Technogym Personal Selection TUV User manual

S ERVICE & MAINTENANCE MANUAL
Rev. 1.0

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
P
®
P
trademark is property of Technogym S.p.A.
The Personal Selection TÜV
P
™
P
trademark is property of Technogym S.p.A.

Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0
Page i
Contents
1. GENERAL NOTICES...........................................................................................................................................1.1
1.1. I NTRODUCTION ................................................................................................................................................... 1.1
1.2. R ECOMMENDATIONS .......................................................................................................................................... 1.1
1.3. G ENERAL RULES FOR REPAIR PROCEDURES ........................................................................................................ 1.2
2. TECHNICAL CHARACTERISTICS..................................................................................................................2.1
2.1. P RODUCT CODE : MACHINES ................................................................................................................................2.1
2.2. C ODIFICA DI PRODOTTO : P ANCHE ...................................................................................................................... 2.1
2.3. E QUIPMENTS : MECHANICAL CHARACTERISTICS .................................................................................................. 2.3
2.3.1. D6946 – Upper Back.........................................................................................................................2.3
2.3.2. D6950 – Rotary Torso.......................................................................................................................2.3
2.3.3. D6951 – Leg Press............................................................................................................................2.4
2.3.4. D6957 – Abdominal Crunch..............................................................................................................2.4
2.3.5. D6958 – Lower Back.........................................................................................................................2.5
2.3.6. D6971 – Vertical Traction ................................................................................................................2.5
2.3.7. D6980 – Low Row.............................................................................................................................2.6
2.3.8. D6990 – Leg Curl..............................................................................................................................2.6
2.3.9. D6991 – Leg Extension .....................................................................................................................2.7
2.4. B ENCH : MECHANICAL CHARACTERISTICS ........................................................................................................... 2.8
2.4.1. D6P915 – Crunch Bench...................................................................................................................2.8
2.4.2. D6P920 – Adjustable Bench..............................................................................................................2.8
2.5. A MBIENT SPECIFICATIONS .................................................................................................................................. 2.9
2.6. C ONFORMITY TO REGULATIONS .......................................................................................................................... 2.9
3. INSTALLING AND MOVING THE MACHINES............................................................................................3.1
3.1. S PECIFICATIONS AND REQUIREMENTS ................................................................................................................ 3.1
3.2. M OVING ............................................................................................................................................................. 3.3
3.2.1. Moving without wheels......................................................................................................................3.3
3.2.2. Moving with wheels...........................................................................................................................3.3
4. ACCESSORIES.....................................................................................................................................................4.1
5. WHAT IF …...........................................................................................................................................................5.1
5.1. T HE WEIGHT STACK DOES NOT SLIDE SMOOTHLY ............................................................................................... 5.1
5.2. T HE WEIGHT STACK CABLE IS NOT TAUT ............................................................................................................. 5.2
5.2.1. Adjusting the tension of the cable with crimped fitting .....................................................................5.2
5.2.2. Adjusting the tension of the cable with doubling pulley....................................................................5.2
5.3. T HE MACHINE IS NOT FLAT ................................................................................................................................. 5.4
5.4. T HE LEVERS OF DUAL - AXIS MACHINES ARE NOT ALIGNED .................................................................................. 5.5
5.5. T HE SLIDING BARS OF THE L EG P RESS SEAT ARE NOT ALIGNED .......................................................................... 5.6
5.6. T HE T UBE S TART T O W ABBLE ........................................................................................................................... 5.7
6. HOW TO DISASSEMBLE THE ….....................................................................................................................6.1
6.1. F RONT WEIGHT STACK CASING ........................................................................................................................... 6.1
6.2. T OP .................................................................................................................................................................... 6.2
6.3. S EAT ON LOW MACHINES .................................................................................................................................... 6.3
6.4. S EAT ON TALL MACHINES ................................................................................................................................... 6.5
6.5. L EG P RESS S EAT ................................................................................................................................................. 6.7
6.6. E ASY START FOR TALL MACHINES ...................................................................................................................... 6.9
6.7. R ELEASE LEVER ................................................................................................................................................ 6.11
6.8. S ELECTOR SWITCH FOR ADDITIONAL WEIGHT ................................................................................................... 6.13
6.8.1. Machines with cross with crimped cable fitting..............................................................................6.13
6.8.2. Machines with cross with doubling pulley ......................................................................................6.14

