Technogym MA05 User manual

SERVICE &MAINTENANCE MANUAL
Rev. 1.2

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 Element™trademark is property of Technogym S.p.A.

ELEMENT LINE: Service & Maintenance Manual - rev. 1.2
Page i
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. PRODUCT CODING...............................................................................................................................................2.3
2.2.1. Machines codes ...................................................................................................................................2.3
2.2.2. Benches codes......................................................................................................................................2.3
2.3. EQUIPMENTS:MECHANICAL CHARACTERISTICS..................................................................................................2.4
2.3.1. MA05 – Adductor ................................................................................................................................2.4
2.3.2. MA10 – Abductor ................................................................................................................................2.4
2.3.3. MA15 – Shoulder Press.......................................................................................................................2.5
2.3.4. MA20 – Chest Press ............................................................................................................................2.5
2.3.5. MA30 – Leg Extension ........................................................................................................................2.6
2.3.6. MA35 – Leg Curl.................................................................................................................................2.6
2.3.7. MA40 – Lat Machine...........................................................................................................................2.7
2.3.8. MA45 – Lower Back............................................................................................................................2.7
2.3.9. MA50 – Leg Press ...............................................................................................................................2.8
2.3.10. MA55 – Arm Curl................................................................................................................................2.8
2.3.11. MA60 – Arm Extension........................................................................................................................2.9
2.3.12. MA65 – Abdominal Crunch.................................................................................................................2.9
2.3.13. MA70 – Pectoral ...............................................................................................................................2.10
2.3.14. MA75 – Glute ....................................................................................................................................2.10
2.3.15. MA80 – Ercolina...............................................................................................................................2.11
2.3.16. MA85 – Ercolina Crossover Cable ...................................................................................................2.11
2.3.17. MA90 – Ercolina Rehab....................................................................................................................2.12
2.3.18. MA95 – Low Row..............................................................................................................................2.12
2.3.19. PA01 – Inclined bench ......................................................................................................................2.13
2.3.20. PA02 – Vertical bench.......................................................................................................................2.13
2.3.21. PA03 –Crunch bench.........................................................................................................................2.14
2.3.22. PA04 – Adjustable bench ..................................................................................................................2.14
2.3.23. PA05 –Lower Back bench .................................................................................................................2.15
2.3.24. PA06 –Scott bench.............................................................................................................................2.15
2.3.25. PA07 – Horizontal bench..................................................................................................................2.16
2.4. AMBIENT SPECIFICATIONS................................................................................................................................2.16
2.5. CONFORMITY TO REGULATIONS........................................................................................................................2.16
3. INSTALLING AND MOVING THE MACHINES..............................................................................................3.1
3.1. SPECIFICATIONS AND REQUIREMENTS ................................................................................................................3.1
3.2. INSTALLING AND MOVING THE MACHINES ..........................................................................................................3.1
3.3. LIFTING AND MOVING.........................................................................................................................................3.2
3.4. INSTALLING THE MACHINE ALREADY ASSEMBLED..............................................................................................3.3
3.5. INSTALLING THE MACHINE TO BE ASSEMBLED....................................................................................................3.4
3.5.1. MA50 – Leg Press ...............................................................................................................................3.4
3.5.2. MA85 – Ercolina Crossover Cable .....................................................................................................3.5
3.5.3. PA02 – Vertical Bench ........................................................................................................................3.8
3.6. MACHINE SECURING.........................................................................................................................................3.10
3.6.1. Fixing a wall: Ercolina, Ercolina Rehab e Cross Cables.................................................................3.10
3.6.2. Fixing the ceiling: Cavi Incrociati ....................................................................................................3.12
4. ACCESSORIES.......................................................................................................................................................4.1

