Luxline service manual.pub
Contents
1. Any cable supplied by Zest as per given specification that is found to be incorrect on delivery will be at the cost to the client Complete the following details Company Order placed by Fax no Tel no Cable type Quantity Model No Serial Asset Weight stack Cable length A B C D ZP No kg mm Form completed by 10 Zest Manufacturing Pty Ltd trading as Zest Fitness SSS 7e lt i 5 Celie Road PO Box 236 T 27 0 21 701 3203 Retreat Steenberg F 27 0 21 701 3225 FITNESS 7945 7947 www zestfitness com Cape Town South Africa info zestfitness com UPHOLSTERY SPECIFICATION FORM Please supply the following information with your purchase order and fax to 021 701 3225 Upholstery can not be supplied unless all relevant information is received Since we strife to improve our hand build units the position of the fixing holes may vary from unit to unit for this reason all upholstery parts will be supplied without nut inserts However the upholstered part will come with an easy to follow instruction special designed nut inserts M8 x 35 cap screws washers and a Brad pointed 11 dia drill bit Please note State a brief description of the part such as Backrest Seat Arm support etc The physical length and width of the existing part The Model and serial asset no can be found on the plate on the base of the unit Any upholstered part supp2. grease oils and stubborn dirt Zest Surface Cleaner is a detergent and solvent based all in one and complies well above all SABS 1344 requirements Cleaning warm water HEAVY duty dilute 1 10 MEDIUM duty dilute 1 50 LIGHT duty dilute 1 200 Wipe down soiled upholstery with a soft damp cloth Follow up by wiping away any residual cleaning solution with a well rinsed clean cloth Protection To further restore its lustre and create a barrier between the body fluids and the vi nyl apply a light coat of ZEST sheen on a clean damp cloth Do not use Alcohol acetone or organic solvents for cleaning Replacement Should the upholstery and or pads require replacement kindly complete the annex Upholstery Specification form and send this with your order to us 8 Inspect handgrips for wear or damage and replace as necessary When replacing hand grips check the length and cut the new hand grip with a hobby knife according to size before sliding them back on Ensure the handle bar is clean and free of any lubricant 9 Check the bushes for wear or excess friction by actually doing an exercise If any rotating bushes are tight or squeaking lubricate with a drop of light engine oil In a rare event a glass rein forced nylon bush can be replaced by removing the shaft and the brass lock pin from the bush housing before the bush is pulled out When the bush has been re placed re drill the pin hole 2 8mm and
3. lowest plate lift the whole stack and drop 100mm 4 Check the operating smoothness of the weight stack by lifting the weight a few times to its highest position If any shuddering occurs wipe the guide rods clean over their entire length and then lubricate with a light coat of medium weight automotive engine oil It is also important to check that there is lateral move ment of the guide bars if tight then lower the two bushes slightly until the grommets above the bush and the guide bars are able to move freely FITNESS 2 zest 5 Check the cable slack before the weight stack is lifted if more then 15mm cable should be adjusted Cable Bolt adjustment Fine adjustment can then be done by turning the cable bolt on the weight stack down to reduce the free move ment If the bolt cannot be turned down enough turn the bolt up until 15mm thread is visible Adjust the cable now on the other end by undoing the two grub screws on the cam then slide the cable further through the bush to reduce the free movement and re tighten If necessary do a final adjustment by turning the bolt on the weight stack down Cable Eye adjustment To reduce the cable slack first turn down the nylon lock and un hook the cable loosen the lock nut on top of the weight stack and turn the eye bolt further down into the weight stack hook the cable back in the eye bolt and che
