TGO TGO810 Instruction Manual

Maintenance
Guidelines
Revision Status: UK 02.9

www.tgogc.com
[email protected]
www.tgogc.com
[email protected]
3
Content
Maintenance Overview
Site Owners Maintenance Obligations 4
Maintenance Guidelines 6
Before you start the maintenance 6
Maintenance Logbook 8
Notes 9
Fault Report 10
Product Maintenance
Pull Up/Assisted Pull Up - TGO810 12
Dips/Leg Raise - TGO800 14
Triple Step Up - TGO905 15
Leg Press/Bench - TGO951 16
Ski Machine - TGO920 18
Oblique/Treadmill - TGO8041 20
Cross Trainer - TGO861 22
Recumbent Bike - TGO891 24
Hand Bike - TGO907 26
Spinning Bike - TGO970 28
Lat Pull Down/Shoulder Press - TGO825 30
Chest Press/Seated Row - TGO835 32
Cardio Fitness Module - UKTGOGC11 34
Cardio Energy Module - UKTGOGC11 35
Energy Product Maintenance
Energy Cross Trainer - TGO862 36
Energy Cross Trainer - LGH - TGO862 38
Energy Recumbent Bike - TGO892 40
Energy Recumbent Bike - LGH - TGO892 42
Energy Product Maintenance Continued
Energy Hand Bike - TGO908 44
Energy Hand Bike - LGH - TGO908 46
Energy Spinning Bike - TGO971 48
Energy Spinning Bike - LGH - TGO971 50
EDU - TGO100 52
Energy Equipment General System Configuration 54
EDU General System Configuration 55

www.tgogc.com
[e-mail]
www.tgogc.com
[email protected]
5
Site Owners Maintenance
Obligations
Revision 1
Maintenance of your outdoor gym
The guarantee of your equipment, which you will need to sign and send back, is subject to routine
maintenance being carried out.
Maintenance methodology
• Checks
• Diagnosis
• Maintenance
• Replacements
During maintenance you may require additional grips and a selection of fixings, fastenings and
tools. In addition touch up paint is available. All replacements are available from The Great
Outdoor Gym Company. When maintenance is performed on a coastal site, non-ferrous tools must
be used. Maintenance work may also require work to be done on electrical equipment. You can
purchase new parts or signage by calling your representative or emailing us on maintenance@
tgogc.com
To validate the guarantee of the equipment TGO require the maintenance outlined below to
be carried out routinely. There is a basic daily/weekly/monthly inspection to be included in
maintainer’s duties. It is the main quarterly inspection that must be logged via the maintenance
log sheets. Records of quarterly maintenance logs must be retained for a minimum of 5 years by
the site owner.
In the unlikely event of equipment either breaking or becoming defective through normal wear
and tear, the site owner will need to make a warranty claim. Please ask TGO for an official claim
form. The warranty does not cover vandalism and is not valid unless quarterly maintenance has
been completed and evidenced by the completion of the maintenance log sheets. If equipment
needs to be removed, the equipment can be removed by the site owner and the site needs to be
made safe to prevent the creation of a trip hazard.
Subsequent Services
1) Site owners responsibilities- daily/weekly/monthly {recommended)
• Wipe off any graffiti with anti-graffiti wipes
• Sweep the site and remove litter
• Clean down surfaces
• Repaint any chips that have occurred if need be with the correct paint
• Check for any damage, establish whether or not it is vandalism, and report this to the TGO
with an accompanying digital photo. TGO may recommend that the facility is closed until
the faultor damage is rectified. Ensure the equipment and outdoor gym site is left safe.
www.tgogc.com
[email protected]
2) Site owners responsibilities every three months (not optional)
• Perform daily/weekly/monthly responsibilities
• Use the maintenance log sheets to check over each and every piece of equipment. The
Distributor and or the site owner must keep copies of maintenance logs for a minimum
of 5 years from the date of purchase and produce these if required on any warranty claim.
(NB: failure to carry this out each quarter will invalidate all product warranties).
• Repaint any chips that might have occurred with the correct paint.
• Lubricate joints and parts identified with suitable lubricating oil.
Recommended oils are: ACgo, Ambersil 40 or SM4 (WD40 type water dispersants are
not suitable)
• Look in detail at each item of equipment in turn working from the top down
& checking that all of the components are present, secure and functional.
• Check also that all plastic caps etc. if fitted, are in place.
• Check chains & connectors (if fitted) are not worn.
• Where limiters are incorporated check they are functioning correctly.
• Check by shaking the whole unit for any free play to the ground mounting or foundations.
• Tighten bolts and nuts if loose and report incidents to TGO.
• Look out for hazards and if necessary close down site.
• Check for any damage, establish whether or not it is vandalism, and report this to TGO
with an accompanying digital photo. Action this as appropriate which might include
ensuring the facility is not available to use if appropriate until resolved.
• Replace bearings where necessary
• Ensure equipment is left safe
All spare parts are available for replacement from TGO or their suppliers
Annual inspection
At least one independent annual inspection should be undertaken by a suitably qualified
inspector preferably a Register of Play Inspectors International (RPII) Annual Inspector or
equivalent.
For emergencies
Contact TGO on [phone]

