Technical Newsletter

By: Technogym After Sales Service N. 111 – March/April/May/June 2011

Technogym After Sales Service: e-mail: Service@technogym.com - fax: +39-0547-650150

02 11

Contents Excite Line • Malfunctions after Full System Restore • Procedure for returning parts to

Technogym HQ VISIO • Defective Red KINGSTON recovery stick • VISIOWEB parts • New SW version New Bike Excite • Adjustable pedal cranks A0000347-

A0000439 New Recline Excite • Adjustable pedal cranks A0000347-

A0000439 • New pedal axle • Damage to carriage flat cable (HS/touch

sensor signal) Run/Run Now Excite • "Burns" on tread belt • Breakage of elevation micro switch due to

crushing • ACTIVE WTV: machine restarts with

"striped" screen • ALE drive firmware vers. 2.64 Jog/Jog Now Excite • Breakage of elevation micro switch due to

crushing (2) Step Excite • Chain lubrication message continues to

appear Vario Excite • Creaking noise of pedal lever belt on

handlebar pulley • Automatic braking at high speed Crossover Excite • MAX braking when getting on the machine

Selection Line • Lat Machine: roller holder frame • M957-Abdominal Crunch: upgrading

shoulder rest to new Selection Update solution

• ABDUCTOR/ADDUCTOR: New solution for exercise position selector plate (2)

Element Line • MB43 – DAP: Jamming of first weight

stack plate • MB15, MB20, MB55, MB60, MB70, PA01,

PA02: conformity for users up to 180 kg • ABDUCTOR/ADDUCTOR: New solution for

exercise position selector plate (2) PURESTRENGTH • MG50-Leg Press: warping of footrest

plates KINESIS • Kinesis ONE – Omega: breakage of handle Free Weight Line • F001/F002/V001/V002: Breakage of

plastic bushings Kinesis Personal • Noisiness of motor arm assembly Run Personal • Malfunctions after Full System Restore TGS Components • New Wellness Expert: Problems entering

messages in Russian

Introduction

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Newsletters easier to read!

To make it easier to read the Newsletter, new icons have been added alongside the titles that give an immediate, visual indication of the type of content. The table below contains the key to the new icons.

Problem Solution

The item contains information about how to solve a known

problem.

Important Modification

A modification that is important for the user's safety or for preventing damage to the

machine.

Technical Modification

A modification that introduces improvements, upgrades or

simple aesthetic changes to the product.

Useful information

The item contains specific or more detailed information

about a product

Useful tools

The item provides information about useful tools, instruments

or products.

SW releases

The item contains information about new SW versions.

Excite Line TN 2011/02 - 30 June 2011

2011/02

Contents • 1BMalfunctions after Full System Restore

• Procedure for returning parts to Technogym HQ

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Malfunctions after Full System Restore If, after a Full System Restore, the machine exhibits certain malfunctions, such as selecting undesired languages or unexpected responses to the keys pressed on the display, the cause of the problem may be a complete loss of the Touch Screen calibration. To correct this problem and avoid the selection of undesired functions or settings, starting from VISIOWEB SW version 5.24.70, on the first machine power-up following a Full System Restore, the touch screen calibration procedure is automatically launched. If this updated SW version is not installed, the touch screen calibration procedure can be invoked by repeatedly pressing the touch-screen, 4 or 5 times, when the SW version appears on the display during the power-up sequence. If this procedure fails, connect a USB mouse and perform the same operation, but click the left mouse button instead of pressing the screen.

Procedure for returning parts to Technogym HQ

We would like to stress the importance of correctly managing the return of components to Technogym HQ from the countries involved in this activity and listed in the following table, using the form attached below. Observing the procedure makes it possible to ensure a more prompt and efficient service to everyone.

CODE COMPONENT COUNTRIES INVOLVED

W0004477XX ALE DRIVER W0004102XX AT UL DRIVER W0006316XX-# 15" VISIO W0006324XX-# 19" VISIO W0006837XX-# 15" VISIO JOG W0006728XX-# 19" VISIO RUN NOW W0005981XX-# 19" VISIO RUN PERS W0006920XX-# VISIOWEB 15" W0006921XX-# VISIOWEB 19" NOW W0006922XX-# VISIOWEB 15" JOG W0006923XX-# VISIOWEB HOME W0006931XX-# VISIOWEB 19" EXCITE T0000017AA ALE MED

ITALIA UK

USA GERMANY BENELUX FRANCE ESPANIA AUSTRIA SUISSE

DENMARK SWEDEN NORWAY IRELAND

With the “#” character replaced by the desired variant suffix. NOTE: Please note that the code to be specified in the form is that of the component being replaced.

