Technogym Run XT Service Maintenance Manual

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SERVICE & MAINTENANCE MANUAL

PRELIMINARY

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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.r.l. The Run XT™ trademark is property of Technogym S.r.l.

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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. MECHANICAL CHARACTERISTICS...................................................................................................................2.1

2.2. ELECTRICAL CHARACTERISTICS.....................................................................................................................2.1

2.3. AMBIENT SPECIFICATIONS.............................................................................................................................2.1

2.4. CONFORMITY TO REGULATIONS .....................................................................................................................2.1

2.5. WIRING DIAGRAM FOR THE 220 MODEL........................................................................................................ 2.2

2.5.1. Connectors.......................................................................................................................................2.2

2.5.2. Wiring..............................................................................................................................................2.3

2.6. WIRING DIAGRAM FOR THE 220 USA MODEL.................................................................................................2.6

2.7. WIRING DIAGRAM FOR THE 110 MODEL........................................................................................................ 2.8

3. PRINCIPLES OF OPERATION ......................................................................................................................3.1

3.1. BLOCK DIAGRAM..........................................................................................................................................3.1

3.2. TREAD-BELT MOTOR DRIVE...........................................................................................................................3.4

3.3. U P-DOWN MOTOR DRIVE...............................................................................................................................3.6

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

4.1. CONNECTING TO THE TGS.............................................................................................................................4.1

5. INSTALLATION INSTRUCTIONS................................................................................................................. 5.1

5.1. SPECIFICATIONS AND REQUIREMENTS............................................................................................................5.1

5.2. INSTALLATION .............................................................................................................................................5.1

5.3. FIRST POWER-ON..........................................................................................................................................5.2

6. TROUBLESHOOTING....................................................................................................................................6.1

6.1. THE DISPLAY DOES NOT ILLUMINATE............................................................................................................. 6.2

6.2. THE DISPLAY SHOWS “E1” OR “E2”...............................................................................................................6.6

6.3. THE DISPLAY SHOWS “E3” OR “E4”...............................................................................................................6.8

6.3.1. The inverter display shows E1, E2, E3, E4 or E5.............................................................................. 6.9

6.3.2. The inverter display shows E6 or E7...............................................................................................6.11

6.3.3. The inverter display shows E8, E10 or E11.....................................................................................6.12

6.3.4. The inverter display shows E9 ........................................................................................................6.14

6.3.5. The inverter display shows E12 ...................................................................................................... 6.16

6.3.6. The inverter display shows E14 ...................................................................................................... 6.17

6.3.7. The inverter display does not show any error..................................................................................6.18

6.4. THE BELT MOTOR IS JERKING.......................................................................................................................6.20

6.5. THE BELT MOTOR STARTS WITH DELAY........................................................................................................6.21

6.6. THE DISPLAYED SPEED IS INCORRECT...........................................................................................................6.23

6.7. THE DISPLAY SHOWS “E5”..........................................................................................................................6.26

6.8. THE UP-DOWN MOVES IN ONLY ONE DIRECTION............................................................................................ 6.31

6.9. THE DISPLAYED ELEVATION IS INCORRECT...................................................................................................6.34

6.10.THERE IS NO HEART RATE SIGNAL................................................................................................................6.35

6.11.THE HEART RATE SIGNAL IS INCORRECT ....................................................................................................... 6.36

7. DISASSEMBLY OF COMPONENTS..............................................................................................................7.1

7.1. DISASSEMBLING THE DISPLAY.......................................................................................................................7.1

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7.2. DISASSEMBLING THE EPROM .........................................................................................................................7.2

7.3. DISASSEMBLING THE CPU BOARD................................................................................................................... 7.3

7.4. DISASSEMBLING THE KEYBOARD...................................................................................................................7.4

7.5. DISASSEMBLING THE CARDIO RECEIVER.........................................................................................................7.5

7.6. DISASSEMBLING THE EMERGENCY BUTTON.................................................................................................... 7.8

7.7. DISASSEMBLING THE MOTOR GUARD............................................................................................................7.10

7.8. DISASSEMBLING THE FRONT PLATE.............................................................................................................. 7.11

7.9. DISASSEMBLING THE RUNNING TRACK......................................................................................................... 7.12

7.10.DISASSEMBLING THE DRIVEN ROLLER, THE DRIVING ROLLER, THE TREAD BELT AND THE MOTOR BELT............7.14

7.11.DISASSEMBLING THE BELT MOTOR...............................................................................................................7.17

7.12.DISASSEMBLING THE ELECTRONIC CIRCUIT BOARDS ..................................................................................... 7.19

7.13.DISASSEMBLING THE INVERTER...................................................................................................................7.20

7.14.DISASSEMBLING THE UP-DOWN MOTOR BELT ...............................................................................................7.21

7.15.DISASSEMBLING THE UP-DOWN MOTOR........................................................................................................ 7.22

7.16.DISASSEMBLING THE UP-DOWN MOTOR BRUSHES..........................................................................................7.25

7.17.DISASSEMBLING THE ELEVATION BARS ........................................................................................................ 7.26

7.18.DISASSEMBLING THE LEAD SCREW NUTS ......................................................................................................7.27

7.19.DISASSEMBLING THE LIMIT SWITCHES..........................................................................................................7.29

7.20.DISASSEMBLING THE PHOTOCELL ................................................................................................................7.30

8. ADJUSTMENTS............................................................................................................................................... 8.1

8.1. TENSIONING A NEW TREAD BELT .................................................................................................................. 8.1

8.2. TENSIONING A USED TREAD BELT ..................................................................................................................8.2

8.3. CENTERING THE TREAD BELT........................................................................................................................8.3

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

8.5. TENSIONING THE U P-DOWN MOTOR BELT.......................................................................................................8.6

8.6. ALIGNING THE ELEVATION BARS ................................................................................................................... 8.7

8.7. CALIBRATING THE TREAD BELT SPEED...........................................................................................................8.8

8.8. CENTERING THE PHOTOCELL.........................................................................................................................8.9

9. MACHINE CONFIGURATION.......................................................................................................................9.1

9.1. CHANGING THE SETTINGS ON THE DISPLAY PANEL..........................................................................................9.1

9.1.1. Language used .................................................................................................................................9.1

9.1.2. Measurement system......................................................................................................................... 9.1

9.1.3. Maximum time.................................................................................................................................. 9.2

9.1.4. Activating the “+” and “−” keys......................................................................................................9.2

9.1.5. Disabling the function keys...............................................................................................................9.2

9.1.6. Enabling the “ENTER” key ..............................................................................................................9.2

9.2. MAINTENANCE INFORMATION....................................................................................................................... 9.3

9.2.1. Hours on ..........................................................................................................................................9.3

9.2.2. Hours of use ..................................................................................................................................... 9.3

9.2.3. Hours of motor use...........................................................................................................................9.3

9.2.4. Minutes of up-down motor use..........................................................................................................9.3

9.2.5. Distance travelled ............................................................................................................................9.3

9.3. CHANGING THE MAINTENANCE INFORMATION................................................................................................9.3

9.3.1. Hours on ..........................................................................................................................................9.3

9.3.2. Hours of use ..................................................................................................................................... 9.4

9.3.3. Hours of motor use...........................................................................................................................9.4

9.3.4. Minutes of up-down motor use..........................................................................................................9.4

9.3.5. Distance travelled ............................................................................................................................9.4

9.4. PROGRAMMING THE HITACHI J100 INVERTER ............................................................................................. 9.5

9.4.1. Version E2........................................................................................................................................ 9.5

9.4.2. Versions E3, E4 and E5.................................................................................................................... 9.5

10.SCHEDULED MAINTENANCE....................................................................................................................10.1

11.APPENDIX......................................................................................................................................................11.1

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11.1.TECHNICAL NOTES ON CARDIO RECEIVERS ................................................................................................... 11.1

11.1.1. type of ASIC................................................................................................................................. 11.1

11.1.2. Presence of electromagnetic fields...............................................................................................11.2

11.1.3. Reducing receiver sensitivity ....................................................................................................... 11.2

11.1.4. Mechanical vibrations .................................................................................................................11.3

11.1.5. Position of the receiver................................................................................................................11.3

11.1.6. Routing of cables.........................................................................................................................11.5

11.2.HITACHI J100 INVERTER ERROR CODES.....................................................................................................11.6

11.3.MULTIMETER MEASUREMENTS....................................................................................................................11.8

11.3.1. AC voltage ...................................................................................................................................11.8

11.3.2. DC voltage .................................................................................................................................. 11.8

11.3.3. AC and DC current......................................................................................................................11.9

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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 specific meanings:

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 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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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 circulars, 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.

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

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2. TECHNICAL CHARACTERISTICS

2.1. MECHANICAL CHARACTERISTICS

Width 80 cm Length 190 cm Height 142 cm Weight 183 kg

2.2. ELECTRICAL CHARACTERISTICS

There are two separate models of the machine for 220 and 110 V mains electricity supplies, which differ in certain components detailed in paragraph 2.7. :

110 Model 220 and 220 USA Models

Mains voltage 115 VAC 230 VAC Frequency 50 - 60 Hz 50 - 60 Hz Consumption ~ 1800 Watt - 8 A ~ 1800 Watt - 8 A Fuses 5x20 4 A slow-blow 5x20 4 A slow-blow

2.3. AMBIENT SPECIFICATIONS

Temperature Operating from 5° to 35° C

Storage from -20 to 55° C

Humidity Operating from 30% to 80% non-

condensing

Storage from 5% to 85% non-condensing

2.4. CONFORMITY TO REGULATIONS

The machine conforms to the following directives:

• EMC Directive 89/336/EEC.

• LVD Directives 73/23/EEC and 93/68/EEC.

And is therefore certified with the EC Mark.

The US version of the machine, both for 110 and 220 V mains supply, conforms to the UL 1950 standard.