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4.1. BARBELL HOLDER,PLATES HOLDER AND DUMBELL HOLDER..............................................................................4.1
4.1.1. A0000230: Barbell Rack.....................................................................................................................4.1
4.1.2. A0000231: Plate Rack.........................................................................................................................4.2
4.1.3. A0000421: Urethane - Encased Dumbell Rack...................................................................................4.2
4.1.4. A0000364: Chrome Dumbbell Rack....................................................................................................4.3
4.2. WHAT TO ORDER TO AUGMENT THE WEIGHT STACK ...........................................................................................4.4
5. HOW TO DISASSEMBLE THE ….......................................................................................................................5.1
5.1. WEIGHT STACK CASING......................................................................................................................................5.1
5.2. DISASSEMBLING THE WEIGHT STACK..................................................................................................................5.2
5.3. SEAT ON LOW MACHINES....................................................................................................................................5.3
5.4. SEAT ON TALL MACHINES...................................................................................................................................5.4
5.5. LEG PRESS SEAT.................................................................................................................................................5.6
5.6. RELEASE LEVER..................................................................................................................................................5.8
5.7. DISASSEMBLING UNLOCKING LEVER ON ABDUCTOR -ADDUCTOR ...................................................................5.10
5.8. DISASSEMBLING SHOULDER REST LEVER ON ABDOMINAL CRUNCH .................................................................5.12
5.9. DISASSEMBLING ROLLERS ADJUSTING SYSTEM ON LAT MACHINE ....................................................................5.13
5.10.DISASSEMBLING HANDLES ADJUSTING SYSTEM ON CHEST PRESS.....................................................................5.15
5.11.DISASSEMBLING EASY START SYSTEM ON PECTORAL.......................................................................................5.17
5.12.DISASSEMBLING THE ADDITIONAL WEIGHT ......................................................................................................5.18
6. WHAT IF ….............................................................................................................................................................6.1
6.1. THE WEIGHT STACK DOES NOT SLIDE SMOOTHLY ...............................................................................................6.1
6.2. THE WEIGHT STACK CABLE IS NOT TAUT.............................................................................................................6.2
6.3. THE MACHINE IS NOT FLAT .................................................................................................................................6.3
6.4. THE LEVERS OF DUAL-AXIS MACHINES ARE NOT ALIGNED..................................................................................6.4
7. SPECIAL OPERATIONS.......................................................................................................................................7.1
7.1. LOCKING DOWN THE CABLE FIXING DOWELS......................................................................................................7.1
7.2. LOCKING DOWN THE PULLEYS............................................................................................................................7.2
7.3. LOCKING DOWN THE DOWELS ON THE ARM EXTENSION LEVER..........................................................................7.3
8. WEIGHT STACK CABLE.....................................................................................................................................8.1
8.1. LENGTH OF THE WEIGHT STACK CABLES.............................................................................................................8.1
8.2. ROUTING OF THE WEIGHT STACK CABLE.............................................................................................................8.2
8.2.1. MA05 – Adductor ................................................................................................................................8.2
8.2.2. MA10 – Abductor ................................................................................................................................8.3
8.2.3. MA15 – Shoulder Press.......................................................................................................................8.3
8.2.4. MA20 – Chest Press ............................................................................................................................8.4
8.2.5. MA25 – Vertical Traction....................................................................................................................8.4
8.2.6. MA30 – Leg Extension ........................................................................................................................8.5
8.2.7. MA35 – Leg Curl.................................................................................................................................8.5
8.2.8. MA40 – Lat Machine...........................................................................................................................8.6
8.2.9. MA45 – Lower Back............................................................................................................................8.6
8.2.10. MA50 – Leg Press ...............................................................................................................................8.7
8.2.11. MA55 – Arm Curl................................................................................................................................8.7
8.2.12. MA60 – Arm Extension........................................................................................................................8.8
8.2.13. MA65 – Abdominal Crunch.................................................................................................................8.8
8.2.14. MA70 – Pectoral .................................................................................................................................8.9
8.2.15. MA75 – Glute ......................................................................................................................................8.9
8.2.16. MA80 – Ercolina...............................................................................................................................8.10
8.2.17. MA85 – Ercolina Cross Over Cable .................................................................................................8.10
8.2.18. MA90 – Ercolina Rehab....................................................................................................................8.11
8.2.19. MA95 – Low Row..............................................................................................................................8.11
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

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9.2.1. Cleaning the frame and painted parts.................................................................................................9.2
9.3. MONTHLY MAINTENANCE OPERATIONS..............................................................................................................9.3
9.3.1. Check the cross, bars and weight stack plates ....................................................................................9.3
9.3.2. Check the cables..................................................................................................................................9.3
9.3.3. Check the mechanisms.........................................................................................................................9.3
9.3.4. Check the gas springs..........................................................................................................................9.3
9.3.5. Check the weight stack stops...............................................................................................................9.4
9.3.6. Check the Leg Press seat mechanism..................................................................................................9.4
9.3.7. Checking the seat mechanism on low machines..................................................................................9.4
9.3.8. Checking the seat mechanism on tall machines ..................................................................................9.4
9.3.9. Checking the upholstery......................................................................................................................9.4
9.3.10. Checking various rubber parts............................................................................................................9.4
9.4. TWICE-YEARLY MAINTENANCE OPERATIONS......................................................................................................9.5
9.4.1. Check the pulleys.................................................................................................................................9.5
9.4.2. Check the cam group...........................................................................................................................9.5
9.4.3. Check the lever stops...........................................................................................................................9.5
9.4.4. Replacing the cables............................................................................................................................9.5
9.4.5. Lubricating the release systems...........................................................................................................9.5
9.4.6. Screw and bolt check...........................................................................................................................9.6
9.4.7. Checking for mechanism play .............................................................................................................9.6
9.4.8. Checking cross alignment....................................................................................................................9.6
10.APPENDIX.............................................................................................................................................................10.1
10.1.TOOLS TO USE ..................................................................................................................................................10.1

