Technogym BIOSTRENGTH LINE User manual

SERVICE & MAINTENANCE MANUAL
REV. 2.1

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 and 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 Biostrength™ trademark is property of Technogym S.p.A.

BIOSTRENGTH LINE: Service & Maintenance manual - rev. 2.1
Page i
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 SPECIFICATIONS .......................................................................................................................2.1
2.1. MECHANICAL CHARACTERISTICS ......................................................................................................................2.1
2.1.1. Abdominal Crunch................................................................................................................................2.1
2.1.2. Lower Back ...........................................................................................................................................2.1
2.1.3. Leg Extension .......................................................................................................................................2.2
2.1.4. Leg Curl................................................................................................................................................2.2
2.1.5. Vertical Traction...................................................................................................................................2.2
2.1.6. Shoulder Press......................................................................................................................................2.3
2.1.7. Chest Press ...........................................................................................................................................2.3
2.1.8. Rowing Torso........................................................................................................................................2.3
2.1.9. Leg Press ..............................................................................................................................................2.4
2.2. ELECTRICAL CHARACTERISTICS ........................................................................................................................2.4
2.3. AMBIENT SPECIFICATIONS.................................................................................................................................2.5
2.4. CONFORMITY TO REGULATIONS ........................................................................................................................2.5
2.5. UNIFIED BOARD VERSION ..................................................................................................................................2.6
2.5.1. Type 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 wiring diagram .......................................................................................................................2.41
2.6.3. Type C wiring diagram.......................................................................................................................2.50
2.6.4. Type D wiring diagram.......................................................................................................................2.59
3. OPERATING PRINCIPLE ...................................................................................................................................3.1
3.1. BLOCK DIAGRAM ..............................................................................................................................................3.1
3.1.1. Power Entry..........................................................................................................................................3.2
3.1.2. Power Switch ........................................................................................................................................3.2
3.1.3. Fuses.....................................................................................................................................................3.2
3.1.4. Filter .....................................................................................................................................................3.2
3.1.5. Voltage selector board..........................................................................................................................3.2
3.1.6. Power supply ........................................................................................................................................3.2
3.1.7. Transformer ..........................................................................................................................................3.2
3.1.8. Display..................................................................................................................................................3.3
3.1.9. Bio Servo Board....................................................................................................................................3.3
3.1.10.LP driver board ....................................................................................................................................3.4
3.1.11.Wire encoder.........................................................................................................................................3.5
3.1.12.Solenoid ................................................................................................................................................3.5
3.1.13.Weight stack motor ...............................................................................................................................3.5
3.1.14.Seat motor.............................................................................................................................................3.5
3.1.15.LP seat motor........................................................................................................................................3.6
3.1.16.Zero sensor ...........................................................................................................................................3.6
3.1.17.Safety device .........................................................................................................................................3.6
3.2. SOLENOID MANAGEMENT..................................................................................................................................3.8
3.2.1. Mechanics.............................................................................................................................................3.8
3.2.2. Controls ................................................................................................................................................3.8

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3.2.3. The signals involved .............................................................................................................................3.9
3.3. WEIGHT STACK MOTOR MANAGEMENT ...........................................................................................................3.12
3.3.1. Mechanics...........................................................................................................................................3.12
3.3.2. Controls ..............................................................................................................................................3.13
3.3.3. The signals involved ...........................................................................................................................3.14
3.4. SEAT MOTOR MANAGEMENT ...........................................................................................................................3.18
3.4.1. Mechanics...........................................................................................................................................3.18
3.4.2. Controls ..............................................................................................................................................3.18
3.4.3. The signals involved ...........................................................................................................................3.20
3.5. SEAT MOTOR MANAGEMENT FOR LEG PRESS ..................................................................................................3.24
3.5.1. Mechanics...........................................................................................................................................3.24
3.5.2. Controls ..............................................................................................................................................3.24
3.5.3. The signals involved ...........................................................................................................................3.26
3.6. WIRE ENCODER MANAGEMENT .......................................................................................................................3.30
3.6.1. Mechanics...........................................................................................................................................3.30
3.6.2. Controls ..............................................................................................................................................3.30
3.6.3. The signals involved ...........................................................................................................................3.30
4. ACCESSORIES......................................................................................................................................................4.1
5. INSTALLATION INSTRUCTIONS ....................................................................................................................5.1
5.1. SPECIFICATIONS AND REQUIREMENTS ...............................................................................................................5.1
5.2. INSTALLATION ..................................................................................................................................................5.1
5.3. FIRST POWER-ON...............................................................................................................................................5.1
6. TROUBLESHOOTING.........................................................................................................................................6.1
6.1. MANUAL COMPONENTS TEST ...........................................................................................................................6.2
6.1.1. Weight stack motor ...............................................................................................................................6.2
6.1.2. Zero sensor status .................................................................................................................................6.3
6.1.3. Seat motor.............................................................................................................................................6.4
6.1.4. Solenoid ................................................................................................................................................6.5
6.2. AUTOMATIC COMPONENTS TEST .......................................................................................................................6.7
6.2.1. Monitoring communication between the Bio servo board and the CPU board....................................6.7
6.2.2. Counter display.....................................................................................................................................6.8
6.3. RESET 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 PROCEDURE DURING USE........................................................................................................................6.14
6.4.1. Weight stack motor failure..................................................................................................................6.14
6.4.2. Seat motor test ....................................................................................................................................6.14
6.5. THE LCD DISPLAYS THE MESSAGE “HW FAULT: CHECK BATTERY” ...............................................................6.16
6.6. THE LCD DISPLAYS THE MESSAGE “HW FAULT: CHECK TGS” ......................................................................6.17
6.7. THE LCD DISPLAYS THE MESSAGE “HW FAULT: CHECK FPGA”....................................................................6.19
6.8. THE LCD DISPLAYS THE MESSAGE “ADD-ON WEIGHT PROBLEM = MAGNET”..................................................6.20
6.9. THE LCD DISPLAYS THE MESSAGE “WEIGHT STACK PROBLEM = FAIL” ..........................................................6.24
6.10.THE LCD DISPLAYS THE MESSAGE “WEIGHT STACK PROBLEM = MOTOR”......................................................6.25
6.11.THE LCD DISPLAYS THE MESSAGE “WEIGHT STACK PROBLEM = ENCODER” ..................................................6.28
6.12.THE LCD DISPLAYS THE MESSAGE “WEIGHT STACK PROBLEM = LIMIT SWITCH SENSOR”...............................6.30
6.13.THE LCD DISPLAYS THE MESSAGE “SEAT PROBLEM = FAIL” ..........................................................................6.32
6.14.THE LCD DISPLAYS THE MESSAGE “EMERGENCY ACTIVATED” ......................................................................6.33
6.15.THE LCD DISPLAYS THE MESSAGE “SEAT PROBLEM = MOTOR”......................................................................6.35
6.15.1.For Leg Press .....................................................................................................................................6.35
6.15.2.For Leg Extension, Leg Curl, Vertical Traction, Shoulder Press, Chest Press and Rowing Torso....6.38
6.16.THE LCD DISPLAYS THE MESSAGE “SEAT PROBLEM = ENCODER” ..................................................................6.40

