Matrix G7-S77-02 User manual

JOHNSON
Issue date
Edition
01
Doc No.
Revision
date
Edition time
Page
24
G7-S77-02
CALF EXTENSION
SERVICE MANUAL
Approval
Review
Editor
Allen Sun
Allen Sun
Hans Kong

CONTENTS
CHAPTER 1：SERIAL NUMBER LOCATION........................................................................................... 1
CHAPTER 2：MAINTENANCE & SAFETY................................................................................................2
CHAPTER 3:ASSEMBLY INSTRUCTION...................................................................................................4
CHAPTER 4：TROUBLESHOOTING......................................................................................................... 6
4.1 The Repetition Display Is Blank Or Is Not Counting Movements............................................. 6
4.2 Incremental Weight Pin Is Loose Or Feels Sloppy......................................................................8
4.3 Weight Stack Pin Will Not Go Into Some Or All Weight Plates................................................. 9
4.4 The Weight Stack Cable Is Falling Off A Pulley Or Cam.......................................................... 10
4.5 Repetition Magnet Has Fallen Off Or Is Missing........................................................................11
4.6 Rom Plunger Or Pull Pins Does Not Move Easily.....................................................................12
CHAPTER 5：PARTS REPLACEMENT................................................................................................... 13
5.1 Testing The Unit.............................................................................................................................. 13
5.2 Top Cover.........................................................................................................................................13
5.3 Repetition Counter......................................................................................................................... 14
5.4 Side Cover....................................................................................................................................... 15
5.5 Repetition Sensor........................................................................................................................... 16
5.6 Incremental Weight Pin..................................................................................................................17
5.7 Weight Plate.................................................................................................................................... 19
5.8 Weight Stack Pulley....................................................................................................................... 21
5.9 Head & Back & Seat Pad.............................................................................................................. 22
5.10 Adjustable Handle........................................................................................................................ 23
CHAPTER 6：PARTS LIST.........................................................................................................................24

1
CHAPTER 1：SERIAL NUMBER LOCATION

2
CHAPTER 2：MAINTENANCE & SAFETY
IMPORTANT SAFETY INFORMATION
It is the sole responsibility of the purchaser of MATRIX products to instruct all individuals, whether
they are the end user or supervising personnel on proper usage of the equipment.
It is recommended that all users of MATRIX exercise equipment be informed of the following
information prior to its use.
Do not use any equipment in any way other than designed or intended by the manufacturer. It is
imperative that MATRIX equipment be used properly to avoid injury.
INSTALLATION
STABLE AND LEVEL SURFACE: MATRIX exercise equipment must be installed on a stable base
and properly leveled.
SECURING EQUIPMENT: Manufacturer recommends that all stationary MATRIX strength
equipment be secured to the floor to stabilize equipment and eliminate rocking or tipping over. This
must be performed by a licensed contractor.
Under no circumstances should you slide equipment across the floor due to risk of tipping. Use
proper materials handling techniques and equipment recommended by OSHA. All anchor points
must be able to withstand 750 lbf. (3.3 kN) pull-out force.
MAINTENANCE
DO NOT use any equipment that is damaged and or has worn or broken parts. Use only
replacement parts supplied by your country’s local MATRIX dealer.
MAINTAIN LABELS AND NAMEPLATES: Do not remove labels for any reason. They contain
important information. If unreadable or missing, contact your MATRIX dealer for a replacement.
MAINTAIN ALL EQUIPMENT: Preventative maintenance is the key to smooth operating equipment
as well as keeping your liability to a minimum. Equipment needs to be inspected at regular
intervals.
Ensure that any person(s) making adjustments or performing maintenance or repair of any kind is
qualified to do so. MATRIX dealers will provide service and maintenance training at our corporate
facility upon request.
ADDITIONAL NOTES
This equipment should only be used in supervised areas where access and control is specifically
regulated by the owner. It is up to the owner to determine who is allowed access to this training
equipment. The owner should consider a user’s: degree of reliability, age, experience, etc.
This training equipment meets industry standards for stability when used for its intended purpose in
accordance with the instructions provided by the manufacturer.
This equipment is for indoor use only. This training equipment is a Class S product (designed for
use in a commercial environment such as a fitness facility). This training equipment is in
compliance with EN ISO 20957-1 and EN 957-2.

