service maintenance manual - technogym · total pulley: service & maintenance manual - rev. 2.0...

SERVICE & MAINTENANCE MANUAL

REV. 2.0

The information contained in this manual is intended for QUALIFIED TECHNICIANS who have completed a specific TECHNOGYM training course and are authorized to perform machine start-

up and adjustment procedures as well as extraordinary maintenance or repairs which require a thorough knowledge of the machine, its operation, its safety devices and working procedures.

CAREFULLY READ THE INFORMATION CONTAINED IN THIS MANUAL BEFORE PERFORMING ANY MAINTENANCE

PROCEDURES ON THE MACHINE

DANGEROUS VOLTAGES PRESENT EVEN WHEN THE MACHINE IS TURNED OFF

NOTE The information contained in this document is subject to change without notice. Technogym does not guarantee this documentation in any way. Technogym shall not be held responsible for any errors contained in this manual and declines all liability for accidents or damages resulting from the supply, characteristics or use of this manual. This document contains proprietary information that is protected by copyright. All rights reserved. No part of this document may be photocopied, reproduced or translated into another language without the prior written consent of Technogym. The Technogym™ trademark is property of Technogym S.p.A. The Vario Pulley™ trademark is property of Technogym S.p.A.

Total Pulley: Service & Maintenance Manual - rev. 2.0

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

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

2. TECHNICAL CHARACTERISTICS.................................................................................................................. 2.1 2.1. MECHANICAL CHARACTERISTICS ..................................................................................................................... 2.1 2.2. AMBIENT SPECIFICATIONS ................................................................................................................................ 2.1 2.3. CONFORMITY TO REGULATIONS........................................................................................................................ 2.1

3. INSTALLATION INSTRUCTIONS.................................................................................................................... 3.1 3.1. SPECIFICATIONS AND REQUIREMENTS .............................................................................................................. 3.1 3.2. LIFTING AND HANDLING THE MACHINE............................................................................................................. 3.1 3.3. INSTALLATION.................................................................................................................................................. 3.2

4. DISASSEMBLY OF COMPONENTS................................................................................................................. 4.1 4.1. DISASSEMBLING THE FRAME FOR THE LAT EXERCISES ...................................................................................... 4.1 4.2. DISASSEMBLING THE ADJUSTMENT BAR ........................................................................................................... 4.2 4.3. DISASSEMBLING THE HANDLEBAR.................................................................................................................... 4.3 4.4. DISASSEMBLING THE GUARDS .......................................................................................................................... 4.4 4.5. DISASSEMBLING THE ELASTIC BANDS............................................................................................................... 4.6 4.6. DISASSEMBLING THE WEIGHT STACK CABLE..................................................................................................... 4.8 4.7. DISASSEMBLING THE PULLEYS CABLE ............................................................................................................ 4.10 4.8. DISASSEMBLING THE DOUBLING MECHANISM CABLE...................................................................................... 4.11 4.9. DISASSEMBLING THE WEIGHT STACK.............................................................................................................. 4.12 4.10. DISASSEMBLING THE CABLE OUTPUT ASSEMBLY ............................................................................................ 4.14

5. ADJUSTMENTS.................................................................................................................................................... 5.1 5.1. CABLE TENSION................................................................................................................................................ 5.1

5.1.1. Pulleys cable ..................................................................................................................................... 5.1 5.1.2. Weight stack cable ............................................................................................................................ 5.2

5.2. ADJUSTING THE STOP ON THE WEIGHT STACK CABLE........................................................................................ 5.3 5.3. ADJUSTING THE WEIGHT DOUBLING MECHANISM CABLE .................................................................................. 5.4 5.4. ADJUSTING THE STOPS POSITION ON THE WEIGHT STACK BAR........................................................................... 5.5 5.5. ADJUSTING THE CABLE FOR LAT EXERCISES ..................................................................................................... 5.6