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6.16.1.For Leg Press .....................................................................................................................................6.40
6.16.2.For Leg Extension, Leg Curl, Vertical Traction, Shoulder Press, Chest Press and Rowing Torso....6.43
6.17.THE DISPLAY DOES NOT TURN ON ...................................................................................................................6.45
6.18.THE MACHINE DOES NOT READ THE TGS: THE RED LED ON THE KEY READER IS NOT LIT ..............................6.50
7. DISASSEMBLY OF COMPONENTS .................................................................................................................7.1
7.1. ABDOMINAL CRUNCH .......................................................................................................................................7.1
7.1.1. Disassembling the display ....................................................................................................................7.1
7.1.2. Removing the electronic display boards...............................................................................................7.2
7.1.3. Removing the EPROM..........................................................................................................................7.4
7.1.4. Disassembling the TLCBR chip ............................................................................................................7.5
7.1.5. Disassembling the main keyboard ........................................................................................................7.6
7.1.6. Disassembling the plexiglas weight stack guard ..................................................................................7.7
7.1.7. Disassembling the weight stack pulleys................................................................................................7.8
7.1.8. Disassembling the weight stack cover ..................................................................................................7.9
7.1.9. Disassembling the additional weight..................................................................................................7.11
7.1.10.Disassembling the encoder .................................................................................................................7.12
7.1.11.Disassembling the solenoid ................................................................................................................7.13
7.1.12.Disassembling the selector brush .......................................................................................................7.14
7.1.13.Disassembling the zero sensor............................................................................................................7.15
7.1.14.Disassembling the weight stack selection system................................................................................7.16
7.1.15.Disassembling the weight stack selection chain .................................................................................7.17
7.1.16.Disassembling the weight stack motor................................................................................................7.18
7.1.17.Disassembling the cross stops ............................................................................................................7.19
7.1.18.Disassembling the cross......................................................................................................................7.20
7.1.19.Disassembling the sinker ....................................................................................................................7.21
7.1.20.Disassembling the weight 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 electrical box .........................................................7.26
7.1.25.Disassembling the bell guard .............................................................................................................7.28
7.1.26.Disassembling the weight stack frame guard .....................................................................................7.29
7.1.27.Disassembling the weight stack cable.................................................................................................7.30
7.1.28.Disassembling the bell ........................................................................................................................7.31
7.1.29.Disassembling the primary shaft - secondary shaft chain ..................................................................7.32
7.1.30.Disassembling the primary shaft ........................................................................................................7.33
7.1.31.Disassembling the secondary shaft.....................................................................................................7.35
7.1.32.Disassembling the weight stack frame pulley .....................................................................................7.37
7.1.33.Disassembling the mat ........................................................................................................................7.38
7.1.34.Disassembling the power entry...........................................................................................................7.39
7.1.35.Disassembling the starter plate and fuses ..........................................................................................7.40
7.2. LOWER BACK..................................................................................................................................................7.41
7.2.1. Disassembling the display ..................................................................................................................7.41
7.2.2. Removing the electronic display boards.............................................................................................7.42
7.2.3. Removing the EPROM........................................................................................................................7.44
7.2.4. Disassembling the TLCBR chip ..........................................................................................................7.45
7.2.5. Disassembling the main keyboard ......................................................................................................7.46
7.2.6. Disassembling the plexiglas weight stack guard ................................................................................7.47
7.2.7. Disassembling the weight stack pulleys..............................................................................................7.48
7.2.8. Disassembling the weight stack cover ................................................................................................7.49
7.2.9. Disassembling the additional weight..................................................................................................7.51
7.2.10.Disassembling the encoder .................................................................................................................7.52
7.2.11.Disassembling the solenoid ................................................................................................................7.53
7.2.12.Disassembling the selector brush .......................................................................................................7.54
7.2.13.Disassembling the zero sensor............................................................................................................7.55
7.2.14.Disassembling the weight stack selection system................................................................................7.56
7.2.15.Disassembling the weight stack selection chain .................................................................................7.57

