Caloo CV-606 User manual
CV-606 STEPPER
Variable Resistance Equipment
INSTRUCTION MANUAL
Caloo Ltd
CALOO LTD
Unit 9A, Triangle Business Park, Wendover Road, Stoke Mandeville,
Buckinghamshire, HP22 5BL.
www.caloo.co.uk | 01296 614448 | [email protected]
INSTRUCTION MANUAL
Model No.: CV-606 Stepper
Caloo Ltd
Thank you for purchasing our product.
Please read this instructions before installing and exercising, and keep it for future reference.
Failure to follow instructions may cause injury to you.
WARNING
1. This unit is intended for youths and adults or users having an overall height greater than 1
400 mm.
2. Before beginning any fitness program, obtain a complete physical examination from your
physician.
3. Do not overexercise. If you feel any painful sensation or have abnormal symptoms, stop your
workout immediately and consult your physician.
4. Maximum allowed weight of a user is 150 kg. Maximum allowed number of user is one
person. Other user is prohibited to enter the training zone while the unit is in use.
STEPPER
CV-606
INSTRUCTION:
1. Place both of your feet on the pedals and grip
the handles.
2. Move the pedals up and down in a smooth
motion to simulate walking up stairs.
3. Turn the dial clockwise or anticlockwise to
increase or decrease your exercise difficulty.
FUNCTION:
Improves leg muscle strength and the coordination
of upper and lower body.
Safety Standard EN16630:2015
Year of Production To be completed at time of manufacture.
Manufacturer Caloo Ltd.
Address Unit 12, Boxted Farm, Berkhamsted
Road, Hemel Hempstead, HP1 2SG
Contact 01442 265489
INSTALLATION
Model No.: CV-606 Stepper
Product Size: 965 x 379 x 1437 mm
Free Height of Fall:450 mm
Net Weight: 91.3 kg
1. DATA SHEET
Caloo Ltd
INSTALLATION
Model No.: CV-606 Stepper
2. IMPACT AREA AND TRAINING SPACE
Area Size: 3969mm x 3381mm, 11 m2,
Required Surface: Any
Caloo Ltd
1500
1500
1500
R1500
3381
3969
3.1 MOUNTING AREA HAS NO CONCRETE SURFACE
For this type of mounting area, a concrete block is needed. All dimensions in mm.
INSTALLATION
Model No.: CV-606 Stepper
Caloo Ltd
3. FOUNDATION OPTIONS
①pylon foundation
①
A
260
50
500
600
INSTALLATION
Model No.: CV-606 Stepper
Caloo Ltd
A: Pylon Foundation Bolts
1. Make the concrete block according to above drawings
2. Embed 4 foundation bolts into the concrete block.
3. Wait for the concrete block to cure completely. Recommended curing time: 48 hours.
A: Pylon Expansion Bolts
1. Make sure the concrete surface is clean and flat.
2. Drill 4 expansion bolt holes with a concrete hammer accoring to above drawing.
3. Use a hammer to mount the expansion bolts into the concrete ground.
A
3.2 MOUNTING AREA HAS CONCRETE SURFACE
180
260
600
600
Caloo Ltd
INSTALLATION
Model No.: CV-606 Stepper
This fitness unit has been factory aligned and tested before shipment. But it is still highly
recommended that the unit has a thorough checking before mounting.
4.1 SPARE PARTS IN PACKAGE
4.2 UNPACKING AND CHECKING
1. Take off the protective foam films around the product. Do not use sharp objects to cut off
the films in case the unit surface might be scratched.
2. Place the unit on a flat and clean surface.
3. Check for cracks or open areas in the painted coating.
4. Check the dial on the pylon. Turn the dial clockwise or anticlockwise to see if the turning is
smooth.
5. Check the screws and bolts. All the screws and bolts should have been be tightened and
covered with caps unless the screws have a half round head.
6. Check the plastic pipe caps.
7. Check the plastic grips and/or pedals.
8. Contact your dealer and do not mout the unit if a defect is spotted.
Never mount or even operate the unit until all the checking process has finished and no defe-
acts have been found.
4. PRE-MOUNTING
3.1
No. Desc. Qty
A pylon foundation bolt 4
3.2
No. Desc. Qty
A pylon expansion bolt 4
Caloo Ltd
INSTALLATION
Model No.: CV-606 Stepper
1. Place the unit on a flat and solid ground surface.
2. Loose and unfix the screws on each side panel. There are 12 screws on each side panel.
3. Disassemble the side panels from the unit.
4. Place the unit onto the mounting surface. As shown above.
5. Tighten the foundation bolts or the expansion bolts. Use a socket set and straight bar
to tighten fully. Please note: a set of grips or adjustable spanner will not tighten fully.
6. Assemble the side panels and tighten the Anti-theft screws.
Make sure the checking process has finished before mounting.
5. MOUNTING
After all the mounting process is done, the unit needs to go through another thorough
checking and testing before it’s open to use.
