Technogym Kinesis Station 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 or use of this manual.
This document contains proprietary information that is protected by copyright. All rights reserved.
No part of this document may be photocopied, reproduced or translated into another language
without the prior written consent of Technogym.
The Technogym®trademark is property of Technogym S.p.A.
The Kinesis ONE™trademark is property of Technogym S.p.A.

KINESIS ONE: 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 CHARACTERISTICS....................................................................................................................2.1
2.1. PRODUCT CODES ................................................................................................................................................2.1
2.2. MECHANICAL CARATTERISTICS..........................................................................................................................2.2
2.3. AMBIENT SPECIFICATIONS..................................................................................................................................2.2
2.4. CONFORMITY TO REGULATIONS .........................................................................................................................2.3
3. CABLES PASSAGE................................................................................................................................................3.1
4. ACCESSORIES .......................................................................................................................................................4.1
4.1. GENERIC ACCESSORIES.......................................................................................................................................4.1
5. INSTALLATION AND HANDLING MACHINES..............................................................................................5.1
5.1. SPECIFICATIONS AND REQUIREMENTS ................................................................................................................5.1
5.2. INSTALLATION....................................................................................................................................................5.1
6. DISASSEMBLY PART...........................................................................................................................................6.1
6.1. REAR PANEL DISASSEMBLY ................................................................................................................................6.2
6.2. FORNT PANEL DISASSEMBLY ..............................................................................................................................6.3
6.3. REAR CABLE DISASSEMBLY................................................................................................................................6.4
6.3.1. Rear cable disassembly .......................................................................................................................... 6.4
6.3.2. Rear cable reassembly............................................................................................................................ 6.5
6.4. REMOVING WEIGHT STACK CABLE (HANDLES)...................................................................................................6.7
6.4.1. Weight stack cable and handles disassembly ......................................................................................... 6.7
6.4.2. Weight stack cable reassembly............................................................................................................... 6.8
6.5. ARMS DISASSEMBLY....................................................................................................................................6.16
6.5.1. Lower arms........................................................................................................................................... 6.16
6.5.2. Upper arms........................................................................................................................................... 6.17
6.6. PULLEY DISASSEMBLY .....................................................................................................................................6.18
6.7. CAM DISASSEMBLY..........................................................................................................................................6.19
6.8. ROTATING PULLEY SYSTEM DISASSEMBLY .......................................................................................................6.20
6.9. WEIGHT STACK DISASSEMBLY..........................................................................................................................6.22
6.10.FOOT ADJUSTMENT DISASSEMBLY....................................................................................................................6.24
7. ADJUSTMENT........................................................................................................................................................7.1
7.1. THE WEIGHT STACK IS NOT FLOWING FLUID .......................................................................................................7.1
7.2. THE CABLE OF WEIGHT STACK IS NOT IN TENSION ..............................................................................................7.2
7.3. ADJUSTING THE FRONT PANEL POSITION ............................................................................................................7.3
7.4. THE MACHINE IS NOT FLAT .................................................................................................................................7.5
7.5. ADJUSTMENT WEIGHT STACK STOP.....................................................................................................................7.6
8. SCHEDULED MAINTENANCE...........................................................................................................................8.1
8.1. ORDINARY MAINTENANCE OPERATIONS .............................................................................................................8.2
8.1.1. External cleaning operations ................................................................................................................. 8.2
8.1.2. Cleaning the covering panels ................................................................................................................. 8.2
8.1.3. Check the cross, bars and weight stack plates ....................................................................................... 8.2
8.1.4. Check the cables..................................................................................................................................... 8.3
8.1.5. Check the cross limit switch ................................................................................................................... 8.3
8.1.6. Checking various rubber parts............................................................................................................... 8.3
8.2. EXTRA-ORDINARY MAINTENANCE OPERATIONS ..............................................................................................8.4

KINESIS ONE: Service & Maintenance Manual rev. 2.1
Page ii
8.2.1. Check the pulleys.................................................................................................................................... 8.4
8.2.2. Check the weight stack rod stops............................................................................................................ 8.4
8.2.3. Replacing the cables............................................................................................................................... 8.4
8.2.4. Screw and bolt check.............................................................................................................................. 8.4
8.2.5. Checking for mechanism play ................................................................................................................ 8.4
8.2.6. Checking cross alignment ...................................................................................................................... 8.4
9. APPENDICE............................................................................................................................................................9.1
9.1. TOOLS TO USE ....................................................................................................................................................9.1

KINESIS ONE: Service & Maintenance Manual rev. 2.1
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 drawings which
illustrate the procedure being described.
This manual contains notices and symbols which have a specific meanings:
WARNING: non observance may result in accident or injury.
CAUTION: non observance may cause damage to the machine.
Information about the operation in progress.
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 disassembling sequence described in this manual.