Excite Line TN 2011/02 - 30 June 2011

2011/02

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VISIO TN 2011/02 - 30 June 2011

2011/02

Contents

• Defective Red KINGSTON recovery stick • 4BVISIOWEB parts

• New SW version

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Defective Red KINGSTON recovery stick Please note that the problem previously reported on red KINGSTON recovery sticks only affects the ones for VISIOWEB (0WR00800AA), and not those for VISIO (0WR00788AA). The new recovery stick, opportunely modified and correctly functioning, now has the code 0WR00800AB (see figure below).

. The 0WR00788AA recovery stick for VISIO instead continues to be usable and available.

VISIOWEB parts Replacement parts are available for some VISIOWEB components, which are listed in the corresponding parts catalog. In particular, these are: DESCRIPTION Digital/analog tuner board (DTV board) LCD Inverter Wi-Fi antennas Wi-Fi Board Touch screen External Display housing Headphone connector Main assembly (CPU-LCD-plate support)

VISIO TN 2011/02 - 30 June 2011

2011/02

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New SW version

The new SW version 5.24.70 is available and downloadable using PC Synch. The principal characteristics and functions introduced with respect to previous versions are detailed in the update summary file, available in the "News" section of the TG Direct "Home" page.

ATTENTION please take into account the following, before and during the SW upgrade. - When updating from versions older than 5. 16.26, it is necessary to reconfigure

the network settings, due to the change of Network Manager. - In general, the VISIO settings and configurations are retained, but to avoid any

inconvenience, the configurations can be saved to a USB key using the corresponding function in the Service Menu (2501).

- To update the SW it is not necessary to perform a Full System Restore, but only to use the “Upload Synch” function in the Service Menu (2501).

- The update lasts approximately 10 minutes. - At the end, remove the USB stick and press EXIT. The machine will be

automatically restarted. This restart also takes approximately 10 minutes, because the libraries and service packs are reinstalled.

- It is always advisable to also check the firmware version of the DTV-Board, and upgrade it to the latest version. To do this, use the function provided in the Service Menu (2501).

- After completing the update, check that all the VISIO functions are working correctly, and in particular: 1. Serial Number setting. 2. Receiver type setting. 3. “Wellness System Present” setting. 4. “Date”, “Time”, “Time Zone” setting.

New Bike Excite TN 2011/02 - 30 June 2011

2011/02

Contents • Adjustable pedal cranks A0000347-A0000439

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Adjustable pedal cranks A0000347-A0000439 To prevent breakage of the pedal cranks and possible premature wear of other components, all of the parts are now made of steel instead of aluminum. The new material has gone into production as of April, and any components ordered from now on as replacement parts will be made of steel. The codes of the components are given in the respective exploded drawings.

New Recline Excite TN 2011/02 - 30 June 2011

2011/01

Contents

• 7BAdjustable pedal cranks A0000347-A0000439 • 8BNew pedal axle

• Damage to carriage flat cable (HS/touch sensor signal)

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Adjustable pedal cranks A0000347-A0000439 To prevent breakage of the pedal cranks and possible premature wear of other components, all of the parts are now made of steel instead of aluminum. The new material has gone into production as of April, and any components ordered from now on as replacement parts will be made of steel. The codes of the components are given in the respective exploded drawings.

New pedal axle

A modification has been made to the pedal axle indicated in the figure below, to make it stronger and correct the fillet radius at some points where the axle diameter changes, to increase its resistance to shear stress during pedaling.

The new axle is fully interchangeable with the old one and has order code 0P001075AC.

Damage to carriage flat cable (HS/touch sensor signal)

We have found that the damage to the flat cable, which carries the HS and touch sensor signals from the carriage into the frame, is caused by pinching of the cable between the carriage and frame. To correct this problem, a new solution is now in production that includes a plastic chain to guide the movement of the cable, preventing it from following an incorrect path and being pinched during the motion of the carriage. The figure below shows some stages of the assembly, in which the new components are visible.