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7.2.16.Disassembling the weight stack motor................................................................................................7.58
7.2.17.Disassembling the cross stops ............................................................................................................7.59
7.2.18.Disassembling the cross......................................................................................................................7.60
7.2.19.Disassembling the sinker ....................................................................................................................7.61
7.2.20.Disassembling the weight stack plates................................................................................................7.62
7.2.21.Disassembling the bars.......................................................................................................................7.63
7.2.22.Disassembling the seat guard.............................................................................................................7.64
7.2.23.Disassembling the electrical box ........................................................................................................7.65
7.2.24.Disassembling the electronic components of the electrical box .........................................................7.66
7.2.25.Disassembling the bell guard .............................................................................................................7.68
7.2.26.Disassembling the weight stack frame guard .....................................................................................7.69
7.2.27.Disassembling the weight stack cable.................................................................................................7.70
7.2.28.Disassembling the release lever cable................................................................................................7.71
7.2.29.Disassembling the bell ........................................................................................................................7.73
7.2.30.Disassembling the primary shaft - secondary shaft chain ..................................................................7.74
7.2.31.Disassembling the primary shaft ........................................................................................................7.75
7.2.32.Disassembling the secondary shaft.....................................................................................................7.77
7.2.33.Disassembling the weight stack frame pulley .....................................................................................7.79
7.2.34.Disassembling the mat ........................................................................................................................7.80
7.2.35.Disassembling the power entry...........................................................................................................7.81
7.2.36.Disassembling the starter plate and fuses ..........................................................................................7.82
7.3. LEG EXTENSION..............................................................................................................................................7.83
7.3.1. Disassembling the display ..................................................................................................................7.83
7.3.2. Removing the electronic display boards.............................................................................................7.84
7.3.3. Removing the EPROM........................................................................................................................7.86
7.3.4. Disassembling the TLCBR chip ..........................................................................................................7.87
7.3.5. Disassembling the main keyboard ......................................................................................................7.88
7.3.6. 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
7.3.10.Disassembling the additional weight..................................................................................................7.94
7.3.11.Disassembling the encoder .................................................................................................................7.95
7.3.12.Disassembling the solenoid ................................................................................................................7.96
7.3.13.Disassembling the selector brush .......................................................................................................7.97
7.3.14.Disassembling the zero sensor............................................................................................................7.98
7.3.15.Disassembling the weight stack selection system................................................................................7.99
7.3.16.Disassembling the weight stack selection chain ...............................................................................7.100
7.3.17.Disassembling the weight stack motor..............................................................................................7.101
7.3.18.Disassembling the cross stops ..........................................................................................................7.102
7.3.19.Disassembling the cross....................................................................................................................7.103
7.3.20.Disassembling the sinker ..................................................................................................................7.104
7.3.21.Disassembling the weight stack plates..............................................................................................7.105
7.3.22.Disassembling the bars.....................................................................................................................7.106
7.3.23.Disassembling the seat guard...........................................................................................................7.107
7.3.24.Disassembling the seat motor ...........................................................................................................7.108
7.3.25.Disassembling the electrical box ......................................................................................................7.110
7.3.26.Disassembling the electronic components of the electrical box .......................................................7.111
7.3.27.Disassembling the bell guard ...........................................................................................................7.113
7.3.28.Disassembling the weight stack frame guard ...................................................................................7.114
7.3.29.Disassembling the weight stack cable...............................................................................................7.115
7.3.30.Disassembling the bell ......................................................................................................................7.116
7.3.31.Disassembling the primary shaft - secondary shaft chain ................................................................7.117
7.3.32.Disassembling the primary shaft ......................................................................................................7.118
7.3.33.Disassembling the secondary shaft...................................................................................................7.120
7.3.34.Disassembling the weight stack frame pulley ...................................................................................7.122
7.3.35.Disassembling the mat ......................................................................................................................7.123
7.3.36.Disassembling the power entry.........................................................................................................7.124

