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BIOSTRENGTH LINE
Technogym BIOSTRENGTH LINE User Manual
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S
ERVICE
&
MAINTENANCE MANUAL
R
EV
. 2.1
2
Table of Contents
Default Chapter
5
Table of Contents
5
1 General Notices
17
Introduction
17
Recommendations
17
General Rules for Repair Procedures
18
2 Technical Specifications
19
Mechanical Characteristics
19
Abdominal Crunch
19
Lower Back
19
Leg Extension
20
Leg Curl
20
Vertical Traction
20
Shoulder Press
21
Chest Press
21
Rowing Torso
21
Leg Press
22
Electrical Characteristics
22
Ambient Specifications
23
Conformity to Regulations
23
Unified Board Version
24
Type Awiring Diagram
24
Type Bwiring Diagram
30
Type Cwiring Diagram
37
Type Dwiring Diagram
44
Separated Board Version
52
Type Awiring Diagram
52
Type Bwiring Diagram
59
Type Cwiring Diagram
68
Type Dwiring Diagram
77
3 Operating Principle
89
Block Diagram
89
Power Entry
90
Power Switch
90
Fuses
90
Filter
90
Voltage Selector Board
90
Power Supply
90
Transformer
90
Display
91
Bio Servo Board
91
LP Driver Board
92
Wire Encoder
93
Solenoid
93
Weight Stack Motor
93
Seat Motor
93
LP Seat Motor
94
Zero Sensor
94
Safety Device
94
Solenoid Management
96
Mechanics
96
Controls
96
The Signals Involved
97
Weight Stack Motor Management
100
Mechanics
100
Controls
101
Mechanics
106
Controls
106
S Eat Motor Management
106
Seat Motor Management for Leg Press
112
Mechanics
112
Controls
112
The Signals Involved
114
Wire Encoder Management
118
Mechanics
118
Controls
118
The Signals Involved
118
4 Accessories
121
5 Installation Instructions
123
Specifications and Requirements
123
Installation
123
First Power
123
6 Troubleshooting
125
Manual Components Test
126
Weight Stack Motor
126
Zero Sensor Status
127
Seat Motor
128
Solenoid
129
Automatic Components Test
131
Monitoring Communication between the Bio Servo Board and the CPU Board
131
Counter Display
132
Reset Procedure
133
Buffer Battery Test
133
TGS Interface Test
133
FPGA Test
133
Solenoid Test
134
Weight Stack Motor Test
134
Seat Motor Test
136
Test Procedure During Use
138
Weight Stack Motor Failure
138
Seat Motor Test
138
The Lcd Displays the Message "Hw Fault: Check Battery
140
The Lcd Displays the Message "Hw Fault: Check Tgs
141
The Lcd Displays the Message "Hw Fault: Check Fpga
143
The Lcd Displays the Message "Add-On Weight Problem = Magnet
144
The Lcd Displays the Message "Weight Stack Problem = Fail
148
The Lcd Displays the Message "Weight Stack Problem = Motor
149
The Lcd Displays the Message "Weight Stack Problem = Encoder
152
The Lcd Displays the Message "Weight Stack Problem = Limit Switch Sensor
154
The Lcd Displays the Message "Seat Problem = Fail
156
The Lcd Displays the Message "Emergency Activated
157
The Lcd Displays the Message "Seat Problem = Motor
159
For Leg Press
159
The Lcd Displays the Message "Seat Problem = Encoder
164
For Leg Press
164
The Display Does Not Turn on
169
The Machine Does Not Read the Tgs: the Red Led on the Key Reader Is Not Lit
174
7 Disassembly of Components
175
Abdominal Crunch
175
Disassembling the Display
175
Removing the Electronic Display Boards
176
Removing the EPROM
178
Disassembling the TLCBR Chip
179
Disassembling the Main Keyboard
180
Disassembling the Plexiglas Weight Stack Guard
181
Disassembling the Weight Stack Pulleys
182
Disassembling the Weight Stack Cover
185
Disassembling the Additional Weight
185
Disassembling the Encoder
186
Disassembling the Solenoid
187
Disassembling the Selector Brush
188
Disassembling the Zero Sensor
189
Disassembling the Weight Stack Selection System
190
Disassembling the Weight Stack Selection Chain
191
Disassembling the Weight Stack Motor
192
Disassembling the Cross Stops
193
Disassembling the Cross
194
Disassembling the Sinker
195
Disassembling the Weight Stack Plates
196
Disassembling the Bars
197
Disassembling the Seat Guard
198
Disassembling the Electrical Box
200
Disassembling the Electronic Components of the Electrical Box
200
Disassembling the Bell Guard
203
Disassembling the Weight Stack Frame Guard
203
Disassembling the Weight Stack Cable
204
Disassembling the Bell
205
Disassembling the Primary Shaft
206
Disassembling the Secondary Shaft
209
