Technogym Runrace Service Maintenance Manual
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Technogym Runrace Service Maintenance Manual

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MAINTENANCE MANUAL
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. 2.0
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Noor
March 11, 2025

What year was run race HC 1200 manufactured

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Mr. Anderson
May 14, 2025

The Technogym RunRace HC1200 was manufactured before or during the year 2014, as it was listed in an auction held on 21 March 2014.

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Summary of Contents for Technogym Runrace

  • Page 1 & ERVICE MAINTENANCE MANUAL . 2.0...
  • Page 3 The information contained in this document is subject to change without notice. Technogym does not guarantee this documentation in any way. Technogym shall not be held responsible for any errors contained in this manual and declines all liability for accidents or damages resulting from the supply, characteristics or use of this manual.

  • Page 5: Table Of Contents

    RUNRACE : Service & Maintenance Manual - rev. 2.0 Contents 1. GENERAL NOTICES............................1.1 1.1............................. 1.1 NTRODUCTION 1.2............................ 1.1 ECOMMENDATIONS 1.3....................1.2 ENERAL RULES FOR REPAIR PROCEDURES 2. TECHNICAL CHARACTERISTICS ........................2.1 2.1........................2.1 ECHANICAL CHARACTERISTICS 2.2........................2.1 LECTRICAL CHARACTERISTICS 2.3.
  • Page 6 RUNRACE : Service & Maintenance Manual - rev. 2.0 4.4.1. RS-232 Port..........................4.4 4.4.2. RS-485 Ports ..........................4.4 5. INSTALLATION INSTRUCTIONS ........................5.1 5.1......................5.1 PECIFICATIONS AND REQUIREMENTS 5.2.............................. 5.1 NSTALLATION 5.3............................5.2 IRST POWER 6. TROUBLESHOOTING............................6.1 6.1......................6.2 HE DISPLAY DOES NOT ILLUMINATE 6.2.
  • Page 7 RUNRACE : Service & Maintenance Manual - rev. 2.0 7.23..................7.31 ISASSEMBLING THE UP DOWN MOTOR BRUSHES 7.24...................... 7.32 ISASSEMBLING THE ELEVATION BARS 7.25....................7.33 ISASSEMBLING THE LEAD SCREW NUTS 7.26....................... 7.34 ISASSEMBLING THE MICROSWITCHES 7.27.
  • Page 8 RUNRACE : Service & Maintenance Manual - rev. 2.0 10.2.1. Internal cleaning operations ......................10.2 10.2.2. Lubricating the tread belt......................10.2 10.2.3. Lubricating the elevation bars ....................10.2 10.2.4. Checking the state of wear ......................10.2 10.2.5. Checking and centering the tread belt ..................10.3 10.2.6.

  • Page 9: General Notices

    1. GENERAL NOTICES 1.1. INTRODUCTION This document is reserved for Technogym Service technicians, and is intended to provide authorized personnel with the necessary information to correctly carry out repairs and maintenance. A thorough knowledge of the technical information contained in this manual is essential for completing the professional training of the operator.

  • Page 10: 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.

  • Page 11: Technical Characteristics

    RUNRACE : Service & Maintenance Manual - rev. 2.0 2. TECHNICAL CHARACTERISTICS 2.1. MECHANICAL CHARACTERISTICS Width 90 cm Length 224 cm Height 140 cm Weight 270 Kg 2.2. ELECTRICAL CHARACTERISTICS Mains voltage 230 VAC Frequency 50 - 60 Hz Consumption...

  • Page 12: Wiring Diagrams

    RUNRACE : Service & Maintenance Manual - rev. 2.0 2.5. WIRING DIAGRAMS Over time, the machine has undergone modifications for component upgrades and improvements. In certain cases, these modification have entailed changes to the wiring diagram. In the interests of simplicity, the following paragraphs give the diagrams for the most important versions.
  • Page 13 RUNRACE : Service & Maintenance Manual - rev. 2.0 ONNECTORS • CPU board Name Type of connector Connection AMP MATE-N-LOCK 15-pin F To up-down and inverter interface boards AMP MATE-N-LOCK 12-pin F To serial ports AMP MODU II 6-pin M...
  • Page 14 RUNRACE : Service & Maintenance Manual - rev. 2.0 IRING RN-1: Internal connection cable CPU board – Patch cable CPU board Signal Color Patch cable +12 V Blue 1 + 5 V Brown 1 Ground Gray 1 Ground White 1...
  • Page 15 RUNRACE : Service & Maintenance Manual - rev. 2.0 RN-3Q: Internal connection cable CPU – Patch cable CPU board Signal Color Patch cable Blue 1 Brown 1 Gray1 White Violet BUS A Black BUS B Orange Brown 2 Not used...
  • Page 16 RUNRACE : Service & Maintenance Manual - rev. 2.0 RN-13Q: Emergency button cable CPU – Emergency button – Patch cable Emergency Signal Color CPU board Patch cable button Reference Black NC contact (5 Vdc) NC contact Green Red faston + 12 Vdc...
  • Page 17 RUNRACE : Service & Maintenance Manual - rev. 2.0 RN-11Q: Up-down motor power supply cable Up-down board – Rectifier bridge Up-down board Signal Color Rectifier bridge 48 VAC Ground Black − RN-12Q: Photocell cable Up-down board – Photocell Up-down board...

  • Page 18: Model With Sj100 Inverter

    RUNRACE : Service & Maintenance Manual - rev. 2.0 2.5.2. 220 SJ100 MODEL WITH INVERTER Valid from SN. 0200531. Page 2.8...
  • Page 19 RUNRACE : Service & Maintenance Manual - rev. 2.0 ONNECTORS • CPU board Name Type of connector Connection AMP MATE-N-LOCK 15-pin F To up-down and inverter interface boards AMP MATE-N-LOCK 12-pin F To serial ports AMP MODU II 6-pin M...
  • Page 20 RUNRACE : Service & Maintenance Manual - rev. 2.0 IRING RN-1: Internal connection cable CPU board – Patch cable CPU board Signal Color Patch cable +12 V Blue 1 + 5 V Brown 1 Ground Gray 1 Ground White 1...
  • Page 21 RUNRACE : Service & Maintenance Manual - rev. 2.0 RN-3: Internal connection cable CPU – Patch cable CPU board Signal Color Patch cable Blue 1 Brown 1 Gray White Violet BUS A Black BUS B Orange Brown 2 Level of the oil tank...
  • Page 22 RUNRACE : Service & Maintenance Manual - rev. 2.0 RNIMQ-13S: Emergency button cable CPU – Emergency button CPU board Signal Color Emergency button Reference Brown NC contact Blue RN-5TQ: Inverter cable Inverter interface board – Inverter – Motor thermal cutout Inverter interf.
  • Page 23 RUNRACE : Service & Maintenance Manual - rev. 2.0 RN-11: Up-down motor power supply cable Up-down board – Rectifier bridge Up-down board Signal Color Rectifier bridge 48 VAC Ground Black − RN-12: Photocell cable Up-down board – Photocell Up-down board...

