrew the screw a and its nut using 2 17 gauge wr...

Page 357: ...steps described in paragraphs 7 5 7 Removing the seat 7 5 8 Disassembling the front guard and 7 5 11 Disassembling the upright guard 1 Unscrew the 2 screws a using a 5 gauge hexagonal T wrench for eac...

Page 358: ...ront of the machine For each part of the SECONDARY PRESTART CABLE 7 Unscrew the 3 dowels e using a 4 gauge hexagonal T wrench 8 Remove the SECONDARY PRESTART CABLE with the aid of a pair of pliers 9 R...

Page 359: ...om the wall socket For each side of the weight stack 2 Remove the 2 caps a of the GUARD using a small flat screwdriver 3 Unscrew the 2 screws under the 2 caps a using a medium sized Philips screwdrive...

Page 360: ...cribed in paragraph 7 5 11 Disassembling the upright guard or 7 5 14 Disassembling the rear guard 1 Disconnect the connector a from the solenoid cable 2 Unscrew the 2 screws b using a 5 gauge hexagona...

Page 361: ...ar guard 1 Switch the machine on 2 Follow the steps described in paragraph 9 2 Configuring the technical parameters until the final procedure that moves the brush into position as shown in the figure...

Page 362: ...en unscrew the screw b of the WEIGHT STACK CABLE terminal until it is free of the cross Figure 7 5 17 2 2 Unscrew the 3 dowels c using a 4 gauge hexagonal T wrench 3 Remove the cable with the aid of a...

Page 363: ...ing the rear guard For each PULLEY 1 Unscrew the screw a and the nut b using 2 17 gauge wrenches 2 Remove the PULLEY To reassemble the PULLEYS follow the above steps in reverse order For easier disass...

Page 364: ...7 5 14 Disassembling the rear guard and 7 5 18 Disassembling the pulleys 1 Loosen the counter nut a using a 13 gauge wrench 2 Disconnect the connector b from the cable 3 Remove the ZERO SENSOR To reas...

Page 365: ...5 11 Disassembling the upright guard and 7 5 14 Disassembling the rear guard 1 Use a 17 gauge wrench to unscrew the 2 screws a 2 Lift the rear pulley group Figure 7 5 20 2 3 Unscrew the 2 screws b us...

Page 366: ...8 Loosen the 4 nuts g using a 4 gauge universal wrench 9 Remove the WEIGHT STACK SELECTION SYSTEM frame by shifting it towards the inside of the machine then lifting it up To reassemble the WEIGHT STA...

Page 367: ...ch 3 Unscrew the screw b using a jointed 5 gauge hexagonal wrench until the CHAIN is removed from the upper guide If this is not possible unscrew the screw c using a 3 gauge hexagonal T wrench to disa...

Page 368: ...stack selection chain 1 Loosen the dowel a using a 2 5 gauge hexagonal T wrench 2 Slide the pinion b from the motor shaft 3 Unscrew the 3 screws c using a 4 gauge hexagonal T wrench 4 Remove the MOTOR...

Page 369: ...d unplug the power cord from the wall socket For each side of the weight stack 2 Remove the cap a of the GUARD using a small flat screwdriver 3 Unscrew the 5 screws b one of which is under the cap a u...

Page 370: ...the rear lever guard For each lever group 1 Loosen the 2 dowels a using a 4 gauge hexagonal T wrench 2 Remove the LEVER CABLE with the aid of a pair of pliers 3 Remove the LEVER CABLE by sliding it ou...

Page 371: ...s a using a 13 gauge tube wrench 2 Remove the counter weight Hold the counter weight up before unscrewing the last nut 3 Loosen the screw b using a 6 gauge hexagonal T wrench 4 Use a 30 gauge Allen wr...

Page 372: ...tube wrench 4 Remove the washer 5 Use the extractor provided in the machine service box to remove the LEVER tightening the extractor screw using a 24 gauge wrench To reassemble the LEVERS working fir...

Page 373: ...assembling the rear lever guard and 7 5 26 Disassembling the levers For each side of the weight stack 1 Remove the cap a of the GUARD using a small flat screwdriver 2 Unscrew the 4 screws b one of whi...

Page 374: ...he power cord from the wall socket 2 Use a 3 gauge hexagonal T wrench to unscrew the 2 screws a on both the front and back 3 Remove the Plexiglas cover Figure 7 5 28 2 4 Unscrew the 6 screws a using a...

Page 375: ...bed in paragraphs 7 5 23 Disassembling the rear lever guard 7 5 26 7 5 27 Disassembling the front lever guard and 7 5 28 Disassembling the weight stack cover For each side of the weight stack 1 Use a...

Page 376: ...stack cover and 7 5 29 Disassembling the column extension For each column 1 Use an 8 gauge T wrench to unscrew the 2 screws a 2 Remove the COLUMN by bending it down When removing the first column make...

Page 377: ...the columns limited solely to the right hand column 1 Remove the ADDITIONAL WEIGHT a by sliding it out from the side Press the solenoid pin inward so that it does not interfere with the additional we...

Page 378: ...right hand column 1 Release the slot a of the ENCODER wire from the hook Figure 7 5 32 2 2 Disconnect the connector b of the ENCODER cable 3 Cut the clamp c 4 Disconnect the connector d from the enco...

Page 379: ...weight stack cover and 7 5 29 Disassembling the column extension For each of the 2 counter weight vibration bars 1 Unscrew the 2 dowels a using a 4 gauge hexagonal T wrench Hold the BAR up before unsc...

Page 380: ...4 gauge hexagonal T wrench 3 Remove the counter weight 4 Disconnect the solenoid cable connector 5 Unhook the encoder cable Figure 7 5 34 2 6 Raise the CROSS until the cross sinker is released from t...

Page 381: ...graph 7 5 34 Disassembling the cross and weight stack plates 1 Place the cross on a bench or flat surface 2 Unscrew the 2 screws a using an 8 gauge hexagonal T wrench 3 Remove the cable connector flan...

Page 382: ...2 Use a large flat screwdriver to release the 3 pressure fasteners A holding the LARGE MAT against the frame 3 Remove the LARGE MAT by pulling it upward 4 Use a large flat screwdriver to release the...

Page 383: ...ps described in paragraph 7 5 36 Disassembling the mats only for the large right hand mat 1 Disconnect the connectors a 2 Unscrew the 4 screws b using a 6 gauge hexagonal T wrench 3 Remove the DISPLAY...

Page 384: ...sassembling the mats 1 Unscrew the screw a using a 4 gauge hexagonal T wrench 2 Remove the Plexiglas guard b The screw a remains inside the Plexiglas guard 3 Disconnect the 3 connector fastons c 4 Rem...

Page 385: ...7 Removing the seat 7 5 8 Disassembling the front guard and 7 5 11 Disassembling the upright guard 1 Loosen the 2 screws a using a 5 gauge hexagonal T wrench 2 Remove the STARTING PLATE AND FUSES bei...

Page 386: ...plug the power cord from the wall socket 2 Use a medium Philips screwdriver to unscrew the 4 self tapping screws a holding the DISPLAY Hold the DISPLAY up before unscrewing the last screw Figure 7 6 1...

Page 387: ...l Philips screwdriver to unscrew the 5 screws f 5 Remove the CPU and LED BOARDS 6 To separate the CPU and LED boards disconnect the 2 connectors and 4 coupling elements When finished configure the mac...

Page 388: ...LCD located under the LED board 1 Remove the CPU and LED BOARDS 2 Disconnect the 2 connectors 3 Unscrew the 4 screws holding the board to the shell using a small Philips screwdriver 4 Remove the LCD...

Page 389: ...M 1 Insert the EPROM A into the left hand seat and EPROM B into the right hand seat 2 Insert the EPROM pins in the seats starting from the bottom so that the holes in the top seat remain free 3 Make s...

Page 390: ...the CHIP a from its seat using an integrated circuit extractor Figure 7 6 4 2 To re mount the CHIP 1 Make sure the reference notch b on the CHIP is aligned with the reference notch c on its seat 2 Ma...

Page 391: ...KEYBOARD and remove it To replace the new KEYBOARD with the display resting on a bench 1 Remove the film protecting the adhesive 2 Begin attaching the adhesive part starting from left to right without...