www.tgogc.com
[email protected]
Maintenance Guidelines
The Great Outdoor Gym Company Ltd retains all intellectual property rights including copyright with
respect to the contents of this document, which may not be copied or in any other way reproduced, either
in part or in its entirety, without express and prior permission. Original ideas presented in this document
may neither be implemented nor adapted without appropriate formal consent.
Before you start the maintenance
The TGO product range has been designed to require very little maintenance to keep it running smoothly
and looking great. However, as many of the pieces have moving parts these will need light maintenance
to keep everything operating as they should. Please make sure you use this manual when carrying out
maintenance on your gym. If you have any queries regarding the products or their maintenance then please
get in touch with the team, email us at [e-mail]. This manual outlines all the different levels of
maintenance requirements for each product in the TGO range.
Equipment
To carry out the light maintenance inspections you will need the ‘TGO Light Maintenance Kit’. Included in
this kit is:
- Security Drive Bit Set
Pinned Hex and Pinned Torx Various Sizes
- Touch Up Pen
Green
Black
Silver
- GT85 (200ml)
You will also need some other basic tools to assist you. These are:
- Socket Wrench
- Cleaning Wipes
- Non-ferrous tools (for use on coastal sites)
- Bucket of water/cloth (For cleaning)
- G3 Compound
Bearing replacement tools:
- Portable brazing torch (equivalent to a Vulcane Express 472 with a type 14 Nozzle and Map/pro Gas)
- Loctite 270
Prohibited Equipment
Power tools for tightening and loosening bolts are prohibited. This includes drills and impact wrenches.
Using these types of power tools increases the risk of damaging the fixing and paint around the joint.
Spares
You may require spare parts from time to time for each product. Please refer to the product specific spares
lists at the back of this document for details.
www.tgogc.com
[email protected]
7
Frequency
The frequency of maintenance required will vary according to the quality of inspections and popularity of
site or item of equipment. The minimum level of maintenance is high quality maintenance every quarter. a
light daily /weekly/monthly check is still recommend.
Recording
A record of maintenance undertaken on each item of equipment shall be maintained, including
photographs and written details of location, date and time of the visit, the work completed and the
person(s) completing the work.
Annual Inspections
An independent annual inspection is recommended to ensure the gym conforms with EN 16630.
Cleaning
It is recommend the units are hand cleaned with water and a non-abrasive cleaners. Do not use a jet
washer.
Removing Salt Deposits -
The best method of cleaning is by regular washing of the coating using a solution of warm water and mild
detergent. All surfaces should be cleaned using a soft cloth or sponge, using nothing harsher than natural
bristle brushes.
Do NOT under any circumstances use strong solvents or solutions containing:
• Chlorinated Hydrocarbons
• Esters
• Ketones
• Abrasive Cleaner or polish
Surface Settled Rust -
You may find surface rust above paint work or on weld lines. This is nothing to worry about, it is usual small
particles that have rested on the surface that cause the rust. Clean the equipment with the G3 Compound
to remove any surface settled rust
Variation of gym equipment
Gym equipment may vary slightly from the images and diagrams.
They will all still operate in the same manner and require the same
level of maintenance.
Assembly/Disassembly of equipment
As fixing are removed or added panels may move and cause damage
to the paint if the equipment is operated. Always check that there is a
clearance gap between moving components. E.g. on the cross trainer
between the Crank disc and cladding.
Energy equipment and gyms
When working on any energy equipment take precautions against electric
shock by isolating the batteries, equipment DC input and isolator unit
where applicable

www.tgogc.com
[e-mail]
Notes Product Date
DD/MM/YY
9
Maintenance Logbook
To validate the guarantee of the equipment TGO require the maintenance to be carried out quarterly
(every three months) and recorded in this Logbook and retained for a minimum of 5 years by the site
owner.
Notes
Please use this area where required to record any details you may need when performing any maintenance
www.tgogc.com
[email protected]
Company Name Date Signature
Year XX
DD/MM/YY
Independent annual inspection
Year XX
Independent annual inspection
Year XX
Independent annual inspection
Year XX
Independent annual inspection
Year XX
Independent annual inspection
www.tgogc.com
[email protected]

www.tgogc.com
[email protected]
REF FAULT POSSIBLE CAUSE RECOMMENDED ACTION
1
Stiff Brake set too strong
Electrical short
Bushing worn
Material ingress
Misalignment
Loosen brake
Check wiring/LGH for damage
Replace bushing, lubricate bushing
Check for material ingress and remove
Inspect moving components
2
Loose Brake set too weak
Worn gears
Misaligned gear
Broken gearbox
Generator brush not contacting
Tighten brake
Inspect and replace worn gear/s
Align and Loctite grub screw
Replace faulty part/s
Inspect and replace worn/faulty part/s
3
Noisy Brake disc dirty
Material ingress
Worn parts
Misalignment
Clean brake disc
Remove ingressed material and clean
Replace worn part/s
Check dissimilar moving components are not touching
4
Paint
Damage
Due to vandalism
Due to mechanical failure
Salt deposit
Graffiti
Clean area and repaint with TGO approved paint
Repair cause, and action as above
Clean with warm water and mild detergent
Clean with anti-graffiti wipes
5
Jammed Material ingress
Misalignment
Over forced
Check for material ingress and remove
Inspect moving components
Apply force in correct direction/dismantle equipment
6
No power No USB power
No LED strip light
No USB power & LED strip light
Inspect and replace USB board
Inspect and replace LED strip
Inspect mechanical gearing and LGH, Replace faulty part/s
11
www.tgogc.com
[email protected]
Main Axle
Stub Axle
Footplate/Pedal/Tread Plate
Crank Disc Cover
Oilite Bearing
Ball Bearing
Handle/Grip
Handle Arm/Support
Upper Pivot Point
Lower Pivot Point
Main Frame/Body
Signage
Base Plate
Seat
Back Rest
Bumb Stop/Limiter
ID Label/
Production
Number
Fault Report
When trying to repair the TGO equipment follow the maintenance methodology.
Maintenance methodology
• Checks
• Diagnosis
• Maintenance
• Replacements
Without proper checks on the equipment it will be impossible to progress any further.
Below is a list of basic fault terms and possible causes and recommended actions.
Part Identication
Where possible the most accurate name or description for the part is to be used. It is understandable that
not all the names will be accurate. On the next page are some examples of common terminology to use.