6. SCHEDULED MAINTENANCE ......................................................................................................................... 6.1 6.1. DAILY MAINTENANCE OPERATIONS .................................................................................................................. 6.1

6.1.1. Cleaning the frame and the guards................................................................................................... 6.1 6.2. MONTHLY MAINTENANCE OPERATIONS ............................................................................................................ 6.2

6.2.1. Setting up the operation .................................................................................................................... 6.2 6.2.2. Checking the cross, weight stack rods, doubling mechanism forks and weight stack plates ............ 6.2 6.2.3. Checking the elastic bands................................................................................................................ 6.2 6.2.4. Checking the various rubber parts.................................................................................................... 6.2

6.3. TWICE-YEARLY MAINTENANCE OPERATIONS.................................................................................................... 6.3 6.3.1. Setting up the operation .................................................................................................................... 6.3 6.3.2. Carrying out the routine maintenance procedure............................................................................. 6.3 6.3.3. Checking the pulleys ......................................................................................................................... 6.3 6.3.4. Checking the clamping of screws and bolts ...................................................................................... 6.3 6.3.5. Replacing the cables ......................................................................................................................... 6.3 6.3.6. Checking the weight stack cross alignment ...................................................................................... 6.3

7. FUNCTIONAL TESTS ......................................................................................................................................... 7.1

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Page ii

7.1. WEIGHT STACK CABLE ASSEMBLY TEST ........................................................................................................... 7.1 7.2. HOUSING ASSEMBLY TEST ................................................................................................................................ 7.1 7.3. MECHANICAL RESISTANCE DEVICE ASSEMBLY TEST......................................................................................... 7.1

8. APPENDIX............................................................................................................................................................. 8.1 8.1. LIST OF CRITICAL SPARE PARTS ........................................................................................................................ 8.1 8.2. TOOLS TO BE USED ........................................................................................................................................... 8.2

9. VARIO PULLEY IFI ............................................................................................................................................ 9.1


1. GENERAL NOTICES

1.1. INTRODUCTION

This document is reserved for Technogym Service technicians, and is intended to provide authorized personnel with the necessary information to correctly carry out repairs and maintenance. A thorough knowledge of the technical information contained in this manual is essential for completing the professional training of the operator. In order to facilitate consultation, the paragraphs are accompanied by schematic drawings which illustrate the procedure being described. This manual contains notices and symbols which have a specific meaning:

WARNING: non observance may result in accident or injury.

ATTENTION: non observance may cause damage to the machine.

Information about the operation in progress.

OBSERVE: observation about the operation in progress.

1.2. RECOMMENDATIONS

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

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

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

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

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

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

Page 1.1


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 Newsletters, which may contain more up-to-date information on

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

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

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


2. TECHNICAL CHARACTERISTICS

2.1. MECHANICAL CHARACTERISTICS

Width 101.5 cm 40 inch Length 93.4 cm 36.7 inch Height 24.3 cm 96 inch Weight 200 Kg 442 lb

2.2. AMBIENT SPECIFICATIONS

Operating from 10° to 25° C Temperature Storage from 10° to 25° C Operating from 20% to 90% non-condensing Humidity Storage from 20% to 90% non-condensing

2.3. CONFORMITY TO REGULATIONS

The machine conforms to:

Standards Europe Risk analysis EN 1441

Fixed exercise equipment EN 957-1 EN 957-2

Directive Europe Medical devices 93/42/CEE

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Pagina 2.2

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3. INSTALLATION INSTRUCTIONS

3.1. SPECIFICATIONS AND REQUIREMENTS

For correct installation of the machine, make sure that: 1. The machine is installed on a level surface that is free of vibrations and has sufficient carrying

capacity for the combined weight of the machine and user. 2. The place of installation is not dusty or sandy. 3. The place of installation complies with the operating temperature and humidity conditions set

out in paragraph 2.2.

3.2. LIFTING AND HANDLING THE MACHINE

To move the machine, use the moving roller (see following figure) or standard lifting and handling equipment.