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2.5. WIRING DIAGRAM FOR THE 220 MODEL

2.5.1. CONNECTORS

• CPU board

name type of connector connection

CN1 AMP MATE-N-LOCK 12-pin F. to up-down and inverter interface boards CN2 AMP MODU II 2-pin M. to emergency button CN4 AMP MODU II 4-pin M. to cardio receiver

• Power supply

name type of connector connection

CN1 PANDUIT 6-pin to mains electricity supply CN2 PANDUIT 8-pin to inverter interface board

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Status (pulse every ½

• Inverter interface board

name type of connector connection

CN1 AMP MATE-N-LOCK 6-pin F. to inverter CN2 AMP MATE-N-LOCK 12-pin F. to CPU board CN4 AMP MOD I 4-pin M to power supply

• Up-down board

name type of connector connection

CN1 AMP MOD II 4-pin M. to photocell CN2 AMP MATE-N-LOCK 4-pin F. to CPU board CN3 AMP MATE-N-LOCK 6-pin F. to up-down motor CN4 AMP MATE-N-LOCK 2-pin F. to mains electricity supply CN5 Sauro 2-pin to transformer CN6 Sauro 2-pin to rectifier bridge

2.5.2. WIRING

CPU/CN1 Signal Color Inverter interf.

1 +12 V Blue 1 1 2 + 5 V Brown 1 2 3 ground Gray 1 3 4 -12 V White 5 5 not used Violet 12 6 Tread belt speed

7 Start Black 8 8 Inverter alarm Orange 9 9

10 Up Pink - 2 11 Down Blue 2 - 3 12 ground Gray 2 - 4

RX-1: Internal connection cable

CPU – Inverter interface board – Up-down board

board /CN2

Red 10 -

reference (PWM)

Brown 2 - 1

degree)

Up-down

board/CN2

CPU/CN4 Signal Color Receiver

BK-7: Heart rate monitor cable

CPU – Cardio receiver

1 +5 V Red 1 2 Pulse per beat Blue 2 3 ground Black 3

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RX-13: Emergency button cable

CPU – Emergency button

CPU/CN2 Signal Color Emergency

button

1 NC contact Brown 1 2 Reference Blue 2

RX-5: Inverter cable

Inverter interface board – Inverter – Motor thermal cutout

Inverter interf.

board / CN1

1 Reference White PV24 -

- Thermal cutout reference Red PV24 1

- NC thermal cutout Red 1 2 2 Start Gray FW 3 NC Alarm Violet AL1 4 Alarm reference Red AL0 5 Inverter control

6 Inverter control

Signal Color Inverter Motor thermal

cutout

Brown 0 -

(0-10 Vdc)

Black L -

reference

RX-14: Belt motor cable

Inverter – Belt motor

Inverter Signal Color Belt motor

U Phase U Blue U V Phase V Black V

W Phase W Brown W

PE ground Yellow-Green Casing

RX-6: Up-down motor cable

Up-down board – Up-down motor – Limit Switches

Up-down

board / CN3

1 Motor power supply Brown 1 - 2 Motor ground Blue 2 - 3 NO upper limit White - 3 4 NC lower limit switch Violet - - 2 6 Limit switch ground Black - 1 1

Signal Color Up-down

motor

UpperLSLower

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RX-11: Up-down motor power supply cable

Up-down board – Rectifier bridge

Up-down board Signal Color Rectifier bridge

CN6

1 48 Vac Red + 2 Ground Black

RX-12: Photocell cable

Up-down board – Photocell

Up-down

board / CN1

1 + 5 Vdc Red 1 2 Clock Orange 2 3 Direction Blue 3 4 ground Black 4

Signal Color Photocell

−

RX-8: Low voltage power supply cable

Power supply – Inverter interface board

Power supply/

CN2

1 + 5 V Yellow 4

2-4-5 Ground Black 3

3 + 12 V Red 2 6 - 12 V Blue 1

The high voltage power supply cables and the ground connections are not described here, in that they can be easily determined from the wiring diagram above.

Signal Color Inverter interf.

board / CN4

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2.6. WIRING DIAGRAM FOR THE 220 USA MODEL

The differences between the 220 USA Model and the 220 Model are:

• power supply cable;

• high voltage wiring;

• use of separate filters for the inverter and the power supply - up-down board;

• presence of an additional emergency device called a "Safety Switch" in series with the standard

emergency button. This device consists of a reed relay and a magnet, connected to a cable which clips onto the user running on the machine. If the user moves away from the display, the cable is pulled taut and eventually detaches the magnet when the distance becomes excessive. The absence of the magnet causes the reed relay to commutate from closed to open, generating the emergency signal. The safety switch requires cable RX-13 to be modified as follows:

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RX-13 USA: Emergency cable

CPU – Emergency button – Safety switch reed relay

CPU/CN2 Signal Color Emergency

button

1 NC contact Brown 1 -

- NC contact Blue 2 1 2 Reference Orange - 2

OBSERVE: An upgrade kit is available (code 0WK247) for installing the safety switch on European machines.

The other cables are unchanged. Therefore, for their description, refer to the details provided for the 220 Model.

Safety

reed relay

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2.7. WIRING DIAGRAM FOR THE 110 MODEL

The differences between the 110 Model and the 220 Model are:

• the automatic circuit breaker is 20 A - class D instead of 10 A - class C;

• autotransformer 110 - 220;

• mains lead with different cable section and plug;

• presence, as on the 220 USA Model, of the safety switch.

As regards the wiring, the safety switch uses cable RX-13 USA, while the other cables remain unvaried. Therefore, for their description, refer to the details provided for the 220 and 220 USA Models.

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3. PRINCIPLES OF OPERATION

3.1. BLOCK DIAGRAM

The machine block diagram is shown in the figure below:

(1) CARDIO TRANSMITTER

It is worn by the person using the machine, and transmits to the cardio receiver one pulse for every heart beat that is detected.

(2) CARDIO RECEIVER

It is connected to the machine’s CPU board and receives the pulses sent by the transmitter. Its reception area is approximately a circle of 1 meter of radius. If there is electromagnetic noise

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(produced by high voltage lines, radio transmitters, monitors, motors, etc.) within its reception area, the receiver becomes saturated and stops receiving any signal. If there are 2 transmitters within its area of reception, it will receive signals from both, and may produce an error or irregular reading.

(3) CPU BOARD

This is the heart of the machine, which controls all the machine functions by executing the program stored in EPROM. It receives information from the user (age, weight, etc.) during set-up of the training session, from the cardio receiver (user’s heart rate), from the inverter interface board and from the up-down interface board. It controls the speed selected with the “+” “−” keys and the elevation selected with the “↑” “↓” keys or according to the chosen training program. It receives the error signal from the inverter interface board and the status signal from the up-down interface board

(4) INVERTER INTERFACE BOARD

Receives from the display a PWM signal proportional to the selected speed, and converts it into a continuous voltage for controlling the inverter. Receives the error signal generated by the inverter in the event of problems and transmits it to the display. Receives the low voltages output by the power supply and passes them to the display. There are 2 LEDs on the board: DL1 illuminates when the tread belt is moving, while DL2 illuminates when the inverter does not detect any error conditions and therefore the alarm signal is inactive.

(5) UP-DOWN BOARD

Receives from the display the enable signal for elevation motion and converts it into a control for the up-down motor. Generates its power supply and the DC power supply for the motor by means of a transformer and rectifier bridge. Determines the motor position, and hence the treadmill elevation, by means of the photocell. Generates and sends to the display a motion status signal at every 0.5% variation in the elevation. Checks the lower and upper travel limits by means of 2 limit switches. The board includes 2 LEDs associated to the limit switches, which are normally illuminated: DL1 comes off when the upper limit switch is tripped, while DL3 comes off if the lower limit switch is tripped.

(6) INVERTER

This is the device which supplies the three-phase belt motor. It receives a DC control voltage from the inverter interface board. Variations in this voltage cause corresponding variations in the operating frequency of the inverter/motor, and hence change the speed of the tread belt. It handles motor drive errors and, in the event of an error, shuts down the power supply to the motor and sends an alarm signal through the interface board to the display. The event which caused the error is memorized as an error code.

(7) PHOTOCELL

This is the device which provides feedback on the motion of the up-down motor. It transmits one pulse for each slot detected on the encoder which is fixed to the gearmotor, and a signal indicating the direction of movement. The up-down board, receiving the pulses, sends the status signal to the display which stops the motor when the number of pulses received coincides with the desired elevation.

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(8) UP-DOWN MOTOR

It is a DC motor which, by means of a mechanical reduction unit and a timing belt, turns the lead screw nuts on the threaded elevation bars, causing the machine to be raised or lowered depending on the direction of rotation.

(9) BELT MOTOR

An asynchronous three-phase motor which, by means of a pulley and a poly-v belt, turns the driving roller of the tread belt. Each motor phase is equipped with a normally-closed bimetallic safety which opens when the temperature exceeds a preset threshold, in order to safeguard the integrity of the motor. The 3 bimetallic safeties are connected in series and reach the inverter as a NC external input signal. When this contact opens, the inverter generates an alarm.

(10) LIMIT SWITCHES

There are 2 limit switches which control the range of motion of the elevation mechanism. These switches are positioned at the travel limits of the elevation bars, and change state when pressed and/or released. The lower limit switch is NC, while the upper one is NO.

(11) POWER SUPPLY

Receives the mains voltage at its input and outputs the DC voltages (+5 V, +12 V and −12 V) which supply the display and the inverter interface board.

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3.2. TREAD-BELT MOTOR DRIVE

The tread belt is actuated by the motor through a linkage consisting of the motor pulley, the driving roller and the belt which connects them. In this way, a given belt motor speed corresponds to a predetermined linear tread belt speed. The belt motor is controlled by the inverter which generates a variable-frequency sine wave signal: variations in frequency cause the motor speed and hence the tread belt speed to vary.