Disassembling the Weight Stack Frame Pulley
211
Disassembling the Mat
212
Disassembling the Power Entry
213
Disassembling the Starter Plate and Fuses
214
Lower Back
215
Disassembling the Display
215
Removing the Electronic Display Boards
216
Removing the EPROM
218
Disassembling the TLCBR Chip
219
Disassembling the Main Keyboard
220
Disassembling the Plexiglas Weight Stack Guard
221
Disassembling the Weight Stack Pulleys
222
Disassembling the Weight Stack Cover
225
Disassembling the Additional Weight
225
Disassembling the Encoder
226
Disassembling the Solenoid
227
Disassembling the Selector Brush
228
Disassembling the Zero Sensor
229
Disassembling the Weight Stack Selection System
230
Disassembling the Weight Stack Selection Chain
231
Disassembling the Weight Stack Motor
232
Disassembling the Cross Stops
233
Disassembling the Cross
234
Disassembling the Sinker
235
Disassembling the Weight Stack Plates
236
Disassembling the Bars
237
Disassembling the Seat Guard
238
Disassembling the Electrical Box
240
Disassembling the Electronic Components of the Electrical Box
240
Disassembling the Bell Guard
243
Disassembling the Weight Stack Frame Guard
243
Disassembling the Weight Stack Cable
244
Disassembling the Release Lever Cable
245
Disassembling the Bell
247
Disassembling the Primary Shaft
248
Disassembling the Secondary Shaft
251
Disassembling the Weight Stack Frame Pulley
253
Disassembling the Mat
254
Disassembling the Power Entry
255
Disassembling the Starter Plate and Fuses
256
Leg Extension
257
Disassembling the Display
257
Removing the Electronic Display Boards
258
Removing the EPROM
260
Disassembling the TLCBR Chip
261
Disassembling the Main Keyboard
262
Disassembling the Seat Keyboard
263
Disassembling the Plexiglas Weight Stack Guard
264
Disassembling the Weight Stack Pulleys
265
Disassembling the Weight Stack Cover
266
Disassembling the Additional Weight
268
Disassembling the Encoder
269
Disassembling the Solenoid
270
Disassembling the Selector Brush
271
Disassembling the Zero Sensor
272
Disassembling the Weight Stack Selection System
273
Disassembling the Weight Stack Selection Chain
274
Disassembling the Weight Stack Motor
275
Disassembling the Cross Stops
276
Disassembling the Cross
277
Disassembling the Sinker
278
Disassembling the Weight Stack Plates
279
Disassembling the Bars
280
Disassembling the Seat Guard
281
Disassembling the Seat Motor
282
Disassembling the Electrical Box
284
Disassembling the Electronic Components of the Electrical Box
285
Disassembling the Bell Guard
287
Disassembling the Weight Stack Frame Guard
288
Disassembling the Weight Stack Cable
289
Disassembling the Bell
290
Disassembling the Primary Shaft
291
Disassembling the Secondary Shaft
294
Disassembling the Weight Stack Frame Pulley
296
Disassembling the Mat
297
Disassembling the Power Entry
298
Disassembling the Starter Plate and Fuses
299
Leg Curl
300
Disassembling the Display
300
Removing the Electronic Display Boards
301
Removing the EPROM
303
Disassembling the TLCBR Chip
304
Disassembling the Main Keyboard
305
Disassembling the Seat Keyboard
306
Disassembling the Plexiglas Weight Stack Guard
307
Disassembling the Weight Stack Pulleys
308
Disassembling the Weight Stack Cover
309
Disassembling the Additional Weight
311
Disassembling the Encoder
312
Disassembling the Solenoid
313
Disassembling the Selector Brush
314
Disassembling the Zero Sensor
315
Disassembling the Weight Stack Selection System
316
Disassembling the Weight Stack Selection Chain
317
Disassembling the Weight Stack Motor
318
Disassembling the Cross Stops
319
Disassembling the Cross
320
Disassembling the Sinker
321
Disassembling the Weight Stack Plates
322
Disassembling the Bars
323
Disassembling the Seat Guard
324
Disassembling the Seat Motor
325
Disassembling the Electrical Box
327
Disassembling the Electronic Components of the Electrical Box
328
Disassembling the Bell Guard
330
Disassembling the Weight Stack Frame Guard
331
Disassembling the Weight Stack Cable
332
Disassembling the Bell
333
Disassembling the Primary Shaft
334
Disassembling the Secondary Shaft
337
Disassembling the Weight Stack Frame Pulley
339
Disassembling the Mat
340
Disassembling the Power Entry
341
