BioStrength FLEXabilityLine 10 ING

SERVICE & MAINTENANCE MANUAL Rev. 1.0

The information contained in this manual is intended for QUALIFIED TECHNICIANS who have completed a specific TECHNOGYM training course and are authorized to perform machine start-

up and adjustment procedures as well as extraordinary maintenance or repairs which require a thorough knowledge of the machine, its operation, its safety devices and working procedures.

CAREFULLY READ THE INFORMATION CONTAINED IN THIS MANUAL BEFORE PERFORMING ANY MAINTENANCE

PROCEDURES ON THE MACHINE

DANGEROUS VOLTAGES PRESENT EVEN WHEN THE MACHINE IS TURNED OFF

NOTE The information contained in this document is subject to change without notice. Technogym does not guarantee this documentation in any way. Technogym shall not be held responsible for any errors contained in this manual and declines all liability for accidents or damages resulting from the supply, characteristics or use of this manual. This document contains proprietary information that is protected by copyright. All rights reserved. No part of this document may be photocopied, reproduced or translated into another language without the prior written consent of Technogym. The Technogym trademark is property of Technogym S.p.A. The FLEXability trademark is property of Technogym S.p.A.

FLEXability LINE: Service & Maintenance Manual - rev. 1.0

Contents 1. GENERAL NOTICES............................................................................................................................................. 1.1

1.1. INTRODUCTION................................................................................................................................................... 1.1 1.2. RECOMMENDATIONS .......................................................................................................................................... 1.1 1.3. GENERAL RULES FOR REPAIR PROCEDURES ........................................................................................................ 1.2

2. TECHNICAL CHARACTERISTICS.................................................................................................................... 2.1 2.1. COLOUR OPTIONS ............................................................................................................................................... 2.2 2.2. EQUIPMENTS: MECHANICAL CHARACTERISTICS.................................................................................................. 2.3

2.2.1. ME05 Anterior / ME15 Anterior Wood ............................................................................................ 2.3 2.2.2. ME10 Posterior / ME20 Posterior Wood......................................................................................... 2.3

2.3. AMBIENT SPECIFICATIONS .................................................................................................................................. 2.4 2.4. CONFORMITY TO REGULATIONS.......................................................................................................................... 2.4

3. INSTALLING AND MOVING THE MACHINES .............................................................................................. 3.1 3.1. SPECIFICATIONS AND REQUIREMENTS ................................................................................................................ 3.1 3.2. INSTALLING THE MACHINES ............................................................................................................................... 3.1

3.2.1. Anterior ............................................................................................................................................... 3.1 3.2.2. Posterior.............................................................................................................................................. 3.3

3.3. MOVING 3.5 3.3.1. Anterior ............................................................................................................................................... 3.5 3.3.2. Posterior.............................................................................................................................................. 3.5

4. ACCESSORIES ....................................................................................................................................................... 4.1

5. WHAT IF ............................................................................................................................................................. 5.1 5.1. THE MACHINE IS NOT FLAT ................................................................................................................................. 5.1


5.2. THE CARRIAGE DOES NOT MOVES SMOOTHLY..................................................................................................... 5.2 5.2.1. Anterior ............................................................................................................................................... 5.2 5.2.2. Posterior.............................................................................................................................................. 5.2

5.3. THE ENCODER CABLE HAS TO BE REPLACED ....................................................................................................... 5.3 5.3.1. Anterior ............................................................................................................................................... 5.3 5.3.2. Posterior.............................................................................................................................................. 5.5

6. HOW TO DISASSEMBLEANTERIOR............................................................................................................ 6.1 6.1. WOODEN CASING................................................................................................................................................ 6.1 6.2. KNEE REST UPHOLSTERY .................................................................................................................................... 6.2 6.3. KNEE REST CARRIAGE ........................................................................................................................................ 6.4 6.4. CARRIAGE BELT.................................................................................................................................................. 6.7 6.5. HANDLEBAR / CARRIAGE BRAKING LEVER ......................................................................................................... 6.9 6.6. ELBOW REST UPHOLSTERY ............................................................................................................................... 6.10 6.7. ENCODER DEVICE ............................................................................................................................................. 6.11 6.8. TIMER DEVICE .................................................................................................................................................. 6.14 6.9. BRAKE LEVER................................................................................................................................................... 6.16 6.10. FRONT FOOTBOARD .......................................................................................................................................... 6.18

7. HOW TO DISASSEMBLEPOSTERIOR.......................................................................................................... 7.1 7.1. WOODEN CASING................................................................................................................................................ 7.1 7.2. LOWER CASING................................................................................................................................................... 7.2 7.3. BACK-REST UPHOLSTERY ................................................................................................................................... 7.3 7.4. FEET-REST UPHOLSTERY..................................................................................................................................... 7.4 7.5. HANDLEBAR....................................................................................................................................................... 7.5

Page i


Page ii

7.6. FEET POSITION LEVER ADJUSTING DEVICE .......................................................................................................... 7.6 7.7. LEVER CASINGS.................................................................................................................................................. 7.9 7.8. CATENA LEVA .................................................................................................................................................. 7.10 7.9. ENCODER ASSEMBLY........................................................................................................................................ 7.11 7.10. TIMER DEVICE .................................................................................................................................................. 7.13 7.11. LEVER ASSEMBLY............................................................................................................................................. 7.14 7.12. BACK-REST CARRIAGE...................................................................................................................................... 7.16 7.13. GAS SPRING AND GAS SPRING UNLOCKING CABLE ............................................................................................ 7.17 7.14. MOVEMENT WHEELS ........................................................................................................................................ 7.19