The machine controls the speed of the belt motor by means of the CPU board and the inverter interface board, as shown in the figure below:

CPU board

StartPWM

Inverter

interface board

Vref

The speed control utilizes 3 signals:

• Start signal

This is the signal generated by the CPU to enable starting of the motor (pin 7-3 of connector CN1 on the CPU board). When the tread belt is stopped this signal is at logic level low (0 Vdc), whereas immediately after the “Start” button on the display is pressed it goes high (4.5 Vdc). The signal enters the inverter interface board (pin 8-3 of connector CN2 on the inverter interface board), is processed and sent to the inverter (pin 2-1 of connector CN1 on the inverter interface board). In the belt-stopped condition it is -24.7 Vdc, while immediately after pressing the “Start” button on the display it is -2.7 Vdc.

Start

Inverter

Alarm

• Speed reference signal

This is the signal generated by the CPU (pins 6-3 of connector CN1) to control the motor speed. It is a PWM signal, that is to say a fixed frequency square wave with a variable duty cycle. The logic of this control has the duty cycle decreasing with increasing speed. The measurement of its DC component with a multimeter shows a value that decreases with increasing speed, from a maximum of approximately 5 Vdc down to a few hundred mVdc. This signal enters the inverter interface board (pins 10-3 of connector CN2), is converted into a variable analogue signal between 0 and 10 Vdc and sent to the inverter (pins 5-6 of connector

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CN1 on the inverter interface board). The signal input to the inverter increases with increasing speed.

The relationship between the speed reference and the inverter frequency is determined by the programming of the inverter.

• Alarm signal

This is the signal generated by the inverter if a problem is detected in the motor drive, or if the motor thermal cutouts open. It enters the inverter interface board (pins 3-4 of connector CN1) and its value is 0 Vdc under normal conditions, 10 Vdc under alarm conditions. The signal is then sent to the inverter interface board (pins 9-3 of connector CN2) to the CPU board (pins 8-3 of connector CN1) and is 5 Vdc under normal conditions, 0 Vdc under alarm conditions. When this alarm signal switches to 0 Vdc, the CPU disables the Start signal, resets the PWM signal and shows the E3 or E4 error message on the display.

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3.3. UP-DOWN MOTOR DRIVE

The elevation of the machine is varied by the up-down motor which, by means of a timing belt, turns the lead screw nuts on the 2 elevation bars. The motor has an integral encoder wheel which, by means of a photocell, provides the motor motion control signal: each motor revolution corresponds to a predetermined number of pulses and to a predetermined displacement on the elevation bars. The direction of rotation of the motor determines whether the treadmill moves upward or downward.

The machine controls the elevation through the CPU board and the up-down interface board as shown in the figure below:

CPU board

StatusDownUp

Up-down

interface board

The elevation control utilizes 3 signals:

• Up signal

This is the signal generated by the CPU (pins 10-12 of connector CN1) to enable movement of the up-down motor in the upward direction. Under normal conditions the signal is at logic level low (0 Vdc), and it goes high (5 Vdc) to actuate the motor. The signal remains high for the entire duration of the movement. The signal enters the up-down board (pin 2-4 of connector CN2) and enables movement of the motor in the desired direction.

• Down signal

This is the signal generated by the CPU (pin 11-12 of connector CN1) to enable movement of the up-down motor in the downward direction. Under normal conditions the signal is at logic level low (0 Vdc), and it goes high (5 Vdc) to actuate the motor. The signal remains high for the entire duration of the movement. The signal enters the up-down board (pin 3-4 of connector CN2) and enables movement of the motor in the desired direction.

• Status signal

This is the signal generated by the up-down board whenever the photocell detects a number of pulses corresponding to an 0.5% variation in the elevation. This signal (pin 1-4 of connector CN2 of the up-down board) is normally at logic level low (0Vdc) and goes high (5 Vdc) for a few msec. The CPU board receives this signal (pin 9-12 of connector CN1) which indicates the actual elevation of the machine. Comparing it with the desired elevation value, the CPU determines

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whether to keep the Up or Down signal asserted to continue the movement or, if the desired elevation has been reached, to reset the Up or Down signal. If, after having asserted the Up or Down signal, the CPU board does not receive any Status signal within a predetermined period of time (a few seconds), it resets the asserted signal and displays error code E5 to indicate absence of movement.

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4. ACCESSORIES

4.1. CONNECTING TO THE TGS

The machine can be connected to the Technogym System by means of the 9-pin D-type connector situated on the back of the display, which provides the RS 232 serial port for connecting the TGS reader.

The serial port is connected to the CPU by the cable described below, which is supplied in the upgrade kit:

TGSRN2XT: Internal cable

CPU - 9-pin connector

CPU/CN2 Signal Color DB9 male

1 + 12 V yellow 1 2 Tx brown 3 5 Rx white 2 6 ground green 5

To prevent interference with the cardio receiver, route the cable behind cable RX-1 and connector CN1 of the CPU board, as described in paragraph 11.1. .

For all further information, including troubleshooting, refer to the following manual: “Technogym System: Installation Guide”.

Page 4.1

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Page intentionally left blank

Page 4.2

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5. INSTALLATION INSTRUCTIONS

5.1. SPECIFICATIONS AND REQUIREMENTS

For correct machine installation, make sure that:

1. The machine is installed on a level surface that is free of vibrations and has sufficient carrying

capacity for the combined weight of the machine and user.

2. The environment is dust or sand free.

3. The environment meets the operating temperature and humidity conditions specified in paragraph

2.3. .

4. The machine is not positioned close to sources of heat, sources of electromagnetic noise

(television sets, electric motors, antennas, high voltage lines, appliances etc…) or medical equipment.

5. To eliminate any interference with the cardio receiver, there should not be any transmitters at a

distance of 100 cm from the display.

6. The mains voltage must match the value specified on the machine rating plate.

7. The electrical system must be provided with an efficient ground connection.

8. The wall outlet used should be reserved for the machine and have a rating of at least 1800 Watt.

9. Do not connect other machines or users to the same wall outlet.

10. Position the mains lead of the machine where is will not be underfoot. For this purpose, it is

recommended to use the special trackways supplied with the machine.

5.2. INSTALLATION

To correctly install the machine, proceed as follows:

1. Ensure that the specifications and requirements for installation have been met (see paragraph 5.1.

2. Remove the machine from its packing materials: one carton fixed to a wooden pallet for overseas

shipment, one nylon bag for Italy. For machines shipped in cartons, the side uprights and handles are disassembled and placed on the tread belt.

3. Position the machine as specified above, on a level surface that is free of vibrations and has

sufficient carrying capacity for the combined weight of the machine and the user.

4. For machines which shipped in a carton, it is necessary to reassemble the components that were

disassembled for transport. Follow the procedure for assembling the side uprights and handles described in the "Operating and service instructions" supplied with each machine.

5. Connect the mains lead to the inlet socket on the machine.

6. Place the on/off switch in the “0” position.

7. Plug the mains lead into the electrical outlet.

Page 5.1

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5.3. FIRST POWER-ON

After completing the installation procedure, the machine is ready to be powered up. To turn on the machine, simply toggle the on/off switch from the 0 position to the 1 position.

When the machine is turned on it will perform a power-on test which:

• sounds the buzzer;

• lights all the LEDs.

• resets the elevation

After completing this power-on test the machine enters standby mode, awaiting a keyboard command.

To check the correct operation of the machine:

• get on the machine;

• press the "Start" key on the keyboard to begin exercising;

• check that the belt motor starts;

• press the “+” and “−” keys on the keyboard and check that the tread belt speed changes

accordingly;

• press the “↑” and “↓“ keys on the keyboard and check that the machine elevation changes

accordingly;

• put on the heart rate transmitter and check that the machine correctly measures the heart rate

value.

Page 5.2

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6. TROUBLESHOOTING

The troubleshooting procedures are shown in the form of flow charts. In order to facilitate consultation, the following standard box shapes are used.

This type of box is the START point of the troubleshooting procedure. It typically contains a description of the problem or malfunction.

This type of box represents a decision point in the troubleshooting procedure. It typically contains a description of the DECISION to be made, with an outcome that can be either a positive (YES) or negative (NO) response.

This type of box corresponds to a step in the troubleshooting procedure where an ACTION must be carried out. It typically contains a description of the ACTION necessary to resolve the problem. Therefore, after executing the specified ACTION:

1. Check whether the problem has been resolved;

2. If the problem persists, it is recommended to resume the troubleshooting

procedure from the point before the action was carried out.

A circled number (such as that shown on the left) next to a box of the troubleshooting procedure indicates that detailed instructions for performing that particular check or action are provided below the flowchart.

A circled letter (such as that shown on the left) is used to highlight a point in the procedure. Typically, this indicator is used in page changes.

Page 6.1

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6.1. THE DISPLAY DOES NOT ILLUMINATE

THE DISPLAY

DOES NOT

ILLUMINATE

Is the fuse OK?

YES

Is mains lead OK?

YES

Does the wall output supply the

correct voltage?

Replace the blown fuse

Replace the mains lead

Connect machine to a

suitable

electrical output

Is the mains voltage present at

the power supply input?

Continued on the following page.

Page 6.2

YES

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RUN XT: Service & Maintenance Manual - rev. 2.0

YES

Are DC voltages output by the

power supply correct?

YES

Do all DC voltages reach the

display?

Do all DC voltages reach the

inverter interface board?

Replace the power

supply: see paragraph

7.12.

YES

Replace the display

CPU board: see

paragraph 7.3.

Replace cable RX-8

connecting the power

supply to the inverter

interface board

Are all DC voltages present at

the output of the inverter

interface board?

Replace cable RX-1

*alternator interface

board to the display

Continued on the following page.

YES

connecting the

Replace the inverter interface board: see

par. 7.12.

Page 6.3

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Is the mains voltage present at

the output of the power input

socket?

YES

Is the mains voltage present at

the input to the automatic circuit

breaker?

YES

Is the mains voltage present at

the output of the automatic

circuit breaker?

Replace the power input socket of the

machine

Replace the cable

connecting the input

socket to the

automatic circuit

breaker

Replace the

automatic circuit

breaker

Replace the wiring between the filter -

fuse holder - power

suppl

YES

Is the mains voltage present at

the input to the filter?

YES

Is the mains voltage present at

the output of the filter?

