Technical 04 Newsletter 09 - Technogym Direct · Technical Newsletter By: Technogym After Sales Service N. 103– July/August 2009 ... which is very similar in appearance to the one

Technical Newsletter

By: Technogym After Sales Service N. 103– July/August 2009

Technogym After Sales Service: e-mail: [email protected] - fax: +39-0547-650150

04 09

Contents Excite Line • New brake boards for self powered

machines Run Excite • Checking the current draw with the

"Manual inverter test" function • Improved coupling of rear guard and foot

rest VARIO Excite • Creaking noise during exercise Selection Line • Floor anchoring kit Element Line • Floor anchoring kit • Deterioration of "additional weight" guides • Pectoral: damage to cam travel stop

Easy Line • Abdominal/Back - Leg Extension/Leg Curl

New frame • Easy Lamp does not work if not connected

to the mains PURESTRENGTH • New stretching handle Kinesis Personal • Yellowing of exercise handle Free Weight Line • Loosening of GAxx dumbbells TGS Components • Freezing up of New Wellness Expert • Isocontrol installation manual Service Products • “ISOFLEX TOPAS L32” grease • “Kritox GPL 205” grease

Excite Line TN 2009/04 - 28 August 2009

2009/04

Contents • New brake boards for self powered machines

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New brake boards for self powered machines A new model of brake interface board is now available for self-powered machines. The new board, which is very similar in appearance to the one currently used on mains-powered machines, is housed in a plastic box rather than in a metal box as before, and requires a special cable for connection to the alternator and the battery. Like the preceding boards, the new brake boards will be supplied as replacement parts pre-programmed for the machine on which they are to be installed, using the specific codes shown below:

CODE DESCRIPTION R0005917AB New Bike/ New Recline SP R0006641AA Synchro 2009 SP R0002060AC Synchro SP R0002780AC Step SP R0005607AB Wave SP R0005608AB Top SP

The new boards are NOT interchangeable with the old ones. Installing them on machines previously equipped with the old version requires the following:

1. An adapter cable for connecting to the alternator and battery. The adapter cable is always supplied with the new board, when ordering the codes given above.

2. Carrying out the "Standard setting" procedure in the technical menu. The new brake boards do not require a specific high kit SW version to function correctly. The only drawback of using a version released before November 2008 (approx.) is that the low kit SW version will be incorrectly displayed by the specific function of the machine technical menu. In particular, the firmware versions of the new brake boards all have 4 digits, so if the version displayed is "253" it means that a new model of brake board is installed but the high kit SW version is unable to read it correctly.

Run Excite TN 2009/04 - 28 August 2009

2009/03

Contents

• 1BChecking the current draw with the "Manual inverter test" function

• Improved coupling of rear guard and foot rest

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Checking the current draw with the "Manual inverter test" function

Following the elimination of the encoder on the machine's tread-belt motor, please note the following changes to the "Manual inverter test" function in the troubleshooting menu. The test, which displays the inverter output drive values during movements of the tread belt motor, shows:

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• Speed • Current (x10) • Voltage During the test it is possible to vary the speed using the + and – speed keys, to check that the values vary accordingly. In case of errors related to high current consumption (such as E01), we recommend performing a test that consists of walking on the treadmill at a pre-established speed and checking the current consumption, according to the table below.

USER WEIGHT FREQUENCY/SPEED CURRENT DRAW

60 Kg 1500Hz / 5 Km/h 5 A 70 Kg 1500Hz / 5 Km/h 5.3 A 80 Kg 1500Hz / 5 Km/h 5.6 A

On models not equipped with an encoder, in which the speed readout is always "0", use the frequency value given in the table as a reference.

Improved coupling of rear guard and foot rest To correct and improve the coupling between the rear guard and the foot rest, the new solution described below has now been adopted, and can also be used on already installed machines.

Run Excite TN 2009/04 - 28 August 2009

2009/03

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Remove the last of the two foot rest fastener plates from the rear part of the frame, on either side.

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Insert a nut (ref. 1) cod. 0Z439, inside the rear guard, coinciding with the hole for the screw that secures the guard to the frame (on either side), as shown in the figure below. Use a couple of drops of Loctite to fix the nut to the guard.