Page 392: ...KEYBOARD and remove it To replace the new KEYBOARD with the display resting on a bench 1 Remove the film protecting the adhesive 2 Begin attaching the adhesive part starting from left to right without...

Page 393: ...Page 7 219 7 6 7 REMOVING THE SEAT Figure 7 6 7 1 1 Shut off the equipment and unplug the power cord from the wall socket 2 Use a 17 gauge wrench to unscrew the 4 screws a 3 Remove the SEAT To replac...

Page 394: ...ent and unplug the power cord from the wall socket For each side 3 Remove the cap a of the GUARD using a small flat screwdriver 4 Unscrew the screw under the cap a using a medium sized Philips screwdr...

Page 395: ...paragraph 7 6 8 Disassembling the front guard 1 Unscrew the screw a using a 4 gauge hexagonal T wrench 2 Open the cover of the ELECTRICAL BOX 3 Disconnect the cable connectors c 4 Unscrew the 4 nuts...

Page 396: ...e the board To disassemble the FPGA BOARD b 1 Disconnect the 4 connectors 2 Disconnect the 4 plastic coupling elements 3 Remove the board To disassemble the IMP BOARD c 1 Lift the board 2 Disconnect t...

Page 397: ...ctor switch 3 Unscrew the holding screw a using an 8 gauge wrench 4 Remove the transformer To disassemble the 110 220 SELECTOR SWITCH g 1 Unsolder the cables 2 Unscrew the holding nut 3 Remove the sel...

Page 398: ...moving the seat and 7 6 8 Disassembling the front guard For each side 1 Remove the 2 caps a of the GUARD using a small flat screwdriver 2 Unscrew the 2 screws under the 2 caps a using a medium sized P...

Page 399: ...7 Removing the seat 7 6 8 Disassembling the front guard and 7 6 11 Disassembling the upright guard 1 Disconnect the connector from the motor cable 2 Unscrew the screw a and its nut using 2 17 gauge wr...

Page 400: ...steps described in paragraphs 7 6 7 Removing the seat 7 6 8 Disassembling the front guard and 7 6 11 Disassembling the upright guard 1 Unscrew the 2 screws a using a 5 gauge hexagonal T wrench for eac...

Page 401: ...ront of the machine For each part of the SECONDARY PRESTART CABLE 7 Unscrew the 3 dowels e using a 4 gauge hexagonal T wrench 8 Remove the SECONDARY PRESTART CABLE with the aid of a pair of pliers 9 R...

Page 402: ...om the wall socket For each side of the weight stack 2 Remove the 2 caps a of the GUARD using a small flat screwdriver 3 Unscrew the 2 screws under the 2 caps a using a medium sized Philips screwdrive...

Page 403: ...cribed in paragraph 7 6 11 Disassembling the upright guard or 7 6 14 Disassembling the rear guard 1 Disconnect the connector a from the solenoid cable 2 Unscrew the 2 screws b using a 5 gauge hexagona...

Page 404: ...ar guard 1 Switch the machine on 2 Follow the steps described in paragraph 9 2 Configuring the technical parameters until the final procedure that moves the brush into position as shown in the figure...

Page 405: ...en unscrew the screw b of the WEIGHT STACK CABLE terminal until it is free of the cross Figure 7 6 17 2 2 Unscrew the 3 dowels c using a 4 gauge hexagonal T wrench 3 Remove the cable with the aid of a...

Page 406: ...ing the rear guard For each PULLEY 1 Unscrew the screw a and the nut b using 2 17 gauge wrenches 2 Remove the PULLEY To reassemble the PULLEYS follow the above steps in reverse order For easier disass...

Page 407: ...7 6 14 Disassembling the rear guard and 7 6 18 Disassembling the pulleys 1 Loosen the counter nut a using a 13 gauge wrench 2 Disconnect the connector b from the cable 3 Remove the ZERO SENSOR To reas...

Page 408: ...6 11 Disassembling the upright guard and 7 6 14 Disassembling the rear guard 1 Use a 17 gauge wrench to unscrew the 2 screws a 2 Lift the rear pulley group Figure 7 6 20 2 3 Unscrew the 2 screws b us...

Page 409: ...8 Loosen the 4 nuts g using a 4 gauge universal wrench 9 Remove the WEIGHT STACK SELECTION SYSTEM frame by shifting it towards the inside of the machine then lifting it up To reassemble the WEIGHT STA...

Page 410: ...ch 3 Unscrew the screw b using a jointed 5 gauge hexagonal wrench until the CHAIN is removed from the upper guide If this is not possible unscrew the screw c using a 3 gauge hexagonal T wrench to disa...

Page 411: ...stack selection chain 1 Loosen the dowel a using a 2 5 gauge hexagonal T wrench 2 Slide the pinion b from the motor shaft 3 Unscrew the 3 screws c using a 4 gauge hexagonal T wrench 4 Remove the MOTOR...

Page 412: ...d unplug the power cord from the wall socket For each side of the weight stack 2 Remove the cap a of the GUARD using a small flat screwdriver 3 Unscrew the 5 screws b one of which is under the cap a u...

Page 413: ...the rear lever guard For each lever group 1 Loosen the 2 dowels a using a 4 gauge hexagonal T wrench 2 Remove the LEVER CABLE with the aid of a pair of pliers 3 Remove the LEVER CABLE by sliding it ou...

Page 414: ...s a using a 13 gauge tube wrench 2 Remove the counter weight Hold the counter weight up before unscrewing the last nut 3 Loosen the screw b using a 6 gauge hexagonal T wrench 4 Use a 30 gauge Allen wr...

Page 415: ...tube wrench 4 Remove the washer 5 Use the extractor provided in the machine service box to remove the LEVER tightening the extractor screw using a 24 gauge wrench To reassemble the LEVERS working fir...

Page 416: ...assembling the rear lever guard and 7 6 26 Disassembling the levers For each side of the weight stack 1 Remove the cap a of the GUARD using a small flat screwdriver 2 Unscrew the 4 screws b one of whi...

Page 417: ...the power cord from the wall socket 2 Use a 3 gauge hexagonal T wrench to unscrew the 2 screws a on both the front and back 3 Remove the Plexiglas cover Figure 7 6 28 2 4 Unscrew the 8 screws a using...

Page 418: ...raphs 7 6 23 Disassembling the rear lever guard 7 6 26 Disassembling the levers 7 6 27 Disassembling the front lever guard and 7 6 28 Disassembling the weight stack cover For each side of the weight s...

Page 419: ...g the weight stack cover and 7 6 29 Disassembling the column extension For each column 1 Use an 8 gauge T wrench to unscrew the 2 screws a 2 Remove the COLUMN by bending it down When removing the firs...

Page 420: ...the columns limited solely to the right hand column 1 Remove the ADDITIONAL WEIGHT a by sliding it out from the side Press the solenoid pin inward so that it does not interfere with the additional we...

Page 421: ...right hand column 1 Release the slot a of the ENCODER wire from the hook Figure 7 6 32 2 2 Disconnect the connector b of the ENCODER cable 3 Cut the clamp c 4 Disconnect the connector d from the enco...

Page 422: ...sembling the weight stack cover and 7 6 29 Disassembling the column extension For each of the 2 counter weight vibration bars 1 Unscrew the 2 dowels a using a 4 gauge hexagonal T wrench Hold the BAR u...

Page 423: ...10 lbs For each bar 2 Disconnect the solenoid cable connector 3 Unhook the encoder cable 4 5 Raise the CROSS until the cross sinker is released from the WEIGHT STACK PLATES and lock in this position...

Page 424: ...graph 7 6 34 Disassembling the cross and weight stack plates 1 Place the cross on a bench or flat surface 2 Unscrew the 2 screws a using an 8 gauge hexagonal T wrench 3 Remove the cable connector flan...

Page 425: ...2 Use a large flat screwdriver to release the 3 pressure fasteners A holding the LARGE MAT against the frame 3 Remove the LARGE MAT by pulling it upward 4 Use a large flat screwdriver to release the...

Page 426: ...ps described in paragraph 7 6 36 Disassembling the mats only for the large right hand mat 1 Disconnect the connectors a 2 Unscrew the 4 screws b using a 6 gauge hexagonal T wrench 3 Remove the DISPLAY...

Page 427: ...sassembling the mats 1 Unscrew the screw a using a 4 gauge hexagonal T wrench 2 Remove the Plexiglas guard b The screw a remains inside the Plexiglas guard 3 Disconnect the 3 connector fastons c 4 Rem...