YES

Is the fuse holder continuity OK?

Replace the cable

connecting the

automatic circuit

breaker to the filter

Replace the filter

Replace the fuse

holder

Page 6.4

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Follow the procedure step by step to correctly diagnose the problem. Take particular care with the checks highlighted by circled numbers, which are described in detail below:

WARNING: Carry out these checks with the machine powered up.

(1) Slightly lift connector CN1 on the power supply. Place the tester probes between pins 4 and 6

on that connector. The measured voltage should be approximately 220 Vac or 110 Vac depending on the type of mains electricity supply.

(2) Slightly lift connector CN2 on the power supply in order to access the pins with the tester

probes. Check that all the output voltages of the power supply are correct by referring to paragraph 2.5.2. “Wiring”.

(3) As for point (2) but on connector CN1 of the display CPU board.

(4) As for point (2) but on connector CN4 of the inverter interface board.

(5) As for point (2) but on connector CN2 of the inverter interface board.

(6) Slightly lift the Fastons on the machine power inlet socket. Place the tester probes between the

live and neutral terminals of the connector. The measured voltage should be approximately 220 Vac or 110 Vac depending on the type of mains electricity supply.

(7) As for point (6) but on the input of the automatic circuit breaker.

(8) As for point (6) but on the output of the automatic circuit breaker.

(9) As for point (6) but on the input of the filter.

(10) As for point (6) but on the output of the filter.

(11) Using the tester probes, check the continuity of the fuse holder by measuring its resistance.

This is correct if the measured value is less than a few Ohms.

On certain machines, it has been found that the display turns off after the “Clear” key is pressed. To solve this problem, mount a 15 Ohm 5 W resistor between pins 3 and 4 of connector CN4 of the inverter interface board. This modification is standard on machines starting from SN D241U 50000010 (USA), D240 50003665 (ITA) and D240 50003649 (UK) (production date 13/02/98).

Page 6.5

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6.2. THE DISPLAY SHOWS “E1” OR “E2”

These messages are related to the emergency button. The machine displays:

• E1 if the emergency button is pressed during a training session.

• E2 if the emergency button is pressed at the start of a training session.

THE DISPLAY

SHOWS E1 / E2

Did the user press the emergency

button during the training session or

at the start?

Is the SW version up to date?

YES

Is the voltage at the emergency

button terminals correct?

YES

Correct operation

Update the SW of the

machine

YES

Replace the emergency

button: see paragraph

7.6.

Replace cable RX-13

between the CPU board

and the emergency button

YES

Is the voltage at the output of the

CPU board correct?

Replace the CPU board:

see paragraph 7.3.

Follow the procedure step by step to correctly diagnose the problem. Take particular care with the checks highlighted by circled numbers, which are described in detail below:

Page 6.6

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(1) The SW version must be higher than EUR 2.4, USA 2.3, TGS EUR 2.2 or TGS USA 2.3.

(2) Place the tester probes between the terminals of the emergency button. When the button is

pressed the measured voltage should be +5Vdc, when it is released it should be 0 Vdc.

(3) Place the tester probes between pins 1 and 2 of connector CN2 of the CPU board. The

measured voltage should be +5Vdc.

Page 6.7

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6.3. THE DISPLAY SHOWS “E3” OR “E4”

These messages are related to the belt motor group. The machine displays:

• E3 failure to actuate movement of the belt motor at the start of the training session;

• E4 the movement of the belt motor is interrupted during the training session.

THE DISPLAY

SHOWS "E3" OR

"E4"

Check the error message

displayed and/or

memorized by the inverter

E10

E11

E12

E14

None

The paragraphs below illustrate the troubleshooting procedures for each individual error code.

Page 6.8

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6.3.1. THE INVERTER DISPLAY SHOWS E1, E2, E3, E4 OR E5

These inverter error messages are related to output short-circuit problems.

E2 E3 E4 E5E1

Is the inverter output

short-circuited?

Is there a short-circuit on the

motor cable terminals?

Does the machine resume

correct operation after being

turned off for 1 minute?

YES

Replace the inverter: see

paragraph 7.13.

2 3

YES

Is the belt motor

short-circuited?

YES

Probable interference. The

machine is OK

YES

Replace the belt motor:

see paragraph 7.11.

Replace the belt motor

cable

Replace the inverter: see

paragraph 7.13.

Follow the procedure step by step to correctly diagnose the problem. Take particular care with the checks highlighted by circled numbers, which are described in detail below:

(1) Disconnect the motor cable from the inverter and place the tester probes between its terminals

U-V, U-W and V-W. The measured resistance should be very high, in the order of MOhms. It is difficult to obtain a stable resistance measurement, however, a phase can be considered short-circuited or defective when the measured resistance is in the order of a few tens of Ohms.

Page 6.9

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(2) Place the tester probes between the blue - black, blue - brown and black - brown wires of the

motor cable. The measured resistance should be approximately 3.1 Ohm.

(3) Disconnect the motor cable from the motor and place a tester between its terminals U-V, U-W

and V-W. The measured resistance should be 3.1 Ohm.

Page 6.10

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RUN XT: Service & Maintenance Manual - rev. 2.0

6.3.2. THE INVERTER DISPLAY SHOWS E6 OR E7

These inverter error messages are related to problems with the inverter braking group or the braking resistor.

E7E6

Is the braking resistor

correctly connected to the

inverter?

YES

Is the value of the braking

resistance correct?

YES

Does the machine resume

correct operation after being

turned off for 1 minute?

Reinstate the connection

Replace the braking

resistor

YES

Probable interference. The

machine is OK

Replace the inverter: see

paragraph 7.13.

Follow the procedure step by step to correctly diagnose the problem. Take particular care with the checks highlighted by circled numbers, which are described in detail below:

(1) With the machine turned off, disconnect one of the resistor wires from the inverter terminal

block and place the tester probes across the resistor. The measured resistance should be 150 Ohm.

Page 6.11

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6.3.3. THE INVERTER DISPLAY SHOWS E8, E10 OR E11

These inverter error messages are related to HW and SW problems with the inverter.

E10E8 E11

Does the error occur

frequently?

Does the machine resume

correct operation after being

turned off for 1 minute?

Re-program the inverter:

see paragraph 9.1.

YES

Replace the inverter: see

paragraph 7.13.

Probable interference. The

machine is OK

Does the machine resume

correct operation after being

turned off for 10 minutes?

YES

Programming correct. The

machine is OK

Replace the inverter: see

paragraph 7.13.

Follow the procedure step by step to correctly diagnose the problem. Take particular care with the checks highlighted by circled numbers, which are described in detail below:

Page 6.12

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(1) Determine the frequency of the errors by counting the number of occurrences in the inverter

error memory, and by running targeted checks. An error is considered frequent if it occurs 2 or 3 times a day.

WARNING: incorrect programming of the inverter can cause serious damage to the machine or malfunctioning that is potentially hazardous to the user. Therefore, attempt this operation only if certain of being able to carry out the procedure with the latest SW version.

Page 6.13

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RUN XT: Service & Maintenance Manual - rev. 2.0

6.3.4. THE INVERTER DISPLAY SHOWS E9

This inverter error message is related to low line voltage problems on the inverter power supply.

Does the machine resume

correct operation after being

turned off for 1 minute?

Is the power supply at the

inverter input OK?

Is the supply voltage at the

filter input correct?

YES

Probable low line voltage.

The machine is OK

YES

Replace the inverter: see

paragraph 7.13.

Check and reinstate the

wiring between the power

input socket, automatic

circuit breaker and filter

Is the supply voltage at the

filter output correct?

Replace the filter

YES

Check and reinstate the wiring between the filter

and inverter

Follow the procedure step by step to correctly diagnose the problem. Take particular care with the checks highlighted by circled numbers, which are described in detail below:

(1) Place the tester probes between terminals L1 and N of the inverter. The measured voltage

should be 220 Vac or 110 Vac depending on the type of mains electricity supply.

Page 6.14

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(2) Disconnect the filter power supply cables and place the tester probes on the terminals. The

measured voltage should be 220 Vac or 110 Vac depending on the type of mains electricity supply.

(3) Disconnect the filter output cables and place the tester probes across the filter terminals. The

measured voltage should be 220 Vac or 110 Vac depending on the type of mains electricity supply.

This error may be generated even by brief drops in the line voltage due to overloads or other causes. Therefore, it can be very useful to check the value of the mains voltage recorded in the inverter memory at the time when the error occurred. To obtain the mains voltage, the displayed value must be divided by 0.141 .

Page 6.15

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6.3.5. THE INVERTER DISPLAY SHOWS E12

This inverter error message is related to the opening of the motor thermal cutouts.

E12

YES

Does the machine resume

correct operation after being

turned off for 1 hour?

Is the thermal cutout on the

motor OK?

Probable overheating of

the motor. The machine is

Replace the belt motor:

see paragraph 7.11

YES

Is the wiring between the motor thermal cutout and

the inverter correct?

Replace cable RX-5

YES

Replace the inverter: see

paragraph 7.13

Follow the procedure step by step to correctly diagnose the problem. Take particular care with the checks highlighted by circled numbers, which are described in detail below:

(1) Disconnect the motor thermal cutout cables from the inverter and place the tester probes

between their terminals. The measured resistance should be less than 1 Ohm.

In some cases the value may be higher due to oxidation of the contacts. To reinstate correct operation, it is necessary to perform a special operation which will be described to you on contacting the Technogym Service.

(2) Disconnect the motor thermal cutout cables on both the motor and inverter sides, and place the

tester probes at either end of each wire. The measured resistance should be 0 Ohm.

Page 6.16

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6.3.6. THE INVERTER DISPLAY SHOWS E14

This inverter error message is related to poor isolation between the motor phases and ground.

E14

Are the motor phases

isolated from ground at the

inverter output?

Replace the inverter: see

paragraph 7.13

YES

Are the motor phases isolated from ground?

Replace the belt motor:

see paragraph 7.11.