WARNING: The machine must be moved with great care, due to the risk of it tipping over.

Lift the machine from the weight stack side with a pallet truck or fork lift.

ATTENTION: It is recommended to place some padded material between the frame and the lifting equipment.

ATTENTION: When lifting the machine, do not grasp it from its plastic components.

Pagina 3.1


Pagina 3.2

3.3. INSTALLATION

For correct installation, check first of all that the assembly specifications and requirements (see 3.1. “Specifications and requirements) have been met. Then carry out the steps of the procedure described below:

Figure 3.3-1

1. The machine is supplied completely assembled, packed inside a box, wrapped in cellophane and fixed to a wooden pallet.

Figure 3.3-2

2. Remove the metal staples securing the outer carton to the pallet, then lift the carton; remove the nylon bag from the top.

3. The equipment is supplied with:

a. Lat bar a; b. Lat bar upper frame b; c. Box service c.

4. Remove the machine from the pallet and

place it on the ground, use normal handling equipment.

WARNING: When lifting the machine,

do not grasp it from its plastic components.

5. Position the machine, on a level surface that

is free of vibrations and has sufficient carrying capacity for the combined weight of the machine and user.

Continued on the following page →


Figure 3.3-3

6. Using a 6-mm Allen wrench, remove from the frame of the machine the 2 screws c and the two washer.

Figure 3.3-4

7. Connect the lat frame to the machine, using the screws removed at the step 6.

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Pagina 3.4



4. DISASSEMBLY OF COMPONENTS

4.1. DISASSEMBLING THE FRAME FOR THE LAT EXERCISES

Figure 4.1-1

1. Back off the screws a using a 6-mm Allen wrench, accessing by the holes in the frame b.

2. Remove the frame b. To reassemble the frame, carry out the above steps in reverse order.

Pagina 4.1


Pagina 4.2

4.2. DISASSEMBLING THE ADJUSTMENT BAR

Figure 4.2-1

Carry out the procedure described in paragraph 4.1. “Disassembling the frame for the lat exercises”. 1. Back off the screw a using a 6-mm Allen

wrench.

Figure 4.2-2

2. Back off the screw b using an 8-mm Allen wrench.

3. Remove the adjustment bar. To reassemble the adjustment bar, carry out the above steps in reverse order.


4.3. DISASSEMBLING THE HANDLEBAR

Figure 4.3-1

1. Back off the 8 screws a T25 torx wrench. 2. Remove the two bracket b.

Figure 4.3-2

3. Back off the 2 screws c using an 8-mm Allen wrench.

4. Remove the handlebar. To reassemble the handlebar, carry out the above steps in reverse order.

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Pagina 4.4

4.4. DISASSEMBLING THE GUARDS

Figure 4.4-1

On either side of the machine: 1. Back off the 8 screws a T25 torx wrench. 2. Remove the two bracket b. 3. Remove the rear machine guard.

Figure 4.4-2

4. Back off the 4 screws c in the inner part of the front right guard using an 8-mm wrench and repeat the operation on the left hand side.

5. Back off the screw d using a 4-mm Allen wrench and remove the two upper parts of the front guard.



Figure 4.4-3

To disassemble the lower front guards it is necessary to lift the weight stack, selecting plate number 6.

6. Back off the 2 screws e in the inner part of

the front right lower guard using an 8-mm wrench and repeat the operation on the left hand side.

7. Back off the screws f using a 4-mm Allen wrench and remove the two lower parts of the front guard.

To reassemble the guards, carry out the above steps in reverse order.

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Pagina 4.6

4.5. DISASSEMBLING THE ELASTIC BANDS

Figure 4.5-1

Carry out the procedure described in paragraph 4.4. “Disassembling the guards”, to disassemble the rear machine guard. 1. Rotate the selection knob of the elastic band

that is being replaced, to position 1.