Page 428: ...7 Removing the seat 7 6 8 Disassembling the front guard and 7 6 11 Disassembling the upright guard 1 Loosen the 2 screws a using a 5 gauge hexagonal T wrench 2 Remove the STARTING PLATE AND FUSES bei...

Page 429: ...lug the power cord from the wall socket 2 Use a medium Philips screwdriver to unscrew the 4 self tapping screws a holding the DISPLAY Hold the DISPLAY up before unscrewing the last screw Figure 7 7 1...

Page 430: ...l Philips screwdriver to unscrew the 5 screws f 5 Remove the CPU and LED BOARDS 6 To separate the CPU and LED boards disconnect the 2 connectors and 4 coupling elements When finished configure the mac...

Page 431: ...LCD located under the LED board 1 Remove the CPU and LED BOARDS 2 Disconnect the 2 connectors 3 Unscrew the 4 screws holding the board to the shell using a small Philips screwdriver 4 Remove the LCD...

Page 432: ...M 1 Insert the EPROM A into the left hand seat and EPROM B into the right hand seat 2 Insert the EPROM pins in the seats starting from the bottom so that the holes in the top seat remain free 3 Make s...

Page 433: ...the CHIP a from its seat using an integrated circuit extractor Figure 7 7 4 2 To re mount the CHIP 1 Make sure the reference notch b on the CHIP is aligned with the reference notch c on its seat 2 Ma...

Page 434: ...KEYBOARD and remove it To replace the new KEYBOARD with the display resting on a bench 1 Remove the film protecting the adhesive 2 Begin attaching the adhesive part starting from left to right without...

Page 435: ...KEYBOARD and remove it To replace the new KEYBOARD with the display resting on a bench 1 Remove the film protecting the adhesive 2 Begin attaching the adhesive part starting from left to right without...

Page 436: ...Figure 7 7 7 1 1 Shut off the equipment and unplug the power cord from the wall socket 2 Unscrew the 2 screws a using a 3 gauge hexagonal T wrench 3 Remove the Plexiglas cover Figure 7 7 7 2 4 Pull th...

Page 437: ...Figure 7 7 8 1 1 Shut off the equipment and unplug the power cord from the wall socket 2 Unscrew the 2 screws a using a 3 gauge hexagonal T wrench 3 Remove the Plexiglas cover Figure 7 7 8 2 4 Pull th...

Page 438: ...mbling the rear Plexiglas weight stack guard 1 Unscrew the screw a and the nut b using 2 17 gauge wrenches 2 Remove the PULLEY To replace the PULLEY follow the above steps in reverse order For easier...

Page 439: ...Figure 7 7 10 1 Follow the steps described in paragraphs 7 7 7 Disassembling the rear Plexiglas weight stack guard and 7 7 8 Disassembling the front plexiglas weight stack guard 1 Cut the clamp a Figu...

Page 440: ...tor f from the solenoid cable 6 Remove the spiral cable g and its guide h from the hook i Figure 7 7 10 4 7 Use a 6 gauge hexagonal T wrench to unscrew the 8 screws l 8 Pull the WEIGHT STACK COVER upw...

Page 441: ...e 7 7 11 1 Follow the steps described in paragraph 7 7 10 Disassembling the weight stack cover 1 Remove the ADDITIONAL WEIGHT a by sliding it upward Press the solenoid pin inward so that it does not i...

Page 442: ...embling the rear Plexiglas weight stack guard 1 Release the slot a of the ENCODER wire from the hook Figure 7 7 12 2 2 Disconnect the connector b of the ENCODER cable 3 Use a 4 gauge hexagonal T wrenc...

Page 443: ...steps described in paragraph 7 7 7 Disassembling the rear Plexiglas weight stack guard 1 Disconnect the connector a from the SOLENOID cable 2 Unscrew the 2 screws b using a 5 gauge hexagonal T wrench...

Page 444: ...Switch the machine on 2 Follow the steps described in paragraph 9 2 Configuring the technical parameters until the final procedure that moves the brush into position as shown in the figure alongside...

Page 445: ...agraph 7 7 7 Disassembling the rear Plexiglas weight stack guard 1 Loosen the counter nut a using a 13 gauge wrench 2 Disconnect the connector b from the cable 3 Remove the ZERO SENSOR To reassemble t...

Page 446: ...Page 7 272 7 7 16 REMOVING THE SEAT Figure 7 7 16 1 1 Shut off the equipment and unplug the power cord from the wall socket 2 Use a 17 gauge wrench to unscrew the 4 screws a 3 Remove the SEAT To repla...

Page 447: ...paragraph 7 7 16 Removing the seat For each side 1 Remove the 3 caps a of the GUARD using a small flat screwdriver 2 Unscrew the 3 screws under the 3 caps a using a medium sized Philips screwdriver 3...

Page 448: ...LOSING PANELS Figure 7 7 18 1 Follow the steps described in paragraph 7 7 17 Disassembling the upright guard For each side 1 Use a medium sized Philips screwdriver to unscrew the 3 screws a 2 Remove t...

Page 449: ...erse support plate b by turning it counter clockwise 3 Disconnect the zero sensor cable Figure 7 7 19 2 Working on the inner part of the weight stack 4 Cut the clamp c and disconnect the connector d o...

Page 450: ...ch 3 Unscrew the screw b using a jointed 5 gauge hexagonal wrench until the CHAIN is removed from the upper guide If this is not possible unscrew the screw c using a 3 gauge hexagonal T wrench to disa...

Page 451: ...stack selection chain 1 Loosen the dowel a using a 2 5 gauge hexagonal T wrench 2 Slide the pinion b from the motor shaft 3 Unscrew the 3 screws c using a 4 gauge hexagonal T wrench 4 Remove the MOTOR...

Page 452: ...aragraph 7 7 10 Disassembling the weight stack cover For each CROSS STOP 1 Unscrew the 2 dowels a using a 4 gauge hexagonal T wrench 2 Remove the CROSS STOP by sliding it upward To reassemble the CROS...

Page 453: ...additional weight 7 7 12 Disassembling the encoder 7 7 19 Disassembling the weight stack selection system and 7 7 22 Disassembling the cross stops 1 Use a special tool a to compress all of the weight...

Page 454: ...ibed in paragraph 7 7 23 Disassembling the cross 1 Place the cross on a bench or flat surface 2 Unscrew the 2 screws a using an 8 gauge hexagonal T wrench 3 Remove the cable connector flange b 4 Use a...

Page 455: ...ES Figure 7 7 25 1 Follow the steps described in paragraphs 7 7 10 Disassembling the weight stack cover 7 7 12 Disassembling the encoder and 7 7 23 Disassembling the cross 1 Remove the WEIGHT STACK PL...

Page 456: ...described in paragraph 7 7 10 Disassembling the weight stack cover For each of the 2 counter weight vibration bars 1 Unscrew the 2 dowels a using a 4 gauge hexagonal T wrench Hold the BAR up before u...

Page 457: ...teps described in paragraph 7 7 17 Disassembling the upright guard 1 Disconnect the connector from the motor cable 2 Unscrew the screw a and its nut using 2 17 gauge wrenches 3 Unscrew the screw b and...

Page 458: ...paragraph 7 7 17 Disassembling the upright guard 1 Unscrew the screw a using a 4 gauge hexagonal T wrench 2 Open the cover of the ELECTRICAL BOX 3 Disconnect the cable connectors b 4 For each side un...

Page 459: ...move the card To disassemble the FPGA BOARD b 1 Disconnect the 4 connectors 2 Disconnect the 4 plastic coupling elements 3 Remove the card To disassemble the IMP BOARD c 1 Lift the board 2 Disconnect...

Page 460: ...ctor switch 3 Unscrew the holding screw a using an 8 gauge wrench 4 Remove the transformer To disassemble the 110 220 SELECTOR SWITCH g 1 Unsolder the cables 2 Unscrew the holding nut 3 Remove the sel...

Page 461: ...ragraph 7 7 17 Disassembling the upright guard For type A pulleys 1 Unscrew the screw a and the nut using 2 17 gauge wrenches 2 Remove the pulley For type B pulleys 3 Unscrew the screw b using an 8 ga...