YES

Check and reinstate cable

RX-14

Follow the procedure step by step to correctly diagnose the problem. Take particular care with the checks highlighted by circled numbers, which are described in detail below:

(1) Disconnect the motor cable from the inverter and place the tester probes between terminals U,

V and W of the inverter and the ground screw (PE). The measured resistance should be MOhm or higher.

(2) Disconnect the motor cable from the motor and place the tester probes between its terminals

U, V and W and ground. The measured resistance should be MOhm or higher.

Page 6.17

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6.3.7. THE INVERTER DISPLAY DOES NOT SHOW ANY ERROR

This is an anomalous error condition in which the machine display reports an error but the inverter has not generated an error.

None

Is the SW version up to

date?

YES

Is LED DL2 on the inverter

interface board illuminated?

YES

Update the SW version

Is the alarm signal present

at the inverter output?

YES

Replace the inverter: see

paragraph 7.13.

YES

Is the alarm signal present

at the input to the inverter

interface board?

Check and/or replace cable

RX-5 connecting the

inverter interface board to

the inverter

Page 6.18

Is the alarm present at the

output of the interface

board?

Is the alarm present at the

input to the display?

Replace the CPU board:

see paragraph 7.3.

YES

Replace the inverter interface board: see

paragraph 7.12.

YES

Check and/or replace cable

RX-1 which connects the

inverter interface board to

the CPU board

Page 49

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Follow the procedure step by step to correctly diagnose the problem. Take particular care with the checks highlighted by circled numbers, which are described in detail below:

(1) The SW version must be higher than EUR 2.4, USA 2.3, TGS EUR 2.2 or TGS USA 2.3.

(2) Place the tester probes between terminals AL0 and AL1 of the inverter. Under an alarm

condition the measured voltage should be 0 Vdc, under normal conditions it should be +10 Vdc.

(3) As for point (2) but between pins 3 (signal) and 4 (ground) of connector CN1 on the inverter

interface board.

(4) Place the tester probes between pins 3 (ground) and 9 (signal) of connector CN2 on the

inverter interface board. Under an alarm condition the measured voltage should be 0 Vdc, under normal conditions it should be +5 Vdc.

(5) As for point (4) but between pins 3 (ground) and 8 (signal) of connector CN1 on the CPU

board.

Page 6.19

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6.4. THE BELT MOTOR IS JERKING

THE BELT

MOTOR IS

JERKING

YES

Are the belt motor windings

short-circuited or open-circuited

Replace the belt motor:

see paragraph 7.11.

Does the inverter generate a

balanced voltage on all phases?

Replace the inverter: see

paragraph 7.12.

YES

Check and/or replace

cable RX-14 connecting

the inverter to the belt

motor

Follow the procedure step by step to correctly diagnose the problem. Take particular care with the checks highlighted by circled numbers, which are described in detail below:

(1) Disconnect the motor cable from the motor and place a tester across its terminals U-V, U-W

and V-W. The measured resistance should be approximately 3.1 Ohm.

(2) Run the machine at 12.6 Km/h (European version) or 9.0 mph (USA version) and place a

tester across its terminals U-V, U-W and V-W. The measured voltage should be 220 Vac.

Page 6.20

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6.5. THE BELT MOTOR STARTS WITH DELAY

THE BELT

MOTOR STARTS

WITH DELAY

Are the Start and Speed PWM

signals correct at the output of the

CPU board?

YES

Are the Start signal and the analog

speed reference signal correct at the

output of the inverter interface

board?

YES

Replace the inverter: see

paragraph 7.13.

Replace the CPU board:

see paragraph 7.3.

Replace the inverter interface board: see

paragraph 7.12.

Follow the procedure step by step to correctly diagnose the problem. Take particular care with the checks highlighted by circled numbers, which are described in detail below:

(1) To check the Start signal, place a tester between pins 7 (signal) and 3 (ground) of connector

CN1 on the CPU board. When the belt is halted the measured voltage should be 0 Vdc, whereas immediately after pressing the “Start” key on the display the measured voltage should be 4.5 Vdc. To check the speed PWM signal, place a tester between pins 6 (signal) and 3 (ground) of connector CN1 on the CPU board. When the belt is halted the measured voltage should be 5 Vdc, whereas immediately after pressing the “Start” key on the display the reading should rapidly decrease until it reaches a fixed value corresponding to the selected speed. The variation of the signal must be accompanied by a corresponding variation in the tread belt speed: see Table 6.6-1 or Table 6.6-2.

(2) To check the Start signal, place a tester between pins 2 (signal) and 1 (ground) of connector

CN1 on the inverter interface board. When the belt is halted the reading should be -24.7 Vdc, whereas immediately after pressing the “Start” key on the display the measured value should be

-2.7 Vdc. To check the speed PWM signal, place a tester between pins 5 (signal) and 6

Page 6.21

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(ground) of connector CN1 on the inverter interface board. When the belt is halted the measured value should be 0 Vdc, whereas immediately after pressing the “Start” key on the display the reading should rapidly increase to reach a fixed value corresponding to the selected speed. The variation of the signal must be accompanied by a corresponding variation in the belt speed: see Table 6.6-1 or Table 6.6-2.

Page 6.22

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6.6. THE DISPLAYED SPEED IS INCORRECT

THE DISPLAYED SPEED

IS INCORRECT

Is the relationship between the

displayed speed and the inverter

frequency correct?

Is the inverter control voltage

correct?

Is the inverter control voltage at the

output of the inverter interface board

correct?

YES

The machine is operating

correctly

YES

Replace the inverter: see

paragraph 7.13.

YES

Is the inverter programmed

correctly?

Re-program the inverter:

YES

Check and/or replace

cable RX-5 between the

inverter interface board

and the inverter

see paragraph 9.1.

Is the inverter control PWM signal at

the input of the inverter interface

board correct?

Continued on the following page.

YES

Replace the inverter

interface board: see

paragraph 7.12.

Page 6.23

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Is the inverter control PWM signal at the output of the CPU board correct?

Replace the CPU board:

see paragraph 7.3.

YES

Check and/or replace

cable RX-1 connecting

the CPU board and the

inverter interface board

Follow the procedure step by step to correctly diagnose the problem. Take particular care with the checks highlighted by circled numbers, which are described in detail below:

(1) When the machine is in operation, check that the speed shown on the machine display and

inverter operating frequency correspond to the values shown in the tables below.

• For versions with speed expressed in km/h:

SPEED (Km/h)

CPU BOARD INVERTER

PWM SIGNAL

(Vdc)

ANALOG SIGNAL

(Vdc)

FREQUENCY

(Hz)

INVERTER

INTERFACE BOARD

DISPLAY 6-3/CN1 10-3/CN2 5-6/CN1 L-0 DISPLAY

2.0 4.40 4.40 1.08 1.08 11.2

5.0 3.53 3.53 2.68 2.68 27.5

9.0 2.38 2.38 4.82 4.82 49.3

12.6 1.34 1.34 6.75 6.75 69.0

16.0 0.35 0.35 8.57 8.57 87.6

Table 6.6-1

Page 6.24

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• For versions with the speed expressed in mph:

SPEED

(mph)

CPU BOARD INVERTER

PWM SIGNAL

(Vdc)

ANALOG SIGNAL

(Vdc)

FREQUENCY

(Hz)

INVERTER

INTERFACE BOARD

DISPLAY 6-3/CN1 10-3/CN2 5-6/CN1 L-0 DISPLAY

1.0 4.56 4.56 0.87 0.87 9.0

3.0 3.62 3.62 2.60 2.60 26.5

5.0 2.70 2.70 4.32 4.32 44.1

7.0 1.75 1.75 6.06 6.06 61.7

9.0 0.81 0.81 7.78 7.78 79.3

Table 6.6-2

Obviously, the voltages and frequencies quoted above are nominal values.

(2) Place the tester probes between the terminals 0 (signal) and L (ground) of the inverter. Check

that during machine operation the speed shown on the display and the voltage measured on the inverter correspond to the values shown in Table 6.6-1 or in Table 6.6-2.

(3) See paragraph 9.4.

(4) Place the tester probes between pins 5 (signal) and 6 (ground) of connector CN1 on the

inverter interface board. Check that during machine operation the speed shown on the display and the measured voltage correspond to the values shown in Table 6.6-1 or in Table 6.6-2.

(5) Place the tester probes between pins 10 (signal) and 3 (ground) of connector CN2 of the

inverter interface board. Check that during machine operation the speed shown on the display and the measured voltage correspond to the values shown in Table 6.6-1 or Table 6.6-2.

(6) Place the tester probes between pins 6 (signal) and 3 (ground) of connector CN1 on the CPU

board. Check that during machine operation the speed shown on the display and the measured voltage correspond to the values shown in Table 6.6-1 or in Table 6.6-2.

Page 6.25

Page 56

6.7. THE DISPLAY SHOWS “E5”

THE DISPLAY

SHOWS "E5"

Are LEDs DL1 and DL2 on the

up-down board both illuminated?

YES

RUN XT: Service & Maintenance Manual - rev. 2.0

Is the supply to the up-down motor

correct when the actuation command

arrives?

Does the CPU board send the

correct control signal?

YES

Does the up-down board receive the

correct control signal?

YES

Replace the CPU board:

see paragraph 7.3.

Check and/or replace

cable RX-1 connecting

the CPU board to the

up-down board

Replace the up-down board: see paragraph

Continued on the following page.

Page 6.26

YES

7.12.

Page 57

RUN XT: Service & Maintenance Manual - rev. 2.0

Is fuse F1 of the up-down board OK?

YES

Does the up-down board receive the

mains electricity supply?

YES

Does the voltage at output by the

transformer-rectifier reach the

up-down board?

Replace the fuse

Check and/or replace the

cable connecting the

up-down board to the

filter

YES

Replace the up-down board: see paragraph

7.12.

Is the voltage at the transformer

output correct?

Replace the transformer:

see paragraph 7.12.

Continued on the following page.

YES

Replace the rectifier

bridge: see paragraph

7.12.

Page 6.27

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Is the up-down motor current

correct?

