Technogym FLEXability Line Service Maintenance Manual
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Technogym FLEXability Line Service Maintenance Manual

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ERVICE
MAINTENANCE MANUAL
Rev. 1.0

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  • Page 1 & ERVICE MAINTENANCE MANUAL Rev. 1.0...
  • Page 3 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.

  • Page 5: Table Of Contents

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 Contents 1. GENERAL NOTICES............................. 1.1 1.1. I ..............................1.1 NTRODUCTION 1.2. R ............................1.1 ECOMMENDATIONS 1.3. G ......................1.2 ENERAL RULES FOR REPAIR PROCEDURES 2. TECHNICAL CHARACTERISTICS........................2.1 2.1. C ............................... 2.2 OLOUR OPTIONS 2.2.
  • Page 6 FLEXability LINE: Service & Maintenance Manual - rev. 1.0 7.6. F ......................7.6 EET POSITION LEVER ADJUSTING DEVICE 7.7. L ..............................7.9 EVER CASINGS 7.8. C ..............................7.10 ATENA LEVA 7.9. E ............................7.11 NCODER ASSEMBLY 7.10. T ..............................7.13 IMER DEVICE 7.11.

  • Page 7: General Notices

    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.

  • Page 8: 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.

  • Page 9: Technical Characteristics

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 2. TECHNICAL CHARACTERISTICS The Element machine code is a sequence of 14 alphanumeric characters arranged as follows: FLEXABILITY LINE Characters description key to values Product Line ME = FLEXability Line 05 = Anterior...

  • Page 10: Colour Options

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 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 –...

  • Page 11: Equipments: Mechanical Characteristics

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 2.2. EQUIPMENTS: MECHANICAL CHARACTERISTICS 2.2.1. ME05 – A / ME15 A NTERIOR NTERIOR ME05 – Anterior / ME15 – Anterior Wood Dimensions [P x L x A] 193 x 57 x 124 cm [L x W x H] 75.9 x 22.4 x 48.8 in...

  • Page 12: Ambient Specifications

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 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...

  • Page 13: Installing And Moving The Machines

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 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.
  • Page 14 FLEXability LINE: Service & Maintenance Manual - rev. 1.0 Page 3.2...

  • Page 15: Posterior

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 3.2.2. OSTERIOR Page 3.3...
  • Page 16 FLEXability LINE: Service & Maintenance Manual - rev. 1.0 Page 3.4...

  • Page 17: Moving

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 3.3. MOVING 3.3.1. NTERIOR 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.
  • Page 18 FLEXability LINE: Service & Maintenance Manual - rev. 1.0 Page intentionally left blank Page 3.6...

  • Page 19: Accessories

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 4. ACCESSORIES No accessories are available for these machines. Page 4.1...
  • Page 20 FLEXability LINE: Service & Maintenance Manual - rev. 1.0 Page intentionally left blank Page 4.2...

  • Page 21: What If

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 5. WHAT IF … 5.1. THE MACHINE IS NOT FLAT 5.1.1. NTERIOR The machine disposes of 4 adjusting feet, indicated in the figure to side. Check that all the 4 feet are touching on the floor.

  • Page 22: Anterior

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 5.2. THE CARRIAGE DOES NOT MOVES SMOOTHLY 5.2.1. NTERIOR 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.

  • Page 23: Anterior

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 5.3. THE ENCODER CABLE HAS TO BE REPLACED 5.3.1. NTERIOR To replace the encoder cable / tape, proceed as follow: 1. Disassemble the encoder device as detailed in charter 6 of this manual.
  • Page 24 FLEXability LINE: Service & Maintenance Manual - rev. 1.0 4. Connect the eyelet of the cable to the carriage, as shown in the figure. After completing reassembly procedure, carry on the procedure described in paragraph 8.1. “Adjusting the encoder zero position”.
  • Page 25 FLEXability LINE: Service & Maintenance Manual - rev. 1.0 5.3.2. OSTERIOR 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.
  • Page 26 FLEXability LINE: Service & Maintenance Manual - rev. 1.0 Page intentionally left blank Page 5.6...