  • Page 24: Model

    RUNRACE : Service & Maintenance Manual - rev. 2.0 2.5.3. 220 MODEL Valid from SN. 5866. The differences between the 220 model and the 220 model with SJ100 inverter are: • Inverter cable change from RN-5TQ to RN-5T; • Low voltage power supply cable change from RX-8Q to RN-8;...
  • Page 25 RUNRACE : Service & Maintenance Manual - rev. 2.0 RN-5T: Inverter cable Inverter interface board – Inverter – Motor thermal cutout Inverter interf. Signal Color Inverter Motor thermal board cutout Reference White PV24 Thermal cutout PV24 reference NC thermal cutout...

  • Page 26: Model With Hitachi E2 Inverter

    RUNRACE : Service & Maintenance Manual - rev. 2.0 2.5.4. 220 HITACHI E2 MODEL WITH INVERTER Valid from SN 2043. Page 2.16...

  • Page 27: Model With Lenze Inverter

    RUNRACE : Service & Maintenance Manual - rev. 2.0 2.5.5. 220 LENZE MODEL WITH INVERTER Valid to SN 2042. Page 2.17...
  • Page 28 RUNRACE : Service & Maintenance Manual - rev. 2.0 Page intentionally left blank Page 2.18...

  • Page 29: Principles Of Operation

    RUNRACE : Service & Maintenance Manual - rev. 2.0 3. PRINCIPLES OF OPERATION 3.1. BLOCK DIAGRAM The machine block diagram is shown in the figure below: 3.1.1. C ARDIO 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.

  • Page 30: Cardio Receiver

    RUNRACE : Service & Maintenance Manual - rev. 2.0 3.1.2. C ARDIO 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 (produced by high voltage lines, radio transmitters, monitors, motors, etc.) within its reception area,...

  • Page 31: Inverter Interface Board

    RUNRACE : Service & Maintenance Manual - rev. 2.0 Regardless of whether the Lenze or Hitachi model is used, the inverter and interface board group has the function of driving the tread belt motor at the desired speed, in accordance with the data programmed on the machine CPU board and on the basis of the program saved on the inverter itself.

  • Page 32: Microswitches

    RUNRACE : Service & Maintenance Manual - rev. 2.0 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.

  • Page 33: Tread-Belt Motor Drive

    RUNRACE : Service & Maintenance Manual - rev. 2.0 3.2. TREAD-BELT MOTOR DRIVE 3.2.1. M ECHANICS 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.
  • Page 34 RUNRACE : Service & Maintenance Manual - rev. 2.0 CPU board 10-3 8-3 Alarm Start 10-3 Inverter interface board Alarm Vref Start O-L 1-PV24 AL1-AL0 Inverter 3-PV24 U-V-W Thermal Variable frequency protection The speed control utilizes the following signals: • Start signal This is the signal generated by the CPU board (pin 8-3 of connector CN1) to enable starting of the motor.
  • Page 35 RUNRACE : Service & Maintenance Manual - rev. 2.0 • Variable frequency VAC signal This is the variable frequency alternating voltage generated by the inverter (pin U-V-W) for supplying the motor. The motor speed increases with increasing frequency. • Thermal cutout signal Each motor phase is equipped with a normally-closed thermal cutout which opens when the temperature exceeds a preset threshold.

  • Page 36: Up-Down Motor Drive

    RUNRACE : Service & Maintenance Manual - rev. 2.0 3.3. UP-DOWN MOTOR DRIVE 3.3.1. M ECHANICS 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.
  • Page 37 RUNRACE : Service & Maintenance Manual - rev. 2.0 The elevation control utilizes the following signals: • Up signal This is the signal generated by the CPU board (pins 13-15 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 (-0.4 Vdc), and it goes high (4.0 Vdc) to actuate the motor.
  • Page 38 RUNRACE : Service & Maintenance Manual - rev. 2.0 • Limit switch signal This is the signal from the 2 limit switches which determine the machine’s range of up-down motion. The lower microswitch is a NC contact input to the up-down board (pin 4-6 of connector CN3).

  • Page 39: Automatic Lubrication System

    RUNRACE : Service & Maintenance Manual - rev. 2.0 3.4. AUTOMATIC LUBRICATION SYSTEM Up until serial number 3905, the machine was equipped with an oil reservoir and pump for the automatic lubrication of the tread belt. Starting from serial number 3906, these components have been eliminated, and the automatic tread belt lubrication function is no longer available.

  • Page 40: The Signals

    RUNRACE : Service & Maintenance Manual - rev. 2.0 3.4.3. T HE SIGNALS In machines equipped with a pump, cables RN-3 and RN-4 change as follows: RN-3: Internal connecting cable CPU – Free connector CPU board Signal Color Free Blue 1...
  • Page 41 RUNRACE : Service & Maintenance Manual - rev. 2.0 CPU board 12-9 11-9 10-9 +12 Vdc Oil Low Enable Pump interface board 1-2-3/KR6 4-5/KR6 Oil Low 220 VAC Pump • +12 Vdc signal This is the DC voltage output by the CPU (pin 10-9 of connector CN2) which enters the pump interface board (pin 2-1 of connector K1).
  • Page 42 RUNRACE : Service & Maintenance Manual - rev. 2.0 thermal cutouts of the tread belt motor and sends it to the LENZE inverter interface board. Page 3.14...

  • Page 43: Accessories

    RUNRACE : Service & Maintenance Manual - rev. 2.0 4. ACCESSORIES 4.1. CONNECTING TO THE TGS The machine can be connected to the Technogym System by installing a special upgrade kit, which involves the following: • Installation of a special SW;...

  • Page 44: Connecting To The Printer

    4.2. CONNECTING TO THE PRINTER The machine provides a printing facility through the RS 232 port on the serial port panel. If the machine is equipped with SW for the Technogym System, the print function is not available. The cable for connecting to the printer is as follows: RUNRACE PRINTER CABLE Serial ports –...

  • Page 45: Connecting To An External Device (Ecg And/Or Metabolic Monitor)

    Mortara Instrument X/Scribe TrackMaster In this SW version, the Select Treadmill menu includes the item “Technogym Run Race protocol”. Choose this option. (**) These Esaote models must have the “Stress” program installed, which interfaces the ECG to treadmills. To check whether this program is installed, after switching on the ECG press the FUNC key on the keypad.

  • Page 46: Pin Out Serial Ports

    RUNRACE : Service & Maintenance Manual - rev. 2.0 4.4. PIN OUT SERIAL PORTS 4.4.1. RS-232 P This is a 25 pin female connector. It can be used to connect the printer or an external device. Its pin out is:...

  • Page 47: Installation Instructions

    RUNRACE : Service & Maintenance Manual - rev. 2.0 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.

  • Page 48: First Power-On

    RUNRACE : Service & Maintenance Manual - rev. 2.0 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.