YES

Is the pulse signal at the photocell

output correct?

Lubricate the elevation

bars

Are the elevation bars lubricated?

Replace the up-down motor: see paragraph

YES

7.15.

Replace the photocell: see

paragraph 7.20.

YES

Does the up-down board output the

status signal?

YES

Does the status signal reach the

CPU board?

YES

Replace the up-down board: see

paragraph 7.12.

Check and/or replace cable RX-1 connecting the CPU board to the

up-down board

Page 6.28

Replace the CPU board: see

paragraph 7.3.

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Follow the procedure step by step to correctly diagnose the problem. In particular, carry out the checks described in the flowchart with the machine at an elevation between 0 and +15%.

If the motor momentarily starts and stops immediately afterward, there is probably a problem with the photocell or its cable.

If the machine is locked in one of its travel limit positions, the corresponding limit switch will be tripped, and therefore the machine will be able to move in only one direction. If movement in this direction is impeded due to a problem, the message E5 may appear on the display.

Take particular care with the checks highlighted by circled numbers, which are described in detail below:

(1) Each LED corresponds to a limit switch. DL1 turns off when the upper limit switch is tripped,

while DL3 turns off when the lower limit switch is tripped. If neither of the 2 limit switches is tripped and one of the 2 LEDs is off, refer to paragraph 6.8. “The up-down moves in only one direction”.

(2) Place the tester probes between pins 1 and 2 of connector CN3 on the up-down board. When

the “↑” or “↓” key is pressed the measured value should be approximately 48 Vdc.

(3) Place the tester probes between pins 12 (ground) and 11 (signal) of connector CN1 on the

CPU board. When the “↓” key is pressed the measured value should be approximately 5 Vdc. Place the tester probes between pins 12 (ground) and 10 (signal) of connector CN1 of the CPU board. When the “↑” key is pressed the measured voltage should be approximately 5 Vdc.

(4) Place the tester probes between pins 4 (ground) and 3 (signal) of connector CN2 on the up-

down. board. When the “↓” key is pressed the measured voltage should be approximately 5 Vdc. Place the tester probes between pins 4 (ground) and 2 (signal) of connector CN2 on the up-down board. When the “↑” key is pressed the measured voltage should be approximately 5 Vdc.

(5) Place the tester probes between pins 1 and 2 of connector CN4 on the up-down board. The

measured voltage should be approximately 220 Vac or 110 Vac depending on the type of mains electricity supply.

(6) Place the tester probes between pins 1 and 2 of connector CN6 on the up-down board. The

measured voltage should be approximately 50 Vdc.

(7) Disconnect the yellow transformer cables on the rectifier bridge and place the tester probes

across the 2 terminals. The measured voltage should be 38 Vac.

(8) Place the tester probes in series with the motor cable. When the “↑” or “↓” key is pressed the

measured steady-state current should be less than 6 A. To correctly carry out the measurement procedure refer to 11.3.3. “AC and DC current”.

Page 6.29

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(9) Slightly lift the connector on the photocell and place the tester probes between pins 4 (ground)

and 2 (signal). When the motor moves, the tester should detect the pulses generated by the photocell.

(10) Place the tester probes between pins 4 (ground) and 1 (signal) of connector CN2 on the up-

down. board. When the motor moves, there should be one pulse for each ½ degree change in the machine elevation.

(11) As for step (10), but with the tester probes between pins 12 (ground) and 9 (signal) of

connector CN1 on the CPU board.

Page 6.30

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6.8. THE UP-DOWN MOVES IN ONLY ONE DIRECTION

THE UP-DOWN

MOVES IN ONLY

ONE DIRECTION

YES

Are LEDs DL1 and DL3 on the

up-down board both illuminated?

Is the machine in one of the 2 travel

limit poYEStions?

YES

Does the up-down board receive the

correct control YESgnal in the

inactive direction?

Does the CPU board send the

correct control YESgnal in the

inactive direction?

YES

Replace the up-down board: see paragraph

7.15

YES

Check and/or replace

cable RX-1 connecting

the CPU board to the

up-down board

Replace the CPU board:

Continued on the following page.

see paragraph 7.3.

Page 6.31

Page 62

Is the limit switch associated with the

non-illuminated LED tripped?

RUN XT: Service & Maintenance Manual - rev. 2.0

YES

Check the position and/or

replace the limit switch:

see paragraph 7.19.

Is the power supply to the limit

switch associated with the

non-illuminated LED correct?

Does the up-down board send the

correct power supply to the limit

switch associated with the

non-illuminated LED?

Replace the up-down board: see paragraph

7.12.

YES

Replace the limit switch:

see paragraph 7.19.

YES

Check and/or replace

cable RX-6 connecting

the up-down board to the

limit switches

Follow the procedure step by step to correctly diagnose the problem. Take particular care with the checks highlighted by circled numbers, which are described in detail below:

(1) The machine is considered to have reached a travel limit when the corresponding limit switch is

tripped. The lower limit switch is tripped when its lever is pressed, while the upper limit switch is tripped when its lever is released.

(2) If the machine fails to move downward, place the tester probes between pins 4 (ground) and 3

(signal) of connector CN2 on the up-down board: the measured voltage should be approximately 5 Vdc. If the machine fails to move upward, place the tester probes between pins 4 (ground) and 2 (signal) of connector CN2 on the up-down board: the measured voltage should be approximately 5 Vdc.

Page 6.32

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(3) If the machine fails to move downward, place the tester probes between pins 12 (ground) and

11 (signal) of connector CN1 on the CPU board: the measured voltage should be approximately 5 Vdc. If the machine fails to move upward, place the tester probes between pins 12 (ground) and 10 (signal) of connector CN1 on the CPU board: the measured voltage should be approximately 5 Vdc.

(4) DL1 corresponds to the upper limit switch, while DL3 corresponds to the lower limit switch.

(5) Disconnect the 2 connecting cables of the relevant limit switch and place the tester probes

across them: the measured voltage should be approximately 12 Vdc.

(6) To check the upper limit switch, place the tester probes between pins 6 (ground) and 3 (signal)

of connector CN3 on the up-down board.: the measured voltage should be 12 Vdc. To check the lower limit switch, place the tester probes between pins 6 (ground) and 4 (signal) of connector CN3 on the up-down board: the measured voltage should be 12 Vdc.

Page 6.33

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6.9. THE DISPLAYED ELEVATION IS INCORRECT

THE DISPLAYED

ELEVATION IS INCORRECT

Is the position of the limit switch

correct?

Adjust the position of the

limit switch

YES

Is the up-down motor current

correct?

YES

Is the photocell clean?

YES

Lubricate the elevation

bars

Are the elevation bars lubricated?

Replace the up-down motor: see paragraph

YES

7.15.

Clean the photocell

Replace the photocell and

cable RX-12 connecting

the up-down board and

the photocell: see

paragraph 7.20.

Follow the procedure step by step to correctly diagnose the problem. Take particular care with the checks highlighted by circled numbers, which are described in detail below:

(1) Place the tester probes in series with the motor cable. When the “↑” or “↓” keys are pressed

the measured steady-state current should be less than 6 A. To correctly carry out the measurement procedure refer to 11.3.3. “AC and DC current”.

Page 6.34

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6.10. THERE IS NO HEART RATE SIGNAL

THERE IS NO

CARDIO SIGNAL

Is the supply voltage on the

receiver connector correct?

YES

Replace the receiver: see

paragraph 7.5.

Is the supply voltage on

connector CN4 of the CPU board

correct.

YES

Replace or repair cable

BK-7: see paragraph 7.5.

Replace the display CPU

board: see paragraph 7.3.

Follow the procedure step by step to correctly diagnose the problem. Take particular care with the checks highlighted by circled numbers, which are described in detail below:

(1) Place the tester probes between pins 1 (signal) and 3 (ground) (corresponding to the red and

black wires) of the 4-pin receiver connector: the measured voltage should be +5Vdc.

(2) Place the tester probes between pins 1 (signal) and 3 (ground) (corresponding to the red and

black wires) of connector CN4 on the CPU board of the display: the measured voltage should be +5Vdc.

Page 6.35

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6.11. THE HEART RATE SIGNAL IS INCORRECT

In some case the machine may show “Err” on the heart rate display.

THE HEART RATE

SIGNAL IS

INCORRECT

Is the minimum distance

between machines OK?

YES

Is the receiver positioned

correctly, and are the

connecting cables correctly

routed?

YES

If the TGS is present, is the TGSRN2ST cable correctly

routed?

Move the machines to

the minimum distance:

see paragraph 5.1.

Position the receiver and

the cable correctly: see

paragraph 11.1

Correctly route the cable:

see paragraph 11.1.

Are there sources of

electromagnetic noise near

Continued on the following page.

Page 6.36

YES

the receiver?

Move the machine away

YES

from the electromagnetic

source or attenuate the power of the noise: see

paragraph 11.1.

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Is the transmitter in good

working order?

Use a known good

transmitter

YES

Is the transmitter always

within a distance of 80 cm

from the receiver?

Keep the transmitter

within the minimum

reception distance

YES

Change the receiver.

See paragraph 7.5.

Follow the procedure step by step to correctly diagnose the problem. Take particular care with the checks highlighted by circled numbers, which are described in detail below:

(1) To check for electromagnetic noise near the machine, use a frequency signal monitor

constructed as shown in the schematic below:

The circuit lights the LED for every heart beat and/or disturbance that is received: in this way it possible to determine whether there is any interference, and identify its sources.

(2) Check the battery power level, using a tester if possible. Otherwise use a receiver or another

“reference” machine to check operation up to a distance of about 80 cm from the receiver.

ATTENTION: Consult paragraph 11.1. “Technical notes on cardio receivers” in the Appendix.

Page 6.37

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Page intentionally left blank

Page 6.38

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7. DISASSEMBLY OF COMPONENTS

7.1. DISASSEMBLING THE DISPLAY

1. Turn off the machine and unplug the mains

lead from the wall outlet.