www.tgogc.com
[email protected]
Pull Up/Assisted Pull Up - TGO810
The Maintainer should perform the following checks and actions to the equipment:
General Regular Visit:
• Operate the machine and identify if there are any issues such as noises or stiffness. Try and
diagnose where this is coming from and resolve via maintenance oil or adjustment if possible. If this
problem cannot be resolved, leave the product safe and seek advice from TGO office info@tgogc.
com
• Remove graffiti from paint and signage with non-abrasive cleaners (tested for suitability)
• Inspect and report any damage to signage
• Inspect and report any damage to components
• Check all the fixings to ensure they are tight and secure. Retighten or replace where appropriate
• Specifically check the 8x structural inward facing bolts visible from the outside of the main
framework [see image label 1]. If any of these are loose remove them (one at a time) and replace
with a new fixing ensuring Loctite 270 is applied. If it is difficult to fit the new fixing, then you will
need to clean out the threaded hole in the bearing housing
• Touch up any paint damage
• Specifically check the spoke pins at the bottom. Ensure both are present and correct. If any are
missing, close the piece down and order some more. [See image label 2]
Quarterly (compulsory):
• Perform all general regular visit maintenance listed above.
• Spray all moving parts (joints only) with a 3in1 maintenance oil (not penetrating oil). [See image
label 3]
• Clean off any salt deposits
• Log quarterly site maintenance visit
Bearing replacement [See image label 3]:
• The correct specification of bearing and specific instructions can be supplied by TGO. Bearings
must only be changed with the correct tools. Oilite bearings are used and due to the very soft
material the bearings should be pressed in and not impacted, it may be necessary to ream replaced
Oilite bearings to obtain the correct fit. Replaced Oilite bearings will require additional lubrication
during a settling period
Handle replacement:
• The maintainer should have stock of handles on his or her maintenance visits. The receiving
handle should be cleaned to remove surface contamination. A small amount of adhesive (TGO can
supply appropriate glue) should be applied to the inside of the handle and to the machine handle,
the handle can be rotated onto the arm to give the glue a good coverage in the process. The handle
will be at risk of removal until the glue cures
1
1
3
2
2
3
3
www.tgogc.com
[email protected]
13

www.tgogc.com
[email protected]
Dips/Leg Raise - TGO800
The Maintainer should perform the following checks and actions to the equipment:
General Regular Visit:
• Operate the machine and identify if there are any issues and ensure item is working properly
• Remove graffiti from paint and signage with non-abrasive cleaners (tested for suitability)
• Inspect and order replacement to signage if vandalised
• Inspect and report any damage to backrest
• Visually check for loose components or missing fixings
• Check tightness of all fixings. If loose ensure these are retightened
• Touch up any paint damage
• Leave the site safe
Quarterly (compulsory):
• Perform all general regular visit maintenance listed above.
• If the backrest needs replacement, replace
• Clean off any salt deposits
• Log quarterly site maintenance visit
www.tgogc.com
[email protected]
15
Triple Step Up - TGO905
The Maintainer should perform the following checks and actions to the equipment:
General Regular Visit:
• Operate the machine and identify if there are any issues and ensure item is working properly
• Remove graffiti from paint with non-abrasive cleaners (tested for suitability)
• Ensure no sharp edges have developed on footplates
• Inspect and order replacement to signage if vandalised
• Inspect and report any damage to steps
• Visually check for loose components or missing fixings
• Check tightness of all fixings. If loose ensure these are retightened
• Touch up any paint damage
Quarterly (compulsory):
• Perform all general regular visit maintenance listed above.

www.tgogc.com
[email protected]
2
1
2
www.tgogc.com
[email protected]
17
Leg Press/Bench - TGO951
The Maintainer should perform the following checks and actions to the equipment:
General Regular Visit:
• Remove graffiti from paint and signage with non-abrasive cleaners (tested for suitability)
• Inspect and report any damage to signage
• Inspect and report any damage to components
• Visually check for loose components or missing fixings
• Check tightness of all fixings. If loose ensure these are retightened
• Run the traveller over the full range of movement unloaded and loaded, note and report any
problems, noise or stiffness
• Touch up any paint damage
Quarterly (compulsory):
• Perform all general regular visit maintenance listed above.
• Operate the machine and identify if there are any issues such as noises or stiffness. Try and
diagnose where this is coming from and resolve via maintenance oil or adjustment if possible. If this
problem cannot be resolved, leave the product safe and seek advice from TGO office info@tgogc.
com
• Inspect the visible stop wedges for any damage and report, replace if necessary
• Spray all moving parts (joints only) with a suitable maintenance oil (not penetrating oil)
• Clean the tracks with a light oil based cleaner to prevent fouling
• Oil the track with a 3in1 maintenance oil
• Grease the diagonal surfaces of the brake stops
• Remove traveller if necessary to access polyurethane wheels and other parts
• Clean off any salt deposits
• Log quarterly site maintenance visit
Traveller stops and wheel replacement:
• The traveller stops and polyurethane traveller wheels [see image label 1] are considered to be
service parts and are not covered under the terms of the warranty.
Seat & back pad replacement:
• Saddles and seat pads [see image label 2] are considered to be service parts and are not covered
under the terms of the warranty for wilful damage or vandalism. The correct saddles and seat pads
can be supplied by TGO
Handle replacement:
• Soft handles are considered to be serviced parts. The maintainer should have a stock of handles.
The handle should be cleaned to remove surface contamination. A small amount of adhesive (TGO
can supply appropriate glue) should be applied to the inside of the handle and to the machine
handle, the handle can be rotated onto the arm to give the glue a good coverage in the process. The
handle will be at risk of removal until the glue cures.