  • Page 49: Troubleshooting

    RUNRACE : Service & Maintenance Manual - rev. 2.0 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.

  • Page 50: The Display Does Not Illuminate

    RUNRACE : Service & Maintenance Manual - rev. 2.0 6.1. THE DISPLAY DOES NOT ILLUMINATE This error occurs when the supply voltage fails to reach the display. THE DISPLAY DOES NOT ILLUMINATE Is the fuse OK? Replace the blown fuse...
  • Page 51 RUNRACE : Service & Maintenance Manual - rev. 2.0 Replace the power Are DC v oltages output by the supply power supply correct? Do all DC v oltages reach the Replace the display CPU board display ? Do all DC v oltages reach the...
  • Page 52 RUNRACE : Service & Maintenance Manual - rev. 2.0 Is the mains voltage present at Replace the power input the output of the power input socket of the machine socket? Replace the cable Is the mains voltage present at connecting the input...
  • Page 53 RUNRACE : Service & Maintenance Manual - rev. 2.0 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.

  • Page 54: The Lcd Shows "Emergency Pressed: Exercise Interrupted

    RUNRACE : Service & Maintenance Manual - rev. 2.0 6.2. THE LCD SHOWS “EMERGENCY PRESSED: EXERCISE INTERRUPTED” The machine displays this message if: • The emergency button is pressed during a training session. • The emergency button is damaged. EMERGENCY PRESSED,...

  • Page 55: The Inverter Is Off

    RUNRACE : Service & Maintenance Manual - rev. 2.0 6.3. THE INVERTER IS OFF This condition is related to emergency button or relay. THE INVERTER IS OFF Is the emergency button pressed? Correct operation Is the v oltage at the output of the CPU...
  • Page 56 RUNRACE : Service & Maintenance Manual - rev. 2.0 Is the v oltage at the CN5 patch Replace RN-3Q cable connector correct? Check the CN5-CN6 patch Is the v oltage at the relay correct? connector and/or replace the RN-4Q cable...
  • Page 57 RUNRACE : Service & Maintenance Manual - rev. 2.0 As for point (1) but on pin 1 and 2 of the patch connector CN5. As for point (1) but on pin 0 and 1 of the relay. Place the tester probes between pins 6 and 8 of the relay. The measured voltage should be 0 Ohm.

  • Page 58: The Lcd Shows "Belt Motor Halted

    RUNRACE : Service & Maintenance Manual - rev. 2.0 6.4. THE LCD SHOWS “BELT MOTOR HALTED” WARNING: Old SW version shows “DAMAGE ON THE BELT MOTOR SYSTEM” instead of this message. The machine displays this message if: • it has detected a failure to actuate movement of the belt motor at the start of the training session;...
  • Page 59 RUNRACE : Service & Maintenance Manual - rev. 2.0 HITACHI INVERTER BELT MOTOR HALTED Execute the procedure The inv erter is on? "The inv erter is of f " Check the error message E01-E02-E03-E04-E05 display ed and/or memorized by the inv erter...

  • Page 60: The Inverter Display Shows E01, E02, E03, E04 Or E05

    RUNRACE : Service & Maintenance Manual - rev. 2.0 6.4.1. T E01, E02, E03, E04 HE INVERTER DISPLAY SHOWS These inverter error messages are related to output short-circuit problems. Are the belt and the deck Replace the belt and the...
  • Page 61 RUNRACE : Service & Maintenance Manual - rev. 2.0 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: Disconnect the motor cable from the inverter and place the tester probes between its terminals U-V, U-W and V-W.
  • Page 62 RUNRACE : Service & Maintenance Manual - rev. 2.0 6.4.2. T HE INVERTER DISPLAY SHOWS These inverter error messages are related to problems with the inverter braking group or the braking resistor. Is the braking resistor correctly connected to the...
  • Page 63 RUNRACE : Service & Maintenance Manual - rev. 2.0 6.4.3. T E8, E10 HE INVERTER DISPLAY SHOWS These inverter error messages are related to HW and SW problems with the inverter. Does the error occur Replace the inv erter f requently ? Does the machine resume Probable interf erence.

  • Page 64: The Inverter Display Shows E09

    RUNRACE : Service & Maintenance Manual - rev. 2.0 6.4.4. T HE INVERTER DISPLAY SHOWS This inverter error message is related to low line voltage problems on the inverter power supply. Does the machine resume Probable low line v oltage.
  • Page 65 RUNRACE : Service & Maintenance Manual - rev. 2.0 Disconnect the filter power supply cables and place the tester probes on the terminals. The measured voltage should be 220 VAC. Disconnect the filter output cables and place the tester probes across the filter terminals. The measured voltage should be 220 VAC.

  • Page 66: The Inverter Display Shows E12

    RUNRACE : Service & Maintenance Manual - rev. 2.0 6.4.5. T HE INVERTER DISPLAY SHOWS This inverter error message is related to the opening of the motor thermal cutouts. Does the machine resume Probable ov erheating of the correct operation af ter being motor.

  • Page 67: The Inverter Display Shows E14

    RUNRACE : Service & Maintenance Manual - rev. 2.0 6.4.6. T HE INVERTER DISPLAY SHOWS This inverter error message is related to poor isolation between the motor phases and ground. Are the motor phases isolated from ground at the Replace the inverter...

  • Page 68: The Inverter Display Shows E15

    RUNRACE : Service & Maintenance Manual - rev. 2.0 6.4.7. T HE INVERTER DISPLAY SHOWS This inverter error message is caused by high voltage problems on the inverter power supply line. Does the machine resume Probable high line v oltage.
  • Page 69 RUNRACE : Service & Maintenance Manual - rev. 2.0 Disconnect the filter output cables and place the tester probes across the filter terminals. The measured voltage should be 220 VAC. This error may be generated even by brief drops in the line voltage due to overloads or other causes.

  • Page 70: The Inverter Display Shows E21

    RUNRACE : Service & Maintenance Manual - rev. 2.0 6.4.8. T HE INVERTER DISPLAY SHOWS This inverter error message is associated with problems of high inverter temperature. Probable ov erheating of the Does the machine resume Replace the inv erter inv erter.

  • Page 71: The Inverter Display Does Not Show Any Error

    RUNRACE : Service & Maintenance Manual - rev. 2.0 6.4.9. T HE 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.
  • Page 72 RUNRACE : Service & Maintenance Manual - rev. 2.0 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: 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.

  • Page 73: The Belt Motor Is Jerking

    RUNRACE : Service & Maintenance Manual - rev. 2.0 6.5. THE BELT MOTOR IS JERKING The probable cause of this error is a disconnected phase on the motor or inverter output. THE BELT MOTOR IS JERKING Are the belt motor windings short-...