2. Remove the 2 caps a.

Figure 7.1-1

3. Unscrew the 6 self-tapping screws b which

fix the DISPLAY, using a large Phillips screwdriver.

Support the DISPLAY before removing the last screw.

4. Open the DISPLAY.

To remove the DISPLAY:

1. Disconnect connectors c.

2. Remove the DISPLAY.

Figure 7.1-2

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

Page 7.1

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7.2. DISASSEMBLING THE EPROM

Carry out the procedure described in paragraph

7.1. “Disassembling the display”.

With the display on a work bench:

Remove EPROM a from its socket using an integrated-circuit extractor tool.

Figure 7.2-1

Figure 7.2-2

To reassemble the EPROM:

1. Make sure that reference index b on the

EPROM coincides with reference notch c on the socket.

2. Be careful to center the EPROM pins above

their corresponding holes in the socket.

3. Push the pins into the socket.

The EPROM can be irreversibly damaged if the reference index on the EPROM is not correctly aligned with the notch on the socket, or if its pins are bent.

Page 7.2

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7.3. DISASSEMBLING THE CPU BOARD

Carry out the procedures described in paragraph

7.1. “Disassembling the display”.

With the display placed on a work bench:

1. Disconnect keyboard connector a.

2. Remove the 5 screws b, using a small Phillips

screwdriver.

3. Disconnect the cardio receiver if it is still

connected.

4. Remove the CPU board.

Figure 7.3-1

These procedures must be carried out on a work bench.

To reassemble the CPU BOARD, carry out the above steps in reverse order

Page 7.3

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7.4. DISASSEMBLING THE KEYBOARD

Carry out the procedure described in paragraph

7.1. “Disassembling the display”.

1. Disconnect KEYBOARD connector a.

Figure 7.4-1

With the display placed on a work bench:

1. Use a sharp tool to lift up a corner of the

KEYBOARD and detach it.

To assemble the new KEYBOARD, with the display on a work bench:

1. Remove the backing film which protects the

adhesive.

2. Apply the adhesive part, starting from the left

and working towards the right, without bending the KEYBOARD.

3. Insert the connector in the special slot on the

display and connect it to the CPU board.

4. Remove the protective film.

When reassembling the keyboard, make sure that none of the keys are bent or remain pushed in.

Page 7.4

Figure 7.4-2

The KEYBOARD assembly procedure can only be carried out once, because disassembly damages the tracks and keys.

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7.5. DISASSEMBLING THE CARDIO RECEIVER

Version A: receiver positioned under the display.

1. Place the machine in its maximum elevation

position.

2. Turn off the machine and unplug the mains

lead from the wall outlet.

3. Cut strap a.

Figure 7.5-1

Figure 7.5-2

4. Lift the lexan instruction panel b, and open

the box c which houses the RECEIVER.

5. Disconnect connector d of cable BK-7 from

the RECEIVER.

6. Remove the RECEIVER.

To reassemble the RECEIVER, carry out the above steps in reverse order, positioning it between the 2 foam pads and using a new strap to secure the box.

Page 7.5

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Version B: receiver positioned inside the display, secured by a strap.

Carry out the procedure described in paragraph

7.1. “Disassembling the display”.

With the display on a work bench:

1. Cut the fixing strap e.

2. Disconnect the connector f of RECEIVER

cable BK-7.

To assemble the new RECEIVER, with the display on a work bench:

1. Connect the connector f of RECEIVER cable

BK-7.

2. Position the RECEIVER between the foam

Figure 7.5-3

pads g as shown in the figure at left.

3. Passing the strap through clamp h, fix and

secure with the strap.

Page 7.6

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Version C: receiver housed in a box inside the display.

Carry out the procedure described in paragraph

7.1. “Disassembling the display”.

With the display on a work bench:

1. Unscrew the screws i on RECEIVER housing

2. Disconnect the connector m of RECEIVER

To assemble the new RECEIVER, with the display on a work bench:

box l using a small Phillips screwdriver.

cable BK-7.

3. Connect connector m of RECEIVER cable

BK-7.

Figure 7.5-4

4. Position the RECEIVER in the box as shown

in the figure at left.

5. Lock down the screws i of the RECEIVER

housing box.

WARNING: route the cables as described in paragraph 11.1. “Technical notes on cardio receivers”.

Page 7.7

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7.6. DISASSEMBLING THE EMERGENCY BUTTON

1. Turn off the machine and unplug the mains

lead from the wall outlet.

2. Unscrew the 8 self-tapping screws a which

fix the DISPLAY, using a large Phillips screwdriver.

Figure 7.6-1

Figure 7.6-2

3. Open the display panel support.

4. Disconnect the two EMERGENCY

BUTTON wires b, using a large Phillips screwdriver.

Continued on the following page→

Page 7.8

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Figure 7.6-3

5. Back off the 2 screws c which fix the

EMERGENCY BUTTON to the panel using a large Phillips screwdriver.

6. Firmly gripping the inner part, push and

rotate the EMERGENCY BUTTON to detach it.

Figure 7.6-4

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

For the 4-terminal version of the emergency button, remember to connect the wires in position 1-2 (NC button).

Page 7.9

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7.7. DISASSEMBLING THE MOTOR GUARD

1. Turn off the machine and unplug the mains

lead from the wall outlet.

2. Unscrew the 6 screws a using a large Phillips

screwdriver.

3. Remove the MOTOR GUARD b.

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

Figure 7.7-1

Page 7.10

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7.8. DISASSEMBLING THE FRONT PLATE

1. Carry out the procedure described in

paragraph 7.7. “Disassembling the motor guard”.

2. Unscrew the 4 self-tapping screws a using a

large Phillips screwdriver.

3. Rotate the FRONT PLATE b downward.

The plate remains connected to the frame by two steel cables.

To reassemble the FRONT PLATE, carry out the

Figure 7.8-1

above steps in reverse order.

Page 7.11

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7.9. DISASSEMBLING THE RUNNING TRACK

1. Turn off the machine and unplug the mains

lead from the wall outlet.

2. Unscrew the 2 screws a using a 6-mm Allen

T wrench.

3. Remove the rear caps b on the right and left

hand sides.

4. Unscrew the 2 screws c fixing the footrests

using a 5-mm Allen T wrench.

Figure 7.9-1

Figure 7.9-2

5. Remove the footrests by pulling them toward

the back of the machine.

Continued on the following page→

Page 7.12

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6. Depending on the type of shock absorbers:

• Unscrew the 6 screws d using a 5-mm

Allen T wrench.

• Unscrew the 2 rear screws d using a 5-

mm Allen T wrench, and the 4 front screws using a 5-mm Allen T wrench while holding the nut in place with a 13mm wrench.

7. Remove the 2 footrest guides f.

8. Pull out the RUNNING TRACK from the

side.

The front and rear profiles of the RUNNING TRACK are different, and therefore it is necessary to mark the correct positions in order to avoid errors during the reassembly phase.

Figure 7.9-3

Before reassembling the caps, check that the fixing bolts are in the position indicated in the figure.

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

Page 7.13

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7.10. DISASSEMBLING THE DRIVEN ROLLER, THE DRIVING

ROLLER, THE TREAD BELT AND THE MOTOR BELT

1. Place the machine in the maximum elevation

position.

2. Carry out the procedure described in

paragraphs 7.7. “Disassembling the motor guard” and 7.9. “Disassembling the running track”.

3. Remove the dust guard.

4. Unscrew the 2 screws a using a 6-mm Allen

Figure 7.10-1

T wrench.

Figure 7.10-2

5. Pull out the DRIVEN ROLLER b from its

supports c.

6. Remove the DRIVEN ROLLER.

7. Back off the 4 nuts d (2 are concealed by the

motor in the figure at left) which fix the belt motor to the machine frame using a 13-mm wrench, and holding the screw underneath in place with a 6-mm Allen T wrench.

8. Back off the 2 outer nuts e and the 2 inner

nuts f using a 13-mm wrench.

Page 7.14

Figure 7.10-3

Continued on the following page→

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Figure 7.10-4

9. Move the belt motor toward the DRIVING

ROLLER g and pull outward to remove belt

h from the motor pulley i.

Figure 7.10-5

10. Unscrew the 2 fixing screws of the DRIVING

ROLLER l using a 6-mm Allen T wrench.

11. Disengage the DRIVING ROLLER from its

supports.

12. Remove the MOTOR BELT by pulling it out

from the DRIVING ROLLER.

13. Remove the DRIVING ROLLER.

14. Remove the TREAD BELT.

Figure 7.10-6

Continued on the following page →

Page 7.15

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To reassemble the DRIVEN ROLLER, the DRIVING ROLLER, the TREAD BELT and the MOTOR BELT, carry out the above steps in reverse order.

To ensure correct reassembly, insert the DRIVING ROLLER in the MOTOR BELT before assembling it on the supports.

After completing this procedure, adjust the tension and centering of the TREAD BELT as described in paragraphs 8.1.

8.2. 8.3. and adjust the tension and alignment of the MOTOR BELT as described in paragraph 8.4.

Page 7.16

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7.11. DISASSEMBLING THE BELT MOTOR

1. Carry out the procedure described in

paragraph 7.7. “Disassembling the motor ”.

2. Remove the dust guard.

3. Unscrew the 4 nuts a (2 are concealed by the

motor in the figure at left) which fix the belt motor to the machine frame using a 13-mm wrench and holding the screw underneath in place with a 6-mm Allen T wrench.

4. Back off the 2 outer nuts b and the 2 inner

nuts c using a 13-mm wrench.

5. Move the BELT MOTOR toward the driving

roller.

6. Disengage the motor belt.

Figure 7.11-1

Figure 7.11-2

7. Unscrew the 4 screws d of the BELT

MOTOR cover using a large Phillips screwdriver.

8. Back off the cable clamp e.

9. Open the cover.

Continued on the following page →

Page 7.17

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10. Disconnect the 3 phase conductors f using a

7-mm wrench, the ground conductor g using a large Phillips screwdriver, and the motor thermal cutout h using a small flat-blade screwdriver.