Page 462: ...nches loosen the counter nut a then unscrew the screw b of the WEIGHT STACK CABLE terminal until it is free of the cross Figure 7 7 31 2 2 Unscrew the 2 dowels c using a 4 gauge hexagonal T wrench 3 R...

Page 463: ...isassembling the upright guard and 7 7 30 Disassembling the pulleys limited only to the pulleys on which the cable runs 1 For each arm unscrew the screw a using a 17 gauge wrench 2 Remove the LEVER CA...

Page 464: ...pulleys limited only for the pulley whose support is connected to the DOUBLING CABLE 1 Unscrew the 2 dowels a using a 4 gauge hexagonal T wrench 2 Remove the DOUBLING CABLE with the aid of a pair of...

Page 465: ...al T wrench 2 Unscrew the 2 screws b using a 17 gauge wrench 3 Remove the bearing c 4 Remove the CAM GROUP and place it on a bench Figure 7 7 34 2 With the CAM GROUP on the bench 5 Unscrew the screw d...

Page 466: ...ment and unplug the power cord from the wall socket For each side 3 Remove the cap a of the GUARD using a small flat screwdriver 4 Unscrew the screw under the cap a using a medium sized Philips screwd...

Page 467: ...CABLE Figure 7 7 36 1 Follow the steps described in paragraph 7 7 35 Disassembling the front guard 1 Unscrew the 2 screws a using a 5 gauge hexagonal T wrench for each side 2 Remove the guard b Figur...

Page 468: ...4 gauge hexagonal T wrench 5 Remove the PRESTART CABLE with the aid of a pair of pliers 6 Slide the PRESTART CABLE out the front of the machine To reassemble the PRESTART CABLE follow the above steps...

Page 469: ...LEVER 3 Raise the LEVER slightly and unscrew the screw a using a 17 gauge wrench Figure 7 7 37 2 4 Unscrew the screw b using a 17 gauge wrench 5 Use a 17 gauge wrench to unscrew the 4 screws c 6 Remov...

Page 470: ...Shut off the equipment and unplug the power cord from the wall socket For each MAT 2 Use a large flat screwdriver to release the 3 pressure fasteners A holding the MAT against the frame 3 Remove the M...

Page 471: ...steps described in paragraph 7 7 38 Disassembling the mats only for the right hand mat 1 Disconnect the connectors a 2 Unscrew the 4 screws b using a 6 gauge hexagonal T wrench 3 Remove the DISPLAY SU...

Page 472: ...paragraph 7 7 38 Disassembling the mats only for the right hand mat 3 Raise the right lever slightly 4 Unscrew the screw a using a 4 gauge hexagonal T wrench 5 Remove the Plexiglas guard b The screw a...

Page 473: ...teps described in paragraph 7 7 17 Disassembling the upright guard 1 Loosen the 2 screws a using a 5 gauge hexagonal T wrench 2 Remove the STARTING PLATE AND FUSES being careful not to tear the cables...

Page 474: ...plug the power cord from the wall socket 2 Use a medium Philips screwdriver to unscrew the 4 self tapping screws a holding the DISPLAY Hold the DISPLAY up before unscrewing the last screw Figure 7 8 1...

Page 475: ...l Philips screwdriver to unscrew the 5 screws f 5 Remove the CPU and LED BOARDS 6 To separate the CPU and LED boards disconnect the 2 connectors and 4 coupling elements When finished configure the mac...

Page 476: ...LCD located under the LED board 1 Remove the CPU and LED BOARDS 2 Disconnect the 2 connectors 3 Unscrew the 4 screws holding the board to the shell using a small Philips screwdriver 4 Remove the LCD...

Page 477: ...M 1 Insert the EPROM A into the left hand seat and EPROM B into the right hand seat 2 Insert the EPROM pins in the seats starting from the bottom so that the holes in the top seat remain free 3 Make s...

Page 478: ...the CHIP a from its seat using an integrated circuit extractor Figure 7 8 4 2 To re mount the CHIP 1 Make sure the reference notch b on the CHIP is aligned with the reference notch c on its seat 2 Ma...

Page 479: ...KEYBOARD and remove it To replace the new KEYBOARD with the display resting on a bench 1 Remove the film protecting the adhesive 2 Begin attaching the adhesive part starting from left to right without...

Page 480: ...KEYBOARD and remove it To replace the new KEYBOARD with the display resting on a bench 1 Remove the film protecting the adhesive 2 Begin attaching the adhesive part starting from left to right without...

Page 481: ...Figure 7 8 7 1 1 Shut off the equipment and unplug the power cord from the wall socket 2 Unscrew the 2 screws a using a 3 gauge hexagonal T wrench 3 Remove the Plexiglas cover Figure 7 8 7 2 4 Pull th...

Page 482: ...Figure 7 8 8 1 1 Shut off the equipment and unplug the power cord from the wall socket 2 Unscrew the 2 screws a using a 3 gauge hexagonal T wrench 3 Remove the Plexiglas cover Figure 7 8 8 2 4 Pull th...

Page 483: ...mbling the rear plexiglas weight stack guard 1 Unscrew the screw a and the nut b using 2 17 gauge wrenches 2 Remove the PULLEY To replace the PULLEY follow the above steps in reverse order For easier...

Page 484: ...Figure 7 8 10 1 Follow the steps described in paragraphs 7 8 7 Disassembling the rear plexiglas weight stack guard and 7 8 8 Disassembling the front plexiglas weight stack guard 1 Cut the clamp a Figu...

Page 485: ...tor f from the solenoid cable 6 Remove the spiral cable g and its guide h from the hook i Figure 7 8 10 4 7 Use a 6 gauge hexagonal T wrench to unscrew the 8 screws l 8 Pull the WEIGHT STACK COVER upw...

Page 486: ...e 7 8 11 1 Follow the steps described in paragraph 7 8 10 Disassembling the weight stack cover 1 Remove the ADDITIONAL WEIGHT a by sliding it upward Press the solenoid pin inward so that it does not i...

Page 487: ...embling the rear plexiglas weight stack guard 1 Release the slot a of the ENCODER wire from the hook Figure 7 8 12 2 2 Disconnect the connector b of the ENCODER cable 3 Use a 3 gauge hexagonal T wrenc...

Page 488: ...steps described in paragraph 7 8 7 Disassembling the rear plexiglas weight stack guard 1 Disconnect the connector a from the solenoid cable 2 Unscrew the 2 screws b using a 5 gauge hexagonal T wrench...

Page 489: ...Switch the machine on 2 Follow the steps described in paragraph 9 2 Configuring the technical parameters until the final procedure that moves the brush into position as shown in the figure alongside...

Page 490: ...agraph 7 8 7 Disassembling the rear plexiglas weight stack guard 1 Loosen the counter nut a using a 13 gauge wrench 2 Disconnect the connector b from the cable 3 Remove the ZERO SENSOR To reassemble t...

Page 491: ...Shut off the equipment and unplug the power cord from the wall socket For each MAT 2 Use a large flat screwdriver to release the 3 pressure fasteners A holding the MAT against the frame 3 Remove the M...

Page 492: ...l socket For each side of the machine 2 Unscrew the screw a using a 10 gauge hexagonal T wrench 3 Remove the PRESTART LEVER holding the metal panel b in place to keep it from falling Remove the metal...

Page 493: ...exiglas weight stack guard 7 8 16 Disassembling the mats and 7 8 17 Disassembling the prestart levers 1 Select the minimum weight 5 Kg or 10 lbs 2 Move the levers and block them in the forward positio...

Page 494: ...portion of the UPRIGHT GUARD 8 Remove the 4 caps e 2 on each side from the GUARD using a small flat screwdriver 9 Unscrew the 4 screws under the 4 caps e using a medium sized Philips screwdriver 10 Wi...

Page 495: ...rse support plate b by turning it counter clockwise 3 Disconnect the zero sensor cable Figure 7 8 19 2 Working on the inner part of the weight stack 4 Cut the clamp c and disconnect the connector d of...

Page 496: ...ch 3 Unscrew the screw b using a jointed 5 gauge hexagonal wrench until the CHAIN is removed from the upper guide If this is not possible unscrew the screw c using a 3 gauge hexagonal T wrench to disa...

Page 497: ...stack selection chain 1 Loosen the dowel a using a 2 5 gauge hexagonal T wrench 2 Slide the pinion b from the motor shaft 3 Unscrew the 3 screws c using a 4 gauge hexagonal T wrench 4 Remove the MOTOR...