Figure 4.5-2

2. Remove the elastic band from pin a, leaving it slack.

Continued on the following pages →


Figure 4.5-3

3. Pull out the pin b and remove the elastic band.

To reassemble the elastic band, carry out the above steps in reverse order.

Pagina 4.7


Pagina 4.8

4.6. DISASSEMBLING THE WEIGHT STACK CABLE

Figure 4.6-1

Carry out the procedure described in paragraph 4.4. “Disassembling the guards”, to disassemble the rear machine guard. 1. Remove the counterweight a from its seat. 2. Back off all 4 grub screws b, using a 4-mm

Allen wrench, so as to release the cable.

Figure 4.6-2

3. Unscrew the 3 grub screws c securing the stop to the cable, using a 4-mm Allen wrench.

4. Remove the stop.

During reassembly, lock down the grub screws “b” and “c” using a torque wrench set for 15 Nm.

Figure 4.6-3

5. Back off the counter nut d and then the threaded pin e using a 22-mm wrench.

6. Pull the cable out of the pulley.



To reassemble the cable, carry out the above steps in reverse order, checking that: • the threaded pin e is screwed of about 1 cm

on the weight stack cross; • The grab screws c of the stop are loose. They

will be locked down at the end of the adjusting procedures reported below.

• Only 1 grab screw b of the counterweight is locked down. The others will be locked down at the end of the adjusting procedures reported below.

After completing this procedure, adjust the cable tension as described in paragraph 5.1. “Cable tension” and adjust the position of the stop as described in paragraph 5.2. “Adjusting the stop on the weight stack cable”.

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Pagina 4.10

4.7. DISASSEMBLING THE PULLEYS CABLE

Figure 4.7-1

Carry out the procedure described in paragraph 4.4. “Disassembling the guards”. 1. Pull out the cable from one of the terminal a,

loosing the knot b. 2. Slip off the cable from the pulleys pulling it

from the unloose terminal. To reassemble the cable, carry out the above steps in reverse order.

Reassemble the cable routing it through the pulleys as shown in the figure on the side.

After completing this procedure, adjust the cable tension as described in paragraph 5.1. “Cable tension”.

Figure 4.7-2


4.8. DISASSEMBLING THE DOUBLING MECHANISM CABLE

Figure 4.8-1

Carry out the procedure described in paragraph 4.4. “Disassembling the guards”. 1. Select position 2 on the doubling mechanism,

back off nut a with a 17-mm wrench to release the cable.

Figure 4.8-2

2. Remove the two springs b.

Figure 4.8-3

3. Pull the cable out from hole c, to which it is fixed by means of a knot.

To reassemble the cable, carry out the above steps in reverse order.

After completing this procedure, adjust the cable tension as described in paragraph 5.3. “Adjusting the weight doubling mechanism cable”.

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Pagina 4.12

4.9. DISASSEMBLING THE WEIGHT STACK

Figure 4.9-1

Carry out the procedure described in paragraph 4.4. “Disassembling the guards”. 1. On both sides, back off the two grub screws

a at the base of the weight stack which secure the weight stack rod. Use a 4-mm Allen wrench. The rod will move down by a few centimeters.

Figure 4.9-2

2. On both the weight stack rod, back off the two grub screws b of the weight stack rod stops and remove them. Use a 4-mm Allen wrench.

3. Remove the weight stack rod stops.

Figure 4.9-3

4. Back off the counter nut c and then the threaded pin d using a 22-mm wrench.



Figure 4.9-4

5. Back off the nuts e using a 17-mm wrench locking the screws f using a 6-mm Allen wrench.

Figure 4.9-5

6. Position the pulley support g near the fixed pulleys, in the upper part of the machine.

Figure 4.9-6

7. Remove from the weight stack rods the pulley support h and then all the weight stack plates.

To reassemble the weight stack, carry out the above steps in reverse order.

After completing this procedure, adjust the cable tension as described in paragraph 5.1. “Cable tension” and adjust the position of the stop as described in paragraph 5.2. “Adjusting the stop on the weight stack cable”.