Insert a lock washer cod. 0Z332 between the frame and the side panel as shown in the figure below, on the last fixing screw on the rear part of the machine (on either side).

VARIO Excite TN 2009/04 - 28 August 2009

2009/01

Contents • Creaking noise during exercise

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Creaking noise during exercise If a loud creaking sound is heard during exercise, this may be due to inadequate fixing of the center supporting foot.

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In particular, if the noise comes from the center foot, the problem is caused by the threaded insert situated inside the frame, into which the foot is screwed, which if not securely clamped drags against the frame producing noise. This problem, which concerns only the first machines produced, in which the insert was not optimally fixed, and which had a fork to prevent loosening of the screw rather than the lock nut currently in use, can be corrected as follows: 1. Remove the foot and disengage the fork ref. 1 (this will no longer be used).

2. Use an M10 screw (ref. 2) and an M10 nut (ref. 3) to lock down in place of the foot. Lock

down the screw through at least ten turns.

VARIO Excite TN 2009/04 - 28 August 2009

2009/01

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3. Bring the lock nut up against the frame of the machine, then hold the screw in place with the wrench ref. 4, and tighten the lock nut, continuing to exert force until a high resistance to tightening is felt. This will deform the threaded insert sufficiently to hold it securely inside the frame.

4. Remove the screw and replace it with the foot, using the lock nut as before to clamp the position of the foot once it has been adjusted.

Selection Line TN 2009/04 - 28 August 2009

2009/03

Contents • Floor anchoring kit

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Floor anchoring kit A new kit has been created for anchoring the Selection line machines to the floor.

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It consist of 4 plates that must be fixed under the feet of the machines, and then anchored to the floor. All the materials required for anchoring are included in the kit, complete with instructions for use. The order code for the kit is A0000471.

Element Line TN 2009/04 - 28 August 2009

2009/04

Floor anchoring kit

Contents

• • 6BDeterioration of "additional weight" guides

• Pectoral: damage to cam travel stop

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Floor anchoring kit Two kits have now been defined for anchoring the Element and Element + lines to the floor: one for Ercolina, Ercolina Rehab and Cable Cross, and another for all the other machines.

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The kits consist of 2 "U" shaped plates which are used for anchoring the machine frame to the floor. All the materials required for anchoring are included in the kit, complete with instructions for use. The order codes for the kits are given below: A0000472 to be used for Ercolina, Ercolina Rehab and Cable Cross (Cable Cross requires 2

kits). A0000494 to be used on all the other machines.

Deterioration of "additional weight" guides To avoid rapid wear of the additional weight guides, resulting from excessive friction of the additional weight against them, the distance between the two guides has been increased by 4 mm, and an additional weight support (ref. 1) is now also used that is likewise wider.

Element Line TN 2009/04 - 28 August 2009

2009/04

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This modification has been implemented starting from July 2009 on all the machines of the ELEMENT+ line that include an additional weight. From now on, only the wider version of the additional weight support, cod. 0N000971AC, will be available as a replacement part; assembling it on the machines that predate this modification requires use of a 1.5-2 mm spacer to be placed on the 4 side fixing screws of the additional weight support. One spacer recommended for this purpose is the one with code 0Z334.

Pectoral: damage to cam travel stop Due to recurrent and frequent damage to the limit stop on the cam of the right lever, a new limit stop has been introduced that consists of a rubber part (cod. 0B001820AA) and a fixing screw (cod. 0Z277), as illustrated in the figure below.

This solution is completely interchangeable with the old one, and has been adopted starting from the machine with SN: MB7009000202.

Easy Line TN 2009/04 - 28 August 2009

2009/02

Contents • Abdominal/Back - Leg Extension/Leg Curl New frame

• Easy Lamp does not work if not connected to the mains

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Abdominal/Back - Leg Extension/Leg Curl New frame To help the frame better withstand the bending stresses exerted on its welds during exercise, which may cause them to break, it has been strengthened in certain points most susceptible to these stresses. The codes of the new frames are given in the table below:

MACHINE CODE Abdominal/Back 0D002574AB-CH Leg Extension/Leg Curl 0D002608AE-CH The SN of the first machines produced with the new frames are: MC6509000211 (Abdominal/Back) MC3009000200 (Leg Extension/Leg Curl)

Easy Lamp does not work if not connected to the mains If the lamp fails to work when it is not connected to the electricity supply, we recommend checking the connecting cable of the batteries. In particular, due to a change in the supplier of the batteries used, the Fastons on the new model are tighter than those on the batteries used previously. As a result, the Fastons of the connecting cables do not make a good contact, but remain loose. Tighten the Fastons with a pair of pliers and check whether the lamp now functions correctly; if it doesn't, check that the batteries are not defective.