  • Page 74: The Belt Motor Starts With Delay

    RUNRACE : Service & Maintenance Manual - rev. 2.0 6.6. THE BELT MOTOR STARTS WITH DELAY The problem is caused by the inverter failing to receive the enable signal (Start) or the speed signal. THE BELT MOTOR DOES NOT START OR...
  • Page 75 RUNRACE : Service & Maintenance Manual - rev. 2.0 speed. The variation of the signal must be accompanied by a corresponding variation in the belt speed: see Table 6.7-1. Page 6.27...

  • Page 76: The Displayed Speed Is Incorrect

    RUNRACE : Service & Maintenance Manual - rev. 2.0 6.7. THE DISPLAYED SPEED IS INCORRECT The machine displays this error if: • the calibration is incorrect; • there are HW problems with the CPU board - inverter interface – inverter and motor group.

  • Page 77: Interface Board

    RUNRACE : Service & Maintenance Manual - rev. 2.0 Is the inv erter control PWM signal at Replace the inv erter the input of the inv erter interf ace interf ace board board correct? Is the inv erter control PWM signal at...
  • Page 78 RUNRACE : Service & Maintenance Manual - rev. 2.0 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 6.7-1.

  • Page 79: The Lcd Shows "Grade Movement Out Of Order

    RUNRACE : Service & Maintenance Manual - rev. 2.0 6.8. THE LCD SHOWS “GRADE MOVEMENT OUT OF ORDER” The machine displays this error if it is unable to control the up-down motor. "GRADE MOVEMENT OUT OF ORDER" Are 2 LEDs on the up-down...
  • Page 80 RUNRACE : Service & Maintenance Manual - rev. 2.0 Is fuse F1 of the up-down board Replace the fuse Check and/or replace the Does the up-down board receive cable connecting the the mains electricity supply? up-down board to the filter...
  • Page 81 RUNRACE : Service & Maintenance Manual - rev. 2.0 Lubricate the elevation bars Is the up-down motor current Are the elevation bars lubricated? correct? Replace the up-down motor Is the pulse signal at the Replace the photocell photocell output correct?
  • Page 82 RUNRACE : Service & Maintenance Manual - rev. 2.0 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: Execute the following troubleshooting procedure when the machine does the reset at the start up.
  • Page 83 RUNRACE : Service & Maintenance Manual - rev. 2.0 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. (10) Slightly lift the connector on the photocell and place the tester probes between pins 4 (ground) and 2 (signal).

  • Page 84: The Up-Down Moves In Only One Direction

    RUNRACE : Service & Maintenance Manual - rev. 2.0 6.9. THE UP-DOWN MOVES IN ONLY ONE DIRECTION The machine displays this error if a microswitch is broken or if it is unable to move the up-down motor. THE UP-DOWN MOVES IN ONLY...
  • Page 85 RUNRACE : Service & Maintenance Manual - rev. 2.0 Is the limit switch associated with the Check the position and/or non-illuminated LED tripped? replace the limit switch Is the power supply to the limit switch associated with the non-illuminated Replace the limit switch...
  • Page 86 RUNRACE : Service & Maintenance Manual - rev. 2.0 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: The machine is considered to have reached a travel limit when the corresponding limit switch is tripped.

  • Page 87: The Displayed Elevation Is Incorrect

    RUNRACE : Service & Maintenance Manual - rev. 2.0 6.10. THE DISPLAYED ELEVATION IS INCORRECT The machine displays this error if there is a mismatch between the photocell model and the SW of the up-down board or there is a bad photocell reading due to incorrect calibration, breakage or disturbances produced by the motor brushes as a result of excessively high currents.
  • Page 88 RUNRACE : Service & Maintenance Manual - rev. 2.0 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: See the following table:...

  • Page 89: The Lcd Shows "Warning: Check Battery

    RUNRACE : Service & Maintenance Manual - rev. 2.0 6.11. THE LCD SHOWS “WARNING: CHECK BATTERY” The machine displays this error message on power up whenever it finds inconsistent data in the battery-backed memory. In consequence: • It is normal for the machine to show this message on the first power up after replacing the display;...

  • Page 90: The Lubrication Circuit Does Not Work

    RUNRACE : Service & Maintenance Manual - rev. 2.0 6.13. THE LUBRICATION CIRCUIT DOES NOT WORK The machine displays this error if the lubrication system is not working or if the CPU board fails to provide the necessary control signal.
  • Page 91 RUNRACE : Service & Maintenance Manual - rev. 2.0 WARNING: Run the following checks during a manual lubrication cycle, initiated by simultaneously pressing the “1”, “4” and “7” keys. Follow the procedure below to correctly diagnose the problem. Take particular care with the steps highlighted by circled numbers, which are described in detail below: If the relay is switching, the sound of the contacts closing should be audible.

  • Page 92: The Machine Does Not Print

    RUNRACE : Service & Maintenance Manual - rev. 2.0 6.14. THE MACHINE DOES NOT PRINT The machine displays this error if there are HW errors or if the machine is incorrectly configured. It is in any case recommended to also check whether the printer itself is working correctly.
  • Page 93 RUNRACE : Service & Maintenance Manual - rev. 2.0 Connect the tester on the output connector printer cable A434, while the other end is connected to the machine. Select any training program: as soon as the last input is confirmed and training starts, the machine will transmit the data through the serial port.

  • Page 94: There Is No Heart Rate Signal

    RUNRACE : Service & Maintenance Manual - rev. 2.0 6.15. THERE IS NO HEART RATE SIGNAL The machine displays this error if the receiver is not working or if it is not supplied by the CPU board. THERE IS NO...

  • Page 95: The Heart Rate Signal Is Incorrect

    RUNRACE : Service & Maintenance Manual - rev. 2.0 6.16. THE HEART RATE SIGNAL IS INCORRECT The machine displays this error if the receiver is disturbed by electromagnetic noise. In some case the machine may show “Err” on the heart rate display.
  • Page 96 RUNRACE : Service & Maintenance Manual - rev. 2.0 Is the transmitter in good Use a known good working order? transmitter Is the transmitter always Keep the transmitter within a distance of 80 cm within the minimum from the receiver?

  • Page 97: Disassembly Of Components

    RUNRACE : Service & Maintenance Manual - rev. 2.0 7. DISASSEMBLY OF COMPONENTS 7.1. DISASSEMBLING THE DISPLAY 1. Turn off the machine and unplug the mains lead from the wall outlet. 2. Back off the 2 screws a. 3. Remove guard b.

  • Page 98: Disassembling The Eprom

    RUNRACE : Service & Maintenance Manual - rev. 2.0 7.2. DISASSEMBLING THE EPROM 1. Turn off the machine and unplug the mains lead from the wall outlet. 2. Back off the 4 screws a using a small Philips screwdriver. 3. Remove guard plate b.

  • Page 99: Disassembling The Backup Battery

    RUNRACE : Service & Maintenance Manual - rev. 2.0 7.3. DISASSEMBLING THE BACKUP BATTERY 1. Turn off the machine and unplug the mains lead from the wall outlet. 2. Back off the 4 screws a using a small Philips screwdriver.