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ELEMENT LINE: Service & Maintenance Manual - rev. 1.2
Page 1.1
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.
CAUTION: non observance may cause damage to the machine.
Information about the operation in progress.
observation about the operation in progress.
1.2. RECOMMENDATIONS
Technogym recommends the following steps for planning repair procedures:
•Carefully evaluate the customer’s 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.

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

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Page 2.1
2. TECHNICAL CHARACTERISTICS
The Element machine code is a sequence of 14 alphanumeric characters arranged as follows:
ELEMENT LINE
Characters description key to values
1,2 Element Line MA = Element machine
PA = Element benches
3,4 Machine code See paragraph: 2.1. “Colour options”
5 Weight stack configuration
N= None
0= Standard
2= enhanced +20 Kg (1 )
3= enhanced +30 Kg (2 )
5= enhanced +50 Kg (3 )
6 Additional weight N= None
C= 2.5 Kg additional weight
7 Isocontrol 0= None
1= Isocontrol
-
8,9 Frame colour AL = silver
10,11 Upholstery colour
AN = silver
V0 = black
K0 = aviation blue
M0 = Bordeaux (benches only)
12,13 Rubber colour GG = grey RAL 7024
14 Casing colour A= white
G= grey
J= I-Pac
15 Unit of measurement K= Kg
L= pound
NOTES:
(1 ) Valid on Abdominal Crunch, Abductor, Adductor, Arm Curl, Arm Extension, Leg Extension,
Leg Curl, Lower Back, Shoulder Press and Vertical Traction.
(2 ) Valid on Chest Press, Lat Machine, Low Row and Pectoral.
(3 ) Valid on Ercolina, Ercolina Rehab and Cross Over Cables.

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Page 2.2
For example, a possible product code would be:
MA150N0-ALANGGAK
which is interpreted as follows:
MA 15 0 N 0 - ALANGG A K
Unit of measurement, Kg
Casing colour, white
Rubber colour, grey RAL 7024
Upholstery colour, silver
Frame colour, aluminium
NO, Isocontrol
NO, additional weight
Weight stack configuration, standard
Shoulder Press
Element Line machine
2.1. COLOUR OPTIONS
The following table shows the possible combinations for ordering the Classic Selection line
machines:
CONFIGURATION -1-
CONFIGURATION -2-
CONFIGURAZIONE -3-
FRAME AL - SILVER AL - SILVER AL - SILVER
CASING A - WHITE G –GREY J – I PAC
UPHOLSTERY AN - SILVER V0 - BLACK K0 - BLUE
Table 2-1

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2.2. PRODUCT CODING
2.2.1. MACHINES CODES
Code Machine
05 Adductor
10 Abductor
15 Shoulder Press
20 Chest Press
25 Vertical traction
30 Leg Extension
35 Leg Curl
40 Lat Machine
45 Lower Back
50 Leg Press
55 Arm Curl
60 Arm Extension
65 Abdominal Crunch
70 Pectoral Machine
75 Glute
80 Ercolina
83 Multipower
85 Crossover Cable
90 Ercolina Rehab
95 Low Row
2.2.2. BENCHES CODES
Code Machine
01 Inclined bench
02 Vertical bench
03 Crunch bench
04 Adjustable bench
05 Lower Back bench
06 Scott bench
07 Horizontal bench

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2.3. EQUIPMENTS: MECHANICAL CHARACTERISTICS
2.3.1. MA05 –ADDUCTOR
MA05 - Adductor
stand by max during exercise
141 x 82 x 142 cm
Dimensions 55.5 x 32.3 x 55.9 in
Overall weight 140 Kg – 280 lbs
Standard weight stack 60 Kg – 120 lbs
Enhanced weight stack 80 Kg – 160 lbs
2.3.2. MA10 –ABDUCTOR
MA10 – Abductor
stand by max during exercise
141 x 82 x 142 cm
Dimensions 55.5 x 32.3 x 55.9 in
Overall weight 140 Kg – 280 lbs
Standard weight stack 60 Kg – 120 lbs
Enhanced weight stack 80 Kg – 160 lbs