Page 498: ...aragraph 7 8 10 Disassembling the weight stack cover For each CROSS STOP 1 Unscrew the 2 dowels a using a 4 gauge hexagonal T wrench 2 Remove the CROSS STOP by sliding it upward To reassemble the CROS...

Page 499: ...additional weight 7 8 12 Disassembling the encoder 7 8 19 Disassembling the weight stack selection system and 7 8 22 Disassembling the cross stops 1 Use a special tool a to compress all of the weight...

Page 500: ...ibed in paragraph 7 8 23 Disassembling the cross 1 Place the cross on a bench or flat surface 2 Unscrew the 2 screws a using an 8 gauge hexagonal T wrench 3 Remove the cable connector flange b 4 Use a...

Page 501: ...THE WEIGHT STACK PLATES Figure 7 8 25 1 Follow the steps described in paragraphs 7 8 23 Disassembling the cross and 7 8 24 Disassembling the sinker 1 Remove the WEIGHT STACK PLATES by sliding them up...

Page 502: ...described in paragraph 7 8 10 Disassembling the weight stack cover For each of the 2 counter weight vibration bars 1 Unscrew the 2 dowels a using a 4 gauge hexagonal T wrench Hold the BAR up before u...

Page 503: ...paragraph 7 8 18 Disassembling the upright guard 1 Unscrew the screw a using a 4 gauge hexagonal T wrench 2 Open the cover of the ELECTRICAL BOX 3 Disconnect the cable connectors c 4 For each side uns...

Page 504: ...e the board To disassemble the FPGA BOARD b 1 Disconnect the 4 connectors 2 Disconnect the 4 plastic coupling elements 3 Remove the board To disassemble the IMP BOARD c 1 Lift the board 2 Disconnect t...

Page 505: ...ctor switch 3 Unscrew the holding screw a using an 8 gauge wrench 4 Remove the transformer To disassemble the 110 220 SELECTOR SWITCH g 1 Unsolder the cables 2 Unscrew the holding nut 3 Remove the sel...

Page 506: ...ragraph 7 8 18 Disassembling the upright guard For type A pulleys 1 Unscrew the screw a and the nut using 2 17 gauge wrenches 2 Remove the pulley For type B pulleys 3 Unscrew the screw b using an 8 ga...

Page 507: ...nches loosen the counter nut a then unscrew the screw b of the WEIGHT STACK CABLE terminal until it is free of the cross Figure 7 8 30 2 2 Unscrew the 2 dowels c using a 4 gauge hexagonal T wrench 3 R...

Page 508: ...wrench 2 Remove the DOUBLING CABLE with the aid of a pair of pliers 3 Unscrew the screw b and the nut c using 2 22 gauge wrenches 4 Remove the DOUBLING CABLE by sliding it out of the pulleys To disas...

Page 509: ...M GROUP To disassemble the components of the CAM GROUP place it on a bench or flat surface Then To disassemble the bearings b 1 Turn the shaft until you can see the 2 dowels c which must be loosened u...

Page 510: ...7 8 33 2 3 Unscrew the screw b using a 17 gauge tube wrench 4 Remove the washer 5 Use the extractor provided in the machine service box to remove the LEVER tightening the extractor screw using a 24 ga...

Page 511: ...g the power cord from the wall socket 2 Remove the peg a with a peg remover tool 3 Turn the mobile part of the knob until you see the 2 dowels under the 2 holes b 4 Use a 2 gauge hexagonal T wrench to...

Page 512: ...Disassembling the chest rest release knob 1 Use a medium sized Philips screwdriver to unscrew the 2 screws a 2 Remove the lower portion of the LEVER GUARD Figure 7 8 35 2 3 Use a medium sized Philips...

Page 513: ...and 7 8 35 Disassembling the lever guard For each lever 1 Unscrew the 2 dowels a using a 4 gauge hexagonal T wrench 2 Remove the LEVER CABLE with the aid of a pair of pliers 3 Remove the LEVER CABLE...

Page 514: ...ibed in paragraphs 7 8 33 Disassembling the levers 7 8 34 Disassembling the chest rest release knob and 7 8 35 Disassembling the lever guard For each lever 1 Use a 30 gauge Allen wrench to unscrew the...

Page 515: ...8 16 Disassembling the mats 1 Use a medium sized Philips screwdriver to unscrew the 4 screws a 2 Remove the rear portion of the SEAT GUARD Figure 7 8 38 2 3 Unscrew the 2 screws b using a 4 gauge hexa...

Page 516: ...eps described in paragraph 7 8 38 Disassembling the seat guard 1 Disconnect the connector from the motor cable 2 Unscrew the screw a and the nut b using 2 17 gauge wrenches 3 Unscrew the screw c and t...

Page 517: ...in paragraph 7 8 16 Disassembling the mats only for the left hand mat 2 Unscrew the screw a using a 4 gauge hexagonal T wrench 3 Remove the Plexiglas guard b The screw a remains inside the Plexiglas g...

Page 518: ...teps described in paragraph 7 8 18 Disassembling the upright guard 1 Loosen the 2 screws a using a 5 gauge hexagonal T wrench 2 Remove the STARTING PLATE AND FUSES being careful not to tear the cables...

Page 519: ...t and unplug the power cord from the wall socket 2 Use a medium sized Philips screwdriver to unscrew the screw a Hold the DISPLAY up before unscrewing the screw 3 Turn the display downward Figure 7 9...

Page 520: ...Service Maintenance manual rev 2 1 Page 7 346 Figure 7 9 1 3 5 Open the DISPLAY To remove the DISPLAY 1 Disconnect the connectors c 2 Remove the DISPLAY To re mount the display follow the above steps...

Page 521: ...l Philips screwdriver to unscrew the 5 screws f 5 Remove the CPU and LED BOARDS 6 To separate the CPU and LED boards disconnect the 2 connectors and 4 coupling elements When finished configure the mac...

Page 522: ...LCD located under the LED board 1 Remove the CPU and LED BOARDS 2 Disconnect the 2 connectors 3 Unscrew the 4 screws holding the board to the shell using a small Philips screwdriver 4 Remove the LCD...

Page 523: ...M 1 Insert the EPROM A into the left hand seat and EPROM B into the right hand seat 2 Insert the EPROM pins in the seats starting from the bottom so that the holes in the top seat remain free 3 Make s...

Page 524: ...the CHIP a from its seat using an integrated circuit extractor Figure 7 9 4 2 To re mount the CHIP 1 Make sure the reference notch b on the CHIP is aligned with the reference notch c on its seat 2 Ma...

Page 525: ...KEYBOARD and remove it To replace the new KEYBOARD with the display resting on a bench 1 Remove the film protecting the adhesive 2 Begin attaching the adhesive part starting from left to right without...

Page 526: ...KEYBOARD and remove it To replace the new KEYBOARD with the display resting on a bench 1 Remove the film protecting the adhesive 2 Begin attaching the adhesive part starting from left to right without...

Page 527: ...m the wall socket 2 Use a medium sized Philips screwdriver to unscrew the screw a Hold the DISPLAY up before unscrewing the screw 3 Turn the display downward Figure 7 9 7 2 4 Unscrew the 2 screws a us...

Page 528: ...ASSEMBLING THE PLEXIGLAS WEIGHT STACK GUARD Figure 7 9 8 1 Follow the steps described in paragraph 7 9 7 Disassembling the weight stack cover 1 Pull the PLEXIGLAS upward taking care with the rubber ga...

Page 529: ...EYS 1 Unscrew the screw a using an 8 gauge hexagonal T wrench 2 Remove the PULLEY For each of the 2 SIDE PULLEYS 3 Unscrew the screw b and its nut using 2 17 gauge wrenches 4 Remove the PULLEY To reas...

Page 530: ...ack cover and 7 9 8 Disassembling the plexiglas weight stack guard 1 Release the slot a of the ENCODER wire from the hook Figure 7 9 10 2 2 Disconnect the connector b of the ENCODER cable 3 Use a 4 ga...

Page 531: ...onnect the connector a from the solenoid cable 2 Remove the spiral cable b and its guide c from the hook d Figure 7 9 11 2 3 Cut the clamp e 4 Cut the clamp f 5 Disconnect the patch cord g of the sole...