KINESIS ONE: Service & Maintenance Manual rev. 2.1
Page 1.2
1.3. GENERAL RULES FOR REPAIR PROCEDURES
1. Always mark any parts or positions which may be confused with each other at the time of
reassembly.
2. Use original Technogym spare parts and lubricants of the recommended brands.
3. Use special tools where specified.
4. Consult the Technical Newsletters, which may contain more up-to-date information on adjusts
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.
The tool sizes quoted in this manual are expressed in mm.

KINESIS ONE: Service & Maintenance Manual rev. 2.1
Page 2.1
2. TECHNICAL CHARACTERISTICS
2.1. PRODUCT CODES
The coding of machine takes into account of all possible variants and options available for the
products. The code of the machine, which don’t has the Serial Number, is composed of 16
alphanumeric characters so structured:
Characters Description Key to values
1,2 Machine type M5 = Kinesis
3,4,5, Product version 800 = One
- - -
6,7 Colour of the frame AN = Anthracite
8,9 Colour of the wood panel 19 = Gray Vienna
10,11 Plastic GZ = Black
Thus the machine code will be:
M5800-AN19GZ
which is interpreted as follows:
M5 800 - AN 19 GZ
Plastic colour: Black
Colour of the wood panel: Gray Vienna
Colour of the frame: Anthracite
-
Model: ONE
Machine type: Kinesis

KINESIS ONE: Service & Maintenance Manual rev. 2.1
Page 2.2
2.2. MECHANICAL CARATTERISTICS
KINESIS ONE
Width A1405mm – 55”
Length B1650mm – 65”
Height C2120mm – 83”
Machine weight 361 Kg – 797 lb
Weight stack weight 2x79 Kg - 2x175 lb
2.3. AMBIENT SPECIFICATIONS
Operating from 10° to 25° C
Temperature Storage from 10° to 25° C
Operating from 20% to 90% non-condensing
Humidity Storage from 20% to 90% non-condensing

KINESIS ONE: Service & Maintenance Manual rev. 2.1
Page 2.3
2.4. CONFORMITY TO REGULATIONS
The machine conforms to the following directives:
EUROPA USA
EMI NO
Security EN 957-1 (2005)
EN 957-2 (2003)
Directive 93/42/CE
NO

KINESIS ONE: Service & Maintenance Manual rev. 2.1
Page 2.4
Page intentionally left blank

KINESIS ONE: Service & Maintenance Manual rev. 2.1
Page 3.1
3. CABLES PASSAGE
KINESIS ONE
Rif. Cable code Length (mm)
A 0R000106AA 2300
B 0R000182AB (CRIMPED) 14300
The two modules of the machine and then the routing of the cables are perfectly
symmetrical, on the two sides.

KINESIS ONE: Service & Maintenance Manual rev. 2.1
Page 3.2
Page intentionally left blank

KINESIS ONE: Service & Maintenance Manual rev. 2.1
Page 4.1
4. ACCESSORIES
4.1. GENERIC ACCESSORIES
The accessories supplied are detailed in the User Manual of the machine with the
relevant particulars of use.

KINESIS ONE: Service & Maintenance Manual rev. 2.1
Page 4.2
Page intentionally left blank

KINESIS ONE: Service & Maintenance Manual rev. 2.1
Page 5.1
5. INSTALLATION AND HANDLING
MACHINES
5.1. SPECIFICATIONS AND REQUIREMENTS
For correct machine installation, make sure that:
•The machine is installed on a level surface that is free of vibrations and has sufficient
carrying capacity for the combined weight of the machine and user.
•The place of installation is free of dust and sand.
•The place of installation meets the operating temperature and humidity conditions specified
in paragraph: 2.3. “ Ambient specifications”.
5.2. INSTALLATION
The machine is delivered partially disassembled, wrapped in cellophane, and fixed on top of a
wooden pallet. The machine’s arm group are delivered in cardboard boxes, wrapped in pluriball and
fixed inside the frame of the machine.
Installation and assembly procedure are provided in the proper manual supplied with
the machine.

KINESIS ONE: Service & Maintenance Manual rev. 2.1
Page 5.2
Page intentionally left blank

KINESIS ONE: Service & Maintenance Manual rev. 2.1
Page 6.1
6. DISASSEMBLY PART
To correctly carry out the procedures detailed below, please take care of the following
picture to identify the LEFT and the RIGHT side, of the machine.

KINESIS ONE: Service & Maintenance Manual rev. 2.1
Page 6.2
6.1. REAR PANEL DISASSEMBLY
Figure 6.1-1
1. Unscrew the 2 screws (a), backing off first
of all the lower one and then the higher,
using a 6mm hexagonal wrench.
2. Remove the panel.
Figure 6.1-2
To reassemble the rear panel, follow the
disassembly instructions in reverse order
Be careful during the reassembly to
insert the panel in the proper slot and
bracket (b).