www.tgogc.com
[email protected]
1
1
1
1
1
11
1
2
2
www.tgogc.com
[email protected]
19
Ski Machine - TGO920
The Maintainer should perform the following checks and actions to the equipment:
General Regular Visit:
• Remove graffiti from paint and signage with non-abrasive cleaners (tested for suitability)
• Inspect and report any damage to signage
• Inspect and report any damage to components
• Visually check for loose components or missing fixings
• Check tightness of all fixings. If loose ensure these are retightened
• Operate the machine through the full range of movement, note and report any problems, stiffness
or excessive noise
• Check function of limiters and report any problems
• Touch up any paint damage
Quarterly (compulsory):
• Perform all general regular visit maintenance listed above.
• Operate the machine and identify if there are any issues such as noises or stiffness. Try and
diagnose where this is coming from and resolve via maintenance oil or adjustment if possible. If this
problem cannot be resolved, leave the product safe and seek advice from TGO office info@tgogc.
com
• Spray all moving parts (joints only) with a suitable maintenance oil (not penetrating oil)
• Clean off any salt deposits
• Log quarterly site maintenance visit
Bearing replacement [see image label 1]:
• The correct specification of bearing and specific instructions can be supplied by TGO. Bearings
must only be changed with the correct tools. Oilite bearings are used and due to the very soft
material the bearings should be pressed in and not impacted, it may be necessary to ream replaced
Oilite bearings to obtain the correct fit. Replaced Oilite bearings will require additional lubrication
during a settling period
Handle replacement:
• Soft handles are considered to be serviced parts. The maintainer should have a stock of handles.
The handle should be cleaned to remove surface contamination. A small amount of adhesive (TGO
can supply appropriate glue) should be applied to the inside of the handle and to the machine
handle, the handle can be rotated onto the arm to give the glue a good coverage in the process. The
handle will be at risk of removal until the glue cures.
Ski Machine Base plate retrofit [see image label 2]:
• The single tube frame Ski Machine requires a retrofitted base plate. This will be evident that it is in
place (see photo). Please contact your supplier or TGOGC directly for more information or if you are
unsure if your machine has the retrofit base part fitted. If you do not believe the retrofit base part has
been fitted please ensure the site is safe by removing the Ski Machine or taping off the equipment
from use.

www.tgogc.com
[email protected]
11
www.tgogc.com
[email protected]
21
Oblique/Treadmill - TGO8041
The Maintainer should perform the following checks and actions to the equipment:
General Regular Visit:
• Remove graffiti from paint and signage with non-abrasive cleaners (tested for suitability)
• Inspect and report any damage to signage
• Inspect and report any damage to components
• Visually check for loose components or missing fixings
• Check tightness of all fixings. If loose ensure these are retightened
• Spin the disk(s), loaded and unloaded in both directions also try to lift, note and report any
problems, noise or stiffness
• Touch up any paint damage
Quarterly (compulsory):
• Perform all general regular visit maintenance listed above.
• Operate the machine and identify if there are any issues such as noises or stiffness. Try and
diagnose where this is coming from and resolve via maintenance oil or adjustment if possible. If this
problem cannot be resolved, leave the product safe and seek advice from TGO office info@tgogc.
com
• Spray top & bottom bearings with a suitable maintenance oil (not penetrating oil)
• Clean off any salt deposits
• Log quarterly site maintenance visit
Bearing replacement [see image label 1]:
• The correct specification of bearing can be supplied by TGO. Bearings must only be changed
with the correct tools. Oilite bearings are used and due to the very soft material the bearings
should be pressed in and not impacted, it may be necessary to ream replaced Oilite bearings to
obtain the correct fit. Replaced Oilite bearing will require additional lubrication during a settling
period

www.tgogc.com
[email protected]
2
43
5
1
5
www.tgogc.com
[email protected]
23
Cross Trainer - TGO861
The Maintainer should perform the following checks and actions to the equipment:
General Regular Visit:
• Remove graffiti from paint and signage with non-abrasive cleaners (tested for suitability)
• Inspect and report any damage to signage
• Inspect and report any damage to components
• Visually check for loose components or missing fixings. Specifically the 8 countersunk bolts that
hold the main rotational discs in place. These are accessible via the cover place, by removing the
two countersunk bolts [see image label 1]
• Check tightness of all fixings. If loose ensure these are retightened
• Check the foot plank axle is tightly secured in place. Any lateral movement should be reported to
TGO [see image label 2]
• Turn the crank in both directions, loaded and unloaded, note and report any problems, noise or
excessive stiffness
• Touch up any paint damage
Quarterly (compulsory):
• Perform all general regular visit maintenance listed above.
• Operate the machine and identify if there are any issues such as noises or stiffness. Try and
diagnose where this is coming from and resolve via maintenance oil or adjustment if possible. If this
problem cannot be resolved, leave the product safe and seek advice from TGO office inf[email protected]
• Check the 8 countersunk bolts that hold the main rotational discs in place are tight and secure.
These are accessible via the cover place, by removing the two countersunk bolts. If any of these are
loose remove them (one at a time) and replace with a new fixing ensuring Loctite 270 is applied and
it is firmly tightened. If it is difficult to fit the new fixing, then you will need to clean out the
threaded hole in the central axle [see image label 1]
• Check the foot plank axle is tightly secured in place. If there is any lateral movement then it must be
removed and the flange bolt replaced. Please ensure that Loctite 270 is applied and it is firmly
tightened [see image label 2]
• Check the countersunk bolts in handle bearing positions are tight and secure. If any of these are
loose remove them (one at a time) and replace with a new fixing ensuring Loctite 270 is applied and
it is firmly tightened. If it is difficult to fit the new fixing, then you will need to clean out the
threaded hole [see image label 4 & 5]
• Ensure the drainage holes are free from debris footplates [see image label 3]
• Spray all moving parts (joints only) with a suitable maintenance oil (not penetrating oil) [see image
label 1,2,4 & 5]
• Remove cover if necessary to access bearings
• Clean off any salt deposits
• Log quarterly site maintenance visit
Bearing replacement [see image label 1,2,4 & 5]:
• The correct specification of bearing and specific instructions can be supplied by TGO. Bearings
must only be changed with the correct tools. Oilite bearings are used and due to the very soft
material the bearings should be pressed in and not impacted, it may be necessary to ream replaced
Oilite bearings to obtain the correct fit. Replaced Oilite bearings will require additional lubrication
during a settling period
Handle replacement:
• Soft handles are considered to be serviced parts. The maintainer should have a stock of handles.
The handle should be cleaned to remove surface contamination. A small amount of adhesive (TGO
can supply appropriate glue) should be applied to the inside of the handle and to the machine
handle, the handle can be rotated onto the arm to give the glue a good coverage in the process. The
handle will be at risk of removal until the glue cures.