Page 532: ...the weight stack cover 7 9 8 Disassembling the plexiglas weight stack guard limited solely to the external part and 7 9 11 Disassembling the weight stack cover frame 1 Remove the ADDITIONAL WEIGHT a b...

Page 533: ...in paragraphs 7 9 8 Disassembling the plexiglas weight stack guard limited solely to the external part 1 Disconnect the connector a from the SOLENOID cable 2 Unscrew the 2 screws b using a 5 gauge he...

Page 534: ...internal part 1 Switch the machine on 2 Follow the steps described in paragraph 9 2 Configuring the technical parameters until the final procedure that moves the brush into position as shown in the fi...

Page 535: ...assembling the plexiglas weight stack guard limited solely to the internal part 1 Loosen the counter nut a using a 13 gauge wrench 2 Disconnect the connector b from the cable 3 Remove the ZERO SENSOR...

Page 536: ...y turning it counter clockwise 3 Disconnect the zero sensor cable Figure 7 9 16 2 Working on the outer part of the weight stack 4 Cut the clamp c and disconnect the connector d of the weight stack mot...

Page 537: ...ch 3 Unscrew the screw b using a jointed 5 gauge hexagonal wrench until the CHAIN is removed from the upper guide If this is not possible unscrew the screw c using a 3 gauge hexagonal T wrench to disa...

Page 538: ...stack selection chain 1 Loosen the dowel a using a 2 5 gauge hexagonal T wrench 2 Slide the pinion b from the motor shaft 3 Unscrew the 3 screws c using a 4 gauge hexagonal T wrench 4 Remove the MOTOR...

Page 539: ...graph 7 9 11 Disassembling the weight stack cover frame For each CROSS STOP 1 Unscrew the 2 dowels a using a 4 gauge hexagonal T wrench 2 Remove the CROSS STOP by sliding it upward To reassemble the C...

Page 540: ...onal weight and 7 9 19 Disassembling the cross stops 1 Loosen the 2 screws a using a 4 gauge hexagonal T wrench 2 Remove the 2 counter weights b Figure 7 9 20 2 3 Use a special tool c to compress all...

Page 541: ...ibed in paragraph 7 9 20 Disassembling the cross 1 Place the cross on a bench or flat surface 2 Unscrew the 2 screws a using an 8 gauge hexagonal T wrench 3 Remove the cable connector flange b 4 Use a...

Page 542: ...Figure 7 9 22 1 Follow the steps described in paragraphs 7 9 10 Disassembling the encoder 7 9 11 Disassembling the weight stack cover frame and 7 9 20 Disassembling the cross 1 Remove the WEIGHT STACK...

Page 543: ...scribed in paragraph 7 9 11 Disassembling the weight stack cover frame For each of the 2 counter weight vibration bars 1 Unscrew the 2 dowels a using a 4 gauge hexagonal T wrench Hold the BAR up befor...

Page 544: ...onal T wrench 3 Remove the guard b 4 Use a medium sized Philips screwdriver to unscrew the 4 screws c 5 Slide the front portion of the REAR GUARD forward 6 Remove the 2 caps d 1 on each side of the GU...

Page 545: ...L GUARD Figure 7 9 25 1 Follow the steps described in paragraph 7 9 24 Disassembling the rear guard 1 Use a medium sized Philips screwdriver to unscrew the 3 screws a 2 Slide the 2 parts of the CENTRA...

Page 546: ...26 1 Follow the steps described in paragraphs 7 9 24 Disassembling the rear guard and 7 9 25 Disassembling the central guard 1 Unscrew the screw a using a 4 gauge hexagonal T wrench 2 Open the cover...

Page 547: ...BOARD b 1 Disconnect the 4 connectors 2 Disconnect the 4 plastic coupling elements 3 Remove the card To disassemble the IMP BOARD c 1 Lift the board 2 Disconnect the 2 connectors 3 Disconnect the 4 pl...

Page 548: ...220 SELECTOR SWITCH f 1 Unsolder the cables 2 Unscrew the holding nut 3 Remove the selector switch To disassemble the FILTER g 1 Disconnect the connectors 2 Unscrew the 2 holding nuts To reassemble th...

Page 549: ...described in paragraphs 7 9 24 Disassembling the rear guard and 7 9 25 Disassembling the central guard 1 Unscrew the screw a using a 4 gauge hexagonal T wrench 2 Open the cover of the ELECTRICAL BOX F...

Page 550: ...coupling elements 4 Remove the card To disassemble the TRANSFORMER b 1 Disconnect the secondary cables from the board connectors 2 Unsolder the primary cables from the selector switch 3 Unscrew the ho...

Page 551: ...2 Unscrew the screw a using a 3 gauge T wrench 3 Remove the protective photocell cover b Figure 7 9 30 2 4 Disconnect the connector c 5 Use a small straight screwdriver to unscrew the 2 screws d 6 Re...

Page 552: ...SASSEMBLING THE SEAT MOTOR BRUSHES Figure 7 9 31 1 1 Shut off the equipment and unplug the power cord from the wall socket 2 Manually loosen the protective cover a of the brush 3 Remove the brush To r...

Page 553: ...MICROSWITCH Figure 7 9 32 1 1 Shut off the equipment and unplug the power cord from the wall socket For each MICROSWITCH 2 Disconnect the cable connectors a 3 Unscrew the 2 screws b using a 3 gauge h...

Page 554: ...rew the screw c using a 6 gauge hexagonal T wrench Figure 7 9 33 2 4 Disconnect the cable connectors of the 2 microswitches 5 Use a 4 gauge wrench to unscrew the 17 screws d Hold the MOTOR UNIT up bef...

Page 555: ...9 33 4 11 Unscrew the 4 screws i using a 5 gauge hexagonal T wrench 12 Remove the MOTOR To reassemble the SEAT MOTOR UNIT follow the above steps in reverse order When reassembling the winch adjust th...

Page 556: ...ket For each side 2 Unscrew the screw a using a 6 gauge hexagonal T wrench holding the nut in place with a 17 gauge wrench 3 Remove the pulley b 4 Remove the SEAT Including the motor the SEAT weighs a...

Page 557: ...Figure 7 9 35 1 Follow the steps described in paragraph 7 9 34 Removing the seat For the front and back end guards of the SLIDING BARS 1 For each BAR unscrew the screw c using a 14 gauge hexagonal T w...

Page 558: ...d from the wall socket 2 Unscrew the setting screw of the LEVER RELEASE CABLE using a 13 gauge wrench on the counter nut a and screw b 3 Pull the cable from the release handle passing the blocking bal...

Page 559: ...ed in paragraph 7 9 34 7 Remove the SHOULDER REST GROUP RELEASE CABLE If you need to replace the cable because the seat blocking ball the spring pulls the part into the backrest to recover it you must...

Page 560: ...d Philips screwdriver to unscrew the 6 screws a 4 Remove the 2 backrest guards Figure 7 9 37 2 5 Unscrew the 2 screws b using a 3 gauge hexagonal T wrench 6 Remove the closing cover c 7 Remove the cap...

Page 561: ...nches 14 Remove the gas spring To disassemble the sinker 15 Use a 3 gauge hexagonal T wrench to unscrew the dowel i 16 Use a 30 gauge Allen wrench to unscrew the ring nut l 17 Pull out the sinker from...

Page 562: ...wall socket 2 Use a medium sized Philips screwdriver to unscrew the 4 screws a 3 Slide the CENTRAL TACHOGENERATOR GUARD upwards For each of the 2 SIDE TACHOGENERATOR GUARDS 4 Use a medium sized Philip...

Page 563: ...ws a 3 on each side 2 Slide the rear portion of the FRONT GUARD back 3 Use a medium sized Philips screwdriver to unscrew the 2 screws b 4 Slide the middle portion of the FRONT GUARD upward 5 Remove th...

Page 564: ...THE LEVER MAT RUBBER Figure 7 9 40 1 1 Shut off the equipment and unplug the power cord from the wall socket For each LEVER MAT 2 Unscrew the 5 screws a using a 3 gauge hexagonal T wrench 3 Remove th...

Page 565: ...osite side with a 6 gauge hexagonal T wrench 2 Remove the lever mat Figure 7 9 41 2 3 Unscrew the 4 screws b using a 17 gauge wrench 4 Remove the LEVER counter weight Hold the LEVER counter weight up...