8. SPECIAL OPERATIONS....................................................................................................................................... 8.1 8.1. ADJUSTING THE ENCODER ZERO POSITION .......................................................................................................... 8.1


8.2. ANTERIOR: ADJUSTING THE CARRIAGE BELT TENSION ........................................................................................ 8.3 9. MAINTENANCE..................................................................................................................................................... 9.1

9.1. DAILY MAINTENANCE OPERATIONS .................................................................................................................... 9.1 9.1.1. Cleaning upholstery ............................................................................................................................ 9.1

9.2. WEEKLY MAINTENANCE OPERATIONS ................................................................................................................ 9.2 9.2.1. Cleaning the frame and painted parts ................................................................................................. 9.2

9.3. MONTHLY MAINTENANCE OPERATIONS .............................................................................................................. 9.3 9.3.1. Check the mechanisms......................................................................................................................... 9.3 9.3.2. Check the gas springs.......................................................................................................................... 9.3 9.3.3. Check the rubber stops ........................................................................................................................ 9.3 9.3.4. Checking the carriage mechanism ...................................................................................................... 9.3 9.3.5. Checking the upholstery ...................................................................................................................... 9.3 9.3.6. Checking various rubber parts............................................................................................................ 9.3

9.4. TWICE-YEARLY MAINTENANCE OPERATIONS...................................................................................................... 9.4 9.4.1. Screw and bolt check........................................................................................................................... 9.4 9.4.2. Checking for mechanism play ............................................................................................................. 9.4

10. APPENDIX............................................................................................................................................................. 10.1 10.1. UPHOLSTERY.................................................................................................................................................... 10.1 10.2. TOOLS TO USE .................................................................................................................................................. 10.2


1. GENERAL NOTICES

1.1. INTRODUCTION This document is reserved for Technogym Service technicians, and is intended to provide authorized personnel with the necessary information to correctly carry out repairs and maintenance. A thorough knowledge of the technical information contained in this manual is essential for completing the professional training of the operator. In order to facilitate consultation, the paragraphs are accompanied by schematic drawings which illustrate the procedure being described. This manual contains notices and symbols which have a specific meaning:

WARNING: non observance may result in accident or injury.

ATTENTION: non observance may cause damage to the machine.

Information about the operation in progress.

OBSERVE: observation about the operation in progress.

1.2. RECOMMENDATIONS Technogym recommends the following steps for planning repair procedures: Carefully evaluate the customers description of the machine malfunction and ask all the

necessary questions to clarify the symptoms of the problem. Clearly diagnose the causes of the problem. This manual provides the fundamental theoretical

basis, which must then be integrated by personal experience and attendance at the training courses periodically offered by Technogym.

Rationally plan the repair procedure so as to minimize the downtime necessary for procuring

spare parts, preparing tools, etc. Access the component to be repaired, avoiding any unnecessary operations. In this regard it will

be useful to refer to the disassembly sequence described in this manual.

Page 1.1


Page 1.2

1.3. GENERAL RULES FOR REPAIR PROCEDURES 1. Always mark any parts or positions which may be confused with each other at the time of

reassembly. 2. Use original Technogym spare parts and lubricants of the recommended brands. 3. Use special tools where specified. 4. Consult the Technical Newsletters, which may contain more up-to-date information on

adjustments and maintenance than those contained in this manual. 5. Before starting the repair procedure, make sure that the recommended tools are available and in

good condition. 6. For the procedures described in this manual, use only the specified tools.

OBSERVE: The tool sizes quoted in this manual are expressed in mm.


2. TECHNICAL CHARACTERISTICS The Element machine code is a sequence of 14 alphanumeric characters arranged as follows:

FLEXABILITY LINE Characters description key to values 1,2 Product Line ME = FLEXability Line

3,4 Machine code

05 = Anterior 10 = Posterior 15 = Anterior Wood model 20 = Posterior Wood model

-

5,6 Frame colour AL = Silver AN = Anthracite

7,8 Upholstery colour BB = Brune M0 = Bordeaux

9,10 Rubber colour GG = grey RAL 7024 GD = grey RAL 7039

11,12 Casing 00 = no casing 02 = wooden casing For example, a possible product code would be:

ME050-ALM0GG00 which is interpreted as follows:

ME 05 - AL M0 GG 00

NO casing

Rubber colour, grey RAL 7024

Upholstery colour, silver

Frame colour, silver

Anterior

FLEXability Line

Page 2.1


Page 2.2

2.1. COLOUR OPTIONS The following table shows the possible combinations for ordering the FLEXability line machines:

ME05 ME15 CONFIGURATION -1- CONFIGURATION -2-

FRAME AL - SILVER AN ANTHRACITE

UPHOLSTERY M0 BORDEAUX BB - BRUNE

RUBBER GG GREY (RAL7024) GD GREY (RAL7039)

CASING 00 NO casing 00 NO casing

Table 2-1

ME10 ME20

CONFIGURATION -1- CONFIGURATION -2-

FRAME AL - SILVER AN ANTHRACITE

UPHOLSTERY M0 BORDEAUX BB - BRUNE

RUBBER GG GREY (RAL7024) GD GREY (RAL7039)

CASING 02 Wooden casing 02 Wooden casing


2.2. EQUIPMENTS: MECHANICAL CHARACTERISTICS

2.2.1. ME05 ANTERIOR / ME15 ANTERIOR WOOD

ME05 Anterior / ME15 Anterior Wood

193 x 57 x 124 cm Dimensions [P x L x A]