  • Page 27: How To Disassemble...anterior

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 6. HOW TO DISASSEMBLE…ANTERIOR 6.1. WOODEN CASING On both sides of the machine: 1. Back off the screw a using a 5mm hex wrench. Figure 6.1-1 2. Back off the screw a using a 5mm hex wrench.

  • Page 28: Knee Rest Upholstery

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 6.2. KNEE REST UPHOLSTERY 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 6.2-1 3.
  • Page 29 FLEXability LINE: Service & Maintenance Manual - rev. 1.0 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. Figure 6.2-4 Page 6.3...

  • Page 30: Knee Rest Carriage

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 6.3. KNEE REST CARRIAGE 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 6.3-1 2. Remove the pin b, which is connecting the upholstery support frame to the carriage.
  • Page 31 FLEXability LINE: Service & Maintenance Manual - rev. 1.0 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,...
  • Page 32 FLEXability LINE: Service & Maintenance Manual - rev. 1.0 10. Back off the 4 screws l, using a 6mm hex wrench. Figure 6.3-7 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.

  • Page 33: Carriage Belt

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 6.4. CARRIAGE BELT 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.
  • Page 34 FLEXability LINE: Service & Maintenance Manual - rev. 1.0 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.

  • Page 35: Handlebar / Carriage Braking Lever

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 6.5. HANDLEBAR / CARRIAGE BRAKING LEVER 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.

  • Page 36: Elbow Rest Upholstery

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 6.6. ELBOW REST UPHOLSTERY 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.

  • Page 37: Encoder Device

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 6.7. ENCODER DEVICE 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.
  • Page 38 FLEXability LINE: Service & Maintenance Manual - rev. 1.0 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.
  • Page 39 FLEXability LINE: Service & Maintenance Manual - rev. 1.0 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.

  • Page 40: Timer Device

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 6.8. TIMER DEVICE 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.
  • Page 41 FLEXability LINE: Service & Maintenance Manual - rev. 1.0 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.

  • Page 42: Brake Lever

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 6.9. BRAKE LEVER 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.
  • Page 43 FLEXability LINE: Service & Maintenance Manual - rev. 1.0 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 6.9-4 9. Remove the external circlip f using a flat screwdriver and disconnect the braking lever from the one inside the frame.

  • Page 44: Front Footboard

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 6.10. FRONT FOOTBOARD 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.

  • Page 45: How To Disassemble

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 7. HOW TO DISASSEMBLE…POSTERIOR 7.1. WOODEN CASING On both sides of the machine: 1. Back off the screw a using a 6mm hex wrench. Figure 7.1-1 2. Back off the 2 screws b using a 6mm hex wrench.

  • Page 46: Lower Casing

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 7.2. LOWER CASING 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.

  • Page 47: Back-Rest Upholstery

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 7.3. BACK-REST UPHOLSTERY 1. Back off the screw a using a 5mm hex wrench, on both sides of the machine. Figure 7.3-1 2. Back off the screws b using a 6mm hex wrench.

  • Page 48: Feet-Rest Upholstery

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 7.4. FEET-REST UPHOLSTERY 1. Open the zip-fastener a, in the lower part of the upholstery. Figure 7.4-1 2. Back off the 2 screws b using a 5mm hex wrench. 3. Remove the upholstery from its metal supports.

  • Page 49: Handlebar

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 7.5. HANDLEBAR 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.

  • Page 50: Feet Position Lever Adjusting Device

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 7.6. FEET POSITION LEVER ADJUSTING DEVICE 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.
  • Page 51 FLEXability LINE: Service & Maintenance Manual - rev. 1.0 To disassemble the feet position adjusting lever: 14. Back off the 3 screws o using a 3mm hex wrench and remove the casing. Figure 7.6-4 15. Back off the counter nut p and screw in the adjusting screw q.
  • Page 52 FLEXability LINE: Service & Maintenance Manual - rev. 1.0 Figure 7.6-7 During the reassembly procedure, pay attention to correctly route the cable, following the arrows. Figure 7.6-8 Page 7.8...