  • Page 100: Disassembling The Cpu Board

    RUNRACE : Service & Maintenance Manual - rev. 2.0 7.4. DISASSEMBLING THE CPU BOARD Carry out the procedure described in paragraph 7.1. “Disassembling the display”. With the display placed on a work bench: 1. Remove EPROMs guard plate. 2. Back off the 13 screws a, using a small Philips screwdriver.
  • Page 101 RUNRACE : Service & Maintenance Manual - rev. 2.0 7. Separate the CPU board g from the LED board h, turning it over toward the left and being careful with strip i. 8. Using your hands, disconnect strip i from the CPU board side.

  • Page 102: Disassembling The Keyboard

    RUNRACE : Service & Maintenance Manual - rev. 2.0 7.5. DISASSEMBLING THE KEYBOARD Carry out the procedure described in paragraph 7.1. “Disassembling the display”. With the display placed on a work bench: 1. Remove EPROMs guard plate. 2. Back off the 13 screws a, using a small Philips screwdriver.
  • Page 103 RUNRACE : Service & Maintenance Manual - rev. 2.0 To reassemble the new KEYBOARD, with the display placed on a work bench: 1. Remove the backing film from the adhesive side. 2. Apply the adhesive part, starting from the left and working toward the right, being careful not to bend the KEYBOARD.

  • Page 104: Disassembling The Cardio Receiver

    RUNRACE : Service & Maintenance Manual - rev. 2.0 7.6. DISASSEMBLING THE CARDIO RECEIVER 1. Raise the machine to its maximum incline. 2. Turn off the machine and unplug the mains lead from the wall outlet. If the receiver is situated under the display: 3.

  • Page 105: Disassembling The Emergency Stop Button

    RUNRACE : Service & Maintenance Manual - rev. 2.0 7.7. DISASSEMBLING THE EMERGENCY STOP BUTTON Carry out the procedure described in paragraph 7.1. “Disassembling the display” up until the disconnection of the cables and the disassembly of the right hand side panel which accommodates the EMERGENCY STOP BUTTON.

  • Page 106: Disassembling The Motor Guard

    RUNRACE : Service & Maintenance Manual - rev. 2.0 7.8. DISASSEMBLING THE MOTOR GUARD 1. Turn off the machine and unplug the mains lead from the wall outlet. 2. Back off the 6 screws a using a large Philips screwdriver.

  • Page 107: Disassembling The Side Guards

    RUNRACE : Service & Maintenance Manual - rev. 2.0 7.9. DISASSEMBLING THE SIDE GUARDS 1. Turn off the machine and unplug the mains lead from the wall outlet. For each SIDE GUARD: 2. Back off the 4 screws a using a large Philips screwdriver.

  • Page 108: Disassembling The Front Plate

    RUNRACE : Service & Maintenance Manual - rev. 2.0 7.10. DISASSEMBLING THE FRONT PLATE Carry out the procedure described in paragraph 7.8. “Disassembling the motor guard”. 1. Back off the 4 screws a using a 6-mm hex T wrench. 2. Remove the 2 side plugs b.

  • Page 109: Disassembling Shield Grid For Tread Belt Motor And Inverter

    RUNRACE : Service & Maintenance Manual - rev. 2.0 7.11. DISASSEMBLING SHIELD GRID FOR TREAD BELT MOTOR AND INVERTER Carry out the procedure described in paragraph 7.8. “Disassembling the motor guard”. 1. Remove the dust guard a. Figure 7.11-1 2. Back off the screw b using a medium Phillips screwdriver, in the rear part of the shield grid.

  • Page 110: Disassembling The Rear Roller

    RUNRACE : Service & Maintenance Manual - rev. 2.0 7.12. DISASSEMBLING THE REAR ROLLER 1. Lower the machine to its minimum incline position. 2. Turn off the machine and unplug the mains lead from the wall outlet. 3. Back off the 4 screws a using a 6-mm hex T wrench.
  • Page 111 RUNRACE : Service & Maintenance Manual - rev. 2.0 7. Push the REAR ROLLER forward against the running track. With the rear screw removed, there will be enough space to move REAR ROLLER forward until it comes out of its guide and drops onto the belt.

  • Page 112: Disassembling The Motor Roller

    RUNRACE : Service & Maintenance Manual - rev. 2.0 7.13. DISASSEMBLING THE MOTOR ROLLER 1. Raise the machine to its maximum incline position. 2. Turn off the machine and unplug the mains lead from the wall outlet. To facilitate the subsequent adjustment...

  • Page 113: Disassembling The Brush

    RUNRACE : Service & Maintenance Manual - rev. 2.0 7.14. DISASSEMBLING THE BRUSH 1. Turn off the machine and unplug the mains lead from the wall outlet. 2. Overturn the machine on its right side. If the automatic lubrication system is installed, ensure that the oil reservoir cap is securely closed.

  • Page 114: Disassembling The Tread Belt And Running Track

    RUNRACE : Service & Maintenance Manual - rev. 2.0 7.15. DISASSEMBLING THE TREAD BELT AND RUNNING TRACK Carry out the procedure described in the paragraphs 7.8. “Disassembling the motor guard”, 7.12. “Disassembling the rear roller”, 7.13. “Disassembling the motor roller” and 7.14.
  • Page 115 RUNRACE : Service & Maintenance Manual - rev. 2.0 The upper table of the RUNNING TRACK can be inverted by turning it over. To reassemble the TREAD BELT and the RUNNING TRACK, carry out the above steps in reverse order.

  • Page 116: Disassembling The Shock Absorbers

    RUNRACE : Service & Maintenance Manual - rev. 2.0 7.16. DISASSEMBLING THE SHOCK ABSORBERS Carry out the procedure described in paragraph 7.15. “Disassembling the tread belt and running track”. For the new model: 1. On each side of the machine, back off the 2 nuts a using a 13-mm wrench.

  • Page 117: Disassembling The Tread-Belt Motor

    RUNRACE : Service & Maintenance Manual - rev. 2.0 7.17. DISASSEMBLING THE TREAD-BELT MOTOR Carry out the procedure described in paragraph 7.8. “Disassembling the motor guard” and 7.11. “Disassembling shield grid for tread belt motor and inverter”. 1. Raise the machine to its maximum incline position.
  • Page 118 RUNRACE : Service & Maintenance Manual - rev. 2.0 9. Back off the 4 nuts i (2 are concealed by the motor itself in the figure at left) fixing the tread-belt motor to the machine frame, using a 17-mm wrench and holding the screw underneath in place with a 17-mm wrench.

  • Page 119: Disassembling The Motor Drive-Belt

    RUNRACE : Service & Maintenance Manual - rev. 2.0 7.18. DISASSEMBLING THE MOTOR DRIVE-BELT Carry out the procedures described in paragraphs 7.8. “Disassembling the motor guard” and 7.13. “Disassembling the motor roller”. 1. Back off the 4 nuts a (2 are concealed by the...