[L x W x H] 75.9 x 22.4 x 48.8 in Overall weight ME05 65 Kg 143 lbs Overall weight ME15 69 Kg 152 lbs

2.2.2. ME10 POSTERIOR / ME20 POSTERIOR WOOD

ME10 Posterior / ME20 PosteriorWood

208 x 88.5 x 125 cm Dimensions [P x L x A]

[L x W x H] 81.8 x 34.8 x 49.2 in Overall weight ME10 105 Kg 231 lbs Overall weight ME20 110 Kg 242 lbs

Page 2.3


Page 2.4

2.3. AMBIENT SPECIFICATIONS Operating from 5 to 35 C Temperature Storage from -20 to 55 C Operating from 30% to 80% non-condensing Humidity Storage from 5% to 85% non-condensing

2.4. CONFORMITY TO REGULATIONS The machine conforms to the following directives:

Europe Directive 93/42/CEE

Normative EN 957-1 EN 957-2 Risk rate: I


3. INSTALLING AND MOVING THE MACHINES

3.1. SPECIFICATIONS AND REQUIREMENTS For proper installation of the equipment, make sure that: 1. The equipment is installed on a level, vibration-free surface with a sufficient capacity to support

its weight plus that of the user. 2. The area is not dusty or sandy. 3. You have observed the temperature and humidity operating requirements indicated in paragraph

2.3. Ambient specifications.

3.2. INSTALLING THE MACHINES The machine is supplied on a wooden pallet, wrapped in nylon bag and packed in a carton. The installation instructions are packaged and delivered with the machine. By the way, here below you can find them for any needs.

3.2.1. ANTERIOR

Page 3.1


Page 3.2


3.2.2. POSTERIOR

Page 3.3


Page 3.4


3.3. MOVING

3.3.1. ANTERIOR

Figure 3.3-1

Wheels are placed under the front side of the machine. Lift it up from the frame as shown in the figure above and move the machine.

3.3.2. POSTERIOR

Figure 3.3-2

Wheels are placed under the seat of the machine. Set the horizontal position of the machine, lift it up from the frame as shown in the figure above and move the machine.

Page 3.5


Page 3.6

Page intentionally left blank


4. ACCESSORIES No accessories are available for these machines.

Page 4.1


Page 4.2



5. WHAT IF

5.1. THE MACHINE IS NOT FLAT

5.1.1. ANTERIOR

Figure 5.1-1

The machine disposes of 4 adjusting feet, indicated in the figure to side.

Check that all the 4 feet are touching on the floor.

Before the packaging of the machine, the flatness of each piece is checked on a flat surface. In case the machine is not flat, we suggest to proceed as follow: 1. Completely screw in the central foot c. 2. Adjust the height of the 2 front feet a. 3. If it is not sufficient, adjust also the height of

the rear foot b.

At the end of the procedure, lock down the counter nuts of each feet.

5.1.2. POSTERIOR

Figure 5.1-2

The machine disposes of 2 adjusting feet, indicated in the figure to side. Before the packaging of the machine, the flatness of each piece is checked on a flat surface. In case the machine is not flat, we suggest to adjust the height of the feet a.

At the end of the procedure, lock down the counter nuts of each feet.

At the end of the procedure reassemble what previously disassembled.

Page 5.1


Page 5.2

5.2. THE CARRIAGE DOES NOT MOVES SMOOTHLY

5.2.1. ANTERIOR

Figure 5.2-1

If the carriage does not moves smoothly, we suggest to proceed as follow: 1. Disassemble the carriage casings as detailed

in charter 6 of this manual. 2. Check if the carriage has any play vertically. 3. Adjust the position of the pulleys in the

guides acting on the left eccentric pin a on the right eccentric pin b, using a 5mm hex wrench and a 17mm wrench.


5.2.2. POSTERIOR

Figure 5.2-2

If the carriage does not moves smoothly, we suggest to proceed as follow: 1. Disassemble the lower casings as detailed in

charter 7 of this manual. 2. Check if the carriage has any play vertically. 3. Adjust the position of the pulleys in the

guides acting on the left eccentric pin a, using a 5mm hex wrench and a 17mm wrench.



5.3. THE ENCODER CABLE HAS TO BE REPLACED

5.3.1. ANTERIOR

Figure 5.3-1

To replace the encoder cable / tape, proceed as follow: 1. Disassemble the encoder device as detailed

in charter 6 of this manual. 2. Pass the cable / tape inside the machine

frame as shown in the figure to side.

Figure 5.3-2

3. When the cable come out in the lower side of the frame, pay attention to correctly route it on the rollers indicated by the arrows.

Check that the cable/tape is not twisting round the lever.

Continued on following page

Page 5.3


Page 5.4

Figure 5.3-3

4. Connect the eyelet of the cable to the carriage, as shown in the figure.

After completing the reassembly procedure, carry on the procedure described in paragraph 8.1. Adjusting the encoder zero position.



5.3.2. POSTERIOR

Figure 5.3-4

To replace the encoder cable / tape, proceed as follow: 1. Disassemble the encoder device as detailed

in charter 7 of this manual. 2. Pass the cable / tape inside the machine

frame as shown in the figure to side.

Figure 5.3-5

3. Connect the eyelet of the cable to the carriage, as shown in the figure.



Page 5.5


Page 5.6



6. HOW TO DISASSEMBLEANTERIOR

6.1. WOODEN CASING

Figure 6.1-1

On both sides of the machine: 1. Back off the screw a using a 5mm hex

wrench.

Figure 6.1-2

2. Back off the screw a using a 5mm hex wrench.

3. Back off the 2 screws b using a 5mm hex wrench.

4. Remove the two parts c and d of the wooden casing.

To reassemble the wooden casing, carry out the above steps in reverse order.