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6.9. D ISASSEMBLING UNLOCKING LEVER ON A BDUCTOR - A DDUCTOR ................................................................... 6.16
7. SPECIAL OPERATIONS.....................................................................................................................................7.1
7.1. L OCKING DOWN THE CABLE FIXING DOWELS ...................................................................................................... 7.1
7.2. L OCKING DOWN THE PULLEYS ............................................................................................................................ 7.2
8. WEIGHT STACK CABLE...................................................................................................................................8.1
8.1. L ENGTH OF THE WEIGHT STACK CABLE .............................................................................................................. 8.1
8.2. R OUTING OF THE WEIGHT STACK CABLE ............................................................................................................. 8.2
8.2.1. D6946 – Upper Back.........................................................................................................................8.2
8.2.2. D6950 – Rotary Torso.......................................................................................................................8.2
8.2.3. D6951 – Leg Press............................................................................................................................8.3
8.2.4. D6957 – Abdominal Crunch..............................................................................................................8.3
8.2.5. D6958 – Lower Back.........................................................................................................................8.4
8.2.6. D6971 – Vertical Traction ................................................................................................................8.4
8.2.7. D6980 – Low Row.............................................................................................................................8.5
8.2.8. D6990 – Leg Curl..............................................................................................................................8.5
8.2.9. D6991 – Leg Extension .....................................................................................................................8.6
9. MAINTENANCE...................................................................................................................................................9.1
9.1. D AILY MAINTENANCE OPERATIONS .................................................................................................................... 9.1
9.1.1. Cleaning upholstery ..........................................................................................................................9.1
9.2. W EEKLY MAINTENANCE OPERATIONS ................................................................................................................ 9.2
9.2.1. Cleaning the frame and painted parts...............................................................................................9.2
9.2.2. Cleaning the chrome-plated parts.....................................................................................................9.2
9.3. M ONTHLY MAINTENANCE OPERATIONS .............................................................................................................. 9.3
9.3.1. Check the cross, bars and weight stack plates ..................................................................................9.3
9.3.2. Check the cables................................................................................................................................9.3
9.3.3. Check the mechanisms.......................................................................................................................9.3
9.3.4. Check the gas springs........................................................................................................................9.3
9.3.5. Check the weight stack stops.............................................................................................................9.4
9.3.6. Check the Leg Press seat mechanism................................................................................................9.4
9.3.7. Checking the seat mechanism on low machines................................................................................9.4
9.3.8. Checking the seat mechanism on tall machines ................................................................................9.4
9.3.9. Checking the upholstery....................................................................................................................9.4
9.3.10. Checking various rubber parts..........................................................................................................9.4
9.4. T WICE - YEARLY MAINTENANCE OPERATIONS ...................................................................................................... 9.5
9.4.1. Checking the additional weight.........................................................................................................9.5
9.4.2. Check the pulleys...............................................................................................................................9.5
9.4.3. Check the cam group.........................................................................................................................9.5
9.4.4. Check the lever stops.........................................................................................................................9.5
9.4.5. Replacing the cables..........................................................................................................................9.5
9.4.6. Lubricating the release systems.........................................................................................................9.5
9.4.7. Screw and bolt check.........................................................................................................................9.5
9.4.8. Checking for mechanism play ...........................................................................................................9.6
9.4.9. Checking cross alignment..................................................................................................................9.6
10. FUNCTIONAL TESTS.......................................................................................................................................10.1
10.1. W EIGHT STACK CABLE ASSEMBLY TEST ........................................................................................................... 10.1
10.2. H OUSING ASSEMBLY TEST ................................................................................................................................ 10.1
10.3. M ECHANICAL RESISTANCE DEVICE ASSEMBLY TEST ......................................................................................... 10.1
10.4. S EAT GROUP ASSEMBLY TEST ........................................................................................................................... 10.2
11. APPENDIX...........................................................................................................................................................11.1
11.1. W HAT TO ORDER TO AUGMENT THE WEIGHT STACK ......................................................................................... 11.1
11.2. U PHOLSTERY .................................................................................................................................................... 11.3
11.3. T OOLS TO USE .................................................................................................................................................. 11.4