  • Page 120: Disassembling The Electronic Circuit Boards

    RUNRACE : Service & Maintenance Manual - rev. 2.0 7.19. DISASSEMBLING THE ELECTRONIC CIRCUIT BOARDS Carry out the procedures described in paragraphs 7.8. “Disassembling the motor guard” and 7.10. “Disassembling the front plate”. To disassemble the INVERTER INTERFACE BOARD and the POWER SUPPLY: 1.
  • Page 121 RUNRACE : Service & Maintenance Manual - rev. 2.0 To disassemble the SERIAL PORTS CIRCUIT BOARD: 1. Back off the 4 hexagonal-head screws c using a 7-mm wrench. 2. Remove the SERIAL PORTS CIRCUIT BOARD. To reassemble the ELECTRONIC CIRCUIT BOARDS, carry out the above steps in reverse order.

  • Page 122: Disassembling The Inverter

    RUNRACE : Service & Maintenance Manual - rev. 2.0 7.20. DISASSEMBLING THE INVERTER Carry out the procedure described in paragraph 7.8. “Disassembling the motor guard” and 7.11. “Disassembling shield grid for tread belt motor and inverter”. 1. Remove the cover from the INVERTER, using a small Philips screwdriver to back off the fixing screw, if present.

  • Page 123: Disassembling The Up-Down Motor Belt

    RUNRACE : Service & Maintenance Manual - rev. 2.0 7.21. DISASSEMBLING THE UP-DOWN MOTOR BELT 1. Raise the machine to its maximum incline position. 2. Carry out the procedures described in paragraphs 7.8. “Disassembling the motor guard” and 7.10. “Disassembling the front plate”.

  • Page 124: Disassembling The Up-Down Motor

    RUNRACE : Service & Maintenance Manual - rev. 2.0 7.22. DISASSEMBLING THE UP-DOWN MOTOR Carry out the procedure described in paragraph 7.21. “Disassembling the up-down motor belt” up until the slackening of the belt (step 7). 1. Disconnect the motor supply cable a.
  • Page 125 RUNRACE : Service & Maintenance Manual - rev. 2.0 7. Remove the spacer g. Figure 7.22-3 8. Using a rubber hammer and, if necessary, a pointed tool, knock on the motor shaft and remove it from the lower part of the machine.
  • Page 126 RUNRACE : Service & Maintenance Manual - rev. 2.0 9. Recover the tab h. Figure 7.22-5 10. Disassemble the protective housing of the encoder wheel, using the tool appropriate for the motor model in question: • “BONFIGLIOLI” motor: 10-mm wrench;...

  • Page 127: Disassembling The Up-Down Motor Brushes

    RUNRACE : Service & Maintenance Manual - rev. 2.0 7.23. DISASSEMBLING THE UP-DOWN MOTOR BRUSHES This operation cannot be carried out on all the motor models. Carry out the procedures described in paragraphs 7.8. “Disassembling the motor guard” and 7.10.

  • Page 128: Disassembling The Elevation Bars

    RUNRACE : Service & Maintenance Manual - rev. 2.0 7.24. DISASSEMBLING THE ELEVATION BARS 1. Raise the machine to its maximum incline position. 2. Carry out the procedures described in paragraphs 7.8. “Disassembling the motor guard” and 7.10. “Disassembling the front plate”.

  • Page 129: Disassembling The Lead Screw Nuts

    RUNRACE : Service & Maintenance Manual - rev. 2.0 7.25. DISASSEMBLING THE LEAD SCREW NUTS 1. Raise the machine to its maximum incline position. 2. Carry out the procedures described in paragraphs 7.8. “Disassembling the motor guard” and 7.10. “Disassembling the front plate”.

  • Page 130: Disassembling The Microswitches

    RUNRACE : Service & Maintenance Manual - rev. 2.0 7.26. DISASSEMBLING THE MICROSWITCHES Carry out the procedures described in paragraphs 7.8. “Disassembling the motor guard” and 7.10. “Disassembling the front plate”. 1. Disconnect the cables a. 2. Back off the 2 fixing screws b of the MICROSWITCH support bracket, using a 3- mm hex T wrench.

  • Page 131: Disassembling The Photocell

    RUNRACE : Service & Maintenance Manual - rev. 2.0 7.27. DISASSEMBLING THE PHOTOCELL Carry out the procedures described in paragraphs 7.8. “Disassembling the motor guard” and 7.10. “Disassembling the front plate”. 1. Disconnect connector a on the PHOTOCELL board. 2. Using a 10-mm wrench, back off the 2 cover fixing screws b on the protective housing of the encoder wheel.

  • Page 132: Disassembling The Fans

    RUNRACE : Service & Maintenance Manual - rev. 2.0 7.28. DISASSEMBLING THE FANS Carry out the procedures described in paragraphs 7.8. “Disassembling the motor guard” and 7.11. “Disassembling shield grid for tread belt motor and inverter”. To disassemble the right fan, downflow fan: 1.

  • Page 133: Adjustments

    RUNRACE : Service & Maintenance Manual - rev. 2.0 8. ADJUSTMENTS 8.1. TENSIONING A NEW TREAD BELT 1. After assembling the new tread belt, turn it until the join is underneath and tighten the tread belt until it is just slightly taut.

  • Page 134: Tensioning A Used Tread Belt

    RUNRACE : Service & Maintenance Manual - rev. 2.0 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.

  • Page 135: Centering The Tread Belt

    RUNRACE : Service & Maintenance Manual - rev. 2.0 8.3. CENTERING THE TREAD BELT 1. Start the machine at a speed of 10 km/h (6 mph). 2. Observe the movement of the tread belt, correcting any tendency to shift to the right or...

  • Page 136: Adjusting The Tension And Alignment Of The Tread-Belt Motor Belt

    RUNRACE : Service & Maintenance Manual - rev. 2.0 8.4. ADJUSTING THE TENSION AND ALIGNMENT OF THE TREAD-BELT MOTOR BELT Carry out the procedures described in paragraphs 7.8. “Disassembling the motor guard” and 7.10. “Disassembling the front plate”. 1. Remove the dust guard.
  • Page 137 RUNRACE : Service & Maintenance Manual - rev. 2.0 To adjust the alignment, use a straight-line reference rod d, rested against the driving roller pulley, and make sure that: • The pulley and flywheel are parallel. 1. Repeat steps 3 and 4.

  • Page 138: Tensioning The Up-Down Motor Belt

    RUNRACE : Service & Maintenance Manual - rev. 2.0 8.5. TENSIONING THE UP-DOWN MOTOR BELT Carry out the procedures described in paragraphs 7.8. “Disassembling the motor guard” and 7.10. “Disassembling the front plate”. 1. Place the machine on its maximum elevation position.