www.tgogc.com
[email protected]
2
1
3
www.tgogc.com
[email protected]
25
Recumbent Bike - TGO891
The Maintainer should perform the following checks and actions to the equipment:
General Regular Visit:
• Remove graffiti from paint and signage with non-abrasive cleaners (tested for suitability)
• Inspect and report any damage to signage
• Inspect and report any damage to components
• Visually check for loose components or missing fixings. Specifically the 8 bolts that hold the main
rotational discs in place [see image label 1]
• Check tightness of all fixings. If loose ensure these are retightened
• Check the pedal axle is tightly secured in place. Any lateral movement should be reported to TGO
[see image label 2]
• Turn the pedals and the crank in both directions, note and report any problems, excessive noise or
stiffness (some brake noise and resistance is expected)
• Touch up any paint damage
Quarterly (compulsory):
• Perform all general regular visit maintenance listed above.
• Check for loose components or missing fixings. Specifically the 8 bolts that hold the main rotational
discs in place. If any of these are loose remove them (one at a time) and replace with a new fixing
ensuring Loctite 270 is applied and it is firmly tightened. If it is difficult to fit the new fixing, then
you will need to clean out the threaded hole in the central axle [see image label 1]
• Operate the machine and identify if there are any issues - noises/stiffness. Try and diagnose where
this is coming from and resolve via maintenance oil or adjustment if possible. If this problem cannot
be resolved, leave the product safe and seek advice from TGO office [e-mail]
• Check the pedal axle is tightly secured in place. If there is any lateral movement then it must be
removed and the flange bolt replaced. Please ensure that Loctite 270 is applied and it is firmly
tightened [see image label 2]
• Spray all moving parts (joints only) with a suitable maintenance oil (not penetrating oil)
• Remove cover if necessary to adjust or reset the brakes – brake adjustment should be made by
the correct tool and adjusting the tension screw to each spring plate to achieve a balanced pressure
and appropriate resistance for the intended users. If squeaking of the break is noted
it is recommended a small amount of copper grease paste is put at the back top and bottom ends of
the friction pads against the housing to eliminate resonance [see image label 3]
• Clean off any salt deposits
• Log quarterly site maintenance visit
Bearing replacement:
• The correct specification of bearing and specific instructions can be supplied by TGO. Bearings
must only be changed with the correct tools. Oilite bearings are used and due to the very soft
material the bearings should be pressed in and not impacted, it may be necessary to ream replaced
Oilite bearings to obtain the correct fit. Replaced Oilite bearings will require additional lubrication
during a settling period [see image label 1, 2]
Seat and back pad replacement:
• Seat and back pads are considered to be service parts and are not covered under the terms of the
warranty for wilful damage or vandalism. The correct saddles and seat pads can be supplied by TGO

www.tgogc.com
[email protected]
2
1
3
www.tgogc.com
[email protected]
27
Hand Bike - TGO907
The Maintainer should perform the following checks and actions to the equipment:
General Regular Visit:
• Remove graffiti from paint and signage with non-abrasive cleaners (tested for suitability)
• Inspect and report any damage to signage
• Inspect and report any damage to components
• Visually check for loose components or missing fixings. Specifically the 8 bolts that hold the main
rotational discs in place [see image label 1]
• Check tightness of all fixings. If loose ensure these are retightened
• Check the pedal axle is tightly secured in place. Any lateral movement should be reported to TGO
[see image label 2]
• Turn the pedals and the crank in both directions, note and report any problems, excessive noise or
stiffness (some brake noise and resistance is expected)
• Touch up any paint damage
Quarterly (compulsory):
• Perform all general regular visit maintenance listed above.
• Check for loose components or missing fixings. Specifically the 8 bolts that hold the main rotational
discs in place. If any of these are loose remove them (one at a time) and replace with a new fixing
ensuring Loctite 270 is applied and it is firmly tightened. If it is difficult to fit the new fixing, then
you will need to clean out the threaded hole in the central axle [see image label 1]
• Operate the machine and identify if there are any issues - noises/stiffness. Try and diagnose where
this is coming from and resolve via maintenance oil or adjustment if possible. If this problem cannot
be resolved, leave the product safe and seek advice from TGO office [e-mail]
• Check the pedal axle is tightly secured in place. If there is any lateral movement then it must be
removed and the flange bolt replaced. Please ensure that Loctite 270 is applied and it is firmly
tightened [see image label 2]
• Spray all moving parts (joints only) with a suitable maintenance oil (not penetrating oil)
• Remove cover if necessary to adjust or reset the brakes – brake adjustment should be made by
the correct tool and adjusting the tension screw to each spring plate to achieve a balanced pressure
and appropriate resistance for the intended users. If squeaking of the brake is noted
it is recommended a small amount of copper grease paste is put at the back top and bottom ends of
the friction pads against the housing to eliminate resonance [see image label 3]
• Clean off any salt deposits
• Log quarterly site maintenance visit
Bearing replacement [see image label 1 & 2]:
• The correct specification of bearing and specific instructions can be supplied by TGO. Bearings
must only be changed with the correct tools. Oilite bearings are used and due to the very soft
material the bearings should be pressed in and not impacted, it may be necessary to ream replaced
Oilite bearings to obtain the correct fit. Replaced Oilite bearings will require additional lubrication
during a settling period

