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Technogym Runrace Service Manual

Technogym Runrace
184 pages
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SERVICE & MAINTENANCE MANUAL
REV. 2.0

Table of Contents

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Technogym Runrace Specifications

General IconGeneral
BrandTechnogym
ModelRunrace
CategoryTreadmill
LanguageEnglish

Summary

1. GENERAL NOTICES

1.1. INTRODUCTION

Introduces manual's purpose for qualified technicians.

1.2. RECOMMENDATIONS

Outlines recommended steps for planning repair procedures.

1.3. GENERAL RULES FOR REPAIR PROCEDURES

Provides essential rules for conducting safe and effective repair procedures.

2. TECHNICAL CHARACTERISTICS

2.1. MECHANICAL CHARACTERISTICS

Details physical dimensions and weight of the machine.

2.2. ELECTRICAL CHARACTERISTICS

Specifies electrical properties like voltage, frequency, and fuse rating.

2.3. AMBIENT SPECIFICATIONS

Lists operating and storage conditions for temperature and humidity.

2.4. CONFORMITY TO REGULATIONS

Details machine's compliance with relevant European directives and standards.

2.5. WIRING DIAGRAMS

Presents wiring diagrams for various machine models, crucial for electrical troubleshooting.

4. ACCESSORIES

4.1. CONNECTING TO THE TGS

Explains how to connect the machine to the Technogym System via upgrade kits.

4.2. CONNECTING TO THE PRINTER

Details procedure and specifications for connecting a printer to the machine.

4.3. CONNECTING TO AN EXTERNAL DEVICE (ECG AND/OR METABOLIC MONITOR)

Describes connecting external medical devices for exertion tests.

4.4. PIN OUT SERIAL PORTS

Provides pin-out details for RS-232 and RS-485 serial ports for connectivity.

5. INSTALLATION INSTRUCTIONS

5.1. SPECIFICATIONS AND REQUIREMENTS

Lists requirements for correct machine installation, including surface and environment.

5.2. INSTALLATION

Provides a step-by-step guide for the physical installation of the machine.

5.3. FIRST POWER-ON

Guides users through the initial power-on process and basic operational checks.

6. TROUBLESHOOTING

6.1. THE DISPLAY DOES NOT ILLUMINATE

A flowchart to diagnose and resolve issues where the machine's display fails to turn on.

7. DISASSEMBLY OF COMPONENTS

7.1. DISASSEMBLING THE DISPLAY

Step-by-step instructions for safely removing and disassembling the machine's display unit.

7.2. DISASSEMBLING THE EPROM

Detailed procedure for removing and reassembling EPROMs from circuit boards.

7.3. DISASSEMBLING THE BACKUP BATTERY

Instructions for safely removing and replacing the backup battery, including voltage checks.

7.4. DISASSEMBLING THE CPU BOARD

Comprehensive guide to disassembling and reassembling the CPU board, including connector handling.

7.5. DISASSEMBLING THE KEYBOARD

Instructions for the disassembly and reassembly of the machine's keyboard interface.

7.6. DISASSEMBLING THE CARDIO RECEIVER

Procedure for removing and replacing the cardio receiver unit.

7.7. DISASSEMBLING THE EMERGENCY STOP BUTTON

Steps for safely removing and reinstalling the emergency stop button assembly.

7.8. DISASSEMBLING THE MOTOR GUARD

Instructions for accessing and removing the motor guard for maintenance or inspection.

7.9. DISASSEMBLING THE SIDE GUARDS

Guide for removing the side guards to access internal components of the machine.

7.10. DISASSEMBLING THE FRONT PLATE

Procedure for detaching and removing the front plate, noting its cable attachments.

7.11. DISASSEMBLING SHIELD GRID FOR TREAD BELT MOTOR AND INVERTER

Instructions for removing the shield grid protecting the motor and inverter.

7.12. DISASSEMBLING THE REAR ROLLER

Step-by-step guide for removing the rear roller, including belt tension adjustment notes.

7.13. DISASSEMBLING THE MOTOR ROLLER

Procedure for removing the motor roller, including belt tension adjustment guidance.

7.14. DISASSEMBLING THE BRUSH

Instructions for removing the brush, with a note about the lubrication system.

7.15. DISASSEMBLING THE TREAD BELT AND RUNNING TRACK

Detailed steps for removing the tread belt and running track assembly.

7.16. DISASSEMBLING THE SHOCK ABSORBERS

Guide for removing the shock absorbers, referencing previous disassembly steps.

7.17. DISASSEMBLING THE TREAD-BELT MOTOR

Comprehensive procedure for removing the tread-belt motor, including cable disconnection.

7.18. DISASSEMBLING THE MOTOR DRIVE-BELT

Instructions for removing the motor drive-belt and subsequent tension adjustment.

7.19. DISASSEMBLING THE ELECTRONIC CIRCUIT BOARDS

Guide to removing various electronic boards, including inverter interface, power supply, and up-down board.

7.20. DISASSEMBLING THE INVERTER

Step-by-step instructions for safely removing the inverter unit from the machine.

7.21. DISASSEMBLING THE UP-DOWN MOTOR BELT

Procedure for removing the up-down motor belt, including guard removal and tensioning.

7.22. DISASSEMBLING THE UP-DOWN MOTOR

Detailed guide for removing the up-down motor, including encoder wheel and housing disassembly.

7.23. DISASSEMBLING THE UP-DOWN MOTOR BRUSHES

Instructions for removing the up-down motor brushes, noting model limitations.