New Recline Excite TN 2011/02 - 30 June 2011

2011/02

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The component codes used for this new solution, which is not interchangeable with the previous one, are given in the corresponding exploded drawing. The SN of the first machines incorporating this new solution are: DAD73L11000096 DAD74L11000106 DAD7ML11000001

DAD73C11000085 DAD73W11000169 C4D73L11000002

For already-installed machines there is instead available a new modified code 0WCU0491AA available, which can be assembled in place of the currently installed solution to avoid this problem.

Run/Run Now Excite TN 2011/02 - 30 June 2011

2011/02

Contents

• "Burns" on tread belt • 11BBreakage of elevation micro switch due to crushing

• 12BACTIVE WTV: machine restarts with "striped" screen • ALE drive firmware vers. 2.64

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"Burns" on tread belt There is a new model of tread belt available which is fully interchangeable with the old one, and affords superior resistance to conditions of intensive use. It avoids the wear and damage that affects the central portion of the tread belt, in some cases even leaving residue with an appearance similar to burn marks on the running deck. The codes of the new tread belts for the various machine models are already available, and can be found in the corresponding exploded drawings. NOTE: before replacing the tread belt, carefully clean the running deck with

denatured ethyl alcohol, or replace it if it appears visibly damaged.

Breakage of elevation micro switch due to crushing There is a new bracket available with code 0N001947AA, indicated in the figure below, which protects the elevation travel limit switch in the event of the machine overshooting its descent.

This component can be assembled on any machine using the same fixing screws as the plate upon which the micro switch itself is fixed.

Run/Run Now Excite TN 2011/02 - 30 June 2011

2011/02

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ACTIVE WTV: machine restarts with "striped" screen If on restarting the machine, a striped screen appears similar to that in the figure below, the problem is likely due to breakage of the LCD inverter.

We therefore recommend, as a first step, to immediately replace this component The component code is given in the corresponding exploded drawing.

ALE drive firmware vers. 2.64 Please note that, starting from firmware version 2. 64 of the ALE drive, the errors associated with malfunction of the 2 fans inside the drive have been reintroduced. The errors are signaled and reported with error codes E20 and E21. ATTENTION: During repairs, if the cover of the drive housing is removed, disconnecting the fan mounted upon it, the machine will lock out; it is therefore necessary to open the cover and rest it on one side without disconnecting the fan cable.

Jog/Jog Now Excite TN 2011/02 - 30 June 2011

2011/02

Contents • Breakage of elevation micro switch due to crushing (2)

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Breakage of elevation micro switch due to crushing (2) With reference to the problem reported in the previous Newsletter, please note that in the case of the micro switch being damaged by the machine overshooting its descent, due to a malfunction of the elevation actuator, it is recommended to replace both the actuator and the micro switch, in addition to fitting the bracket with code 0N001881AB indicated in the figure below.

Likewise, if a machine is found to have a defective elevation actuator, it is strongly advisable to also replace the micro switch, even if it appears undamaged, as it may have been improperly used. For the codes, refer to the corresponding exploded drawings.

Step Excite TN 2011/02 - 30 June 2011

2011/01

Contents • Chain lubrication message continues to appear

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Chain lubrication message continues to appear

If the chain lubrication message continues to reappear at each machine power up, even after the chains have just been lubricated, the problem may be due to an incorrect configuration of the specific “Lub. DFloors” parameter, found in the: Menu service (2501) Operating data Lub. DFloors If the parameter value is not set to “16000”, click on it to modify it. NOTE: if the parameter value is incorrect, its setting cannot be corrected by simply

launching the Standard Setting procedure; it has to be modified manually as described above.

Vario Excite TN 2011/02 - 30 June 2011

2011/01

Contents • 16BCreaking noise of pedal lever belt on handlebar pulley

• Automatic braking at high speed

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Creaking noise of pedal lever belt on handlebar pulley If the pedal lever belt makes a creaking sound as it moves over the pulley at the end of the handle (see figure below at left), the problem may be due to the pulley not being perfectly parallel with the belt, due to misalignment of the pulley mounting holes on the frame. To resolve this problem and correct possible misalignment of the frame holes during assembly, a cam and pin are used in production for mounting the pulley (see figure below at right).

This solution can also be implemented on already installed machines by ordering code R0006754AA.