Page 566: ...d For each side 1 Unscrew the 3 dowels a using a 4 gauge hexagonal T wrench 2 Remove the cable with the aid of a pair of pliers 3 Remove the cable from the pulleys To unscrew the joints 4 Unscrew the...

Page 567: ...er cord from the wall socket 2 Remove the 4 caps a 2 on each side of the GUARD using a small flat screwdriver 3 Unscrew the 4 screws under the 4 caps a using a medium sized Philips screwdriver 4 Widen...

Page 568: ...d For each cam 1 Unscrew the 2 dowels a using a 4 gauge hexagonal T wrench 2 Remove the cable with the aid of a pair of pliers 3 Remove the cable from the weight stack pulleys To reassemble the WEIGHT...

Page 569: ...and 7 9 43 Disassembling the weight stack frame guard 1 Unscrew the 2 dowels a using a 4 gauge hexagonal T wrench 2 Remove the cable with the aid of a pair of pliers Figure 7 9 45 2 3 Remove the press...

Page 570: ...of the CAM GROUP place it on a bench or flat surface Then To disassemble the bearings b 1 Unscrew the 2 dowels c using a 3 gauge hexagonal T wrench 2 Remove the bearings To separate the cam block d 1...

Page 571: ...cial pliers provided 2 Use a pushing tool to push the b inside 3 Remove the PULLEYS being careful with the 2 plastic spacers The cable holder is fastened to the frame by the dowel d which may be remov...

Page 572: ...described in paragraph 7 9 43 Disassembling the weight stack frame guard 1 Loosen the 2 screws a using a 5 gauge hexagonal T wrench 2 Remove the STARTING PLATE AND FUSES being careful not to tear the...

Page 573: ...49 1 1 Shut off the equipment and unplug the power cord from the wall socket 2 Use a large flat screwdriver to release the 2 pressure fasteners A holding the MAT against the frame 3 Remove the MAT by...

Page 574: ...sassembling the mat 1 Unscrew the screw a using a 4 gauge hexagonal T wrench 2 Remove the Plexiglas guard b The screw a remains inside the Plexiglas guard 3 Disconnect the 3 connector fastons c 4 Remo...

Page 575: ...set to 5 Kg 10 lbs Subsequent selections of different weights are all related to forward or backward movements by the motor by a preset number of pulses 8 1 1 OFFSET This parameter set to 1000 by def...

Page 576: ...over new version equipment so that it may be rapidly configured in case the data stored in the battery powered RAM are lost or if the electronic boards of the display are replaced The OFFSET value gen...

Page 577: ...moving the weight stack selection system by switching the weight stack motor on and off When it is shut off the motor continues moving for a minimal amount because of inertia although its ends are sh...

Page 578: ...disconnected 1 With the limit switch at the end of its stroke adjust the position of the PRIMARY SHAFT so that it respects the measurements shown in the drawing 2 To do so adjust the position of the l...

Page 579: ...ce manual rev 2 1 Page 8 5 Figure 8 2 1 3 4 Adjust the position of the SECONDARY SHAFT so that it respects the measurements shown in the drawing 5 Mount the primary and secondary shaft connection chai...

Page 580: ...roke and the lever in position 1 adjust the position of the PRIMARY SHAFT so that it respects the measurements shown in the drawing 2 To do so adjust the position of the limit switch by regulating the...

Page 581: ...ce manual rev 2 1 Page 8 7 Figure 8 2 2 3 4 Adjust the position of the SECONDARY SHAFT so that it respects the measurements shown in the drawing 5 Mount the primary and secondary shaft connection chai...

Page 582: ...roke and the lever in position 1 adjust the position of the PRIMARY SHAFT so that it respects the measurements shown in the drawing 2 To do so adjust the position of the limit switch by regulating the...

Page 583: ...ce manual rev 2 1 Page 8 9 Figure 8 2 3 3 4 Adjust the position of the SECONDARY SHAFT so that it respects the measurements shown in the drawing 5 Mount the primary and secondary shaft connection chai...

Page 584: ...ke and the lever in position 1 adjust the position of the PRIMARY SHAFT so that it respects the measurements shown in the drawing 2 To do so adjust the position of the limit switch by regulating the s...

Page 585: ...ce manual rev 2 1 Page 8 11 Figure 8 2 4 3 4 Adjust the position of the SECONDARY SHAFT so that it respects the measurements shown in the drawing 5 Mount the primary and secondary shaft connection cha...

Page 586: ...t with a 17 gauge wrench 3 Connect and power all cables 4 Adjust the starting position of the levers so that They are horizontal using the level The right lever does not strike the left 5 To do so adj...

Page 587: ...with a 17 gauge wrench 3 Connect and power all cables 4 Adjust the starting position of the levers so that They are horizontal using the level They have the maximum stroke limit switches as tight as p...

Page 588: ...the easy start lever so that it respects the measurements shown in the drawing 2 To do so adjust the position of the limit switch under the easy start lever support by regulating the screw and nut wit...

Page 589: ...To adjust the starting position of the levers Set the lever at 2 mm from its internal fastening point Tighten the 2 screws a of the internal lever lock Tighten the center screw b until the bearings ar...

Page 590: ...en they are both pushed and the crossed is resting against the cross limit switches the lever limit switches are 1 mm above the lever itself 8 To do so adjust the position of the limit switch by regul...

Page 591: ...start lever so that it respects the measurements shown in the drawing 2 To do so adjust the position of the limit switch under the easy start lever support by regulating the screw and nut with a 17 ga...

Page 592: ...e drawing 5 To do so adjust the position of the limit switch by regulating the screw and nut with a 24 gauge wrench Figure 8 2 8 4 6 Connect and power all cables 7 Adjust the stopping position of leve...

Page 593: ...the mats so that They have the maximum stroke The block of mats may easily be moved to perform the exercise with the mats connected or disconnected 3 Cut the weight stack cable 5480 mm and the lever c...

Page 594: ...switch limits the cross stroke to avoid possible breakage of mechanical parts due to overly long strokes by the weight stack Therefore with d as the distance between the top of the cross and the botto...

Page 595: ...ntil the cable is still taut but the cross is resting on the weight stack 5 Tighten the counter nut a using a 22 gauge wrench Check the tension of the cable by carrying out a couple of repetitions wit...

Page 596: ...st Press Figure 8 5 1 1 1 Make sure that the easy start lever is properly positioned 2 Adjust the easy start cable tension by means of the nut a holding the screw b in place so that the cable is taut...

Page 597: ...s Figure 8 5 2 1 1 Adjust the length of the 2 parts of the secondary easy start cables so that the easy start lever activates the 2 levers evenly The length of each part of the secondary weight stack...

Page 598: ...Chest Press Rowing Torso and Leg Press The length of the lever cable is shown in the table below Machine Length mm Abdominal Crunch Lower Back Leg Extension Leg Curl Vertical Traction 2800 Shoulder P...

Page 599: ...ng Torso and Leg Press The length of the doubling cable is shown in the table below Machine Length mm Abdominal Crunch Lower Back Leg Extension Leg Curl Vertical Traction Shoulder Press Chest Press 82...

Page 600: ...same for all machines Figure 8 8 1 1 Carry out the procedure described in paragraph 6 1 Manual Components Test until the solenoid of the weight stack selection brush is in front of the zero sensor 2...

Page 601: ...e maximum weight all plates in the weight stack are selected 2 Make sure that the distance between the pin on the first plate and that of the last and the white plastic sliding block of the selection...

Page 602: ...sing an 8 gauge wrench 2 Adjust the CHAIN TENSION by turning the screw b using a jointed 5 gauge hexagonal wrench so that the chain does not shake while moving 3 When the adjustment is complete tighte...

Page 603: ...n the screw fastening the primary shaft pinion to the shaft itself 2 Place a striker rod on the crown of the secondary shaft 3 Align the primary shaft pinion with the striker rod 4 When the alignment...

Page 604: ...st the nut b and the screw c so that there is a drop in the chain of approximately 1 cm in the center between the 2 shafts 3 Test the movement value in the center for the various lever positions Make...

Page 605: ...USTING THE RELEASE CABLE TENSION This operation holds for the Lower Back and Leg Press Figure 8 13 1 1 Loosen the nut a 2 Adjust the screw b so that the cable is taut the release lever has a play of 1...