4. replace the brass pin Older models may not have a brass lock pin in this event we advice to knock in a brass lock pin by drilling a 2 8mm hole 10 mm from housing s edge into the housing and bush This is to ensure that the new bush will not rotate in it s housing Brass pin oee also the general overview of the typical LUXLINE units page 7 and 8 FITNESS 74 Zest 1 0 Ensure the readability of all Instruction cards and warning labels replace as necessary From a safety user responsibility and instruction point of view the instruction card and Warning label must always be readable the in formation for usage is vital for the exercise and illustrates how the unit should be operated 11 Inspect the overall cleanliness of the unit check also for scratches and corrosion Perspiration salts are highly corrosive and will leach into any microscopic opening in even the most impenetrable paint finishes Addressing any signs of paint damage or corrosion when and if they first appear will greatly increase the longevity of your equipment and enhance the overall appear ance Equipment should always be dry and cleaned at least once a week As with the upholstery here again the success formula is using our specially devel oped ZEST surface cleaner on all painted surfaces right from the beginning and once cleaned a ZEST wax emulsion is applied this creates a thin layer of durable wax on the surf
5. FITNESS LUXLINE Strength equipment SERVICE AND MAINTAINENCE MANUAL MAY 2011 74 zest FITNESS To ensure that your Zest equipment provides the user a safe and opti mal functionality and is kept in pristine condition it is vital to establish a Daily quick function amp maintenance inspection in 11 steps This inspection is quick and easy to follow DAILY QUICK FUNCTION amp MAINTENANCE CHECK where applicable Inspect for loose nuts and bolts tighten as required Check the ease of functioning of the pull pin or other methods of ad justing distances or angle positions Check alignment of the weight plates by inserting the weight stack pin in random positions Check the operating smoothness of the weight stack by lifting the stack a few times to its highest position Check the free movement before the weight stack is lifted if more then 15mm cable tension should be adjusted Inspect the cable for kinks damaged or worn outer sheath and ex posed cable wire including all connection points With any visual damage replace cable immediately 7 Check the upholstery for dirt rips and tears clean at least twice a 5 day Inspect handgrips for wear and tear replace as necessary 5 Check the bushes for wear or excess friction by performing the exer cise Ensure the readability of all instruction cards and warning labels re place if necessary Inspect the overall cleanliness of the unit c
6. ace to protect it against perspiration salts and make the removal of skiff marks easier Cleaning warm water duty dilute 1 10 MEDIUM duty 1 50 LIGHT duty 1 200 Wipe down the painted surface with a soft damp cloth until the surface is clean fol low up by wiping away any residual cleaning solution with a well rinsed damp clean cloth Protection To further protect the now cleaned surface and maintain its lustre a light coat of a 1 10 solution of ZEST wax emulsion must be applied on a damp cloth followed with light rub using micro fibre or towelling Do not use Alcohol acetone organic solvents or scouring pads for cleaning Touch up paint is available for any sign of corrosion or to cover any deeper scratches contact Zest Service to order As a side note Exposure to extensive water vapour chlorine and or bromide can adversely affect the finish of the units FITNESS Z zest 12 Schematic overview indicating the replaceable parts of a LUXLINE Z2316 Wem Descipion pefno Descipion Retro Grommet 18 I D 44 M10 S Steel Dome nut NEN Collar S Steel 32 20 x 15 12 ColarSiSteel 36 25 x 15 aa M8 x 8 mm Grub screw 08 Tapered steel pin on cam EE M8 x 25 Allen cap screw M10x10 Grub screw cam mE 5 8 5 w seswiwsahee 6 Pme T wesss e koaro o pumo Note To replace the nylon bushes 15 firs
7. ck if the free movement is 15mm If correct tighten the locknut and turn the nylon cable lock back against the eye bolt Note Replace cable when the other end has a crimped on Thimble 6 Inspect the cable for kinks damaged or worn outer sheath and exposed ca ble wire With any visual damage replace cable immediatel Each new LUXLINE unit is supplied with an extra cable which can easily replace the worn or damaged cable However since we strive to improve our hand built units the cable length may vary from unit to unit Therefore it is strongly advised to re order a new cable immediately by sending the worn cable with the unit s serial num ber to us This way the unit s out of order is minimised For the older units without the extra cable it is advisable to order two cables one to replace the old and one as a future spare Please complete the annex Cable Specification form and send this to us immedi ately v4 Zest FITNESS 7 Check the upholstery for dirt rips and tears Clean at least twice a day To keep the upholstery clean free from perspiration body oils and salts is not that simple The success formula is using our specially developed ZEST surface cleaner on the upholstery right from the beginning and once cleaned a ZEST sheen is ap plied to create a barrier between the body fluids and the vinyl ZEST surface cleaner This cleaner has been designed for surfaces containing