3
CHAPTER 2：MAINTENANCE & SAFETY
PROPER USAGE
1. Do not exceed weight limits of the exercise device.
2. If applicable, set safety stops to appropriate height.
3. If applicable, adjust seat pads, leg pads, foot pads, range of motion adjustment, or any other
type of adjustment mechanisms to a comfortable start position. Make certain that the adjusting
mechanism is fully engaged to prevent unintentional movement and to avoid injury.
4. Sit on bench (if applicable) and get into appropriate position for exercise.
5. Exercise using no more weight than you can safely lift and control.
6. In a controlled manner, perform exercise.
7. Return weight to its fully-supported start position.
TORQUE VALUES
TORQUE VALUES
M10 Bolt (Nyloc Nut & Flowdrill)
77Nm / 57lbf -ft
M8 Bolts
25Nm / 18lbf -ft
M8 Plastic
15Nm / 11lbf -ft
M6 Bolts
15Nm / 11lbf -ft
Pad Bolts
10Nm / 7lbf -ft
TOOLS REQUIRED FOR ASSEMBLY&MAINTENANCE(not included)

4
CHAPTER 3: ASSEMBLY INSTRUCTION

5
CHAPTER 3: ASSEMBLY INSTRUCTION

6
CHAPTER 4：TROUBLESHOOTING
4.1 THE REPETITION DISPLAY IS BLANK OR IS NOT COUNTING MOVEMENTS.
Possible Causes
1) The rep counter battery is dead or disconnected.
2) The rep counter is unplugged from the repetition sensors.
3) The magnet is missing or positioned incorrectly.
4) The repetition sensors are faulty or positioned incorrectly.
5) The rep counter is faulty.
Solution
1) Remove the 4 screws holding on the aluminum wing and top cover. Check that the battery for
the rep counter is firmly seated and has a charge. Replace the battery if needed.
2) Check the connection of the wiring coming from the repetition sensors to the rep counter
(Figure A).
3) Check that the magnet is present and in a position to be read by the repetition sensors (Figure
B). The magnet should be slightly off the center of the sensors.
4) If the rep counter displays a value, but is not counting repetitions, check the position of the
sensors. The sensors should be positioned depending on the model according to the chart on the
following page. If the rep sensors are positioned correctly and still not reading, replace the
repetition sensors (Figure C).(1000096531)
5) If the repetition sensors and battery have been replaced and the issue is still present, replace
the rep counter. (1000096514)

7
CHAPTER 4：TROUBLESHOOTING
4.1 THE REPETITION IS BLANK OR IS NOT COUNTING MOVEMENTS.

8
CHAPTER 4：TROUBLESHOOTING
4.2 INCREMENTAL WEIGHT PIN IS LOOSE OR FEELS SLOPPY
Possible causes
1) The snap ring holding the incremental weight pin in position is damaged or missing.
2) The incremental weight pin is damaged.
Solution
1) Remove the weight stack covers.
a. Remove the 4 screws holding the clear plastic cover over the incremental weight pin and
remove the clear plastic cover.
b. Check the incremental weight pin for damage, replace if needed. (1000398254)
2) Check if the snap ring and washer holding the incremental weight pin to the stack is in place
(Figure A & B).
a. If this snap ring is missing, install a new snap ring. (1000102910)
b. If the snap ring is in place, but not holding the incremental weight pin in place, it may not be
properly installed in the groove in the pin.
c. If the snap ring is in place and properly installed in the groove, but the pin is still loose, replace
the snap ring (the ring may be too stretched out to be affective).

9
CHAPTER 4：TROUBLESHOOTING
4.3 WEIGHT STACK PIN WILL NOT GO INTO SOME OR ALL WEIGHT PLATES
Possible Causes
1) The weight stack pin is bent.
2) The cable is attached too loosely or too tightly.
3) The weight plates are not seated correctly at the bottom of the guide rods.
4) The top weight plate bushings are damaged.
Solution
1) Check the weight stack pin for straightness. Replace if needed (Figure A).(1000398482)
2) Check the tightness of the cable. If the cable is too loose or too tight:
a. Remove the 4 screws holding down the aluminum wing and top cover. Detach the rep counter
wire and set aside the aluminum wing and top cover.
b. Loosen the 2 bolts holding the 2 pulleys in place at the top of the weight stack frame (Figure B).
NOTE: A short 8 mm Allen wrench may be needed for some models.
c. Rotate the 2 pulley assemblies to remove the slack from the cable, and then re-tighten the 2
pulley bolts.
3) Remove the clips holding the weight stack guide rods on the top frame (Figure C).
a. Lean the guide rods towards the unit frame and shake back and forth so that the weight plates
are seated at the bottom of the guide rods without any gap between plates.
4) Replace the top weight plate bushings. (1000408503)
FIGURE A
FIGURE B FIGURE C

10
CHAPTER 4：TROUBLESHOOTING
4.4 THE WEIGHT STACK CABLE IS FALLING OFF A PULLEY OR CAM
Possible Causes
1) The cable is too loose or too tight.
2) The cable is routed incorrectly.
Solution
1) Check the tightness of the cable. Make sure that it is tensioned properly.
2) Check the routing of the cable through the weight stack.
a. Make sure that the cable is not routed around a standoff in the weight stack frame (Figure A).
b. Follow the routing of the cable. The cable should be centered on pulleys and cams before
being tensioned.