Pagina 4.13


Pagina 4.14

4.10. DISASSEMBLING THE CABLE OUTPUT ASSEMBLY

Figure 4.10-1

1. Remove the two pulleys b backing off the screws c on either side of the plate a, using a 3-mm Allen wrench.

2. Remove the pulleys. 3. Pull out the cable from terminal, loosing the

knot d.

Figure 4.10-2

4. Slip-off the cable through pin f and lock it in order to avoid it slip-off through the pulleys.

5. Remove the seeger e, from both the upper pin f and the lower one

6. Remove the pins f. 7. Remove the plate a. To reassemble the cable output assembly, carry out the above steps in reverse order.

After completing this procedure, adjust the cable tension as described in paragraph 5.1. “Cable tension”.


5. ADJUSTMENTS

5.1. CABLE TENSION

5.1.1. PULLEYS CABLE

Figure 5.1-1

Carry out the procedure 5.4. “Adjusting the stops position on the weight stack bar”.

1. Loose the tension of the weight stack cable. 2. Check that the cable passes correctly through

all the pulleys. 3. Adjust the pulleys cable length so that the

distance x between the pulleys support frame and the first weight stack plate is 70-72 cm. To perform the adjustment, change the position of the knot at a cable terminals.

Figure 5.1-2

This adjustment is performed in order to have components “1” and “2” closed, without any contact, if the weight doubling mechanism is set in position 2 and the exercise lever pulls completely out the pulleys cable.

If a new pulleys cable has to be adjusted, after completing the above procedure pull the cable sharply a few times to settle it into place, and then check whether it requires further adjustments. Repeat the procedure at least a couple of times


Pagina 5.1


Pagina 5.2

5.1.2. WEIGHT STACK CABLE

Figure 5.1-3

1. Check the length of the pulleys cable

according the procedure 5.1.1. “Pulleys cable”.

2. Back off the counter nut of the threaded pin

b. 3. Adjust the weight stack cable tension acting

on the traded pin so that the top surface of the counterweight is flush with its locking forks f.

4. Lock down the counter nut of the threaded pin b.

If acting on the threaded pin is not sufficient, shorten the cable length inserting a longer piece into the counterweight.

Check if it’s possible to select all the weight stack plates by the selector pin, with the weight stack in start position.

After completing this procedure, adjust the stop “c” position as described in paragraph 5.2. “Adjusting the stop on the weight stack cable”


5.2. ADJUSTING THE STOP ON THE WEIGHT STACK CABLE

Figure 5.2-1

1. Check that the weight stack cable tension is

correctly adjusted as described in the paragraph 5.1. “Cable tension“.

2. The machine must be in the rest position and

the weight doubling lever must be in position 1.

3. Adjust the stop a so that it is up against the

pulley support b, as shown in the figure at left.

During reassembly, lock down the grub screws using a torque wrench set for 15 Nm.

Pagina 5.3


Pagina 5.4

5.3. ADJUSTING THE WEIGHT DOUBLING MECHANISM CABLE

Figure 5.3-1

1. Select position 2 of the weight doubling lever.

2. Back off the nut a which is used for adjusting

the cable length.

Figure 5.3-2

3. Adjust the cable length so that the part b with the counterweight lock forks is almost up against component c, as shown in the figure.


5.4. ADJUSTING THE STOPS POSITION ON THE WEIGHT STACK BAR

Figure 5.4-1

1. Acting on the grab screws of the stops a, set the distance x to 9 cm.

After completing this procedure:

• set the weight doubling mechanism in position 2;

• pull the exercise lever completely out so as the pulley support “b” reaches the stops

check that the threaded pin “c” do not stroke the lower pulley of the pulley support “b”.