Disassembling the Starter Plate and Fuses
342
Vertical Traction
343
Disassembling the Display
343
Removing the Electronic Display Boards
344
Removing the EPROM
346
Disassembling the TLCBR Chip
347
Disassembling the Main Keyboard
348
Disassembling the Seat Keyboard
349
Removing the Seat
350
Disassembling the Front Guard
351
Disassembling the Electrical Box
352
Disassembling the Electronic Components of the Electrical Box
353
Disassembling the Upright Guard
355
Disassembling the Seat Motor
356
Disassembling the Prestart Cable
357
Disassembling the Rear Guard
359
Disassembling the Solenoid
360
Disassembling the Selector Brush
361
Disassembling the Weight Stack Cable
362
Disassembling the Pulleys
363
Disassembling the Zero Sensor
364
Disassembling the Weight Stack Selection System
365
Disassembling the Weight Stack Selection Chain
367
Disassembling the Weight Stack Motor
368
Disassembling the Rear Lever Guard
369
Disassembling the Lever Cable
370
Disassembling the Cam Group
371
Disassembling the Levers
372
Disassembling the Front Lever Guard
373
Disassembling the Weight Stack Cover
374
Disassembling the Column Extension
375
Disassembling the Columns
376
Disassembling the Additional Weight
377
Disassembling the Encoder
378
Disassembling the Bars
379
Disassembling the Cross and Weight Stack Plates
380
Disassembling the Sinker
381
Disassembling the Mats
382
Disassembling the Display Support
383
Disassembling the Power Entry
384
Disassembling the Starter Plate and Fuses
385
Shoulder Press
386
Disassembling the Display
386
Removing the Electronic Display Boards
387
Removing the EPROM
389
Disassembling the TLCBR Chip
390
Disassembling the Main Keyboard
391
Disassembling the Seat Keyboard
392
Removing the Seat
393
Disassembling the Front Guard
394
Disassembling the Electrical Box
395
Disassembling the Electronic Components of the Electrical Box
396
Disassembling the Upright Guard
398
Disassembling the Seat Motor
399
Disassembling the Prestart Cable
400
Disassembling the Rear Guard
402
Disassembling the Solenoid
403
Disassembling the Selector Brush
404
Disassembling the Weight Stack Cable
405
Disassembling the Pulleys
406
Disassembling the Zero Sensor
407
Disassembling the Weight Stack Selection System
408
Disassembling the Weight Stack Selection Chain
410
Disassembling the Weight Stack Motor
411
Disassembling the Rear Lever Guard
412
Disassembling the Lever Cable
413
Disassembling the Cam Group
414
Disassembling the Levers
415
Disassembling the Front Lever Guard
416
Disassembling the Weight Stack Cover
417
Disassembling the Column Extension
418
Disassembling the Columns
419
Disassembling the Additional Weight
420
Disassembling the Encoder
421
Disassembling the Bars
422
Disassembling the Cross and Weight Stack Plates
423
Disassembling the Sinker
424
Disassembling the Mats
425
Disassembling the Display Support
426
Disassembling the Power Entry
427
Disassembling the Starter Plate and Fuses
428
Chest Press
429
Disassembling the Display
429
Removing the Electronic Display Boards
430
Removing the EPROM
432
Disassembling the TLCBR Chip
433
Disassembling the Main Keyboard
434
Disassembling the Seat Keyboard
435
Disassembling the Rear Plexiglas Weight Stack Guard
436
Disassembling the Front Plexiglas Weight Stack Guard
437
Disassembling the Weight Stack Pulley
438
Disassembling the Weight Stack Cover
439
Disassembling the Additional Weight
441
Disassembling the Encoder
442
Disassembling the Solenoid
443
Disassembling the Selector Brush
444
Disassembling the Zero Sensor
445
Removing the Seat
446
Disassembling the Upright Guard
447
Disassembling the Closing Panels
448
Disassembling the Weight Stack Selection System
449
Disassembling the Weight Stack Selection Chain
450
Disassembling the Weight Stack Motor
451
Disassembling the Cross Stops
452
Disassembling the Cross
453
Disassembling the Sinker
454
Disassembling the Weight Stack Plates
455
Disassembling the Bars
456
Disassembling the Seat Motor
457
Disassembling the Electrical Box
458
Disassembling the Electronic Components of the Electrical Box
459
Disassembling the Pulleys
461
Disassembling the Weight Stack Cable
462
Disassembling the Lever Cable
463
Disassembling the Doubling Cable
464
Disassembling the Cam Group
465