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7.3.37.Disassembling the starter plate and fuses ........................................................................................7.125
7.4. LEG CURL .....................................................................................................................................................7.126
7.4.1. Disassembling the display ................................................................................................................7.126
7.4.2. Removing the electronic display boards...........................................................................................7.127
7.4.3. Removing the EPROM......................................................................................................................7.129
7.4.4. Disassembling the TLCBR chip ........................................................................................................7.130
7.4.5. Disassembling the main keyboard ....................................................................................................7.131
7.4.6. Disassembling the seat keyboard......................................................................................................7.132
7.4.7. Disassembling the plexiglas weight stack guard ..............................................................................7.133
7.4.8. Disassembling the weight stack pulleys............................................................................................7.134
7.4.9. Disassembling the weight stack cover ..............................................................................................7.135
7.4.10.Disassembling the additional weight................................................................................................7.137
7.4.11.Disassembling the encoder ...............................................................................................................7.138
7.4.12.Disassembling the solenoid ..............................................................................................................7.139
7.4.13.Disassembling the selector brush .....................................................................................................7.140
7.4.14.Disassembling the zero sensor..........................................................................................................7.141
7.4.15.Disassembling the weight stack selection system..............................................................................7.142
7.4.16.Disassembling the weight stack selection chain ...............................................................................7.143
7.4.17.Disassembling the weight stack motor..............................................................................................7.144
7.4.18.Disassembling the cross stops ..........................................................................................................7.145
7.4.19.Disassembling the cross....................................................................................................................7.146
7.4.20.Disassembling the sinker ..................................................................................................................7.147
7.4.21.Disassembling the weight stack plates..............................................................................................7.148
7.4.22.Disassembling the bars.....................................................................................................................7.149
7.4.23.Disassembling the seat guard...........................................................................................................7.150
7.4.24.Disassembling the seat motor ...........................................................................................................7.151
7.4.25.Disassembling the electrical 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.Disassembling the weight stack cable...............................................................................................7.158
7.4.30.Disassembling the bell ......................................................................................................................7.159
7.4.31.Disassembling the primary shaft - secondary shaft chain ................................................................7.160
7.4.32.Disassembling the primary shaft ......................................................................................................7.161
7.4.33.Disassembling the secondary shaft...................................................................................................7.163
7.4.34.Disassembling the weight stack frame pulley ...................................................................................7.165
7.4.35.Disassembling the mat ......................................................................................................................7.166
7.4.36.Disassembling the power entry.........................................................................................................7.167
7.4.37.Disassembling the starter plate and fuses ........................................................................................7.168
7.5. VERTICAL TRACTION.....................................................................................................................................7.169
7.5.1. Disassembling the display ................................................................................................................7.169
7.5.2. Removing the electronic display boards...........................................................................................7.170
7.5.3. Removing the EPROM......................................................................................................................7.172
7.5.4. Disassembling the TLCBR chip ........................................................................................................7.173
7.5.5. Disassembling the main keyboard ....................................................................................................7.174
7.5.6. Disassembling the seat keyboard......................................................................................................7.175
7.5.7. Removing the seat.............................................................................................................................7.176
7.5.8. Disassembling the front guard..........................................................................................................7.177
7.5.9. Disassembling the electrical box ......................................................................................................7.178
7.5.10.Disassembling the electronic components of the electrical box .......................................................7.179
7.5.11.Disassembling the upright guard......................................................................................................7.181
7.5.12.Disassembling the seat motor ...........................................................................................................7.182
7.5.13.Disassembling the prestart cable......................................................................................................7.183
7.5.14.Disassembling the rear guard...........................................................................................................7.185
7.5.15.Disassembling the solenoid ..............................................................................................................7.186
7.5.16.Disassembling the selector brush .....................................................................................................7.187
7.5.17.Disassembling the weight stack cable...............................................................................................7.188
7.5.18.Disassembling the pulleys.................................................................................................................7.189