www.tgogc.com
[email protected]
2
13
www.tgogc.com
[email protected]
29
Spinning Bike - TGO970
The Maintainer should perform the following checks and actions to the equipment:
General Regular Visit:00+
• Remove graffiti from paint and signage with non-abrasive cleaners (tested for suitability)
• Inspect and report any damage to signage
• Inspect and report any damage to components
• Visually check for loose components or missing fixings. Specifically the 8 bolts that hold the main
rotational discs in place [see image label 1]
• Check the pedal axle is tightly secured in place. Any lateral movement should be reported to TGO
[see image label 2]
• Turn the pedals and the crank in both directions, note and report any problems, excessive noise or
stiffness (some brake noise and resistance is expected)
• Touch up any paint damage
Quarterly (compulsory):
• Perform all general regular visit maintenance listed above.
• Check for loose components or missing fixings. Specifically the 8 bolts that hold the main rotational
discs in place. If any of these are loose remove them (one at a time) and replace with a new fixing
ensuring Loctite 270 is applied and it is firmly tightened. If it is difficult to fit the new fixing, then
you will need to clean out the threaded hole in the central axle [see image label 1]
• Operate the machine and identify if there are any issues - noises/stiffness. Try and diagnose where
this is coming from and resolve via maintenance oil or adjustment if possible. If this problem cannot
be resolved, leave the product safe and seek advice from TGO office [e-mail]
• Check the pedal axle is tightly secured in place. If there is any lateral movement then it must be
removed and the flange bolt replaced. Please ensure that Loctite 270 is applied and it is firmly
tightened [see image label 2]
• Spray all moving parts (joints only) with a suitable maintenance oil (not penetrating oil)
• Remove cover if necessary to adjust or reset the brakes – brake adjustment should be made by
the correct tool and adjusting the tension screw to each spring plate to achieve a balanced pressure
and appropriate resistance for the intended users. If squeaking of the brake is noted
it is recommended a small amount of copper grease paste is put at the back top and bottom ends of
the friction pads against the housing to eliminate resonance [see image label 3]
• Clean off any salt deposits
• Log quarterly site maintenance visit
Bearing replacement [see image label 1 & 2]:
• The correct specification of bearing and specific instructions can be supplied by TGO. Bearings
must only be changed with the correct tools. Oilite bearings are used and due to the very soft
material the bearings should be pressed in and not impacted, it may be necessary to ream replaced
Oilite bearings to obtain the correct fit. Replaced Oilite bearings will require additional lubrication
during a settling period
Seat and back pad replacement:
• Seat and back pads are considered to be service parts and are not covered under the terms of the
warranty for wilful damage or vandalism. The correct saddles and seat pads can be supplied by TGO

www.tgogc.com
[email protected]
1
1
1
1
2
2
1
1
1
www.tgogc.com
[email protected]
31
Lat Pull Down/Shoulder Press - TGO825
The Maintainer should perform the following checks and actions to the equipment:
General Regular Visit:
• Remove graffiti from paint and signage with non-abrasive cleaners (tested for suitability)
• Inspect and report any damage to signage
• Inspect and report any damage to components
• Visually check for loose components or missing fixings
• Check tightness of all fixings. If loose ensure these are retightened
• Operate the machine through the full range of movement, loaded and unloaded, note and report
any problems, stiffness or noise
• Check function of stops and report any problems
• Touch up any paint damage
Quarterly (compulsory):
• Perform all general regular visit maintenance listed above.
• Operate the machine and identify if there are any issues such as noises or stiffness. Try and
diagnose where this is coming from and resolve via maintenance oil or adjustment if possible. If this
problem cannot be resolved, leave the product safe and seek advice from TGO office info@tgogc.
com
• Specifically check the tear drop pin fixings. If any of these are loose ensure they are removed and
replaced. Please ensure that the correct fixings are used and that Loctite 270 is applied. Ensure the
new fixing is tightened firmly in place. [see image label 1]
• Specifically check the fixings in the main bearing locations. [see image label 2]
• Spray all moving parts (joints only) with a suitable maintenance oil (not penetrating oil) [see image
label 1 & 2]
• Clean off any salt deposits
• Log quarterly site maintenance visit
Bearing replacement [see image label 1 & 2]:
• The correct specification of bearing and specific instructions can be supplied by TGO. Bearings
must only be changed with the correct tools. Oilite bearings are used and due to the very soft
material the bearings should be pressed in and not impacted, it may be necessary to ream replaced
Oilite bearings to obtain the correct fit. Replaced Oilite bearings will require additional lubrication
during a settling period
Handle replacement:
• Soft handles are considered to be serviced parts. The maintainer should have a stock of handles.
The handle should be cleaned to remove surface contamination. A small amount of adhesive (TGO
can supply appropriate glue) should be applied to the inside of the handle and to the machine
handle, the handle can be rotated onto the arm to give the glue a good coverage in the process. The
handle will be at risk of removal until the glue cures.
Stop replacement:
Saddles and seat pad replacement:
• Saddles and seat pads are considered to be service parts and are not covered under the terms of the
warranty for wilful damage or vandalism. The correct saddles and seat pads can be supplied by TGO
Stop replacement:
• The concealed stops are considered to be service parts and are not covered under the terms of the
warranty. The correct stops can be supplied by TGO