Automatic braking at high speed If the user perceives that the machine automatically brakes when very high exercise speeds are reached, please note that this is an intentional protective feature of the machine, to avoid potentially hazardous situations for the user. The maximum permitted speed value is 160 SPM, and if the speed exceeds this by more than 20%, automatic braking is triggered until the speed returns below the permitted limit.

Crossover Excite TN 2011/02 - 30 June 2011

2011/01

Contents • MAX braking when getting on the machine

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MAX braking when getting on the machine A new brake board firmware version is available that implements a maximum braking function when the user gets on the machine. With this new function, a peak braking value is generated when the user first gets on a machine in standby mode, to control the first pedal descent. This feature has been implemented on all machines, to prevent the potential hazard of an uncontrolled pedal descent with a corresponding rapid movement of the upper lever toward the user, which would otherwise occur when a machine is activated from stand-by mode with zero braking on the pedals. Implementing the above function requires the following: MAINS POWERED MACHINES:update the brake board firmware to the versions

specified in the table below. SELF-POWERED MACHINES (SP): replace the brake board with a new model

compatible with the new firmware, cod. R0006700AB, and if necessary update the firmware to the version given in the table below.

NOTE: Using the firmware version which supports this new function on an “old HW”

brake board, or conversely using the new HW brake board with an “old” firmware version, will not cause the machine to lock out, however the machine will operate without providing the new braking function.

BRAKE MODEL KERNEL FIRMWARE

LASER (Black plastic box)

310 3502

MA

INS

PO

WER

ED

MA

CH

INES

NEW EFI (Black plastic box)

210 3102

Crossover Excite TN 2011/02 - 30 June 2011

2011/01

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OLD EFI (Black plastic box)

51 167 M

AIN

S P

OW

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ED

M

AC

HIN

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OLD EFI VISIO

(metal box)

103 167

SELF-

PO

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ED

M

OD

ELS

EFI (black box)

210 3002

Selection Line TN 2011/02 - 30 June 2011

2011/02

Contents

• Lat Machine: roller holder frame • 20BM957-Abdominal Crunch: upgrading shoulder rest to new

Selection Update solution • 21BABDUCTOR/ADDUCTOR: New solution for exercise position

selector plate (2)

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Lat Machine: roller holder frame Following a period during which the roller-holder lever was divided into 2 components (see TN 2010/03), we have now returned to a single-component solution, cod. 0D001116AA, as shown in the figure below.

M957-Abdominal Crunch: upgrading shoulder rest to new Selection Update solution

A kit is available for updating the machine in question to the version with flexible shoulder rests, such as those on the Element and Selection Update machines.

Selection Line TN 2011/02 - 30 June 2011

2011/02

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The kit has code R0006729AA-#, with the # replaced by the desired color suffix. To perform the upgrade it is recommended to also have available the following components, which may become damaged and need to be replaced during assembly: CODE DESCRIPTION Qty. 0C1133-GG Cam guard 1 0K055 Bearing 1 0Z753 Tab 8x7x28 1 0ZS00004 Tab 8x5x50 1 Pin wrenches for 25 and 45-mm rings are also required. NOTE_1: It is NOT possible the upgrade from the flexible shoulder rests to the rigid

old style one. NOTE_2: This upgrade it is NOT possible on Total Abdominal machine.

ABDUCTOR/ADDUCTOR: New solution for exercise position selector plate (2)

With reference to the item in TN 2010/05, please note the following additional points for correctly assembling the new plates.

1. Pre-assemble plates “a” and “b” one on top of the other so that the holes are matched up. 2. One side of plate “a” is marked with a code; this side should be turned facing plate “b”, so

that it is no longer visible once assembled.

Element Line TN 2011/02 - 30 June 2011

2011/02

Contents

• MB43 – DAP: Jamming of first weight stack plate • 23BMB15, MB20, MB55, MB60, MB70, PA01, PA02: conformity

for users up to 180 kg • 24BABDUCTOR/ADDUCTOR: New solution for exercise position

selector plate (2)

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MB43 – DAP: Jamming of first weight stack plate

If the movement of the first weight stack plate appears to be obstructed, the cause might be that the Power Mode elastic is too taut. To correct the problem, the elastic has been lengthened by 40 cm in both the version with standard weight stack and in the one with augmented weight stack. The codes of the new elastics used on the two machine versions and the corresponding lengths are given in the table below. CODE DESCRIPTION Length 0R000194AC Standard weight stack elastic 2614 mm 0R000189AC Augmented weight stack elastic 2514 mm The SN of the first machines produced with this modification are: MB4311100125 (standard weight stack) MB4311100128 (augmented weight stack)

MB15, MB20, MB55, MB60, MB70, PA01, PA02: conformity for users up to 180 kg

To make the machines in question suitable for users up to 180 kg, the seat support frame has been modified as illustrated below.