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7.5.19.Disassembling the zero sensor..........................................................................................................7.190
7.5.20.Disassembling the weight stack selection system..............................................................................7.191
7.5.21.Disassembling the weight stack selection chain ...............................................................................7.193
7.5.22.Disassembling the weight stack motor..............................................................................................7.194
7.5.23.Disassembling the rear lever guard..................................................................................................7.195
7.5.24.Disassembling the lever cable ..........................................................................................................7.196
7.5.25.Disassembling the cam group...........................................................................................................7.197
7.5.26.Disassembling the levers ..................................................................................................................7.198
7.5.27.Disassembling the front lever guard.................................................................................................7.199
7.5.28.Disassembling the weight stack cover ..............................................................................................7.200
7.5.29.Disassembling the column extension ................................................................................................7.201
7.5.30.Disassembling the columns...............................................................................................................7.202
7.5.31.Disassembling the additional weight................................................................................................7.203
7.5.32.Disassembling the encoder ...............................................................................................................7.204
7.5.33.Disassembling the bars.....................................................................................................................7.205
7.5.34.Disassembling the cross and weight stack plates .............................................................................7.206
7.5.35.Disassembling the sinker ..................................................................................................................7.207
7.5.36.Disassembling the mats ....................................................................................................................7.208
7.5.37.Disassembling the display support ...................................................................................................7.209
7.5.38.Disassembling the power entry.........................................................................................................7.210
7.5.39.Disassembling the starter plate and fuses ........................................................................................7.211
7.6. SHOULDER PRESS .........................................................................................................................................7.212
7.6.1. Disassembling the display ................................................................................................................7.212
7.6.2. Removing the electronic display boards...........................................................................................7.213
7.6.3. Removing the EPROM......................................................................................................................7.215
7.6.4. Disassembling the TLCBR chip ........................................................................................................7.216
7.6.5. Disassembling 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.Disassembling the electronic components of the electrical box .......................................................7.222
7.6.11.Disassembling the upright guard......................................................................................................7.224
7.6.12.Disassembling the seat motor ...........................................................................................................7.225
7.6.13.Disassembling the prestart cable......................................................................................................7.226
7.6.14.Disassembling the rear guard...........................................................................................................7.228
7.6.15.Disassembling the solenoid ..............................................................................................................7.229
7.6.16.Disassembling the selector brush .....................................................................................................7.230
7.6.17.Disassembling the weight stack cable...............................................................................................7.231
7.6.18.Disassembling the pulleys.................................................................................................................7.232
7.6.19.Disassembling the zero sensor..........................................................................................................7.233
7.6.20.Disassembling the weight stack selection system..............................................................................7.234
7.6.21.Disassembling the weight stack selection chain ...............................................................................7.236
7.6.22.Disassembling the weight stack motor..............................................................................................7.237
7.6.23.Disassembling the rear lever guard..................................................................................................7.238
7.6.24.Disassembling the lever cable ..........................................................................................................7.239
7.6.25.Disassembling the cam group...........................................................................................................7.240
7.6.26.Disassembling the levers ..................................................................................................................7.241
7.6.27.Disassembling the front lever guard.................................................................................................7.242
7.6.28.Disassembling the weight stack cover ..............................................................................................7.243
7.6.29.Disassembling the column extension ................................................................................................7.244
7.6.30.Disassembling the columns...............................................................................................................7.245
7.6.31.Disassembling the additional weight................................................................................................7.246
7.6.32.Disassembling the encoder ...............................................................................................................7.247
7.6.33.Disassembling the bars.....................................................................................................................7.248
7.6.34.Disassembling the cross and weight stack plates .............................................................................7.249
7.6.35.Disassembling the sinker ..................................................................................................................7.250
7.6.36.Disassembling the mats ....................................................................................................................7.251

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7.6.37.Disassembling the display support ...................................................................................................7.252
7.6.38.Disassembling the power entry.........................................................................................................7.253
7.6.39.Disassembling the starter plate and fuses ........................................................................................7.254
7.7. CHEST PRESS ................................................................................................................................................7.255
7.7.1. Disassembling the display ................................................................................................................7.255
7.7.2. Removing the electronic display boards...........................................................................................7.256
7.7.3. Removing the EPROM......................................................................................................................7.258
7.7.4. Disassembling the TLCBR chip ........................................................................................................7.259
7.7.5. Disassembling the main keyboard ....................................................................................................7.260
7.7.6. Disassembling the seat keyboard......................................................................................................7.261
7.7.7. Disassembling the rear Plexiglas weight stack guard ......................................................................7.262
7.7.8. Disassembling the front plexiglas weight stack guard......................................................................7.263
7.7.9. Disassembling the weight stack pulley .............................................................................................7.264
7.7.10.Disassembling the weight stack cover ..............................................................................................7.265
7.7.11.Disassembling the additional weight................................................................................................7.267
7.7.12.Disassembling the encoder ...............................................................................................................7.268
7.7.13.Disassembling the solenoid ..............................................................................................................7.269
7.7.14.Disassembling the selector brush .....................................................................................................7.270
7.7.15.Disassembling the zero sensor..........................................................................................................7.271
7.7.16.Removing the seat.............................................................................................................................7.272
7.7.17.Disassembling the upright guard......................................................................................................7.273
7.7.18.Disassembling the closing panels.....................................................................................................7.274
7.7.19.Disassembling the weight stack selection system..............................................................................7.275
7.7.20.Disassembling the weight stack selection chain ...............................................................................7.276
7.7.21.Disassembling the weight stack motor..............................................................................................7.277
7.7.22.Disassembling the cross stops ..........................................................................................................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 motor ...........................................................................................................7.283
7.7.28.Disassembling the electrical box ......................................................................................................7.284
7.7.29.Disassembling the electronic components of the electrical box .......................................................7.285
7.7.30.Disassembling the pulleys.................................................................................................................7.287
7.7.31.Disassembling the weight stack cable...............................................................................................7.288
7.7.32.Disassembling the lever cable ..........................................................................................................7.289
7.7.33.Disassembling the doubling cable ....................................................................................................7.290
7.7.34.Disassembling the cam group...........................................................................................................7.291
7.7.35.Disassembling the front guard..........................................................................................................7.292
7.7.36.Disassembling the prestart cable......................................................................................................7.293
7.7.37.Disassembling the levers ..................................................................................................................7.295
7.7.38.Disassembling the mats ....................................................................................................................7.296
7.7.39.Disassembling the display support ...................................................................................................7.297
7.7.40.Disassembling the power entry.........................................................................................................7.298
7.7.41.Disassembling the starter plate and fuses ........................................................................................7.299
7.8. ROWING TORSO ............................................................................................................................................7.300
7.8.1. Disassembling the display ................................................................................................................7.300
7.8.2. Removing the electronic display boards...........................................................................................7.301
7.8.3. Removing the EPROM......................................................................................................................7.303
7.8.4. Disassembling the TLCBR chip ........................................................................................................7.304
7.8.5. Disassembling the main keyboard ....................................................................................................7.305
7.8.6. Disassembling the seat keyboard......................................................................................................7.306
7.8.7. Disassembling the rear plexiglas weight stack guard ......................................................................7.307
7.8.8. Disassembling the front plexiglas weight stack guard......................................................................7.308
7.8.9. Disassembling the weight stack pulley .............................................................................................7.309
7.8.10.Disassembling the weight stack cover ..............................................................................................7.310
7.8.11.Disassembling the additional weight................................................................................................7.312
7.8.12.Disassembling the encoder ...............................................................................................................7.313