Page 6.1


Page 6.2

6.2. KNEE REST UPHOLSTERY

Figure 6.2-1

1. Back off the 4 screws a using a 3mm hex wrench, on the left side of the machine.

2. Remove the carriage left side casing.

Figure 6.2-2

3. Back off the screw b using a 4mm hex wrench, which is acting as knee rest movement limit stop, on the plate c.

Figure 6.2-3

4. Pull the knee rest upholstery up and back off the 4 screws d on the rear side using a Phillips screwdriver.

5. Push down the plastic casing.



Figure 6.2-4

6. Back off the 4 screws e using a 5mm hex wrench.

To reassemble the knee rest upholstery, carry out the above steps in reverse order.

Page 6.3


Page 6.4

6.3. KNEE REST CARRIAGE

Figure 6.3-1

Carry out the procedure described in paragraph 6.2. Knee rest upholstery. 1. Back off the 2 screws a using a 6mm hex

wrench.

Figure 6.3-2

2. Remove the pin b, which is connecting the upholstery support frame to the carriage.

Pay attention to the c and d spacers position and remember to insert them again during the reassembly procedure.

Figure 6.3-3

3. On both sides of the machine, remove the external circlip using a flat screwdriver and remove the support frame from the adjustment device.



Figure 6.3-4

4. Tilt the machine on the right side. 5. Back off the nut f using a 13mm wrench and

a 4mm hex wrench. 6. Disconnect the cable, indicated by the arrow,

of the encoder device which shows the carriage position, fixing it to avoid that it will be swallowed into the frame by the encoder device spring.

7. Back off the screws g of the belt fixing device on the carriage, using a 5mm hex wrench.

Figure 6.3-5

8. Back off the 2 screws h using a Phillips screwdriver and remove the rear lower casing.

Figure 6.3-6

9. Back off the 4 screws i using a Phillips screwdriver and remove the rear upper casing.


Page 6.5


Page 6.6

Figure 6.3-7

10. Back off the 4 screws l, using a 6mm hex wrench.

Figure 6.3-8

11. On both the sides of the machine, back off the screw m using a 5mm hex wrench and remove the pin which act as a rear limit stop for the carriage.

Figure 6.3-9

12. It is now possible to disassemble the 2 flat wheels n and the 3 shaped wheels o.

To reassemble the knee rest carriage, carry out the above steps in reverse order.

After completing the reassembly procedure, carry on the procedures described in paragraph 8.1. Adjusting the encoder zero position and 8.2. Anterior: adjusting the carriage belt tension.


6.4. CARRIAGE BELT

Figure 6.4-1

1. Tilt the machine on one side. 2. Back off and remove the foot a. 3. Back off the 4 screws b using a Phillips

screwdriver. 4. Remove the front lower and upper casings.

Figure 6.4-2

5. Back off the 3 screws c using a Phillips screwdriver and remove the rear lower casing.

Figure 6.4-3

6. Back off the screws d of the belt fixing device on the carriage, using a 5mm hex wrench.


Page 6.7


Page 6.8

Figure 6.4-4

7. Fasten the lever of the carriage brake device to the handlebar, so that the belt is completely free.

8. Remove the belt from the machine. To reassemble the carriage belt, carry out the above steps in reverse order.



6.5. HANDLEBAR / CARRIAGE BRAKING LEVER

Figure 6.5-1

1. Back off the 3 screws a using a 4mm hex wrench.

2. Remove the display casing b.

During the reassembly procedure, pay attention to place the upper edge of the casing in the slot of the handlebar.

Figure 6.5-2

To disassemble the handlebar: 1. On both the sides of the machine, back off

the 2 screws c using a 6mm hex wrench. 2. Remove the handlebar.

Figure 6.5-3

To disassemble the carriage braking lever: 1. Remove the external circlip d using a flat

screwdriver and disconnect the braking lever g from the lever inside the frame.

2. Back off the 4 nuts e using an 8mm wrench, locking down the screw using a 3mm hex wrench.

3. Remove the fixing brackets f and the lever. To reassemble the carriage braking lever, carry out the above steps in reverse order.

Page 6.9


Page 6.10

6.6. ELBOW REST UPHOLSTERY

Figure 6.6-1




Figure 6.6-2

3. Back off the 4 screws c that are fixing the timer/encoder display, using a Phillips screwdriver.

4. Back off the 4 screws d that are fixing the elbow rest upholstery, using 6mm hex wrench.

Figure 6.6-3

5. Pass the timer/encoder assembly e through the hole of the elbow rest f and remove the upholstery.

To reassemble the elbow rest upholstery, carry out the above steps in reverse order.


6.7. ENCODER DEVICE

Figure 6.7-1




Figure 6.7-2


Figure 6.7-3

4. Tilt the display assembly on the elbow rest. 5. Back off the 2 nuts d using a 5mm wrench.


Page 6.11


Page 6.12

Figure 6.7-4

6. Bent a little bit the plastic support indicated by the arrow and pull out the plate e, paying attention to the rollers f, which are driving the graduated tape.

During the reassembly procedure, pay attention to pass correctly the tape on the rollers.

7. Remove the tape and its winding g from the

plastic support.

Before to reassemble the tape winding, preload it with 3 turns.

Figure 6.7-5

8. Back off the 4 screws h using a 3mm hex wrench and remove the carriage left side casing.

Figure 6.7-6

9. Tilt the machine on the right side. 10. Back off the nut i using a 13mm wrench and

a 4mm hex wrench. 11. Disconnect the cable, indicated by the arrow,

of the encoder device which shows the carriage position, fixing it to avoid that it will be swallowed into the frame by the encoder device spring.