Personal Selection TÜV: Service & Maintenance Manual - rev. 1.0
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 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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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
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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2. TECHNICAL CHARACTERISTICS
The Personal Selection TÜV machine code is a sequence of alphanumeric characters arranged as
follows:
2.1. PRODUCT CODE: MACHINES
PERSONAL SELECTION TÜV
Characters description key to values
1,2,3 Personal Selection TÜV D69 = machine
4,5 Machine code See Table 2-1
6 Weight stack configuration 0= standard
3= enhanced
-
7,8 Frame colour AL = Silver
9,10 Upholstery colour R0 = Brillant green
11 Front casing colour C= grey
12,13 Plastic parts colour GG = RAL 7024
14 Unit of measurement K= Kg
Code Machine Code Machine
46 Upper Back 71 Vertical Traction
50 Rotary Torso 80 Low Row
51 Leg Press 90 Leg Curl
57 Abdominal Crunch 91 Leg Extension
58 Lower Back
Table 2-1
2.2. CODIFICA DI PRODOTTO: PANCHE
PERSONAL SELECTION TÜV
Characters description key to values
1,2,3,4 Personal Selection TÜV D6P9 = bench
5,6 Bench code See Table 2-2
-
7,8 Frame colour AL = Silver
9 Upholstery colour R= Brillant green
Code Machine Code Machine
15 Crunch Bench 20 Adjustable bench
Table 2-2

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For example, a possible product code would be:
D69510-ALR0CGGK
which is interpreted as follows:
D69 51 0 - AL R0 C GG K
Unit of measurement, Kg
Plastic parts colour RAL 7024
Gray casing colour
Brillant green upholstery colour
Silver frame colour
Weight stack configuration
Leg Press
Personal Selection TÜV

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2.3. EQUIPMENTS: MECHANICAL CHARACTERISTICS
2.3.1. D6946 – UPPER BACK
D6946 – Upper Back
stand by max during exercise
119 x 114 x 148.5 cm 119 x 142 x 148.5 cm
Dimensions 47 x 45 x 58 in 47 x 56 x 58 in
Overall weight 197 Kg – 394 lbs
Standard weight stack 65 Kg – 130 lbs
Enhanced weight stack 95 Kg – 190 lbs
2.3.2. D6950 – ROTARY TORSO
D6950 – Rotary Torso
stand by max during exercise
118.5 x 112x 148.5cm 118.5 x 112x 148.5cm
Dimensions 47 x 44 x 58 in 47 x 44 x 58 in
Overall weight 197 Kg – 394 lbs
Standard weight stack 65 Kg – 130 lbs
Enhanced weight stack 95 Kg – 190 lbs

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2.3.3. D6951 – LEG PRESS
D6951 – Leg Press
stand by max during exercise
207 x120 x 180 cm 207 x120 x 180 cm
Dimensions 81 x 47 x 71 in 81 x 47 x 71 in
Overall weight 572 Kg – 1144 lbs
Standard weight stack 190 Kg – 380 lbs
Enhanced weight stack 250 Kg – 500 lbs
2.3.4. D6957 – ABDOMINAL CRUNCH
D6957 – Abdominal Crunch
stand by max during exercise
128 x 105 x 148.5 cm 142 x 105 x 148.5 cm
Dimensions 50 x 41 x 58 in 56 x 41 x 58 in
Overall weight 207 Kg – 414 lbs
Standard weight stack 65 Kg – 130 lbs
Enhanced weight stack 95 Kg – 190 lbs

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2.3.5. D6958 – LOWER BACK
D6958 – Lower Back
stand by max during exercise
121 x 103 x 148.5 cm 140 x 103 x 148.5 cm
Dimensions 48 x 40 x 58 in 55 x 40 x 58 in
Overall weight 212 Kg – 424 lbs
Standard weight stack 65 Kg – 130 lbs
Enhanced weight stack 95 Kg – 190 lbs
2.3.6. D6971 – VERTICAL TRACTION
D6971 – Vertical Traction
stand by max in usage
150 x 131.5 x 186 cm 167 x 145.5 x 186 cm
Dimensions 59 x 52 x 73 in 59 x 57 x 73 in
Overall weight 292 Kg – 584 lbs
Standard weight stack 100 Kg – 200 lbs
Enhanced weight stack 130 Kg – 260 lbs