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7.8.13.Disassembling the solenoid ..............................................................................................................7.314
7.8.14.Disassembling the selector brush .....................................................................................................7.315
7.8.15.Disassembling the zero sensor..........................................................................................................7.316
7.8.16.Disassembling the mats ....................................................................................................................7.317
7.8.17.Disassembling the prestart levers.....................................................................................................7.318
7.8.18.Disassembling the upright guard......................................................................................................7.319
7.8.19.Disassembling the weight stack selection system..............................................................................7.321
7.8.20.Disassembling the weight stack selection chain ...............................................................................7.322
7.8.21.Disassembling the weight stack motor..............................................................................................7.323
7.8.22.Disassembling the cross stops ..........................................................................................................7.324
7.8.23.Disassembling the cross....................................................................................................................7.325
7.8.24.Disassembling the sinker ..................................................................................................................7.326
7.8.25.Disassembling the weight stack plates..............................................................................................7.327
7.8.26.Disassembling the bars.....................................................................................................................7.328
7.8.27.Disassembling the electrical box ......................................................................................................7.329
7.8.28.Disassembling the electronic components of the electrical box .......................................................7.330
7.8.29.Disassembling the pulleys.................................................................................................................7.332
7.8.30.Disassembling the weight stack cable...............................................................................................7.333
7.8.31.Disassembling the doubling cable ....................................................................................................7.334
7.8.32.Disassembling the cam group...........................................................................................................7.335
7.8.33.Disassembling the levers ..................................................................................................................7.336
7.8.34.Disassembling the chest rest release knob........................................................................................7.337
7.8.35.Disassembling the lever guard .........................................................................................................7.338
7.8.36.Disassembling the lever cable ..........................................................................................................7.339
7.8.37.Disassembling the lever shaft ...........................................................................................................7.340
7.8.38.Disassembling the seat guard...........................................................................................................7.341
7.8.39.Disassembling 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 electronic display boards...........................................................................................7.347
7.9.3. Removing the EPROM......................................................................................................................7.349
7.9.4. Disassembling the TLCBR chip ........................................................................................................7.350
7.9.5. Disassembling the main keyboard ....................................................................................................7.351
7.9.6. Disassembling the seat keyboard......................................................................................................7.352
7.9.7. Disassembling the weight stack cover ..............................................................................................7.353
7.9.8. Disassembling the plexiglas weight stack guard ..............................................................................7.354
7.9.9. Disassembling the weight stack pulleys............................................................................................7.355
7.9.10.Disassembling the encoder ...............................................................................................................7.356
7.9.11.Disassembling the weight stack cover frame ....................................................................................7.357
7.9.12.Disassembling the additional weight................................................................................................7.358
7.9.13.Disassembling the solenoid ..............................................................................................................7.359
7.9.14.Disassembling the selector brush .....................................................................................................7.360
7.9.15.Disassembling the zero sensor..........................................................................................................7.361
7.9.16.Disassembling the weight stack selection system..............................................................................7.362
7.9.17.Disassembling the weight stack selection chain ...............................................................................7.363
7.9.18.Disassembling the weight stack motor..............................................................................................7.364
7.9.19.Disassembling the cross stops ..........................................................................................................7.365
7.9.20.Disassembling the cross....................................................................................................................7.366
7.9.21.Disassembling the sinker ..................................................................................................................7.367
7.9.22.Disassembling the weight stack plates..............................................................................................7.368
7.9.23.Disassembling the bars.....................................................................................................................7.369
7.9.24.Disassembling the rear guard...........................................................................................................7.370
7.9.25.Disassembling the central guard ......................................................................................................7.371
7.9.26.Disassembling the main electrical box .............................................................................................7.372
7.9.27.Disassembling the electronic components of the main electrical box ..............................................7.373
7.9.28.Disassembling the secondary electrical box.....................................................................................7.375