12. Remove the cable/tape from the machine frame.



Figure 6.7-7

To reassemble the encoder device: 1. Tilt the machine on one side. 2. Back off and remove the foot l. 3. Back off the 4 screws m using a Phillips

screwdriver. 4. Remove the front lower casing.

Figure 6.7-8

5. Pass the cable/tape through the machine frame taking care to the correct route on the rollers indicated by the arrows.

6. Proceed carry out the disassembling steps in reverse order.


Page 6.13


Page 6.14

6.8. TIMER DEVICE

Figure 6.8-1




Figure 6.8-2


Figure 6.8-3

4. Remove the knob d, pulling it out from the top.



Figure 6.8-4

5. Back off the screw e using a Phillips screwdriver.

6. Remove the fixing plate f. 7. Back off the nut g using a 11mm wrench. 8. Remove the timer from the rear side of the

display. To reassemble the timer device, carry out the above steps in reverse order.

Page 6.15


Page 6.16

6.9. BRAKE LEVER

Figure 6.9-1




Figure 6.9-2

3. Tilt the machine on the left side. 4. Fasten the lever of the carriage brake device

to the handlebar, so that the brake is not activated.

Figure 6.9-3

5. Screw an M6x40 screw (code 0Z160) c into the spring d to compress it and to release the tension on the brake lever.

6. Release the braking lever, fastened at step 4.



Figure 6.9-4

7. Remove the external circlip d from the pin e using the proper pliers.

8. Remove the pin, pulling it out from the bottom.

Figure 6.9-5

9. Remove the external circlip f using a flat screwdriver and disconnect the braking lever from the one inside the frame.

Figure 6.9-6

10. Remove the external circlip g using a flat screwdriver and disconnect the brake lever h from the one inside the frame.

To reassemble the brake lever, carry out the above steps in reverse order.

Page 6.17


Page 6.18

6.10. FRONT FOOTBOARD

Figure 6.10-1

1. Tilt the machine on one side. 2. Back off and remove the foot a. 3. Back off the 4 screws b using a Phillips

screwdriver. 4. Remove the front upper and lower casing.

Figure 6.10-2

5. Back off the 4 screws c using a 6mm hex wrench.

6. Remove the footboard. To reassemble the footboard, carry out the above steps in reverse order.


7. HOW TO DISASSEMBLEPOSTERIOR

7.1. WOODEN CASING

Figure 7.1-1

On both sides of the machine: 1. Back off the screw a using a 6mm hex

wrench.

Figure 7.1-2


3. Remove the two parts c and d of the wooden casing.

To reassemble the wooden casing, carry out the above steps in reverse order.

Page 7.1


Page 7.2

7.2. LOWER CASING

Figure 7.2-1

1. Back off the screws a using a Phillips screwdriver.

2. Use a flat screwdriver to bent the plastic fin of the casing a little bit, where indicated by the arrow.

3. Remove the lower casing. To reassemble the lower casing, carry out the above steps in reverse order.


7.3. BACK-REST UPHOLSTERY

Figure 7.3-1

1. Back off the screw a using a 5mm hex wrench, on both sides of the machine.

Figure 7.3-2

2. Back off the screws b using a 6mm hex wrench.

3. Remove the upholstery from the machine. To reassemble the back-rest upholstery, carry out the above steps in reverse order.

Page 7.3


Page 7.4

7.4. FEET-REST UPHOLSTERY

Figure 7.4-1

1. Open the zip-fastener a, in the lower part of the upholstery.

Figure 7.4-2


3. Remove the upholstery from its metal supports.

To reassemble the feet-rest upholstery, carry out the above steps in reverse order.


7.5. HANDLEBAR

Figure 7.5-1

1. Remove the cap a and back off the screw you can access, using a 6mm wrench.

2. Remove the handlebar pulling it out in the direction indicated by the arrow.

To reassemble the handlebar, carry out the above steps in reverse order.

Page 7.5


Page 7.6

7.6. FEET POSITION LEVER ADJUSTING DEVICE

Figure 7.6-1

To disassemble the feet position lever: 1. Back off the 3 screws a using a Phillips

screwdriver. 2. Back off the 2 screws b using a 4mm hex

wrench. 3. Remove the lower and upper casing.

Figure 7.6-2

4. Cut the cable tie c. 5. Back off the screw d using a 5mm hex

wrench, locking down the nut using a 13mm wrench.

6. Disconnect gas spring from the feet position lever.

7. Remove the external circlip e. 8. Pull out the pin f and remove the lever g.

Figure 7.6-3

To disassemble the gas spring: 9. Cut the cable tie h. 10. Back off the counter nut i using a 6mm

wrench. 11. Pull out the cable from the unlocking device

of the gas spring. 12. Remove the external circlip l using a flat

screwdriver. 13. Pull out the pin m and remove the gas spring.



Figure 7.6-4

To disassemble the feet position adjusting lever: 14. Back off the 3 screws o using a 3mm hex

wrench and remove the casing.

Figure 7.6-5

15. Back off the counter nut p and screw in the adjusting screw q.

16. Back off the screw r to remove the cable s from its slot in the frame.

During the reassembly procedure, carry out the above steps in reverse order: screw in the screw q and place the cable s in its slot. To adjust the tension of the cable, back off the screw q until the unlocking device of the gas spring is completely released and then lock down the counter nut again.

Figure 7.6-6

17. Remove the external circlip t. 18. Disconnect the spring from the lever u where

indicated by the arrows and remove the lever.