Make sure that no nuts or washers fall inside the BELT MOTOR.

11. Remove the BELT MOTOR.

Figure 7.11-3

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

When locking down the cover screws, make sure that the conductors inside the box are correctly positioned to avoid pinching them with the cover.

After completing the procedure, adjust the tension and alignment of the MOTOR BELT as described in paragraph 8.4. .

Page 7.18

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7.12. DISASSEMBLING THE ELECTRONIC CIRCUIT BOARDS

1. Carry out the procedures described in

paragraphs 7.7. “Disassembling the motor guard” and 7.8. “Disassembling the front plate”.

2. Cut any straps fixing the cables to the grille

protecting the ELECTRONIC CIRCUIT BOARDS.

3. Unscrew the 7 plastic hexagonal-head screws

a which secure the protective grille using a 7mm wrench.

4. Remove the protective grille.

Figure 7.12-1

To disassemble an ELECTRONIC CIRCUIT BOARD:

5. Disconnect all the connectors.

6. Unscrew the screws fixing it to the plate

support using a 7-mm socket wrench.

7. Manually unscrew the fixing studs of the

protective grille.

8. Remove the ELECTRONIC CIRCUIT

BOARD.

To remove the up-down board it is sufficient to disconnect the red and black cables; the yellow cables pertain to the transformer.

To reassemble the ELECTRONIC CIRCUIT BOARDS, carry out the above steps in reverse order.

After reassembling the inverter interface board, calibrate the speed as instructed in paragraph 8.7. .

Page 7.19

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using a

7.13. DISASSEMBLING THE INVERTER

1. Carry out the procedure described in

paragraph 7.7. “Disassembling the motor guard”.

2. Remove the INVERTER cover, using a small

Phillips screwdriver to unscrew the fixing screw, if present.

Figure 7.13-1

Figure 7.13-2

3. Disconnect the electrical cables a

small flat-head screwdriver for the logic signals (upper terminal block) and a medium flat-blade screwdriver for the power signals (lower terminal block).

4. Disconnect the yellow-green ground

conductor of the inverter using a medium Phillips screwdriver.

5. Unscrew the 4 fixing screws b using a 4-mm

Allen T wrench.

6. Remove the INVERTER.

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

After completing this procedure, calibrate the speed as instructed in paragraph 8.7. .

Page 7.20

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7.14. DISASSEMBLING THE UP-DOWN MOTOR BELT

1. Place the machine in its maximum elevation

position.

2. Carry out the procedures described in

paragraphs 7.7. “Disassembling the motor guard” and 7.8. “Disassembling the front plate”.

3. Overturn the machine on the right hand side.

4. Using a large Phillips screwdriver, unscrew

the 4 self-tapping screws a.

5. Remove the belt guard b.

Figure 7.14-1

6. Holding the pivot in place with a 5-mm Allen

T wrench, back off the self-tapping nut of belt tensioner c using a 17-mm wrench.

7. Rotate the belt tensioner to slacken the

BELT.

8. Remove the BELT.

When removing the BELT, be careful not to rotate the lead screw nuts.

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

After completing this procedure, adjust the tension of the UP-DOWN MOTOR BELT as instructed in paragraph 8.5. .

Figure 7.14-2

Page 7.21

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7.15. DISASSEMBLING THE UP-DOWN MOTOR

1. Carry out the procedure described in

paragraph 7.14. “Disassembling the up-down motor belt” up to the slackening of the belt (step 7).

2. Disconnect the motor power supply cable and

the photocell cable.

3. If present, use a 10-mm wrench to remove

the 2 fixing screws from the cover of the protective housing of encoder wheel a

4. Open the cover.

Figure 7.15-1

Figure 7.15-2

5. Use a 10-mm wrench to remove screw b.

6. Disassemble encoder wheel a.

7. Remove the spacer c.

Continued on the following page →

Page 7.22

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8. Strike the motor shaft with a rubber hammer,

and, using a pointed tool if necessary, remove the shaft from the lower side of the machine.

Figure 7.15-3

Figure 7.15-4

9. Recover the tab d.

Continued on the following page→

Page 7.23

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DOWN MOTOR using a 4-mm Allen T

10. Disassemble protective housing of the

encoder wheel, using, depending on the type of motor:

• “BONFIGLIOLI” motor: 10-mm wrench;

• “SITI” motor: 8-mm wrench.

11. Unscrew the 4 fixing screws of the UP-

wrench and holding the nut in place with a 10-mm wrench.

12. Remove the UP-DOWN MOTOR.

Figure 7.15-5

To reassemble the UP-DOWN MOTOR, carry out the above steps in reverse order.

After completing the procedure, adjust the tension of the up-down motor belt as instructed in paragraph 8.5. .

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7.16. DISASSEMBLING THE UP-DOWN MOTOR BRUSHES

It is not possible to carry out this procedure on all types of motors.

1. Carry out the procedures described in

paragraphs 7.7. “Disassembling the motor guard” and 7.8. “Disassembling the front plate”.

2. Manually, or using a small flat-head

screwdriver, unscrew the protective caps a of the brushes.

3. Remove the BRUSHES b.

Figure 7.16-1

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

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Remove, unscrewing them by hand, the 2

7.17. DISASSEMBLING THE ELEVATION BARS

1. Place the machine in its maximum elevation

position.

2. Carry out the operations described in

paragraphs 7.7. “Disassembling the motor guard” and 7.8. “Disassembling the front plate”.

3. Overturn the machine on its right hand side.

4. Unscrew the two fixing screws of wheels a

using two 6-mm T wrenches.

Figure 7.17-1

Figure 7.17-2

5. Remove wheel b.

6. Remove the wheel shaft c.

7. Remove spacer d.

ELEVATION BARS e.

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

During the reassembly phase, lubricate the elevation bars with MOLYKOTE GN PLUS grease.

After completing the procedure, adjust the alignment of the ELEVATION BARS as instructed in paragraph 8.6. .

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7.18. DISASSEMBLING THE LEAD SCREW NUTS

1. Place the machine in its maximum elevation

position.

2. Carry out the procedures described in

paragraphs 7.7. “Disassembling the motor guard” and 7.8. “Disassembling the front plate”.

3. Overturn the machine on its right hand side.

4. Using a large Phillips screwdriver unscrew

the 4 self-tapping screws a.

5. Remove the belt guard b.

Figure 7.18-1

Figure 7.18-2

6. Carry out the procedure described in

paragraph 7.17. “Disassembling the elevation bars”.

7. Back off the bearing clamp screw c using a 4-

mm Allen T wrench.

8. Rotate the clamp d.

9. Unscrew the 4 screws e using a 4-mm Allen

T wrench.

Continued on the following page →

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Figure 7.18-3

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10. Remove the LEAD SCREW NUT GROUP.

To reassemble the LEAD SCREW NUT GROUP, carry out the above steps in reverse order.

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7.19. DISASSEMBLING THE LIMIT SWITCHES

1. Carry out the procedures described in

paragraphs 7.7. “Disassembling the motor guard” and 7.8. “Disassembling the front plate”.

To remove the LIMIT SWITCHES:

2. Disconnect the cables a.

3. Unscrew the 2 fixing screws b of the LIMIT

SWITCH support bracket using a 3-mm Allen T wrench.

4. Remove the LIMIT SWITCH group and the

supporting bracket.

Figure 7.19-1

Figure 7.19-2

5. To remove the LIMIT SWITCHES from the

supporting bracket, unscrew the 2 screws c using a 3-mm Allen T wrench while holding the nut underneath in place with an 8-mm wrench.

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

When reconnecting the cables, remember that the UPPER LIMIT SWITCH is connected between terminals 1 and 3, and the LOWER LIMIT SWITCH is between terminals 1 and 2.

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7.20. DISASSEMBLING THE PHOTOCELL

1. Carry out the procedures described in

paragraphs 7.7. “Disassembling the motor guard” and 7.8. “Disassembling the front plate”.

2. Disconnect connector a on the PHOTOCELL

board.

3. Using a 10-mm wrench, unscrew the 2 screws

fixing the cover of the protective housing of encoder wheel b if present.

4. Open the cover.

Figure 7.20-1

5. Unscrew the 2 screws fixing the

PHOTOCELL board to the support using a small Phillips screwdriver.

6. Remove the PHOTOCELL board.

There are 2 versions of photocell, distinguished by the name of the printed circuit board on which they are mounted, which require a specific version of the SW for the up-down board microcontroller:

• board GF970711 operates with SW

RX42V2;

• board GF920415 operates with SW

RUNXT42.

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

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8. ADJUSTMENTS

8.1. TENSIONING A NEW TREAD BELT

1. After assembling the new tread belt, tighten

the tread belt until it is just slightly taut.

2. Place a tape measure along the right hand

edge of the tread belt, and use a pen make two reference marks on the tread belt at a distance of exactly 1 meter from each other.

Figure 8.1-1

Figure 8.1-2

3. Lock down the right hand tread belt tensioner

screw a until the distance between the reference marks increases by 7 mm.

4. Lock down the left hand tread belt tensioner

screw until the driven roller is aligned with the crosspiece.

After completing this procedure, any further adjustments should be performed using only the left-hand tensioning screw.

After completing this procedure, check the centering of the tread belt as instructed in paragraph 8.3.

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8.2. TENSIONING A USED TREAD BELT

1. After completing reassembly of the used tread

belt, lock down the rear right hand screw a until measurement L in Figure 8.2-2 corresponds to the value shown on the red decal b on the inside of the rear right hand cap.

2. Lock down the left hand tread belt tensioning

screw until the drive roller is aligned with the crosspiece.

Figure 8.2-1

Figure 8.2-2

Use a gauge to measure the distance between the surface of the driven roller and the outer edge of spacer c.

This procedure is normally carried out after replacing the driving or driven rollers, or in those cases where it is necessary to reassemble the used tread belt: it is not possible to carry out the procedure as described in 8.1. because the tread belt is not elastic.

After completing this procedure, check the centering of the tread belt as described in paragraph8.3. .

Page 8.2