www.tgogc.com
[email protected]
1
22
1
1
1
1
1
www.tgogc.com
[email protected]
33
Chest Press/Seated Row - TGO835
The Maintainer should perform the following checks and actions to the equipment:
General Regular Visit:
• Remove graffiti from paint and signage with non-abrasive cleaners (tested for suitability)
• Inspect and report any damage to signage
• Inspect and report any damage to components
• Visually check for loose components or missing fixings
• Check tightness of all fixings. If loose ensure these are retightened
• Operate the machine through the full range of movement, loaded and unloaded, note and report
any problems, stiffness or noise
• Check function of stops and report any problems
• Touch up any paint damage
Quarterly (compulsory):
• Perform all general regular visit maintenance listed above.
• Operate the machine and identify if there are any issues such as noises or stiffness. Try and
diagnose where this is coming from and resolve via maintenance oil or adjustment if possible. If this
problem cannot be resolved, leave the product safe and seek advice from TGO office info@tgogc.
com
• Specifically check the tear drop pin fixings. If any of these are loose ensure they are removed and
replaced. Please ensure that the correct fixings are used and that Loctite 270 is applied. Ensure the
new fixing is tightened firmly in place. [see image label 1]
• Spray all moving parts (joints only) with a suitable maintenance oil (not penetrating oil)
• Clean off any salt deposits
• Log quarterly site maintenance visit
Bearing replacement [see image label 1]:
• The correct specification of bearing and specific instructions can be supplied by TGO. Bearings
must only be changed with the correct tools. Oilite bearings are used and due to the very soft
material the bearings should be pressed in and not impacted, it may be necessary to ream replaced
Oilite bearings to obtain the correct fit. Replaced Oilite bearings will require additional lubrication
during a settling period
Handle replacement:
• Soft handles are considered to be serviced parts. The maintainer should have a stock of handles.
The handle should be cleaned to remove surface contamination. A small amount of adhesive (TGO
can supply appropriate glue) should be applied to the inside of the handle and to the machine
handle, the handle can be rotated onto the arm to give the glue a good coverage in the process. The
handle will be at risk of removal until the glue cures.
Stop replacement [see image label 2]:
• The concealed stops are considered to be service parts and are not covered under the terms of the
warranty. The correct stops can be supplied by TGO
Saddles and seat pad replacement:
• The correct saddles and seat pads can be supplied by TGO and instructions for replacements can be
sought by TGO

www.tgogc.com
[e-mail]
35
Cardio Energy Module - UKTGOGC11
It may be necessary at some stage to replace the Ball Bearings located within the Cardio Energy Module.
The Cardio Energy Module is the mechanical heart of the Energy Equipment. This should rarely need
visiting, but in the event it does, TGOGC have provided some basic instructions (below) on how to access
it. You will find a Cardio Energy Module on the following equipment at both standard and Coastal sites:
Cardio Fitness Module - UKTGOGC11
It may be necessary at some stage to replace the Ball Bearings located within the Cardio Fitness Module.
The Cardio Fitness Module is the mechanical heart of Cardio Equipment. This should rarely need visiting,
but in the event it does, TGOGC have provided some basic instructions (below) on how to access it.
You will find a Cardio Fitness Module on the following equipment at both standard and Coastal sites:
www.tgogc.com
[email protected]
1
3
4
The Ball Bearings is located
inside Bearing Housing
running on the Main Axle.
There are four (4) M10 Pin
Torx Screws per side that
attaches from outside the
unit and go through the
Crank Cover Disc. Loctite
has been applied to each
M10 Pin Torx Screws
Heat is required to loosen
the Loctite on the M10 Pin
Torx Screws. Apply using
the recommended or similar
Portable brazing torch.
Apply the heat directly to
each M10 Pin Torx Screw,
apply heat momentarily to
each and move on to the
next working in a radial
pattern. This could take
several minutes to fully
heat the length of the
Screw.
Note 1: Never heat one bolt
or area for an extended
period of time, always
allow for a pause to ensure
the paint does not become
effected.
Once the Loctite has been
loosen, the M10 Pin Torx
Screws can be removed
normally.
When assembling the Cardio
Energy Module use the
Loctite listed in the ‘TGO
Light Maintenance Kit’ on
the four (4) M10 Pin Torx
Screws per side
2
5
• TGO861 - Cross Trainer
• TGO891 - Recumbent Bike
• TGO907 - Hand Bike
• TGO970 - Spinning Bike
• TGO862 - Energy Cross Trainer
• TGO892 - Energy Recumbent Bike
• TGO908 - Energy Hand Bike
• TGO971 - Energy Spinning Bike
Note: These images are as a reference only, the precise
components vary between different equipment.
Note: These images are as a reference only, the precise
components vary between different equipment.
1
3
4
The Ball Bearings is located
inside Bearing Housing
running on the Main Axle.
There are four (4) M10 Pin
Torx Screws per side that
attaches from outside the
unit and go through the
Crank Cover Disc. Loctite
has been applied to each
M10 Pin Torx Screws
Heat is required to loosen
the Loctite on the M10Pin
Torx Screws. Apply using
the recommended or similar
Portable brazing torch.
Apply the heat directly to
each M10 Pin Torx Screw,
apply heat momentarily to
each and move on to the
next working in a radial
pattern. This could take
several minutes to fully
heat the length of the
Screw.
Note 1: Never heat one bolt
or area for an extended
period of time, always
allow for a pause to ensure
the paint does not become
effected.
Once the Loctite has been
loosen, the M10x50 Pin Torx
Screws can be removed
normally.
When assembling the Cardio
Fitness Module use the
Loctite listed in the ‘TGO
Light Maintenance Kit’ on
the four (4) M10 Pin Torx
Screws per side
2
5
66
www.tgogc.com
[email protected]
1
22
1