During the reassembly procedure, put some grease between the lever u and the pin.

To reassemble the feet position lever adjusting device, carry out the above steps in reverse order.

During the reassembly procedure, fix the cable again using a cable tie.


Page 7.7


Page 7.8

Figure 7.6-7

Figure 7.6-8

During the reassembly procedure, pay attention to correctly route the cable, following the arrows.


7.7. LEVER CASINGS

Figure 7.7-1

1. Back off the 3 screws a using a 3mm hex wrench and remove the internal casing.

Figure 7.7-2

2. Back off the 2 screws b using a Phillips screwdriver.

3. Back off the 2 screws c using a 4mm hex wrench.

4. Remove the front and the rear casings.

Figure 7.7-3

To disassemble casings indicated by the arrows: 5. Move the back rest upholstery carriage,

approximately in a central position. 6. Move the feet rest lever completely up, to

release the tension of the chain e. 7. Back off the 4 screws d using a 4mm hex

wrench, moving a little bit the chain. 8. Remove the casings. To reassemble the casings, carry out the above steps in reverse order.

Page 7.9


Page 7.10

7.8. CATENA LEVA

Figure 7.8-1

Carry out the procedure described in paragraph 7.7. Lever casings. 1. Move the back rest upholstery carriage,

approximately in a central position. 2. Move the feet rest lever completely up, to

release the tension of the chain. 3. Open the chain connecting links indicated by

the arrows and remove the chain. To reassemble the chain, carry out the above steps in reverse order.

WARNING: a bad assembling of the chain connecting link may result in accident or injury for the user.


7.9. ENCODER ASSEMBLY

Figure 7.9-1

Carry out the procedure described in paragraph 7.7. Lever casings. 1. Open the two plastic fin a and remove the

encoder pulley from the shaft. 2. Back off the 2 screws b, using a 6mm hex

wrench, to remove the complete encoder/display assembly.

Figure 7.9-2

To disassemble the encoder cable: 3. Back off the screw c using a Phillips

screwdriver. 4. Cut the cable tie d which fix the cable on the

pulley.

During the reassembly procedure, use a cable tie again to fix the cable.

During the reassembly procedure, pay attention to correctly route the cable behind the pin inside the frame, as shown in the picture to side.

Figure 7.9-3

5. Back off the screws e using a 3mm hex wrench.

6. Remove the rear casing of the display.


Page 7.11


Page 7.12

Figure 7.9-4

7. Back off the 4 screws f using a Phillips screwdriver, which is fixing the timer/encoder display to the frame.

Figure 7.9-5

8. Back off the 2 nuts g using a 5mm wrench. 9. Bent a little bit the plastic fin indicated by

the arrow and pull out the plate h, paying attention to the rollers i, which are driving the graduated tape.

During the reassembly procedure, pay attention to pass correctly the tape on the rollers.

10. Remove the tape and its winding l from the

plastic support.

Before to reassemble the tape winding, preload it with 3 turns.

To reassemble the encoder assembly, carry out the above steps in reverse order.



7.10. TIMER DEVICE

Figure 7.10-1


2. Remove the display rear casing.

Figure 7.10-2

3. Remove the knob b.

Figure 7.10-3

4. Back off the screw c using a Phillips screwdriver.

5. Remove the fixing plate d. 6. Back off the nut e using a 11mm wrench. 7. Remove the timer from the rear side of the

display. To reassemble the timer device, carry out the above steps in reverse order.

Page 7.13


Page 7.14

7.11. LEVER ASSEMBLY

Figure 7.11-1

Carry out the procedure described in paragraphs 7.2. Lower casing and 7.3. Back-rest upholstery. 1. Back off the 2 screws a using a 4mm hex

wrench. 2. Remove the rear casings.

Figure 7.11-2

3. Back off the nut b using a 17mm wrench and disconnect the chain tie rod from the frame.

Figure 7.11-3

4. Disconnect the spring c from the lever frame.



Figure 7.11-4

5. Remove the 2 bolts d backing off the nuts on the opposite side using a 19mm wrench.

WARNING: 2 people are needed to carry out this procedure.

Figure 7.11-5

6. Remove the lever assembly from the lower frame with carriage.

To reassemble the lever assembly, carry out the above steps in reverse order.

Page 7.15


Page 7.16

7.12. BACK-REST CARRIAGE

Figure 7.12-1

Carry out the procedure described in paragraphs 7.2. Lower casing and 7.12. Back-rest carriage. 1. Back off the screw a and its nut using an

8mm hex wrench and a 17mm wrench. 2. Disconnect the gas spring from the frame.

Figure 7.12-2

3. Back off the 4 screws b on the right side of the machine, using an 8mm hex wrench.

4. Pull out the carriage assembly c from the right side.

Figure 7.12-3

5. Remove the plastic protection d and the side guide e.

6. It is now possible to disassemble the carriage wheels:

a. Shaped wheels on the right; b. Flat wheels on the left.

To reassemble the carriage assembly, carry out the above steps in reverse order.


7.13. GAS SPRING AND GAS SPRING UNLOCKING CABLE

Figure 7.13-1

Carry out the procedure described in paragraphs 7.2. Lower casing and 7.12. Back-rest carriage. To disassemble the gas spring: 1. Back off the screw a and its nut using an

8mm hex wrench and a 17mm wrench. 2. Disconnect the gas spring from the frame.

Figure 7.13-2

3. Open the hook b which is fixing the gas spring unlocking cable on the spring. Rotate it clock-wise and pull it out from the bottom (see the figure at side).