  • Page 139: Aligning The Elevation Bars

    RUNRACE : Service & Maintenance Manual - rev. 2.0 8.6. ALIGNING THE ELEVATION BARS 1. With the machine turned over on one side, turn one of the elevation bars until the wheel shaft holes on both bars are aligned. 2. Use a gauge to make sure that both elevation bars project by the same distance A from the lead screw nuts.

  • Page 140: Calibrating The Tread Belt Speed

    RUNRACE : Service & Maintenance Manual - rev. 2.0 8.7. CALIBRATING THE TREAD BELT SPEED Carry out the procedure described in paragraph 7.8. “Disassembling the motor guard”. The operations described below must be carried out with the machine powered they...

  • Page 141: Centering The Photocell

    RUNRACE : Service & Maintenance Manual - rev. 2.0 8.8. CENTERING THE PHOTOCELL Carry out the procedures described in paragraphs 7.8. “Disassembling the motor guard” e 7.10. “Disassembling the front plate”. 1. Using a 10-mm wrench, unscrew the 2 fixing screws of the cover of the protective housing of the encoder wheel.

  • Page 142: Adjusting The Lcd Backlighting

    RUNRACE : Service & Maintenance Manual - rev. 2.0 8.9. ADJUSTING THE LCD BACKLIGHTING After the machine has been switched on for at least 1 hour, without switching it off: 1. Adjust trimmer P1 on the back of the display to obtain the desired level of LCD luminosity.

  • Page 143: Adjusting The Buzzer Tone

    RUNRACE : Service & Maintenance Manual - rev. 2.0 8.10. ADJUSTING THE BUZZER TONE Turn on the machine and, when the buzzer is sounded during the start-up procedure: 1. Adjust trimmer P2 on the back of the display to obtain the desired buzzer tone.
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  • Page 145: Machine Configuration

    RUNRACE : Service & Maintenance Manual - rev. 2.0 9. MACHINE CONFIGURATION 9.1. HW MACHINE CONFIGURATION The HW machine configuration is done via the 2 banks of 4 dip-switches at the rear of the CPU board, proceeding as follows: 9.1.1. E NABLE USE OF EXTERNAL DEVICE Using dip-switch No.1 of the right hand bank at the rear of the CPU board, select the type of...
  • Page 146 RUNRACE : Service & Maintenance Manual - rev. 2.0 • Dip-switch No. 2: unit of measurement for speed: Left hand bank Dip-switch 2 Unit of measurement Km/h • Dip-switches No. 3 and 4: type of protocol used: Left hand bank...

  • Page 147: Configuration Of Sw Parameters

    RUNRACE : Service & Maintenance Manual - rev. 2.0 9.2. CONFIGURATION OF SW PARAMETERS The only configurable parameters are those for the machine lubrication. To change these values, simultaneously press the when the 01 keys when the machine is in standby mode. The following...

  • Page 148: Partial Display Of Working Parameters

    RUNRACE : Service & Maintenance Manual - rev. 2.0 9.3. PARTIAL DISPLAY OF WORKING PARAMETERS In order to check the state of wear of the machine and correctly carry out routine machine maintenance, a special procedure is provided for viewing the values of the working parameters. This is a “partial”...

  • Page 149: Number Of Manual Lubrication Cycles

    RUNRACE : Service & Maintenance Manual - rev. 2.0 9.3.4. N UMBER OF MANUAL LUBRICATION CYCLES The total number of manual lubrication cycles carried out. The following message appears on the LCD: N O . M A N U A L L U B R I C A T I O N S = After 10 seconds, it automatically goes on to the next view.

  • Page 150: Complete Display Of Working Parameters

    RUNRACE : Service & Maintenance Manual - rev. 2.0 9.4. COMPLETE DISPLAY OF WORKING PARAMETERS In order to check the state of wear of the machine and correctly carry out routine maintenance, a special procedure is provided for viewing the working parameters. This is a “complete” procedure in that the lubrication parameters shown are those pertaining to the duration and frequency.

  • Page 151: Number Of Manual Lubrication Cycles

    RUNRACE : Service & Maintenance Manual - rev. 2.0 K m . C O V E R E D F R O M L A S T L U B R I C A T . = X X X X After 10 seconds, it automatically goes on to the next view.

  • Page 152: Modifying The Working Parameters

    RUNRACE : Service & Maintenance Manual - rev. 2.0 9.5. MODIFYING THE WORKING PARAMETERS The procedure for setting the values of the machine’s working parameters (for example, after having replaced the CPU board) is accessed by simultaneously pressing the 01 keys when the machine is in standby mode.

  • Page 153: Lubrication Duration

    RUNRACE : Service & Maintenance Manual - rev. 2.0 “XXX” indicates the value currently in memory, while “000” is the new value to be modified. After entering the desired value using the number keys, press ENTER to confirm. 9.5.4. L UBRICATION DURATION This option is used for configuring the duration of an automatic lubrication cycle.

  • Page 154: Programming The Hitachi Sj100 Inverter

    RUNRACE : Service & Maintenance Manual - rev. 2.0 9.6. PROGRAMMING THE HITACHI SJ100 INVERTER The inverter can be programmed using the special keypad installed on board the machine. It is necessary to correctly configure the values of the main functions labeled with an F, and those of the extended functions labeled with A, b, C and H.

  • Page 155: Modified Parameter Settings

    RUNRACE : Service & Maintenance Manual - rev. 2.0 9.6.1. M ODIFIED PARAMETER SETTINGS The following table shows the parameters which must be configured with a different value from the inverter defaults: Parameter Description Value Base frequency Maximum frequency setting...

  • Page 156: Programming The Hitachi J100 Inverter

    RUNRACE : Service & Maintenance Manual - rev. 2.0 9.7. PROGRAMMING THE HITACHI J100 INVERTER 9.7.1. V ERSION Version E2 of the HITACHI J100 inverter can be programmed only by using the special external keyboard DRW 100 EA to copy the correct version of the EPROM program supplied by the manufacturer.
  • Page 157 RUNRACE : Service & Maintenance Manual - rev. 2.0 To display the parameters of the extended functions: 8. Press the FUNC key until function F 14 appears. 9. Press the 1 key to display the code of the extended function: for example the display will show 0 to indicate A 0.
  • Page 158 RUNRACE : Service & Maintenance Manual - rev. 2.0 EXTENDED FUNCTIONS FUNCTION Value Default FUNCTION Value Default A 37 A 38 A 39 A 40 A 41 A 42 A 43 A 48 A 49 A 50 A 10 A 51...

  • Page 159: Programming The Lenze 644 Inverter

    RUNRACE : Service & Maintenance Manual - rev. 2.0 9.8. PROGRAMMING THE LENZE 644 INVERTER The LENZE inverter can be programmed only by using the keypad eventually installed on-board the machine. With the inverter powered up, the display shows the parameters for function C50 (work frequency).
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  • Page 161: Scheduled Maintenance

    RUNRACE : Service & Maintenance Manual - rev. 2.0 10. SCHEDULED MAINTENANCE To keep the machine in perfect working order and prevent the risk of malfunction, it is necessary to perform the scheduled maintenance operations set out in the table below. There are 3 basic types of maintenance operations: •...