8. f the equipment is not used for its intended purpose mishandled and or abused All warranty will be null and void in the event of a repair or a modification being executed by any technical service without the written prior authorisation of Zest Manufacturing Pty Ltd Notice The information contained in this manual is subject to change without notice Zest Manufacturing Pty Ltd shall not be liable for errors contained herein or for inci dental or consequential damages in connection with furnishing performance or use of this manual No part of this manual may be photocopied reproduced or translated to another lan guage without the prior written consent of Zest Manufacturing Pty Ltd Zest Manufacturing Pty Ltd trading as Zest Fitness 7e lt i 5 Calie Road PO Box 236 T 27 0 21 701 3203 Retreat Steenberg F 27 0 21 701 3225 u FITNESS 7945 7947 www zestfitness com Cape Town South Africa info zestfitness com CABLE SPECIFICATION FORM Please supply the following information with your purchase order and fax to 021 701 3225 Cable can not be supplied unless all relevant information is received Please note 1 The physical length of the existing cable should be accurately measured as illustrated below 2 There are 4 cable types B C and D and should be clearly indicated 3 The Model and serial asset no can be found on the plate on the base of the unit 4
9. heck also for scratches and corrosion Overview typical LUXLINE units and their parts 7 8 Annex Cable amp Upholstery Specification Form 2 Zest FITNESS 1 Inspect for loose nuts and bolts tighten as required Bolts and nuts are secured with a spring washer it is however essential from a safety point of view to ensure all bolts and nuts are tightened 2 Check the ease of functioning of the pull pin or other methods of adjusting PULL PIN ADJUSTMENT The spring loaded pin should click in any location ow hole without force In failing to do so unscrew the knurled cap re place pin if bent Replace spring if damaged then lightly grease the entire pin before returning into the housing Should the up or down movement be difficult remove any burr which may have been formed around the location holes with a smooth file PULL TWIST ADJUSTMENT If force is required to twist and lock this adjustment in a differ ent position a burr may have been formed on the slot groove Remove the stud and lift the shaft out of its casing the burr can now easily filed away with a smooth file 3 Check alignment of the weight plates by inserting the weight stack pin in random positions The alignment might be out if the unit has recently been moved and or is not level Check and level the weight stack support by placing spacers under the legs Once level insert the selector pin in the
10. lied by Zest as per given specification that is found to be incorrect on delivery will be at the cost to the client ee Complete the following details Customer Order placed by Fax no Tel no Description Colour Length Width Model No Serial Asset mm mm ZP Customer signature Date 11
11. tly remove the tapered pin 13 by carefully tapping with a hammer the thin end to loosen it then remove the collar 12 and pull out the shaft The bushes can now be replaced See also ref 9 on page 5 FITNESS Z zest 12 Schematic overview indicating the replaceable parts of a LUXLINE Z2205 hem Deci perno Jem puyss 2 jamas ie N00 An cap Demi eats s20 25 n jexmOnem u Hmm s umm o 5 wonne T emet S emen o mosnom O 74 Zest FITNESS WARRANTY The basic framework of our new LUXLINE equipment carries a warranty against breakage for a period of 10 ten years Dumbbells EZ Bars and loose Weight plates are warranted against breakage for a period of 1 one year All non frame fixtures and moving parts are warranted against defective work manship and or materials for a period of 1 one year Parts subject to normal wear and tear are not included in the warranty These include plastic coated cables handgrips and other rubber items nylon bushes bearings foot covers pin cords and upholstery The powder coating is warranted for a period of 3 three years Damaged and the consequential corrosion thereof caused by scraping chipping and abrasive cleaning is not covered by the warranty Our warranty shall be null and void i
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