4. Disconnect the cable from the gas spring. 5. Back off the screw c and its nut using an

8mm hex wrench and a 17mm wrench. 6. Remove the gas spring.

Figure 7.13-3

To disassemble the gas spring unlocking cable: 1. Back off the nut d using a 10mm wrench. 2. Pull out the adjusting screw from the frame

support.


Page 7.17


Page 7.18

Figure 7.13-4

3. Back off the nuts e using a 10mm wrench. 4. Pull out the cable from its support on the

frame. 5. Open the hook b which is fixing the gas

spring unlocking cable on the spring. Rotate it clock-wise and pull it out from the bottom (see the figure at side).

6. Disconnect the cable from the gas spring. 7. Remove the cable pulling it out from the

bottom side of the carriage.

Pay attention not to scratch or bent the gas spring stem.

To reassemble the gas spring and/or gas spring unlocking cable, carry out the above steps in reverse order.


7.14. MOVEMENT WHEELS

Figure 7.14-1


2. Remove the 2 lateral casings.

Figure 7.14-2

3. Back off the screw b and its nut using an 8mm hex wrench and a 17mm wrench.

To reassemble the wheel, carry out the above steps in reverse order.

Page 7.19


Page 7.20



8. SPECIAL OPERATIONS The term special operations refers to those procedures whose correct execution is fundamental for the safe and reliable operation of the machine.

8.1. ADJUSTING THE ENCODER ZERO POSITION

8.1.1. ANTERIOR

Figure 8.1-1

To adjust the encoder zero position, proceed as follow: 1. Remove the left side carriage casing. 2. Move the carriage completely ahead toward

the display. 3. Adjust the position of the pin where the

encoder cable is fixed, in its slot of the carriage so that the value indicated by the arrow on the display is zero (use a 4mm hex wrench and a 13mm wrench).


Page 8.1


Page 8.2

8.1.2. POSTERIOR

Figure 8.1-2

To adjust the encoder zero position, proceed as follow: 1. Carry out the procedure described in

paragraph 7.7. Lever casings. 2. Move the lever to set it completely

horizontally. 3. Back off the screw a and adjust the position

of the pin where the encoder cable is fixed, in its slot of the pulley so that the value indicated by the arrow on the display is zero (use a 4mm hex wrench).



8.2. ANTERIOR: ADJUSTING THE CARRIAGE BELT TENSION

Figure 8.2-1

To adjust the tension of the carriage belt proceed as follow: 1. Remove the rear lower casing, as detailed at

charter 6 of this manual. 2. Act on the eccentric pin a using a 5mm ex

wrenched and a 17mm wrench, to adjust the belt tension.


Page 8.3


Page 8.4



9. MAINTENANCE To keep the machine in perfect working order and forestall possible problems it is necessary to carry out the scheduled maintenance operations described below. The maintenance operations can essentially be classified according to the frequency with which they need to be performed: Daily maintenance operations; Weekly maintenance operations; Monthly maintenance operations; Twice yearly maintenance operations. The operations require different levels of operator qualification. The following paragraphs describe the recommended procedures.

9.1. DAILY MAINTENANCE OPERATIONS

These operations can be carried out by the machine owner and do not require any special skills.

The daily machine maintenance consists of simple external cleaning, for the purposes of general hygiene. For the daily maintenance of the machine, proceed as follows:

9.1.1. CLEANING UPHOLSTERY 1. We recommend that you perform this operation daily. 2. Clean the upholstery of the machine using a cloth moistened with Clean Well.

CAUTION: do not use alcohol, benzene, or chemical products in general.

Page 9.1


Page 9.2

9.2. WEEKLY MAINTENANCE OPERATIONS


The weekly machine maintenance operations consists of simple cleaning, lubrication and checking the emergency stop to ensure the correct and safe functioning of the machine. For the weekly maintenance operations, proceed as follows:

9.2.1. CLEANING THE FRAME AND PAINTED PARTS 1. Clean the frame and painted parts of the machine using a cloth moistened with Clean Well.

CAUTION: do not use alcohol, benzene, or chemical products in general.


9.3. MONTHLY MAINTENANCE OPERATIONS


The monthly machine maintenance operations consists of simple cleaning, lubrication and checking the state of wear to ensure the correct and safe functioning of the machine. For the monthly maintenance of the machine, proceed as follows:

9.3.1. CHECK THE MECHANISMS 1. Check the wear status of the machine mechanisms: lever arms, shafts, lever systems. Repair

and/or replace any worn parts. 2. Lubricate the mechanisms using MOLYKOTE LONGTERM W 2.

9.3.2. CHECK THE GAS SPRINGS 1. Check the efficiency of the gas spring, making sure it sufficiently cushions the stem return to its

outward position. 2. Clean the stem using a dry cloth.

CAUTION: do NOT lubricate the gas spring stem for any reason.

9.3.3. CHECK THE RUBBER STOPS 1. Check the wear status of the stops. Repair and/or replace any worn parts. 2. Check the position of the stops and make sure they are firmly fastened in place.

9.3.4. CHECKING THE CARRIAGE MECHANISM 1. Check the wear status of the pulleys and carriage guides. Repair and/or replace any worn parts. 2. Clean the carriage support guide bars using alcohol.

9.3.5. CHECKING THE UPHOLSTERY 1. Check the wear status of the upholstery. Replace any worn parts.

9.3.6. CHECKING VARIOUS RUBBER PARTS

These operations apply to handles, knobs, frame guards, feet 1. Check the wear status of the rubber parts used on the machine. Repair and/or replace any worn

parts.