Pagina 5.5


Pagina 5.6

5.5. ADJUSTING THE CABLE FOR LAT EXERCISES

Figure 5.5-1

1. With the cable for Lat exercises set as shown in the picture:

• the cable terminal with the ring is hooked

at the pin a; • the cable routes on the back of the pin b; • lat bar is connected to the harness catch. Adjust the length of the cable so that the distance x between the harness catch terminal and the pulley c is of about 5 cm.

If a new cable is being installed, after completing the above procedure pull the cable sharply a few times to settle it into place, and then check whether it requires further adjustments. Repeat the procedure at least a couple of times


6. SCHEDULED MAINTENANCE To keep the machine in perfect working order, it is necessary to carry out certain scheduled maintenance actions in order to forestall possible problems. There are essentially 3 types of maintenance operations: • Daily maintenance operations; • Monthly maintenance operations; • Twice-yearly maintenance operations. The prescribed frequency differs for each type of operation, as does the required level of operator qualification. The following paragraphs detail the recommended procedures.

6.1. DAILY MAINTENANCE OPERATIONS

These operations can be carried out by the machine owner and do not require any special skills.

The daily maintenance operations are simple cleaning actions for the purposes of general hygiene.

For the daily maintenance of the machine, proceed as follows:

6.1.1. CLEANING THE FRAME AND THE GUARDS 1. Using a cloth moistened with a solution of water and mild soap (non acidic), clean the frame

and the guards of the machine.

Never spray the cleaning product directly on the machine.

ATTENTION: do not use alcohol, petrol or chemical products in general.

Pagina 6.1


Pagina 6.2

6.2. MONTHLY MAINTENANCE OPERATIONS

These operations can be carried out by the machine owner and do not require any special skills.

The monthly maintenance operations involve simple cleaning and lubrication actions and checks on the state of wear, in order to ensure correct and safe operation of the machine. For the monthly maintenance of the machine, proceed as follows:

6.2.1. SETTING UP THE OPERATION 1. Open the machine guards.

6.2.2. CHECKING THE CROSS, WEIGHT STACK RODS, DOUBLING MECHANISM FORKS AND WEIGHT STACK PLATES

1. Check the state of wear of the bushings of the cross and of the weight stack plates. Repair and/or replace any worn components.

2. Check the condition of the chrome plating of the weight stack rods. Repair and/or replace any worn parts.

3. Check the state of wear of the weight stack rods and the weight stack rest pads. Repair and/or replace any worn parts.

4. Check the fixing of the weight stack rods. Repair and/or replace any worn parts. 5. Using a paper towel slightly moistened with ethyl alcohol, wipe the weight stack rods and the

forks of the weight doubling mechanism to remove any dust and deposits.

ATTENTION: remove any surface rust using a steel wool pad. 6. Lubricate the rods and bushings of the weight stack plates and cross using the oil provided in

the service box.

6.2.3. CHECKING THE ELASTIC BANDS 1. Check the state of wear of the elastic bands on the machine, paying particular attention to any

hardened areas or cracks in the plastic cable shield. Replace any worn parts.

6.2.4. CHECKING THE VARIOUS RUBBER PARTS

These operations are applied to the padding of the shoulder rest, handles, platforms and feet.

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

parts.


6.3. TWICE-YEARLY MAINTENANCE OPERATIONS

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

The twice-yearly maintenance operations involve checking the operation, wear and tension of the mechanical components so as to ensure perfect and safe operation of the machine. For the twice-yearly maintenance of the machine, proceed as follows:

6.3.1. SETTING UP THE OPERATION 1. Open the machine guards.

6.3.2. CARRYING OUT THE ROUTINE MAINTENANCE PROCEDURE 1. Carry out the procedure described in paragraph 6.2. “Monthly maintenance operations”

6.3.3. CHECKING THE PULLEYS 1. Check the state of wear of the pulley races. Repair and/or replace any worn parts.

6.3.4. CHECKING THE CLAMPING OF SCREWS AND BOLTS 1. Check that the screws and bolts are securely clamped, particularly those of the weight stack,

seat adjustments and in general wherever there are moving parts. Lock down any loose components.