6.1 SETTING UP AND CHECKING
1. Dust and clean the whole fitness unit.
2. Check for cracks or open areas in the painted coating.
3. Check the dial on the pylon. Turn the dial clockwise or anticlockwise to see if the turning is
smooth.
4. Check the screws and bolts. All the screws and bolts should have been be tightened and
covered with caps unless the screws have a half round head.
5. Check the plastic pipe caps.
6. Check the plastic grips and pedals.
6.2 TESTING
1. Make sure all the screws and bolts have been tightened before testing.
2. Place both of your feet on the pedals and grip the handles.
3. Move the pedals up and down and check if the movement is sooth and consistent.
4. Turn the dial clockwise or anticlockwise and check if the workout difficulty can be adjust-
ed.
5. The stepper is ready to use when all the testing has finished and no defects have been
found.
6. Should there be any malfunction, contact your dealer.
Caloo Ltd
INSTALLATION
Model No.: CV-606 Stepper
6. POST-MOUNTING
7. CIRCUIT DIAGRAM
Caloo Ltd
DIAGRAM
Model No.: CV-606 Stepper
Y
Q1
Q2
Q3
GR R R
Dial
30A-23V
*Design is subject to change without notice.
Bridge Rectifier
160A
self excited generator
300W 24V
variable resistor
Caloo Ltd
DIAGRAM
Model No.: CV-606 Stepper
8. EXPLODED VIEW
2
4
5
63
1
C
7
8
32
31
33
34
36
37
38
39
48
47
42
43 46
44 45
41
40
C
7
8
9
12
10
11
19
18
14
17
16
15
13
20
27
21
26
36
34
22 23 24 25
A
A
28
53
35
B
B
54
55
56
57
58
59
60
53
52
51
49
62
Caloo Ltd
DIAGRAM
Model No.: CV-606 Stepper
9. SPARE PARTS LIST
Part No. Description Specification Size(mm) Quantity Material
1 Pylon Weldment
1-1 Pylon Front 4T 1146*260 1 SS400
1-2 Pylon Back 4T 1278*260 1 SS400
1-3 Pylon Middle 6T 1270*355 1 SS400
1-4 Pylon Front Top 3T 321*230 1 SS400
1-5 Pylon Base Plate 8T 295*450 1 SS400
1-6 Connecting Shackle Plate 6T 44*52 4 SS400
1-7 Seat Side Plate 8T 108*55 4 SS400
1-8 Seat Connecting Plate 6T 30.5*69 4 SS400
2 Pylon Left Panel 2T 1263*353 1 SS400
3 Pylon Right Panel 2T 1263*352 1 SS400
4 Hexagon Socket Button Head Screw M8 20 24 SS
5 Instruction Panel 2T 314*224 1 UV PLATE
6 Instruction Cover 2T 341*238 1 SS400
7 Connecting Plate 6T 40*185 2 SS400
8 Connecting Plate 6T 40*185 2 SS400
9 Rectangle Shackle Plate Weldment 1
9-1 Rectangle Shackle Left Sleeve Φ40 31 1
45＃
9-2 Rectangle Shackle Right Sleeve Φ48 36 1 ZG200
9-3 Connecting Plate 8T 30*30 1 SS400
10 Closing Ring 28 8
11 Bearing 6902 4
12 Shaft Φ15 66 4
45＃
13 Handle Grip 2 PE
14 Handle Weldment 1
14-1 Main Shackle Φ48*3 1 Q195
14-2 Handle Φ28*3 350 1 Q195
14-3 Connecting Plate 8T 110*110 1 SS400
15 Dial 1050
16 Screw M4 10 5
17 Switch 1
18 Bearing 6205 4
19 Connecting Shackle Φ25 200 1
45＃
20 Pedal Support Weldment L 1
20-1 Square Pipe 50*50*3 2 Q235
20-2 Pedal Plate 4T 317*130 2 Q235
20-3 Sleeve Φ60*6 65 2 Q195
20-4 Sleeve Φ40*10 31 2
45
＃
20-5 Link Pipe Φ28*3 79 2 Q195
20-6 Connecting Shackle Plate 6T 44*52 4 SS400
21 Pedal Support Weldment R 1
22 Anti-Theft Cap Socket 24 PP
23 Flat Washer Φ10 6 Q235
24 Self-Locking Nut M10 6 304
25 Anti-Theft Cap 24 PP
26 Pedal 327*140 2 ABS
27 Spacing Sleeve Φ38*6 35 1 Q195
28 Bolt M10 25 12 304
31 Hexagon Bolt M10 20 8 Q235
Caloo Ltd
DIAGRAM
Model No.: CV-606 Stepper
Contact your dealer if you need to replace any part.