Page 9.3


Page 9.4

9.4. TWICE-YEARLY MAINTENANCE OPERATIONS

These operations can only be carried out by a qualified technician specifically trained by Technogym and authorized to carry out machine installation and adjustments, as well as special maintenance operations or repairs which require special knowledge of the machine, its operation, safety systems and working procedures.

The six-monthly maintenance operations involve checking the functioning, wear and tension of the mechanical components so as to ensure the correct and safe operation of the machine. For the six-monthly maintenance of the machine, proceed as follows:

9.4.1. SCREW AND BOLT CHECK 1. Make sure that the screws and bolts are firmly tightened, especially in the weight stack and seat

adjustment areas, and around moving parts in general. Tighten any that are loose.

9.4.2. CHECKING FOR MECHANISM PLAY 1. Make sure that the machine mechanisms (lever arms, shafts, starting position adjustments,

leverages) have no play. Repair and/or replace any worn parts.


10. APPENDIX

10.1. UPHOLSTERY UUPPHHOOLLSSTTEERRYY

CCOODDEE MMAACCHHIINNEE CCOODDEE DDEESSCCRRIIPPTTIIOONN QQUUAANNTTIITTYY

0G001166AA- Kneepad 1 0I000501AC-# Kneepad upholstery 1 MA05 Anterior 0I000440AB-# Elbow rest upholstery 1 0I000446AA-# Seat upholstery 1 0I000448AB-# Footrest upholstery 1 MA10 Posterior 0I000452AA-# Headrest upholstery 1 0G001166AA- Kneepad 1 0I000501AC-# Kneepad upholstery 1 MA15 Anterior Wood model 0I000440AB-# Elbow rest upholstery 1 0I000446AA-# Seat upholstery 1 0I000448AB-# Footrest upholstery 1 MA20 Posterior Wood model 0I000452AA-# Headrest upholstery 1

CAUTION: (#) Enter the appropriate upholstery colour code: AN: Silver;

V: Black; K: Aviation blue.

() Enter the appropriate grey colour code: GG: Grigio RAL 7024; GD: Grigio RAL 7039.

Page 10.1


Page 10.2

10.2. TOOLS TO USE The following tools are necessary to carry out all disassembly, adjustment and maintenance operations on the machines: Medium-sized Philips screwdriver; Medium-sized flat screwdriver; 5-gauge wrench; 8-gauge wrench; 10-gauge wrench; 13-gauge wrench; 17-gauge wrench; 19-gauge wrench; 3-gauge hexagonal T-wrench; 4-gauge hexagonal T-wrench; 5-gauge hexagonal T-wrench; 6-gauge hexagonal T-wrench; 8-gauge hexagonal T-wrench; Circlip pliers; Hammer.

CAUTION: Tool measurements are expressed in mm.

TECHNOGYM S.p.A. Via G. Perticari, 20

47035 Gambettola (FC) ITALIA

Tel.: +39 - 0547 650638 Fax: +39 - 0547 650150

e-mail: [email protected]

0SM00499AA-UK

mailto:[email protected]

ContentsGENERAL NOTICESINTRODUCTIONRECOMMENDATIONSGENERAL RULES FOR REPAIR PROCEDURES

TECHNICAL CHARACTERISTICSCOLOUR OPTIONSEQUIPMENTS: MECHANICAL CHARACTERISTICSME05 Anterior / ME15 Anterior WoodME10 Posterior / ME20 Posterior Wood

AMBIENT SPECIFICATIONSCONFORMITY TO REGULATIONS

INSTALLING AND MOVING THE MACHINESSPECIFICATIONS AND REQUIREMENTSINSTALLING THE MACHINESAnteriorPosterior

MOVINGAnteriorPosterior

ACCESSORIESWHAT IF THE MACHINE IS NOT FLATAnteriorPosterior

THE CARRIAGE DOES NOT MOVES SMOOTHLYAnteriorPosterior

THE ENCODER CABLE HAS TO BE REPLACEDAnteriorPosterior

HOW TO DISASSEMBLEANTERIORWOODEN CASINGKNEE REST UPHOLSTERYKNEE REST CARRIAGECARRIAGE BELTHANDLEBAR / CARRIAGE BRAKING LEVERELBOW REST UPHOLSTERYENCODER DEVICETIMER DEVICEBRAKE LEVERFRONT FOOTBOARD

HOW TO DISASSEMBLEPOSTERIORWOODEN CASINGLOWER CASINGBACK-REST UPHOLSTERYFEET-REST UPHOLSTERYHANDLEBARFEET POSITION LEVER ADJUSTING DEVICELEVER CASINGSCATENA LEVAENCODER ASSEMBLYTIMER DEVICELEVER ASSEMBLYBACK-REST CARRIAGEGAS SPRING AND GAS SPRING UNLOCKING CABLEMOVEMENT WHEELS

SPECIAL OPERATIONSADJUSTING THE ENCODER ZERO POSITIONAnteriorPosterior

ANTERIOR: ADJUSTING THE CARRIAGE BELT TENSION

MAINTENANCEDAILY MAINTENANCE OPERATIONSCleaning upholstery

WEEKLY MAINTENANCE OPERATIONSCleaning the frame and painted parts

MONTHLY MAINTENANCE OPERATIONSCheck the mechanismsCheck the gas springsCheck the rubber stopsChecking the carriage mechanismChecking the upholsteryChecking various rubber parts

TWICE-YEARLY MAINTENANCE OPERATIONSScrew and bolt checkChecking for mechanism play

APPENDIXUPHOLSTERYTOOLS TO USE

Documents

BioStrength FLEXabilityLine 10 ING