11
CHAPTER 4：TROUBLESHOOTING
4.5 REPETITION MAGNET HAS FALLEN OFF OR IS MISSING
Possible Causes
1) The repetition counter magnet was not secured tightly enough to the repetition counter bracket.
Solution
1) Remove side covers and the 2 screws fixing the magnet frame (Figure A).
2) Install a zip tie to securely attach the magnet to the bracket (Figure B).
3) When installing the zip tie, make sure that the head of the zip tie is on the opposite side of the
bracket from the magnet so that the head does not interfere with the movement of the top weight
plate (Figure C).(1000232864)
Figure A
Figure B Figure C

12
CHAPTER 4：TROUBLESHOOTING
4.6 ADJUSTABLE HANDLE DOES NOT MOVE EASILY
Possible causes
1) The pins are rubbing on the frame creating friction.
Solution
1) Remove the affected pin, add grease (Matrix recommends Super Lube brand grease with PTFE)
and then re-install the pin.(1000401290)

13
CHAPTER 5：PARTS REPLACEMENT
5.1 TESTING THE UNIT
Once the unit or replacement part is fully installed and assembled and properly placed on the floor,
use the following instructions to test the machine:
NOTE: Not all of the replacement instructions will apply to every model.
1) Check that the weight stack pin will slide freely into the weight stack at all positions.
2) Check that the incremental weight pin is tight and moves freely.
3) Check that the cable is tight and properly routed.
4) Check that the seat moves freely and that the seat spring assists the user to move the seat into
a higher position.
5) Check all adjustment handles for function.
6) Check that the arms on the unit are even.
7) Check that the repetition counter is active and working properly.
5.2 TOP COVER
1) Remove the 4 screws going through the aluminum wing into the top cover of the weight stack
(Figure A).
2) Disconnect the repetition counter wire and remove the aluminum wing and top cover from the
weight stack (Figure B).
3) Remove the 4 screws attaching the aluminum wing to the top cover (Figure C).
4) Remove the aluminum wing from the top cover (Figure D).
5) Reverse Steps 1-4 to install a new top cover. (1000424165/1000397869)

14
CHAPTER 5：PARTS REPLACEMENT
5.3 REPETITION COUNTER
1) Remove the 4 screws going through the aluminum wing into the top cover of the weight stack
(Figure A).
2) Disconnect the repetition counter wire and remove the aluminum wing and top cover from the
weight stack (Figure B).
3) Remove the 2 screws attaching the repetition counter to the top cover (Figure C).
4) Remove the repetition counter from the top cover (Figure D).
5) Reverse Steps 1-4 to install a new repetition counter. (1000096514)

15
CHAPTER 5：PARTS REPLACEMENT
5.4 SIDE COVER
1) Remove the 4 screws going through the aluminum wing into the top cover of the weight stack
(Figure A).
2) Disconnect the repetition counter wire and remove the aluminum wing and top cover from the
weight stack (Figure B).
3) Pull up on each weight stack shroud and remove it from the weight stack frame (Figure C).
4) Figure D shows the weight stack with all 3 side covers removed.(098985/098988/
1000397883)
5) Reverse Steps 1-3 to install new side covers.

16
CHAPTER 5：PARTS REPLACEMENT
5.5 REPETITION SENSOR
1) Remove the 4 screws going through the aluminum wing into the top cover of the weight stack
(Figure A).
2) Disconnect the repetition counter wire and remove the aluminum wing and top cover from the
weight stack (Figure B).
3) Remove the side covers from the weight stack frame (Figure C).
4) Remove the 4 screws holding the repetition sensors to the weight stack frame (Figure D).
5) Remove the tie straps holding the repetition sensor wires in place, and remove the repetition
sensors.
6) Reverse Steps 1-5 to install new repetition sensors.(1000096531)

17
CHAPTER 5：PARTS REPLACEMENT
5.6 INCREMENTAL WEIGHT PIN
1) Remove the side covers as outlined in Section 5.4.
2) Remove the 4 screws holding on the clear plastic cover over the incremental weight pin and
remove it (Figures A & B).
3) Remove the 2 screws holding on the reaction block and remove it (Figures C & D).
4) Remove the snap ring holding the incremental weight pin to the top weight plate and remove the
incremental weight pin (Figures E, F, & G).
5) Reverse Steps 1-4 to install a new incremental weight pin.(1000398254)

18
CHAPTER 5：PARTS REPLACEMENT
5.6 INCREMENTAL WEIGHT PIN