On the new frame the two vertically assembled plates are connected together by means of a third welded plate, shown in red in the figure on the right. The new seat frame is fully interchangeable with the old one, and will from now on be used on all production machines.

Element Line TN 2011/02 - 30 June 2011

2011/02

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ABDUCTOR/ADDUCTOR: New solution for exercise

position selector plate (2) With reference to the item in TN 2010/05, please note the following additional points for correctly assembling the new plates.

3. Pre-assemble plates “a” and “b” one on top of the other so that the holes are matched up. 4. One side of plate “a” is marked with a code; this side should be turned facing plate “b”, so

that it is no longer visible once assembled.

PURESTRENGTH Line TN 2011/02 - 30 June 2011

2011/02

Contents • MG50-Leg Press: warping of footrest plates

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MG50-Leg Press: warping of footrest plates

To prevent the footrest plates from becoming warped, so that they no longer perfectly adhere to the frame beneath, the number of fixing screws has been increased from 8 to 12 for each of the 2 footrests, as shown in the figure below.

Obviously, the frame to which they are affixed has also been modified, by adding the corresponding holes. In any case, the new footrests can still be assembled on old frames by simply not using the 4 extra holes. The SN of the first machine produced with this new component is: MG500011100121.

Kinesis TN 2011/02 - 30 June 2011

2011/01

Contents • Kinesis ONE – Omega: breakage of handle

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Kinesis ONE – Omega: breakage of handle

To correct the problems of premature wear and breakage of the exercise handle, the component has been opportunely modified and is now available with order code 0G001290AE-GZ. The SN of the first machines produced with this modification are: M580011100222 M575011100074

Free Weight Line TN 2011/02 - 30 June 2011

2011/01

Contents • F001/F002/V001/V002: Breakage of plastic bushings

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F001/F002/V001/V002: Breakage of plastic bushings

To help prevent breakage of the plastic bushings inside the 1. 25 kg and 2. 5 kg isotonic plates, with hole diameters for both Ø28 and Ø50 barbells, due principally to the bushings falling out, it is recommended to secure the bushings in place using Loctite 480.

Kinesis Personal TN 2011/02 - 30 June 2011

2011/01

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Noisiness of motor arm assembly

If the motor arm assembly makes a "ticking" noise, particularly at the start of an exercise, this could be due to play between the threaded rod and the lower triangular frame, shown in the figure below. To eliminate this play, a wave washer has now been added, inserted in the position indicated in the figure below.

The component has code 0ZR00047AA, and can also be used on already installed machines affected by this problem.

Run Personal TN 2011/02 - 30 June 2011

2011/02

Contents • Malfunctions after Full System Restore

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Malfunctions after Full System Restore If, after a Full System Restore, the machine exhibits certain malfunctions, such as selecting undesired languages or unexpected responses to the keys pressed on the display, the cause of the problem may be a complete loss of the Touch Screen calibration. To correct this problem and avoid the selection of undesired functions or settings, starting from VISIOWEB SW version 5.24.70, on the first machine power-up following a Full System Restore, the touch screen calibration procedure is automatically launched. If this updated SW version is not installed, the touch screen calibration procedure can be invoked by repeatedly pressing the touch-screen, 4 or 5 times, when the SW version appears on the display during the power-up sequence. If this procedure fails, connect a USB mouse and perform the same operation, but click the left mouse button instead of pressing the screen.

TGS Components TN 2011/02 - 30 June 2011

2011/02

Contents • New Wellness Expert: Problems entering messages in Russian

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New Wellness Expert: Problems entering messages in Russian

The problem concerns the impossibility of entering messages in the Russian language, due to the lack of Cyrillic characters. As of 15 March 2011, the image loaded on the machine has been updated and corrected, and the corresponding USB recovery sticks have also been updated. It is also possible to correct the bug and update the device manually, by following the instructions detailed in the procedure “When writing a message in Cyrillic on Wellness Expert, every character is replaced by an exclamation mark” that you can find in the “Known Issues” section of the Technogym Direct site.