6.3.5. REPLACING THE CABLES 1. Replace the machine cables once a year in the case of intensive use of the machine, or every 2

years in the case of normal use.

6.3.6. CHECKING THE WEIGHT STACK CROSS ALIGNMENT 1. With no weight selected, lift up the cross. Check that the selector shaft is correctly centered on

the holes of the plates and that the selector pin can slide easily in to select all the weight stack plates. Manually center the shaft.

Pagina 6.3


Pagina 6.4



7. FUNCTIONAL TESTS Every time maintenance and/or repairs are performed on a machine, it is necessary to carry out a series of mechanical tests to ensure: • that the medical device is working properly; • that the medical device is working safely; • that the exercises are performed according to the biomedical specifications for which the

medical device was designed.

7.1. WEIGHT STACK CABLE ASSEMBLY TEST

Make sure the weight stack cable is properly assembled, ensuring that: • all grub screws of the cable clamp pins have been firmly tightened, selecting the maximum load

and performing one or two repetitions; • all pulleys on which the cable slides have been fastened correctly, by selecting the weight stack

plate n°10 with the doubling lever in position 2 and performing about ten repetitions, making sure that the various pulleys do not make any unusual noises;

• the cable is properly mounted, passing it through all of the pulleys in the correct order, by selecting the weight stack plate n°10 with the doubling lever in position 2 and performing about ten repetitions, making sure it moves smoothly and silently.

• That the tension and length of the cable have been properly adjusted according to the procedures illustrated in chapter 8 of this manual.

7.2. HOUSING ASSEMBLY TEST

Make sure the machine housing is properly assembled, checking that all guards have been mounted correctly, as described in the procedures in chapter 7 of this manual, so that no part of the machine remains unprotected and a possible cause of user accident and injury.

7.3. MECHANICAL RESISTANCE DEVICE ASSEMBLY TEST

Make sure the mechanical resistance devices are properly assembled, such as: • Weight stack: make sure that all plates in the weight stack may be selected using the pin, and

perform around ten repetitions by selecting the weight stack plate n°10 with the doubling lever in position 2;

• Rubber bands: make sure that the rubber bands may be included and excluded without problems, using the 4 knobs on the front of the machine.

Incorrect assembly or adjustment of the various devices could lead to user accidents and injury, or cause non-compliance with the biomedical specifications of the machine when used.

Pagina 7.1


Pagina 7.2



8. APPENDIX

8.1. LIST OF CRITICAL SPARE PARTS

The machine is not composed by any critical spare parts.

Pagina 8.1


Pagina 8.2

8.2. TOOLS TO BE USED

The following tools are required for carrying out the various disassembly, adjustment and maintenance action on the machine: • Medium Phillips screwdriver; • 8-mm wrench; • 17-mm wrench; • 22-mm wrench; • 3-mm Allen T-wrench; • 4-mm Allen T-wrench; • 6-mm Allen T-wrench; • 8-mm Allen T-wrench; • T25 Torx wrench; • Circlip pliers. ATTENTION: The tool sizes are expressed in mm.


9. VARIO PULLEY IFI The IFI machine differs from the standard version as follows: • It does not have an elastic resistance system, and so the knobs for inserting the elastics (see

Photo 9-1) are not installed. • There is a warning sticker on the handle assembly positioning system (see Sticker 1). • The sticker for the adjusting rod has raised yellow writing on a black background (see Sticker

2). • The sticker for the weight stack has raised yellow writing on a black background (see Sticker 3). • The sticker for weight doubling mechanism has raised yellow writing on a black background

(see Sticker 4).

Photo 9-1

Sticker 3

Sticker 2

Sticker 4

Sticker 1

Pagina 9.1


Pagina 9.2


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

47035 Gambettola (FC) ITALIA

Tel.: +39-0547-650638 Fax: +39-0547-650150

e-mail: [email protected]

0SM00299AA-UK

mailto:[email protected]

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