Technogym Unica Evolution User manual

SERVICE & MAINTENANCE MANUAL
Rev. 1.1

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 Unica Evolution™trademark is property of Technogym S.p.A.

UNICA EVOLUTION: Service & Maintenance Manual - rev. 1.1
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 VERSIONS .........................................................................................................................................2.1
2.2. PRODUCT CODE ................................................................................................................................................2.1
2.3. MECHANICAL CHARACTERISTICS .....................................................................................................................2.2
2.4. AMBIENT SPECIFICATIONS................................................................................................................................2.2
2.5. CONFORMITY TO REGULATIONS........................................................................................................................2.2
3. INSTALLING AND MOVING THE MACHINES............................................................................................3.1
3.1. SPECIFICATIONS AND REQUIREMENTS ..............................................................................................................3.1
3.2. INSTALLATION..................................................................................................................................................3.1
3.3. MOVING ...........................................................................................................................................................3.2
4. ACCESSORIES.....................................................................................................................................................4.1
5. WHAT IF …...........................................................................................................................................................5.1
5.1. THE WEIGHT STACK DOES NOT SLIDE SMOOTHLY .............................................................................................5.1
5.2. THE WEIGHT STACK CABLE IS NOT TAUT...........................................................................................................5.2
6. HOW TO DISASSEMBLE THE ….....................................................................................................................6.1
6.1. SEAT GAS SPRING .............................................................................................................................................6.1
6.2. PECTORAL ARM ................................................................................................................................................6.3
6.3. WEIGHT STACK.................................................................................................................................................6.4
7. SPECIAL OPERATIONS.....................................................................................................................................7.1
7.1. LOCKING DOWN THE CABLE FIXING DOWELS....................................................................................................7.1
8. MAINTENANCE...................................................................................................................................................8.1
8.1. CLEANING ........................................................................................................................................................8.1
8.1.1. Cleaning the frame and painted parts..................................................................................................8.1
8.1.2. Cleaning the chrome-plated parts........................................................................................................8.1
8.1.3. Cleaning upholstery .............................................................................................................................8.1
8.2. ROUTINE MAINTENANCE...................................................................................................................................8.3
8.2.1. Check the cross, bars and weight stack plates.....................................................................................8.3
8.2.2. Check the cables...................................................................................................................................8.3
8.2.3. Check the pulleys..................................................................................................................................8.3
8.2.4. Check the mechanisms .........................................................................................................................8.3
8.2.5. Check the gas spring............................................................................................................................8.4
8.2.6. Check the lever limit switch buffers......................................................................................................8.4
8.2.7. Check the cross limit switch.................................................................................................................8.4
8.2.8. Checking the upholstery.......................................................................................................................8.4
8.2.9. Checking various rubber parts.............................................................................................................8.4
8.3. SPECIAL MAINTENANCE....................................................................................................................................8.5
8.3.1. Replacing the cables.............................................................................................................................8.5
8.3.2. Screw and bolt check............................................................................................................................8.5
8.3.3. Checking for mechanism play ..............................................................................................................8.5
8.3.4. Checking cross alignment ....................................................................................................................8.5
9. RECOMMENDED SPARE PARTS ....................................................................................................................9.1
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UNICA EVOLUTION: Service & Maintenance Manual - rev. 1.1
Page ii
9.1. CABLES ............................................................................................................................................................9.1
9.2. UPHOLSTERY....................................................................................................................................................9.1
9.3. SPARE PARTS....................................................................................................................................................9.2
10.WELLNESS MATE CONFIGURATION.........................................................................................................10.1
10.1.USER: MACHINE CONFIGURATION...................................................................................................................10.2
10.1.1.Language............................................................................................................................................10.2
10.1.2.Units of measurement.........................................................................................................................10.2
10.1.3.Pacer display......................................................................................................................................10.3
10.1.4.Pacer speed........................................................................................................................................10.3
10.1.5.Pacer return speed .............................................................................................................................10.3
10.1.6.Display icons during the exercise ......................................................................................................10.4
10.1.7.Value of additional weight .................................................................................................................10.4
10.1.8.Enabling the TGS key.........................................................................................................................10.4
10.1.9.Enable function keys...........................................................................................................................10.5
10.1.10. Display exercise duration................................................................................................................10.5
10.1.11. Display power..................................................................................................................................10.5
10.1.12. Repetition number used for ROM acquisition.................................................................................10.6
10.1.13. Inactive time before reset ................................................................................................................10.6
10.1.14. Default number of repetitions..........................................................................................................10.6
10.1.15. Default number of sets.....................................................................................................................10.7
10.1.16. Default recovery time during the exercise.......................................................................................10.7
10.1.17. Default recovery time during the test..............................................................................................10.7
10.1.18. Clock setting: hours.........................................................................................................................10.8
10.1.19. Clock setting: minutes .....................................................................................................................10.8
10.1.20. Inactive time before end of set.........................................................................................................10.8
10.2.USER: ROM CONFIGURATION ........................................................................................................................10.9
10.3.SERVICE: MACHINE CONFIGURATION............................................................................................................10.10
10.3.1.Machine code ...................................................................................................................................10.10
10.3.2.Minimum ROM length......................................................................................................................10.11
10.3.3.Default ROM start............................................................................................................................10.11
10.3.4.Default ROM length .........................................................................................................................10.11
10.3.5.%ROM first rep................................................................................................................................10.11
10.3.6.Type of encoder used........................................................................................................................10.12
10.3.7.Enable display adjustments..............................................................................................................10.12
10.3.8.Configure type of reader for Wellness System .................................................................................10.13
10.3.9.Configuration of the weight stack ....................................................................................................10.13
10.4.SERVICE: WEIGHT STACK CONFIGURATION...................................................................................................10.15
10.4.1.Complete procedure.........................................................................................................................10.15
10.4.2.Fast procedure .................................................................................................................................10.16
10.5.SERVICE: PERIPHERALS CHECK PANEL..........................................................................................................10.18
10.6.SERVICE: CHECK/SET COUNTERS ..................................................................................................................10.20
10.6.1.Neon lamp on-time...........................................................................................................................10.20
10.6.2.Machine on-time...............................................................................................................................10.20
10.6.3.Number of repetitions.......................................................................................................................10.20
10.6.4.Total weight lifted.............................................................................................................................10.21
10.7.CONFIGURATION: CALIBRATION...................................................................................................................10.22
10.8.RESET PROCEDURE .......................................................................................................................................10.23
11.APPENDIX...........................................................................................................................................................11.1
11.1.TOOLS TO USE ................................................................................................................................................11.1