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7.9.29.Disassembling the electronic components of the secondary electrical box ......................................7.376
7.9.30.Disassembling the seat motor photocell ...........................................................................................7.377
7.9.31.Disassembling the seat motor brushes..............................................................................................7.378
7.9.32.Disassembling the seat movement limitation microswitch................................................................7.379
7.9.33.Disassembling the seat motor unit....................................................................................................7.380
7.9.34.Removing the seat.............................................................................................................................7.382
7.9.35.Disassembling the seat sliding bars..................................................................................................7.383
7.9.36.Disassembling the shoulder rest group release cable ......................................................................7.384
7.9.37.Disassembling the shoulder rest group.............................................................................................7.386
7.9.38.Disassembling the tachogenerator guard.........................................................................................7.388
7.9.39.Disassembling the front guard..........................................................................................................7.389
7.9.40.Disassembling the lever mat rubber .................................................................................................7.390
7.9.41.Disassembling the levers ..................................................................................................................7.391
7.9.42.Disassembling the lever cable ..........................................................................................................7.392
7.9.43.Disassembling the weight stack frame guard ...................................................................................7.393
7.9.44.Disassembling the weight stack cable...............................................................................................7.394
7.9.45.Disassembling the doubling cable ....................................................................................................7.395
7.9.46.Disassembling the cam group...........................................................................................................7.396
7.9.47.Disassembling the weight stack frame pulleys..................................................................................7.397
7.9.48.Disassembling the starter plate and fuses ........................................................................................7.398
7.9.49.Disassembling the mat ......................................................................................................................7.399
7.9.50.Disassembling the power 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 PHASING ............................................................................................................8.4
8.2.1. Abdominal Crunch................................................................................................................................8.4
8.2.2. Lower Back ...........................................................................................................................................8.6
8.2.3. Leg Extension .......................................................................................................................................8.8
8.2.4. Leg Curl..............................................................................................................................................8.10
8.2.5. Vertical Traction.................................................................................................................................8.12
8.2.6. Shoulder Press....................................................................................................................................8.13
8.2.7. Chest Press .........................................................................................................................................8.14
8.2.8. Rowing Torso......................................................................................................................................8.17
8.2.9. Leg Press ............................................................................................................................................8.19
8.3. ADJUSTING THE POSITION OF THE CROSS LIMIT SWITCH...................................................................................8.20
8.4. ADJUSTING THE WEIGHT STACK CABLE TENSION .............................................................................................8.21
8.5. ADJUSTING THE PRESTART CABLE TENSION.....................................................................................................8.22
8.5.1. Adjusting the primary prestart cable tension......................................................................................8.22
8.5.2. Adjusting the secondary prestart cable tension ..................................................................................8.23
8.6. ADJUSTING THE LEVER CABLE ........................................................................................................................8.24
8.7. ADJUSTING THE DOUBLING CABLE ..................................................................................................................8.25
8.8. ADJUSTING THE ZERO SENSOR POSITION..........................................................................................................8.26
8.9. ADJUSTING THE POSITION OF THE WEIGHT STACK SELECTION SYSTEM ............................................................8.27
8.10.ADJUSTING THE TENSION OF THE WEIGHT STACK SELECTION CHAIN ................................................................8.28
8.11.ADJUSTING THE PRIMARY SHAFT - SECONDARY SHAFT CHAIN ALIGNMENT .....................................................8.29
8.12.ADJUSTING THE PRIMARY SHAFT - SECONDARY SHAFT CHAIN TENSION...........................................................8.30
8.13.ADJUSTING THE RELEASE CABLE TENSION.......................................................................................................8.31
8.14.ADJUSTING THE CURRENT LIMIT ON THE WSMI AND SAMI BOARD...............................................................8.32
8.15.LCD CONTRAST..............................................................................................................................................8.33
8.16.BUZZER TONE .................................................................................................................................................8.34
9. CONFIGURING THE MACHINE.......................................................................................................................9.1
9.1. CONFIGURING PARAMETER DEFAULTS...............................................................................................................9.1
9.2. CONFIGURING THE TECHNICAL PARAMETERS ....................................................................................................9.1