  • Page 53: Lever Casings

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 7.7. LEVER CASINGS 1. Back off the 3 screws a using a 3mm hex wrench and remove the internal casing. Figure 7.7-1 2. Back off the 2 screws b using a Phillips screwdriver.

  • Page 54: Catena Leva

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 7.8. CATENA LEVA 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.

  • Page 55: Encoder Assembly

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 7.9. ENCODER ASSEMBLY 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...
  • Page 56 FLEXability LINE: Service & Maintenance Manual - rev. 1.0 7. Back off the 4 screws f using a Phillips screwdriver, which fixing timer/encoder display to the frame. Figure 7.9-4 8. Back off the 2 nuts g using a 5mm wrench.

  • Page 57: Timer Device

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 7.10. TIMER DEVICE 1. Back off the 2 screws a using a 4mm hex wrench. 2. Remove the display rear casing. Figure 7.10-1 3. Remove the knob b. Figure 7.10-2 4. Back off the screw c using a Phillips screwdriver.

  • Page 58: Lever Assembly

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 7.11. LEVER ASSEMBLY 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.
  • Page 59 FLEXability LINE: Service & Maintenance Manual - rev. 1.0 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 7.11-4 6. Remove the lever assembly from the lower frame with carriage.

  • Page 60: Back-Rest Carriage

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 7.12. BACK-REST CARRIAGE 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.

  • Page 61: Gas Spring And Gas Spring Unlocking Cable

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 7.13. GAS SPRING AND GAS SPRING UNLOCKING CABLE 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.
  • Page 62 FLEXability LINE: Service & Maintenance Manual - rev. 1.0 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.

  • Page 63: Movement Wheels

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 7.14. MOVEMENT WHEELS 1. Back off the 2 screws a using a 4mm hex wrench. 2. Remove the 2 lateral casings. Figure 7.14-1 3. Back off the screw b and its nut using an 8mm hex wrench and a 17mm wrench.
  • Page 64 FLEXability LINE: Service & Maintenance Manual - rev. 1.0 Page intentionally left blank Page 7.20...

  • Page 65: Special Operations

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 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.

  • Page 66: Posterior

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 8.1.2. OSTERIOR 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.

  • Page 67: Anterior: Adjusting The Carriage Belt Tension

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 8.2. ANTERIOR: ADJUSTING THE CARRIAGE BELT TENSION 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.
  • Page 68 FLEXability LINE: Service & Maintenance Manual - rev. 1.0 Page intentionally left blank Page 8.4...

  • Page 69: Maintenance

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 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: •...

  • Page 70: Weekly Maintenance Operations

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 9.2. WEEKLY MAINTENANCE OPERATIONS These operations can be carried out by the machine owner and do not require any special skills. 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.

  • Page 71: Monthly Maintenance Operations

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 9.3. MONTHLY MAINTENANCE OPERATIONS These operations can be carried out by the machine owner and do not require any special skills. 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.

  • Page 72: Twice-Yearly Maintenance Operations

    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.

  • Page 73: Appendix

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 10. APPENDIX 10.1. UPHOLSTERY 0G001166AA-§ Kneepad MA05 Anterior 0I000501AC-# Kneepad upholstery 0I000440AB-# Elbow rest upholstery 0I000446AA-# Seat upholstery MA10 Posterior 0I000448AB-# Footrest upholstery 0I000452AA-# Headrest upholstery 0G001166AA-§ Kneepad MA15 Anterior – Wood model...

  • Page 74: Tools To Use

    FLEXability LINE: Service & Maintenance Manual - rev. 1.0 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;...
  • Page 76 TECHNOGYM S.p.A. Via G. Perticari, 20 47035 Gambettola (FC) ITALIA Tel.: +39 - 0547 650638 Fax: +39 - 0547 650150 e-mail: service@technogym.com 0SM00499AA-UK...

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