www.tgogc.com
[email protected]
2
4
3
5
1
5
www.tgogc.com
[email protected]
37
Energy Cross Trainer - TGO862
The Maintainer should perform the following checks and actions to the equipment:
General Regular Visit:
• Remove graffiti from paint and signage with non-abrasive cleaners (tested for suitability)
• Inspect and report any damage to signage
• Inspect and report any damage to components
• Visually check for loose components or missing fixings. Specifically the 8 countersunk bolts that
hold the main rotational discs in place. These are accessible via the cover place, by removing the
two countersunk bolts [see image label 1]
• Check the foot plank axle is tightly secured in place. Any lateral movement should be reported to
TGO [see image label 2]
• Turn the crank in both directions, loaded and unloaded, note and report any problems, noise or
excessive stiffness
• Touch up any paint damage
Quarterly (compulsory):
• Perform all general regular visit maintenance listed above.
• Operate the machine and identify if there are any issues such as noises or stiffness. Try and
diagnose where this is coming from and resolve via maintenance oil or adjustment if possible. If this
problem cannot be resolved, leave the product safe and seek advice from TGO office inf[email protected]
• Check the 8 countersunk bolts that hold the main rotational discs in place are tight and secure.
These are accessible via the cover place, by removing the two countersunk bolts. If any of these are
loose remove them (one at a time) and replace with a new fixing ensuring Loctite 270 is applied and
it is firmly tightened. If it is difficult to fit the new fixing, then you will need to clean out the
threaded hole in the central axle [see image label 1]
• Check the foot plank axle is tightly secured in place. If there is any lateral movement then it must be
removed and the flange bolt replaced. Please ensure that Loctite 270 is applied and it is firmly
tightened [see image label 2]
• Check the bolts in handle bearing positions are tight and secure. If any of these are loose remove
them (one at a time) and replace with a new fixing ensuring Loctite 270 is applied and it is firmly
tightened. If it is difficult to fit the new fixing, then you will need to clean out the threaded hole
[see image label 4 & 5]
• Ensure the drainage holes are free from debris footplates [see image label 3]
• Spray all moving parts (joints only) with a suitable maintenance oil (not penetrating oil) [see image
label 1,2,4 & 5]
• Remove cover if necessary to access bearings
• Clean off any salt deposits
• Log quarterly site maintenance visit
Bearing replacement [see image label 1,2,4 & 5]:
• The correct specification of bearing and specific instructions can be supplied by TGO. Bearings
must only be changed with the correct tools. Oilite bearings are used and due to the very soft
material the bearings should be pressed in and not impacted, it may be necessary to ream replaced
Oilite bearings to obtain the correct fit. Replaced Oilite bearings will require additional lubrication
during a settling period
Handle replacement:
• Soft handles are considered to be serviced parts. The maintainer should have a stock of handles.
The handle should be cleaned to remove surface contamination. A small amount of adhesive (TGO
can supply appropriate glue) should be applied to the inside of the handle and to the machine
handle, the handle can be rotated onto the arm to give the glue a good coverage in the process. The
handle will be at risk of removal until the glue cures.
Energy - General Regular Visit:
• Turn the pedals and the crank in both directions, note and report any problems, excessive noise or
stiffness from the gearing system and or motor.
• Check that USB ports are free from obstruction
• Check the LED console lights activate and move higher in with quicker pedal rotation.
Quarterly (compulsory):
• Perform all general regular visit maintenance listed above.
• Check the tightness of the motor support fixings
• Check the small Spur gear is in line with the internal gear and it hasn’t shifted and scratched the main disk.

www.tgogc.com
[email protected]
www.tgogc.com
[email protected]
39
Remove the graphic plate
from the console via the
four (4) M5 Pin Torx screws.
Retain the screws and put
the graphics plate to one
side.
Remove the four (4), now
exposed, M8 Pin Torx Screws
which hold the console to
the cross trainer frame.
Retain the xings in a safe
place.
NOTE 1: Take care as to not
damage the cabling as the
console is pulled away from
the cross Trainer.
To remove the USB, unplug
the two spade connector
ports. .
Remove the four (4) M3 Nuts
and washers, and slide
the USB board off the M3
inserts.
Reapply the new USB board
and reverse the above
steps to reapply the
console.
1
2
3
4
3
1
2
Energy Cross Trainer - LGH - TGO862
It may be necessary at some stage to maintain and access the LGH or the USB. The LGH is the electrical
heart of the Cardio Charge (Glow and Flow) Cross Trainer and is what manages the electricity produced
from the equipment. This should rarely need visiting, but in the event it does, TGOGC have provided some
basic instructions (below) on how to access it.
The USB is what TGOGC call a consumable item and therefore not warranted by TGO. However, it is a low
cost product and is simple to replace.
1
3
4
Remove the four (4) Lower
M8 Pin Torx Screws and
the two (2) top M8 Pin Torx
Screws, with washers.
The rear clad should be
placed to one side.
NOTE 1: This clad may be
held under tension and
spring mildly upon loosening
the xings.
The LGH will be bolted in a
vertically standing position
as shown in the diagram.
To remove the LGH fully, you
will need to unfasten the
two M4 xings, access from
the rear of the Parakeet
box.
To remove the LGH box
lid, in order to access the
electronics, all four (4) M4
Phillip Head screws will
need to be removed.
NOTE 2: Retain all xing in
a secure location during
maintenance.
NOTE 3: The lid screws
should be torqued to
5-7.5lbf.in, as to retain the
IP rating.
Reverse Procedure to
reassemble.
2
3
2
1