7.24. DISASSEMBLING THE ELEVATION BARS

Procedure for removing the elevation bars, including wheel and shaft disassembly.

7.25. DISASSEMBLING THE LEAD SCREW NUTS

Instructions for removing the lead screw nut group, referencing other disassembly steps.

7.26. DISASSEMBLING THE MICROSWITCHES

Guide for removing microswitches, including cable reconnection notes.

7.27. DISASSEMBLING THE PHOTOCELL

Procedure for removing the photocell board, noting different versions and SW requirements.

7.28. DISASSEMBLING THE FANS

Instructions for removing the machine's fans, including conveyor disassembly if needed.

8. ADJUSTMENTS

8.1. TENSIONING A NEW TREAD BELT

Step-by-step guide for correctly tensioning a new tread belt after installation.

8.2. TENSIONING A USED TREAD BELT

Procedure for tensioning a used tread belt, noting differences from new belt installation.

8.3. CENTERING THE TREAD BELT

Instructions on how to properly center the tread belt while the machine is running.

8.4. ADJUSTING THE TENSION AND ALIGNMENT OF THE TREAD-BELT MOTOR BELT

Guide for adjusting the tension and alignment of the tread-belt motor drive belt.

8.5. TENSIONING THE UP-DOWN MOTOR BELT

Procedure for adjusting the tension of the up-down motor belt for optimal performance.

8.6. ALIGNING THE ELEVATION BARS

Steps to ensure proper alignment of the elevation bars for smooth incline adjustments.

8.7. CALIBRATING THE TREAD BELT SPEED

Procedure for calibrating the tread belt speed by adjusting the inverter interface potentiometer.

8.8. CENTERING THE PHOTOCELL

Instructions for centering the photocell to ensure accurate motor position feedback.

8.9. ADJUSTING THE LCD BACKLIGHTING

Guide for adjusting the LCD backlight for optimal readability.

8.10. ADJUSTING THE BUZZER TONE

Procedure for adjusting the buzzer tone for audible alerts.

9. MACHINE CONFIGURATION

9.1. HW MACHINE CONFIGURATION

Explains hardware configuration using dip-switches on the CPU board for external devices and language.

9.2. CONFIGURATION OF SW PARAMETERS

Details how to configure software parameters, specifically for the machine's lubrication system.

9.3. PARTIAL DISPLAY OF WORKING PARAMETERS

Accessing and viewing partial working parameters like machine utilization and lubrication settings.

9.4. COMPLETE DISPLAY OF WORKING PARAMETERS

Accessing and viewing complete working parameters, including lubrication duration and frequency.

9.5. MODIFYING THE WORKING PARAMETERS

Procedure for modifying machine parameters, particularly for lubrication settings.

9.6. PROGRAMMING THE HITACHI SJ100 INVERTER

Guide for programming the Hitachi SJ100 inverter, including main and extended functions.

9.7. PROGRAMMING THE HITACHI J100 INVERTER

Instructions for programming the Hitachi J100 inverter for different versions (E2, E3, E4, E5).

9.8. PROGRAMMING THE LENZE 644 INVERTER

Guide for programming the Lenze 644 inverter using the onboard keypad.

10. SCHEDULED MAINTENANCE

10.1. EXTERNAL CLEANING OPERATIONS

Instructions for routine external cleaning of the machine, emphasizing safety and proper cleaning agents.

10.2. ROUTINE MAINTENANCE OPERATIONS

Outlines regular maintenance tasks including cleaning, lubrication, and wear checks.

10.3. SPECIAL MAINTENANCE OPERATIONS

Details advanced maintenance tasks requiring qualified technicians, covering checks and component inspections.

11. APPENDIX

11.1. TECHNICAL NOTES ON CARDIO RECEIVERS

Provides detailed technical information on cardio receivers, including components and signal types.

11.2. HITACHI SJ100 INVERTER ERROR CODES

Lists and explains error codes generated by the Hitachi SJ100 inverter for troubleshooting.

11.3. PROCEDURE FOR CLEARING THE ERROR MEMORY ON HITACHI SJ100 INVERTER

Step-by-step guide for clearing error memory on the Hitachi SJ100 inverter.

11.4. PROCEDURE FOR CLEARING PARAMETERS ON HITACHI SJ100 INVERTER

Instructions for resetting Hitachi SJ100 inverter parameters to factory defaults.

11.5. HITACHI J100 INVERTER ERROR CODES

Lists and explains error codes for the Hitachi J100 inverter, aiding in troubleshooting.

11.6. PROCEDURE FOR CLEARING THE ERROR MEMORY ON HITACHI J100 INVERTER

Steps to clear the error memory on Hitachi J100 inverters, including parameter configuration.

11.7. LENZE 644 INVERTER ERROR CODES

Details error codes for the Lenze 644 inverter, categorized by error type.

11.8. DELETING ERRORS ON THE LENZE 644 INVERTER

Procedure for deleting specific error codes from the Lenze 644 inverter memory.

11.9. INSTALLING THE HITACHI INVERTER IN PLACE OF THE LENZE INVERTER

Guide for replacing a Lenze inverter with a Hitachi inverter, detailing necessary modifications and parts.

11.10. LEAKAGE CURRENT PROBLEMS WITH HITACHI E5 INVERTER

Addresses leakage current issues with Hitachi E5 inverter and provides solutions for conformance.

11.11. SPECIAL FUNCTIONS AND PASSWORD

Lists special functions, passwords, and tests available on the machine for diagnostics and configuration.

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