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9.2.1. Machine code........................................................................................................................................9.2
9.2.2. Offset zero sensor .................................................................................................................................9.2
9.2.3. Number of pulses for weight stack selection.........................................................................................9.3
9.2.4. Weight stack motor inertia....................................................................................................................9.3
9.2.5. Weight stack motor selection window...................................................................................................9.4
9.2.6. Distance between plates .......................................................................................................................9.4
9.2.7. Number of pulses for seat selection ......................................................................................................9.5
9.2.8. Seat offset position 0.............................................................................................................................9.6
9.2.9. Seat offset position 9.............................................................................................................................9.6
9.2.10.Seat motor inertia .................................................................................................................................9.7
9.2.11.Minimum ROM length ..........................................................................................................................9.7
9.2.12.Default ROM start ................................................................................................................................9.8
9.2.13.Default ROM length..............................................................................................................................9.8
9.2.14.%ROM first rep.....................................................................................................................................9.9
9.3. CONFIGURING THE USER PARAMETERS............................................................................................................9.11
9.3.1. Language ............................................................................................................................................9.11
9.3.2. Unit of measure ..................................................................................................................................9.11
9.3.3. Using the additional weight................................................................................................................9.12
9.3.4. Using the function keys.......................................................................................................................9.12
9.3.5. Number of which repetition to use for ROM acquisition ....................................................................9.12
9.3.6. “Time-out” setting..............................................................................................................................9.12
9.3.7. Setting the default seat position..........................................................................................................9.13
9.3.8. Enable pacer.......................................................................................................................................9.13
9.3.9. Pacer speed.........................................................................................................................................9.14
9.3.10.Time before load.................................................................................................................................9.14
9.3.11.Perform auto-configuration procedure ..............................................................................................9.14
9.4. TABLE OF FACTORY SETTINGS.........................................................................................................................9.16
9.4.1. User parameters .................................................................................................................................9.16
9.4.2. ROM Parameters ................................................................................................................................9.16
9.4.3. BOSCH weight stack motor parameters .............................................................................................9.16
9.4.4. Plate distance .....................................................................................................................................9.17
9.4.5. Seat motor parameters........................................................................................................................9.17
9.5. DISPLAYING WORKING PARAMETERS ..............................................................................................................9.18
9.5.1. Weight stack motor running time........................................................................................................9.18
9.5.2. Weight 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
9.5.5. Number of fail signals produced by the weight stack motor interface board .....................................9.19
9.5.6. Seat motor running time .....................................................................................................................9.19
9.5.7. Seat motor test cycles..........................................................................................................................9.19
9.5.8. Number of relay switching cycles to move the seat motor upward.....................................................9.19
9.5.9. Number of relay switching cycles to move the seat motor downward ................................................9.20
9.5.10.Number of fail signals produced by the seat motor interface board...................................................9.20
9.5.11.Number of solenoid relay switching cycles.........................................................................................9.20
9.5.12.Machine running time.........................................................................................................................9.20
9.5.13.Number of repetitions carried out on the machine .............................................................................9.21
9.5.14.Total weight lifted using the machine.................................................................................................9.21
9.6. EDITING THE WORKING PARAMETERS..............................................................................................................9.22
9.6.1. Weight stack motor running time........................................................................................................9.22
9.6.2. Weight stack motor test cycles ............................................................................................................9.22
9.6.3. Number of relay switching cycles to move the weight stack motor upward........................................9.22
9.6.4. Number of relay switching cycles to move the weight stack motor downward...................................9.23
9.6.5. Number of fail signals produced by the weight stack motor interface board .....................................9.23
9.6.6. Seat motor running time .....................................................................................................................9.23
9.6.7. Seat motor test cycles..........................................................................................................................9.23
9.6.8. Number of relay switching cycles to move the seat motor upward.....................................................9.23
9.6.9. Number of relay switching cycles to move the seat motor downward ................................................9.24
9.6.10.Number of fail signals produced by the seat motor interface board...................................................9.24

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9.6.11.Number of solenoid relay switching cycles.........................................................................................9.24
9.6.12.Machine running time.........................................................................................................................9.24
9.6.13.Number of repetitions carried out on the machine .............................................................................9.25
9.6.14.Total weight lifted using the machine.................................................................................................9.25
10. SCHEDULED MAINTENANCE........................................................................................................................10.1
10.1.EXTERNAL CLEANING .....................................................................................................................................10.1
10.1.1.Preparing working conditions ............................................................................................................10.1
10.1.2.Cleaning operations ...........................................................................................................................10.1
10.2.INTERNAL CLEANING.......................................................................................................................................10.2
10.2.1.Preparing working conditions ............................................................................................................10.2
10.2.2.Cleaning operations ...........................................................................................................................10.2
10.3.MECHANICAL OPERATIONS .............................................................................................................................10.3
10.3.1.Preparing working conditions ............................................................................................................10.3
10.3.2.Check the weight stack selection system.............................................................................................10.3
10.3.3.Check the weight stack plate springs..................................................................................................10.3
10.3.4.Check the cross, bars and weight stack plates....................................................................................10.3
10.3.5.Check the additional weight ...............................................................................................................10.4
10.3.6.Check the cables .................................................................................................................................10.4
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 ..............................................................10.4
10.3.12. Check the lever limit switch buffers .................................................................................................10.5
10.3.13. Check the cross limit switch.............................................................................................................10.5
10.3.14. Check the Leg Press seat mechanism...............................................................................................10.5
10.3.15. Check the seat mechanism for other machines ................................................................................10.5
10.3.16. Check the Leg Press back and shoulder rest ...................................................................................10.5
10.3.17. Check the wire encoder....................................................................................................................10.5
10.4.ELECTRICAL/ELECTRONIC OPERATIONS...........................................................................................................10.6
10.4.1.Preparing working conditions ............................................................................................................10.6
10.4.2.Check the wiring and connections ......................................................................................................10.6
10.4.3.Check the display................................................................................................................................10.6
10.4.4.Check wear on components ................................................................................................................10.6
10.4.5.Check the component functions ..........................................................................................................10.7
10.5.SOFTWARE CONFIGURATION ...........................................................................................................................10.8
10.5.1.Preparing working conditions ............................................................................................................10.8
10.5.2.Configuration check ...........................................................................................................................10.8
11. APPENDIX ...........................................................................................................................................................11.1
11.1.CONFIGURATION PARAMETERS FOR EXERCISE ROM ACQUISITION..................................................................11.1
11.2.CALCULATING REPETITIONS ............................................................................................................................11.1
11.3.LOCATING THE SERIAL NUMBER......................................................................................................................11.2

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Page 1.1
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 illustrations
highlighting the topic covered.
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.

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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.

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Page 2.1
2. TECHNICAL SPECIFICATIONS
2.1. MECHANICAL CHARACTERISTICS
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.
OBSERVE: The sizes quoted in the following figures are expressed in mm.
2.1.1. ABDOMINAL CRUNCH
2.1.2. LOWER BACK

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Page 2.2
2.1.3. LEG EXTENSION
2.1.4. LEG CURL
2.1.5. VERTICAL TRACTION