10. REPLACEMENT PARTS LIST
Part No. Description Specification Size(mm) Quantity Material
5 Instruction Panel 2T 314*224 1 UV PLATE
13 Handle Grip 2 PE
15 Dial 1050
22 Anti-Theft Cap Socket 24 PP
25 Anti-Theft Cap 24 PP
26 Pedal 327*140 2 ABS
34 Waterproof Washer 2 PE
57 Damper Φ34 25 2 PU
58 Damper Φ46 35 2 PA6
33 Drive Shaft 1
45＃
34 Waterproof Washer 2 PE
35 Synchronous Belt Wheel Large 1 Q235
36 6902 Bearing 6902 2
37 6204 Bearing 6204 6
38 6204 Unilateral Bearing 6204 1
39 Nut M12 2
40 Synchronous Belt Wheel Large 1 Q235
41 Synchronous Belt Wheel Small 1 Q235
42 Bolt M5 100 4
43 Generator Mounting Plate 6T 473*144 1 SS400
44 Generator 1
45 Synchronous Belt Wheel Small 1 Q235
46 Nut M5 4
47 Flat Washer Φ10 10
48 Generator Mounting Plate 6T 485*150 1 SS400
49 Synchronous Belt HTD720-8M 2
51 Nut M16 4
52 Flat Washer Φ16 4
53 Foundation Bolt M16 250 4 Q235
54 Cylinder Φ50*5 135 2 Q195
55 Bolt M8 20 2 304
56 Flat Washer Φ8 2
57 Damper Φ34 25 2 PU
58 Damper Φ46 35 2 PA6
59 Cylinder Cover Φ56 22 2
45＃
60 Piston Rod Φ20 132 2
45
＃
62 Dial Panel Φ63 8 1
45
＃
Caloo Ltd
MAINTENANCE
Model No.: all type
11. MAINTENANCE - to be carried out in conjunction with Caloo inspection and maintenance instructions.
11.1 ROUTINE VISUAL INSPECTION
Frequency of inspection: once a week.
For outdoor fitness unit installed in areas with intensive use, as well as in areas exposed to
frequent damage caused by vandalism, daily inspections are preferred.
■Dial
Turn the dial clockwise or anticlockwise and check if the workout difficulty is changed.
■Bolts and Screws
Over time some bolts may become loose through constant or heavy use, resulting in loose and
unstable structures. This can cause dangerous pinch, crush or shear points, and it is therefore
very important to check all nuts, bolts and screws periodically.
■Nut Cap, Bolt and Aluminium Pedal Inspection
Nut caps are used throughout Caloo Ltd fitness units to cover bolts heads and potentially
sharp bolt threads, except for the anti-theft screws which have a half round head.
1. When you check the nut cap covering a bolt, try to rotate the cap. If it rotates, the bolt needs
to be tightened.
2. To access the bolt, you need to remove the nut cap top: tap gently a screwdriver through the
cap top and pry it loose.
3. Tighten the bolt until the nut cap base is unable to rotate, or until the item is tight against its
support. Be careful not to over-tighten the bolt.
4. Replace the nut cap, bolts and Aluminium pedals if any corrosion is spotted.
■Plastic and Rubber Parts
Check and replace if necessary:
-Pipe caps, nut cap tops
-Rubber handle grips, pedals, seats
-Instruction panel
■Coating
Check for cracks or open areas in the painted coating, and seal with repair paint.
■Cleaning
Clean soiled areas on the fitness unit with soap and water. Pay particular attention to units
installed in areas with high level of salt spray.
11.2 OPERATIONAL INSPECTION
Frequency of inspection: once a quarter.
For outdoor fitness unit installed in areas with intensive use, as well as in areas exposed to
frequent damage caused by vandalism, monthly inspections are preferred.
1. Remove anything tied or added to the fitness unit, e.g. ropes, clothing, stickers etc.
2. Check the fitness unit for missing, loose or broken components.
Caloo Ltd
MAINTENANCE
Model No.: all type
3. Give extra attention to the units with moving parts.
4. Check all nut caps, bolts and Aluminium pedals, and replace if necessary.
5. Check the instruction panel and replace if the instruction printed on it is Illegible.
6. Inspect the coating. If cracks and signs of rust is found in the coating, use repair paint.
7. Check the stability of the fitness unit. If the station feels even slightly detatched from the
foundation, then check the foundation, and tighten or replace the anchorage to remove the unit.
Open the side panels to check the foundation.
8. Clean soiled areas on the fitness unit with soap and water. Pay particular attention to stations
installed in areas with high levels of salt spray.
9. Check the dial on the pylon. Turn the dial clockwise or anticlockwise to see if the turning is
smooth.
11.3 ANNUAL INSPECTION
Frequency of inspection: once a year
Open the side panel of the pylon and check the belts’ abrasion. Replace if necessary.
11.4 FAILURE
If a fitness unit or a component thereof requires replacement, and presents any safety concern,
steps must be taken to restrict access to the fitness facilities until the replacement is done.
Contact your dealer to deug any failure.
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