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2.3.3. MA15 –SHOULDER PRESS
M8A15 – Shoulder Press
stand by max during exercise
144 x 87 x 142 cm
Dimensions 56.7 x 34.3 x 55.9 in
Overall weight 170 Kg – 340 lbs
Standard weight stack 60 Kg – 120 lbs
Enhanced weight stack 80 Kg – 160 lbs
2.3.4. MA20 –CHEST PRESS
MA20 – Chest Press
stand by max during exercise
139 x 83 x 162 cm
Dimensions 54.7 x 32.7 x 63.8 in
Overall weight 190 Kg – 380 lbs
Standard weight stack 90 Kg – 180 lbs
Enhanced weight stack 120 Kg – 240 lbs

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2.3.5. MA30 –LEG EXTENSION
MA30 – Leg Extension
stand by max during exercise
127 x 104 x 142 cm
Dimensions 50 x 41 x 56.9 in
Overall weight 200 Kg – 400 lbs
Standard weight stack 80 Kg – 160 lbs
Enhanced weight stack 100 Kg – 200 lbs
2.3.6. MA35 –LEG CURL
MA35 – Leg Curl
stand by max during exercise
127 x 104 x 142 cm
Dimensions 50 x 41 x 56.9 in
Overall weight 200 Kg – 400 lbs
Standard weight stack 80 Kg – 160 lbs
Enhanced weight stack 100 Kg – 200 lbs

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2.3.7. MA40 –LAT MACHINE
MA40 – Lat Machine
stand by max during exercise
120 x 120 x 223 cm
Dimensions 47.8 x 47.8 x 88 in
Overall weight 270 Kg – 540 lbs
Standard weight stack 90 Kg – 180 lbs
Enhanced weight stack 120 Kg – 240 lbs
2.3.8. MA45 –LOWER BACK
MA45 – Lower Back
stand by max during exercise
120 x 95 x 142 cm
Dimensions 47.8 x 37.4 x 55.9 in
Overall weight 200 Kg – 400 lbs
Standard weight stack 70 Kg – 140 lbs
Enhanced weight stack 90 Kg – 180 lbs

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2.3.9. MA50 –LEG PRESS
MA50 – Leg Press
stand by max during exercise
210 x 115 x 152 cm
Dimensions 82.7 x 45.3 x 59.9 in
Overall weight 570 Kg – 1140 lbs
Standard weight stack 200 Kg – 400 lbs
Enhanced weight stack -
2.3.10. MA55 –ARM CURL
MA55 – Arm Curl
stand by max during exercise
139 x 80 x 142 cm
Dimensions 54.7 x 31.5 x 55.9 in
Overall weight 155 Kg – 310 lbs
Standard weight stack 60 Kg – 120 lbs
Enhanced weight stack 80 Kg – 160 lbs

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2.3.11. MA60 –ARM EXTENSION
MA60 – Arm Extension
stand by max during exercise
141 x 80 x 142 cm
Dimensions 55.5 x 31.5 x 55.9 in
Overall weight 170 Kg – 340 lbs
Standard weight stack 70 Kg – 140 lbs
Enhanced weight stack 90 Kg – 180 lbs
2.3.12. MA65 –ABDOMINAL CRUNCH
MA65 – Abdominal Crunch
stand by max during exercise
133 x 89 x 142 cm
Dimensions 52.4 x 35 x 55.9 in
Overall weight 180 Kg – 360 lbs
Standard weight stack 60 Kg – 120 lbs
Enhanced weight stack 80 Kg – 160 lbs

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2.3.13. MA70 –PECTORAL
MA70 – Pectoral
stand by max during exercise
149 x 82 x 142 cm
Dimensions 59 x 32 x 56 in
Overall weight 190 Kg – 380 lbs
Standard weight stack 90 Kg – 180 lbs
Enhanced weight stack 120 Kg – 240 lbs
2.3.14. MA75 –GLUTE
MA75 – Glute
stand by max during exercise
114 x 132 x 142 cm
Dimensions 45 x 52 x 56 in
Overall weight 225 Kg – 450 lbs
Standard weight stack 60 Kg – 120 lbs
Enhanced weight stack –