UNICA EVOLUTION: Service & Maintenance Manual - rev. 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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UNICA EVOLUTION: Service & Maintenance Manual - rev. 1.1
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
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.

UNICA EVOLUTION: Service & Maintenance Manual - rev. 1.1
2. TECHNICAL CHARACTERISTICS
2.1. PRODUCT VERSIONS
Evolution Unica is available in 2 different versions, either with or without the Wellness Mate. The
version equipped with Wellness Mate is named Unica Evolution Trainer:
Code Description Wellness mate
M310 Unica Evolution NO
M311 Unica Evolution Trainer YES
This manual is referred specifically to the M310 “Unica Evolution” machine version,
however the M311 “Unica Evolution Trainer” differs only in the presence of the
Wellness Mate, and information about this unit is provided in the separate manual:
“Wellness Mate: Service & Maintenance Manual”
2.2. PRODUCT CODE
The following variations have been defined:
• Language:
Code Description
ITA Italian
ING English
FRA French
SPA Spanish
TED German
• Frame color:
Code Color
AL Silver
NB Black
• Upholstery color:
Code Color
M Bordeaux
L Black
X Cream
I Tobacco
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UNICA EVOLUTION: Service & Maintenance Manual - rev. 1.1
Page 2.2
• Packing type:
Code Packing
E Abroad
I Italy
Thus the machine code will be:
M310 - ITA - ALL - E
Packing
Frame and
upholstery color
Language
Machine code
2.3. MECHANICAL CHARACTERISTICS
Width (minimum) 120 cm 47 inch
Width (during exercise) 160 cm 63 inch
Length 184 cm 72 inch
Height 207 cm 82 inch
Weight of the machine 150 Kg 331 lb
Weights pack 90 Kg 198 lb
2.4. 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
2.5. CONFORMITY TO REGULATIONS
The machine conforms to the following directives:
Directive Europe USA
Machinery Safety Directive 89/392/EEC 89/392/EEC