PURESTRENGTH Line TN 2009/04 - 28 August 2009

2009/01

Contents • New stretching handle

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New stretching handle

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stretching handle still used on the Wide Chest Press, Chest Press and Incline Chest Press machines.

The new handle, shown in the photo above, can be ordered using the following codes:

MACHINE CODE Wide Chest Press W0006182AA-NR Chest Press W0006188AA-NR Incline Chest Press W0006190AA-NR

Kinesis Personal TN 2009/04 - 28 August 2009

2009/04

Contents • Yellowing of exercise handle

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Yellowing of exercise handle To minimize the yellowing problem of the clear plastic handles on the machine, the process for producing the component and its material have been modified.

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The new handle, which can be ordered using the code 0G001013AB-K, has been introduced starting from the machine with SN MD05209000148.

Free Weight Line TN 2009/04 - 28 August 2009

2009/01

Contents • Loosening of GAxx dumbbells

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Loosening of GAxx dumbbells In the event of the dumbbells of the Free Weight line (GAxx) frequently working loose, first of all check that the dumbbell has been assembled according to the correct sequence illustrated below, depending on the model:

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The table below gives the correct quantities for each component:

PRODUCT CODE

Washer Ref. 1 (Q.ty)

Safety washer Ref. 2 (Q.ty)

Safety washer Ref. 3 (Q.ty)

Nord lock washer (NL 10 sp)

Ref. 4 (Q.ty)

Self locking Nut Ref. 5 (Q.ty)

GA04 2 - - 1 1

GA06 2 - - 1 1

GA08 1 - - 1 1

GA10 - 1 1 1 1

GA12 - 1 1 1 1

GA14 - 1 1 1 1

GA16 - 1 1 1 1

GA18 - 1 1 1 1

GA20 1 1 1 1 1

GA22 1 1 1 1 1

GA24 1 1 1 1 1

GA26 1 1 1 1 1

GA28 1 1 1 1 1

GA30 1 1 1 1 1

GA32 1 1 1 1 1

ATTENTION:

1. Apply some drops of Loctite 270 (green) before tightening the self locking nut (ref.5).

Free Weight Line TN 2009/04 - 28 August 2009

2009/01

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2. Lock down the self locking nut (ref.5) using a torque wrench set for 50 Nm / 37 Lb*ft

TGS Components TN 2009/04 - 28 August 2009

2009/04

Freezing up of New Wellness Expert Contents

• • Isocontrol installation manual

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Freezing up of New Wellness Expert The problem which caused the Wellness Expert to freeze up completely has been traced to the Touch Screen controller.

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To correct this fault, a recovery kit has been created which includes the new Galax controller board and the components necessary for its installation, including an instruction sheet. It is also necessary to update the drivers for the controller. Those for the Galax can be downloaded from the Technogym Direct (www.tgdirect.technogym.com) website, in the “Product version” section, among the SW for the New Wellness Expert, complete with installation instructions.

The kit can be ordered with code R0006628AA.

Isocontrol installation manual The updated version of the Isocontrol installation manual for both the Selection and Element lines is available for download in the “Technical info Manuals” section of the Technogym Direct (www.tgdirect.technogym.com) website.

Service Products TN 2009/04 - 28 August 2009

2009/02

Contents • “ISOFLEX TOPAS L32” grease • “Kritox GPL 205” grease

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“ISOFLEX TOPAS L32” grease A 90-gram pack of “ISOFLEX TOPAS L32” lubricant grease (with viscosity 14. 5mm2/s ) is available with order code 0V000469AA.

“Kritox GPL 205” grease A 57-gram pack of “Kritox GPL 205” grease is available with order code 0V000476AA. It is necessary to use this grease on the belts of the VARIO Excite machine, as described in the machine's manual.