Disassembling the Front Guard
466
Disassembling the Prestart Cable
467
Disassembling the Levers
469
Disassembling the Mats
470
Disassembling the Display Support
471
Disassembling the Power Entry
472
Disassembling the Starter Plate and Fuses
473
Rowing Torso
474
Disassembling the Display
474
Removing the Electronic Display Boards
475
Removing the EPROM
477
Disassembling the TLCBR Chip
478
Disassembling the Main Keyboard
479
Disassembling the Seat Keyboard
480
Disassembling the Rear Plexiglas Weight Stack Guard
481
Disassembling the Front Plexiglas Weight Stack Guard
482
Disassembling the Weight Stack Pulley
483
Disassembling the Weight Stack Cover
484
Disassembling the Additional Weight
486
Disassembling the Encoder
487
Disassembling the Solenoid
488
Disassembling the Selector Brush
489
Disassembling the Zero Sensor
490
Disassembling the Mats
491
Disassembling the Prestart Levers
492
Disassembling the Upright Guard
493
Disassembling the Weight Stack Selection System
495
Disassembling the Weight Stack Selection Chain
496
Disassembling the Weight Stack Motor
497
Disassembling the Cross Stops
498
Disassembling the Cross
499
Disassembling the Sinker
500
Disassembling the Weight Stack Plates
501
Disassembling the Bars
502
Disassembling the Electrical Box
503
Disassembling the Electronic Components of the Electrical Box
504
Disassembling the Pulleys
506
Disassembling the Weight Stack Cable
507
Disassembling the Doubling Cable
508
Disassembling the Cam Group
509
Disassembling the Levers
510
Disassembling the Chest Rest Release Knob
511
Disassembling the Lever Guard
512
Disassembling the Lever Cable
513
Disassembling the Lever Shaft
514
Disassembling the Seat Guard
515
Disassembling the Seat Motor
516
Disassembling the Power Entry
517
Disassembling the Starter Plate and Fuses
518
Leg Press
519
Disassembling the Display
519
Removing the Electronic Display Boards
521
Removing the EPROM
523
Disassembling the TLCBR Chip
524
Disassembling the Main Keyboard
525
Disassembling the Seat Keyboard
526
Disassembling the Weight Stack Cover
527
Disassembling the Plexiglas Weight Stack Guard
528
Disassembling the Weight Stack Pulleys
529
Disassembling the Encoder
530
Disassembling the Weight Stack Cover Frame
531
Disassembling the Additional Weight
532
Disassembling the Solenoid
533
Disassembling the Selector Brush
534
Disassembling the Zero Sensor
535
Disassembling the Weight Stack Selection System
536
Disassembling the Weight Stack Selection Chain
537
Disassembling the Weight Stack Motor
538
Disassembling the Cross Stops
539
Disassembling the Cross
540
Disassembling the Sinker
541
Disassembling the Weight Stack Plates
542
Disassembling the Bars
543
Disassembling the Rear Guard
544
Disassembling the Central Guard
545
Disassembling the Main Electrical Box
546
Disassembling the Electronic Components of the Main Electrical Box
547
Disassembling the Secondary Electrical Box
549
Disassembling the Electronic Components of the Secondary Electrical Box
550
Disassembling the Seat Motor Photocell
551
Disassembling the Seat Motor Brushes
552
Disassembling the Seat Movement Limitation Microswitch
553
Disassembling the Seat Motor Unit
554
Removing the Seat
556
Disassembling the Seat Sliding Bars
557
Disassembling the Shoulder Rest Group Release Cable
558
Disassembling the Shoulder Rest Group
560
Disassembling the Tachogenerator Guard
562
Disassembling the Front Guard
563
Disassembling the Lever Mat Rubber
564
Disassembling the Levers
565
Disassembling the Lever Cable
566
Disassembling the Weight Stack Frame Guard
567
Disassembling the Weight Stack Cable
568
Disassembling the Doubling Cable
569
Disassembling the Cam Group
570
Disassembling the Weight Stack Frame Pulleys
571
Disassembling the Starter Plate and Fuses
572
Disassembling the Mat
573
Disassembling the Power Entry
574
8 Adjustments
575
Adjusting the Weight Stack Plate Selection
575
Offset
575
Distance between Plates
576
Weight Stack Motor Inertia
577
Adjusting the Mechanisms Phasing
578
Abdominal Crunch
578
Lower Back
580
Leg Extension
582
Leg Curl
584
Vertical Traction
586
Shoulder Press
587
Chest Press
588
Rowing Torso
591
Leg Press
593
Adjusting the Position of the Cross Limit Switch
594
Adjusting the Weight Stack Cable Tension