  • Page 162: Routine Maintenance Operations

    1. With the machine stopped, check the state of wear of the entire surface of the tread belt, turning it by hand. If any anomalies are found, call in the authorized Technogym Technical Service. 2. Check the state of wear of the running track by lifting the tread belt in the middle. If any anomalies are found, call in the authorized Technogym Technical Service.

  • Page 163: Checking And Centering The Tread Belt

    HECKING AND CENTERING THE TREAD BELT 1. With the machine stopped, check the tension of the entire surface of the tread belt, turning it by hand. If any anomalies are found, call in the authorized Technogym Technical Service or adjust the tension.

  • Page 164: Special Maintenance Operations

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

  • Page 165: Checking The Wear Of The Rear Roller

    RUNRACE : Service & Maintenance Manual - rev. 2.0 4. Check the state of wear of the motor roller. Replace if it shows evident signs of wear. 10.3.6. C HECKING THE WEAR OF THE REAR ROLLER 1. Turn off the machine by placing the switch in the 0 position (OFF).

  • Page 166: Checking The Oil Level

    RUNRACE : Service & Maintenance Manual - rev. 2.0 3. If the machine is equipped with a coded receiver (PCD technology), put on the coded strap and wait for the machine to display the measured heart rate. At this point, using a heart rate frequency simulator, check that the machine does not detect its presence and doesn’t alter the...

  • Page 167: Appendix

    11. APPENDIX 11.1. TECHNICAL NOTES ON CARDIO RECEIVERS Technogym utilizes Polar technology for measuring the heart rate frequency of the person training on the machine. The Polar system consists of: • a transmitter, worn by the person training on the machine, which uses 2 electrodes to detect the electrical activity of the heart and transmits the measured heart rate by sending an electromagnetic signal at a frequency of 5 kHz.

  • Page 168: Type Of Asic

    RUNRACE : Service & Maintenance Manual - rev. 2.0 There are 3 types of problems which can typically occur on the heart rate signal: • interference caused by disturbances from sources of electromagnetic noise. These problems cause the heart rate signal to deviate from the rear value, typically making it higher;...

  • Page 169: Reducing Receiver Sensitivity

    RUNRACE : Service & Maintenance Manual - rev. 2.0 of the receiver (detected by the coil) whereas they have no effect on digital components such as the CPU receiver connecting cable. Electromagnetic interference can take different forms: on the one hand, the receiver may detect and hence generate spurious transients or periodic noise pulse, or on the other hand the receiver may become saturated.

  • Page 170: Mechanical Vibrations

    RUNRACE : Service & Maintenance Manual - rev. 2.0 Sensitivity is reduced by soldering a resistor in parallel with the coil. Normally, the receiver already has a 15 KOhm resistor mounted in parallel with the coil, however it is advisable to check for its presence.

  • Page 171: Routing Of Cables

    RUNRACE : Service & Maintenance Manual - rev. 2.0 • the receiver must be directed in such a way that its axis of reception is parallel to that of the transmitter, as shown in the figure below: Figure 11.1-2 Please note that even small departures from the above specifications may considerably impair the accuracy of reception.

  • Page 172: Hitachi Sj100 Inverter Error Codes

    RUNRACE : Service & Maintenance Manual - rev. 2.0 11.2. HITACHI SJ100 INVERTER ERROR CODES The inverter memorizes all the errors detected during operation, in the form of a code which indicates the cause of the error. The table below lists the error codes and their meaning, as referred to in chapter 6.

  • Page 173: Procedure For Clearing The Error Memory On Hitachi Sj100 Inverter

    RUNRACE : Service & Maintenance Manual - rev. 2.0 2. Turn on the machine. 3. Repeatedly press the “1” or “2” key on the inverter keypad until the display shows “d08”. 4. Press the “FUNC” key to display the last error which occurred. The following will sequentially appear: •...
  • Page 174 RUNRACE : Service & Maintenance Manual - rev. 2.0 5. Holding down the three keys, press also Stop/Reset key for about 1 second and wait for about 3 seconds, until the blinking d00 is shown on the display; 6. Now release all keys again. The initializing phase that now begins will be complete as soon as the display 00 appears.

  • Page 175: Hitachi J100 Inverter Error Codes

    RUNRACE : Service & Maintenance Manual - rev. 2.0 11.5. HITACHI J100 INVERTER ERROR CODES The inverter memorizes all the errors detected during operation, in the form of a code which indicates the cause of the error. The table below lists the error codes and their meaning, as referred to in chapter 6.

  • Page 176: Procedure For Clearing The Error Memory On Hitachi J100 Inverter

    RUNRACE : Service & Maintenance Manual - rev. 2.0 • Voltage at the time of the error (this is the DC voltage internal to the inverter; to obtain the actual mains voltage simply divide this value by 0.14). 10. To proceed to display all the errors in reverse chronological order, simply press the “1” key while the error code is being displayed.

  • Page 177: Lenze 644 Inverter Error Codes

    RUNRACE : Service & Maintenance Manual - rev. 2.0 11.7. LENZE 644 INVERTER ERROR CODES The inverter memorizes all the errors detected during operation, in the form of a code which indicates the cause of the error. The table below details the error codes and their meaning:...

  • Page 178: Installing The Hitachi Inverter In Place Of The Lenze Inverter

    RUNRACE : Service & Maintenance Manual - rev. 2.0 11.9. INSTALLING THE HITACHI INVERTER IN PLACE OF THE LENZE INVERTER Replacing the Lenze inverter on the machine with a Hitachi inverter requires a number of modifications to be made: • The Hitachi inverter is smaller, and therefore an adapter plate must be used to mount it on the supports of the Lenze inverter;...

  • Page 179: L Eakage Current Problems With Hitachi E5 Inverter

    • In place of the Schaffner 350/20/29 filter, use the Schaffner FS5458-20-29 filter specially manufactured for Technogym, which has order code 0WB018. This filter is installed as standard on machines with SN 6000120008, or raise the filter off the ground.
  • Page 180 RUNRACE : Service & Maintenance Manual - rev. 2.0 WARNING: The above modifications do not significantly influence the tripping of the automatic circuit breakers, as these are normally calibrated for residual currents of 30 mA, well above the leakage current of the machine under normal conditions. In this case it may be useful to check that: •...

  • Page 181: Special Functions And Password

    RUNRACE : Service & Maintenance Manual - rev. 2.0 11.11. SPECIAL FUNCTIONS AND PASSWORD The table below details the special functions and passwords available on the machine: Keys Password Function 6144 Configuration of SW parameters as described in paragraph 9.2.
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  • Page 184 TECHNOGYM S.p.A. Via G. Perticari, 20 47035 Gambettola (FC) ITALIA Tel.: +39-0547-650438 Fax: +39-0547-650150 e-mail: service@technogym.com 0SMM0021-ING...

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