Page 606: ...all flat screwdriver until the ideal level is reached WARNING do not adjust this trimmer unless strictly necessary In any case always check the reason for the need to increase the current increased fr...

Page 607: ...hines Figure 8 15 1 1 Leave the power cord connected to the power entry 2 Switch the machine on 3 Looking at the LCD turn the trimmer screw P1 using a small flat screwdriver to adjust the contrast unt...

Page 608: ...ved accidentally 1 Leave the power cord connected to the power entry 1 Remove the EPROM a from the CPU Board using a special integrated circuit extractor 2 Switch the machine on the buzzer will sound...

Page 609: ...NICAL PARAMETERS Technical parameters are those that may be changed only by an authorized technician since they have to do with configuring the construction parameters of the equipment The procedure f...

Page 610: ...the Shoulder Press the following will appear on the LCD S E L E C T E D M A C H I N E S H O U L D E R P R E S S B I O The choice of the type of machine alters the procedures described in paragraphs 9...

Page 611: ...e the selection Thus if not otherwise advised maintain this value set at 510 Enter the value then press Enter to continue or Clear to abort 9 2 4 WEIGHT STACK MOTOR INERTIA This option allows you to s...

Page 612: ...ype of motor used and the mechanics used to make the selection This value is factory set to 10 but it may be necessary to change it due to changes in the selection system conditions Enter the value th...

Page 613: ...for Abdominal Crunch and Lower Back This option allows you to set the number of pulses produced by the encoder associated with the seat motor to complete the entire seat stroke T O T A L R A N G E S E...

Page 614: ...ion 3 Shoulder Press 3 Chest Press 3 Rowing Torso 3 Leg Press 25 Enter the value then press Enter to continue or Clear to abort 9 2 9 SEAT OFFSET POSITION 9 This parameter does not appear for Abdomina...

Page 615: ...ress 20 It may be necessary to change it due to changes in the selection system conditions Should you observe that the relays of the seat motor interface board sputter when stopping the motor after ju...

Page 616: ...for exercise ROM acquisition D E F A U L T R O M S T A R T c m X X These distances are factory set as indicated in the table below Machine Cm Abdominal Crunch 5 Lower Back 5 Leg Extension 5 Leg Curl 5...

Page 617: ...F I R S T R E P X X These distances are factory set as indicated in the table below Machine Abdominal Crunch 45 Lower Back 45 Leg Extension 45 Leg Curl 45 Vertical Traction 45 Shoulder Press 45 Chest...

Page 618: ...ge 9 10 Press Enter to continue or Clear to abort At this point the machine will perform a reset procedure during which the following will appear on screen M A C H I N E R E S E T P L E A S E W A I T...

Page 619: ...he password 2406 and pressing Enter to continue the machine begins to offer the configurable parameters in sequence showing the current value and possible alternatives Press the Enter key to move on t...

Page 620: ...T I O N K E Y S N 1 Y 2 X The following options are available NO 1 YES 2 Select the desired option then press Enter to continue or Clear to abort If NO is selected it will be possible to change the m...

Page 621: ...o set the position that the seat will automatically move to at the end of the automatic reset procedure S T A N D B Y S E A T P O S I T I O N X These distances are factory set to their recommended def...

Page 622: ...you to set the timeout in seconds the machine waits when the weight stack is in stand by position before considering that the set is over T I M E B E F O R E L O A D 1 3 0 S E C X X X You may enter an...

Page 623: ...ed the SW will ask you to do 3 reps and according on these reps the SW will automatically define the value of the parameters ROM minimum length default ROM start default ROM length e ROM first rep The...

Page 624: ...ne Code Minimum ROM length Default ROM start Default ROM length ROM first rep Abdominal Crunch 3 3 5 8 45 Lower Back 6 5 5 10 45 Leg Extension 2 15 5 30 45 Leg Curl 5 15 5 30 45 Vertical Traction 1 15...

Page 625: ...23 13 14 22 14 15 23 15 16 23 16 17 23 17 18 23 18 19 23 19 20 23 20 21 23 21 22 23 22 23 40 9 4 5 SEAT MOTOR PARAMETERS Machine Total seat pulse range Offset pos 0 seat pulses Offset pos 9 seat pulse...

Page 626: ...displayed on the LED matrix at this point 9 5 1 WEIGHT STACK MOTOR RUNNING TIME This is the total number of hours for which the weight stack motor has been used M O T O R W E I G H T O N H O U R S X X...

Page 627: ...the total number of hours for which the seat motor has been used M O T O R S E A T O N H O U R S X X X X Press ENTER to continue 9 5 7 SEAT MOTOR TEST CYCLES This parameter does not appear for Abdomi...

Page 628: ...5 10 NUMBER OF FAIL SIGNALS PRODUCED BY THE SEAT MOTOR INTERFACE BOARD This parameter does not appear for Abdominal Crunch and Lower Back The number of fails signals produced by the seat motor interf...

Page 629: ...X Press ENTER to continue 9 5 14 TOTAL WEIGHT LIFTED USING THE MACHINE The total weight lifted by the machine expressed in 100 kg units This value is obtained by adding the weight lifted for each rep...

Page 630: ...ers This means that to edit an existing 4 digit number you must first enter 5 digits to reset the value then enter the desired value The following information will be displayed on the LED matrix at th...

Page 631: ...Change the value shown or press ENTER to continue 9 6 6 SEAT MOTOR RUNNING TIME This parameter does not appear for Abdominal Crunch and Lower Back This is the total number of seconds for which the sea...

Page 632: ...X X X Change the value shown or press ENTER to continue 9 6 10 NUMBER OF FAIL SIGNALS PRODUCED BY THE SEAT MOTOR INTERFACE BOARD This parameter does not appear for Abdominal Crunch and Lower Back The...

Page 633: ...X X X X X X X Change the value shown or press ENTER to continue 9 6 14 TOTAL WEIGHT LIFTED USING THE MACHINE The total weight lifted by the machine This value is obtained by adding the weight lifted...

Page 634: ...BIOSTRENGTH LINE Service Maintenance manual rev 2 1 Page 9 26 Page intentionally left blank...

Page 635: ...chine 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...

Page 636: ...DITIONS 1 Shut off the machine by setting the switch to 0 OFF 2 Unplug the power cord from the wall socket 3 Open all housings the Plexiglas weight stack guards and mats on the machine 10 2 2 CLEANING...

Page 637: ...ght stack guards and mats on the machine 10 3 2 CHECK THE WEIGHT STACK SELECTION SYSTEM 1 Disassemble the weight stack selection system 2 Check the wear status of the weight stack selection system cha...

Page 638: ...ever arms shafts lever systems Repair and or replace any worn parts 2 Check the phasing of the machine mechanisms 3 Lubricate the mechanisms using MOLYKOTE LONGTERM W 2 10 3 8 CHECK THE GAS SPRINGS Pe...

Page 639: ...pair and or replace any worn parts 2 Clean the seat support bars using alcohol 3 Lubricate the pinion and rack of the seat using MOLYKOTE LONGTERM W 2 CAUTION do NOT lubricate the support bars for any...

Page 640: ...inuity of the individual wires Insulation of the individual wires to earth Repair and or replace any substandard parts 2 Check the status of the fuses using a tester 10 4 3 CHECK THE DISPLAY 1 Check t...

Page 641: ...rs for the weight stack motor as described in the paragraph 9 5 1 if the value is greater than 1500 replace the motor as its brushes will soon be worn out 6 Check the number of running hours for the m...

Page 642: ...e recommend that you carry out these operations at least once every 1 months Follow the procedure below for electrical electronic operations 10 5 1 PREPARING WORKING CONDITIONS 1 Open Plexiglas weight...

Page 643: ...using the machine s pre start function Default ROM length This is the default amplitude of the ROM before acquiring the user s actual ROM and is used to correctly fill the ROM LED arc on the display...

Page 644: ...L NUMBER Each machine has 2 labels containing the serial number of the machine One of these labels is accessible externally and is located on the seat support frame the other is accessible by disassem...

Page 645: ......

Page 646: ...0SMM0078 ING TECHNOGYM S p A Via G Perticari 20 47035 Gambettola FC ITALIA Tel 39 0547 650438 Fax 39 0547 650150 e mail service technogym com...

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