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2.3.7. D6980 – LOW ROW
D6980 – Low Row
stand by max during exercise
113.5 x 120.5 x 148 cm 113.5 x 120.5 x 148 cm
Dimensions 44.5 x 47.5 x 58.5 in 44.5 x 47.5 x 58.5 in
Overall weight 268 Kg – 536 lbs
Standard weight stack 95 Kg – 190 lbs
Enhanced weight stack 130 Kg – 260 lbs
2.3.8. D6990 – LEG CURL
D6990 - Leg Curl
stand by max during exercise
130 x 105 x 148.5 cm 141 x 107 x 148.5 cm
Dimensions 51 x 41 x 58 in 55 x 42 x 58 in
Overall weight 254 Kg – 508 lbs
Standard weight stack 95 Kg – 190 lbs
Enhanced weight stack 125 Kg – 250 lbs

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2.3.9. D6991 – LEG EXTENSION
D6991 – Leg Extension
stand by max during exercise
130 x 105 x 148.5 cm 152 x 105 x 148.5 cm
Dimensions 51 x 41 x 58 in 60 x 41 x 58 in
Overall weight 257 Kg – 514 lbs
Standard weight stack 95 Kg – 190 lbs
Enhanced weight stack 125 Kg – 250 lbs
Be aware:
• The weights in the above tables refer to machines with standard weight stack.
• The dimensions are “length x width x height” related to the user in exercise position.
• The stand by dimensions are the minimum machine dimensions without any
disassembling.

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2.4. BENCH: MECHANICAL CHARACTERISTICS
2.4.1. D6P915 – CRUNCH BENCH
D6P915 – Crunch Bench
Standard configuration max in usage
144 x 66 x 115 cm 155 x 66 x 115 cm
Dimensions 52 x 26 x 46 in 61 x 26 x 46 in
Overall weight 44 Kg – 88 lbs
2.4.2. D6P920 – ADJUSTABLE BENCH
D6P920 – Adjustable bench
Standard configuration max in usage
119 x 69 x 45.5 cm 119 x 69 x 130 cm
Dimensions 47 x 28 x 18 in 47 x 28 x 52 in
Overall weight 36 Kg – 72 lbs

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Be aware:
• The dimensions are “length x width x height” related to the user in exercise position.
• The stand by dimensions are the minimum machine dimensions without any
disassembling.
2.5. AMBIENT SPECIFICATIONS
Operating from 5° to 35° C
Temperature Storage from -20 to 55° C
Operating from 30% to 80% non-condensing
Humidity Storage from 5% to 85% non-condensing
2.6. CONFORMITY TO REGULATIONS
The machine conforms to the following directives:
Directive Europe USA
Medical devices 93/42/CEE -
Mechanical safety EN 957-1 (2000)
EN 957-2 (2004) EN 957-1 (2000) EN 957-2 (2004)
In addition all the machines have a Risk rate I.

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3. INSTALLING AND MOVING THE
MACHINES
3.1. SPECIFICATIONS AND REQUIREMENTS
For proper installation of the equipment, make sure that:
1. The equipment is installed on a level, vibration-free surface with a sufficient capacity to support
its weight plus that of the user.
2. The area is not dusty or sandy.
3. You have observed the temperature and humidity operating requirements indicated in paragraph
2.5. “Ambient specifications”.
Photo 3.1-1
1. The machine is supplied on a wooden pallet,
wrapped in nylon bag and packed in a carton.
2. To move the machine, it is necessary to use a
pallet truck or fork lift truck.
Continued on the following page →

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Photo 3.1-2
3. Remove the carton and the nylon bag, and
leave the machine secured to the pallet with
the fixing straps.
4. Position the machine in the place of
installation using a pallet truck, a wheeled
platform (dolly) or by fitting the wheels as
described in paragraph 3.2.2. “Moving with
wheels”.