595
Adjusting the Prestart Cable Tension
596
Adjusting the Primary Prestart Cable Tension
596
Adjusting the Secondary Prestart Cable Tension
597
Adjusting the Lever Cable
598
Adjusting the Doubling Cable
599
Adjusting the Zero Sensor Position
600
Adjusting the Position of the Weight Stack Selection System
601
Adjusting the Tension of the Weight Stack Selection Chain
602
Adjusting the Primary Shaft - Secondary Shaft Chain Alignment
603
Adjusting the Primary Shaft - Secondary Shaft Chain Tension
604
Adjusting the Release Cable Tension
605
Adjusting the Current Limit on the Wsmi and Sami Board
606
Lcd Contrast
607
Buzzer Tone
608
9 Configuring the Machine
609
Configuring Parameter Defaults
609
Configuring the Technical Parameters
609
Machine Code
610
Number of Pulses for Weight Stack Selection
611
Weight Stack Motor Inertia
611
Weight Stack Motor Selection Window
612
Distance between Plates
612
Minimum ROM Length
615
Seat Motor Inertia
615
Default ROM Start
616
Default ROM Length
616
ROM First Rep
617
Configuring the User Parameters
619
Language
619
Unit of Measure
619
Using the Additional Weight
620
Using the Function Keys
620
Time-Out" Setting
620
Enable Pacer
621
Setting the Default Seat Position
621
Pacer Speed
624
Table of Factory Settings
624
User Parameters
624
ROM Parameters
624
Plate Distance
625
Seat Motor Parameters
625
Displaying Working Parameters
626
Weight Stack Motor Running Time
626
Weight Stack Motor Test Cycles
626
Number of Relay Switching Cycles to Move the Weight Stack Motor Downward
626
Number of Fail Signals Produced by the Weight Stack Motor Interface Board
627
Seat Motor Running Time
627
Seat Motor Test Cycles
627
Number of Relay Switching Cycles to Move the Seat Motor Upward
627
Number of Relay Switching Cycles to Move the Seat Motor Downward
628
Number of Fail Signals Produced by the Seat Motor Interface Board
628
Number of Solenoid Relay Switching Cycles
628
Machine Running Time
628
Number of Repetitions Carried out on the Machine
629
Total Weight Lifted Using the Machine
629
Editing the Working Parameters
630
Weight Stack Motor Running Time
630
Weight Stack Motor Test Cycles
630
Number of Relay Switching Cycles to Move the Weight Stack Motor Downward
631
Number of Fail Signals Produced by the Weight Stack Motor Interface Board
631
Seat Motor Running Time
631
Seat Motor Test Cycles
631
Number of Relay Switching Cycles to Move the Seat Motor Upward
631
Number of Relay Switching Cycles to Move the Seat Motor Downward
632
Number of Fail Signals Produced by the Seat Motor Interface Board
632
Number of Solenoid Relay Switching Cycles
632
Machine Running Time
632
Number of Repetitions Carried out on the Machine
633
Total Weight Lifted Using the Machine
633
10 Scheduled Maintenance
635
External Cleaning
635
Preparing Working Conditions
635
Cleaning Operations
635
Internal Cleaning
636
Preparing Working Conditions
636
Cleaning Operations
636
Mechanical Operations
637
Preparing Working Conditions
637
Check the Weight Stack Selection System
637
Check the Weight Stack Plate Springs
637
Check the Cross, Bars and Weight Stack Plates
637
Check the Additional Weight
638
Check the Cables
638
Check the Mechanisms
638
Check the Gas Springs
638
Check the Pulleys
638
Check the Cam Group
638
Check the Primary and Secondary Shaft Connection Chain
638
Check the Lever Limit Switch Buffers
639
Check the Cross Limit Switch
639
Check the Leg Press Seat Mechanism
639
Check the Seat Mechanism for Other Machines
639
Check the Leg Press Back and Shoulder Rest
639
Check the Wire Encoder
639
Electrical/Electronic Operations
640
Preparing Working Conditions
640
Check the Wiring and Connections
640
Check the Display
640
Check Wear on Components
640
Check the Component Functions
641
Software Configuration
642
Preparing Working Conditions
642
Configuration Check
642
11 Appendix
643
Configuration Parameters for Exercise Rom Acquisition
643
Calculating Repetitions
643
Locating the Serial Number
644
4
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Technogym BIOSTRENGTH LINE Specifications
General
Brand
Technogym
Model
BIOSTRENGTH LINE
Category
Fitness Equipment
Language
English
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