UNICA EVOLUTION: Service & Maintenance Manual - rev. 1.1
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
2.4. “Ambient specifications”.
3.2. INSTALLATION
The machine is supplied partially disassembled, packed in three boxes which are tied together and
fixed to a wooden pallet having the dimensions given in the following drawing.
The machine installation and assembly procedures are illustrated in a CD-ROM with video clips
and photographs.
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UNICA EVOLUTION: Service & Maintenance Manual - rev. 1.1
Page 3.2
3.3. MOVING
Once the machine has been assembled, it can be moved over short distances using the two wheels
supplied with the machine.
Figure 3.3-1
1. Screw the two wheels of Figure 3.3-1 into
the special holes on the sides of the weight
stack column using a 17 mm Box wrench.
Figure 3.3-2
2. Insert the ring provided ainto the footrest
and the bottom hook into the Leg Extension
lever as shown in the figures Figure 3.3-2.
Continued on following page →

UNICA EVOLUTION: Service & Maintenance Manual - rev. 1.1
Figure 3.3-3
3. Lift the machine on the rear wheels, using
the anatomical handgrips of the Arm Curl
lever and move the equipment with great
caution, due to the risk of it tipping over.
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UNICA EVOLUTION: Service & Maintenance Manual - rev. 1.1
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UNICA EVOLUTION: Service & Maintenance Manual - rev. 1.1
4. ACCESSORIES
The equipment is supplied with the following accessories:
• lifting ring;
• handle;
• pulley handle;
• ankle strap;
• floor exercise mat;
• set of tools for assembly and adjustments;
• oil for lubrication;
• User’s manual;
• wheels for moving the equipment;
• screws for assembly.
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UNICA EVOLUTION: Service & Maintenance Manual - rev. 1.1
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UNICA EVOLUTION: Service & Maintenance Manual - rev. 1.1
5. WHAT IF …
5.1. THE WEIGHT STACK DOES NOT SLIDE SMOOTHLY
This problem is due to insufficient lubrication of the bars or grime build-up from a mixture of dust
and oil. Clean and lubricate as illustrated below:
Photo 5.1-1
1. Use a paper towel slightly dampened with
ethyl alcohol to clean the weight stack bars
of the machine, removing dust and grime.
2. Reassemble the cross and add a few drops of
the oil found in the service box to the cross
bushings as shown in the photo below.
3. Move the cross up and down, making sure to
distribute the oil evenly along the full length
of the bars.
4. Dry excess oil from the bushings with a dry
cloth.
Do not use too much oil, and dry all
excess thoroughly since too much oil
could cause more dust to build up.
When the bars and bushings are
especially dirty, and only when the cross
alone or at most the cross and one plate
are selected, it may not return to rest on
the other plates but stick a few
centimeters above. Clean and lubricate
the bars thoroughly, as well as inside the
bushings where the bars slide, using a
paper towel moistened with ethyl
alcohol.
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UNICA EVOLUTION: Service & Maintenance Manual - rev. 1.1
Page 5.2
5.2. THE WEIGHT STACK CABLE IS NOT TAUT
This problem is caused by the elongation of the weight stack cable, especially during the initial
period of use. To correct the problem it is therefore necessary to adjust the cable tension.
If the cable is new, perform a few repetitions at maximum load before adjusting its
tension, in order to “pull” the cable.
Figure 5.2-1
1. Select the minimum weight load: the only
weight selected will be that of the cross.
2. Back off the lock nut ausing a 17mm gauge
wrench.
3. Turn the adjusting screw busing a 17mm
gauge wrench and tighten the lock nut
Check the cable tension by performing a
few repetitions with the minimum
weight load and slowly resting the cross
on the weight stack. The cross should
stay properly rested on the weight stack,
with the cable slightly taut.

UNICA EVOLUTION: Service & Maintenance Manual - rev. 1.1
6. HOW TO DISASSEMBLE THE …
6.1. SEAT GAS SPRING
Figure 6.1-1
1. Using the special pliers, remove the snap
ring aand pull out the pin bfrom the lower
part of the seat gas piston.
Figure 6.1-2
2. Remove the plastic cap from the hole on the
frame which allows access to the parts
indicated by the letters in the figure.
3. Remove the snap ring c and pull out the pin d
from the upper part of the seat gas piston.
Continued on following page →
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UNICA EVOLUTION: Service & Maintenance Manual - rev. 1.1
Page 6.2
Figure 6.1-3
4. After releasing the entire seat gas piston
group from the frame, if only the gas piston
is damaged proceed as follows:
• back off the nut esecuring it to the fork,
using a 13-mm wrench;
• back off the lock-nut fusing a 13-mm
wrench and unscrew the component g
which is connected to the cable of the
seat adjustment system.
5. To reassemble the gas piston, follow the
disassembly instructions in reverse order.