Medisoft 800 Series Manuale utente

Series 800 Treadmills

Service Manual

and

troubleshooting guide

870 A/S/C Model

REV. 1/01.07-2019

Service Manual 800 series Rev. 1/01.07.2019

The information contained in this manual is strictly

private and property of Medisoft Ram Italia srl.

This document can not be copied, photocopied,

reproduced entirely or in part without previous

written consents from Medisoft Ram Italia srl

Valid as of 27 July, 2017

Service Manual 800 series Rev. 1/01.07.2019 
 
 
 
Medisoft RAM Italia S.r.l. - All rights reserved 
 
 CONTENTS 
 
Service Manual and troubleshooting guide 
 
- Introduction............................................................................................................................1 
- System breakdowns and diagnostic procedures ....................................................................2 
- Diagnosis of the inclination subsystem .................................................................................2 
1 - Flow chart for the diagnosis of inclination subsystem ..........................................................3 
2 - Transmission check ...............................................................................................................4 
3 - Connection check...................................................................................................................4 
4 - RS232 cable check.................................................................................................................4 
5 - Substitution of RS232 cable ..................................................................................................4 
6 - Inclination check....................................................................................................................5 
7 - Treadmill check .....................................................................................................................5 
8 - Removal of hood....................................................................................................................6 
9 - Control board input check .....................................................................................................6 
10 - Filter board and control board fuses check............................................................................7 
11 - Test control boardand elevation motor..................................................................................8 
12 - Test limit switch ....................................................................................................................9 
13 - Test of 0% limit switch........................................................................................................10 
14 - Substitution of control board...............................................................................................10 
15 - Inclination actuator screw lubrication .................................................................................11 
16 - Substitution of elevation motor ...........................................................................................12 
- Diagnosis of velocity subsystem .........................................................................................13 
1 - Flow chart for the diagnosis of velocity subsystem.............................................................14 
2 - Velocity check.....................................................................................................................15 
3 - Inverter check ......................................................................................................................15 
4 - Control board fuse check.....................................................................................................16 
5 - Test signal control inverter..................................................................................................17 
6 - Substitution of Control Board..............................................................................................17 
7 - Test alimentation inverter....................................................................................................18 
8 - Substitution of inverter........................................................................................................18 
9 - Substitution of velocity motor.............................................................................................19 
- Diagnosis of power subsystem ............................................................................................20 
1 - Flow chart for power subsystem diagnosis..........................................................................21 
2 - Warning light check.............................................................................................................22 
3 - Plug check............................................................................................................................22 
4 - Check imput main switch ....................................................................................................22 
5 - Power cord substitution .......................................................................................................23 
6 - Check output main switch ...................................................................................................23 
7 - Replacement main switch....................................................................................................24 
8 - Replacement warning light..................................................................................................24 
9 - Lock safety switch...............................................................................................................24 
10 - Check emergency buttons....................................................................................................25 
11 - Test switch on......................................................................................................................25 
12 - Check filter board................................................................................................................26 
13 –Contactor test ......................................................................................................................26 
14 - Test alimentation coil contactor...........................................................................................27 

Service Manual 800 series Rev. 1/01.07.2019 
 
 
 
Medisoft RAM Italia S.r.l. - All rights reserved 
 
15 - Replacement contactor.......................................................................................................287 
16 - Test alimentation control board.........................................................................................287 
17 - Trasformer replacement.......................................................................................................28 
18 - Check fuses control board ...................................................................................................28 
19 - Test output J9 connector......................................................................................................29 
20 - Check cable and emergency buttons....................................................................................29 
21 - Security switch test..............................................................................................................30 
- Diagnosis of gliding subsystem...........................................................................................31 
1 - Flow chart for gliding subsystem diagnosis ........................................................................32 
2 - Tautness check of drive belt ................................................................................................34 
3 - Tautening of drive belt.........................................................................................................35 
4 - Lubrication and gliding system check.................................................................................35 
5 - Tautness check of running belt............................................................................................36 
6 - Tautening of running belt ....................................................................................................36 
7 - Replacement of gliding system............................................................................................37 
8 - Disassembling the gliding subsystem..................................................................................40 
9 - Replacing of running belt ....................................................................................................41 
10 - Disposal of running belt.......................................................................................................41 
11 - Deck Cleaning .....................................................................................................................41 
12 - Lubrication of deck..............................................................................................................42 
13 - Clean of rollers and control of bearings ..............................................................................43 
14 - Cleaning of running belt......................................................................................................43 
15 - Wear test drive belt ……………………………………………………………………….43 
16 –Replacement of drive belt...................................................................................................43 
17 - Restoring the gliding subsystem..........................................................................................44 
 
 
- Maintenance planning –Critical Parts…………………………………………………….46 
 
Annex A Transmission protocol technical specifications .............................................................47 
 
 
- Maintenance planning –Critical parts…………………………………………………….46 
- Setting RS232 command execution in MPH or Km / h.......................................................55 
- List of the most important replacement parts......................................................................56 
- Electric wiring diagram .......................................................................................................61 
 
 

Service Manual 800 series Rev. 1/01.07.2019

1 - Introduction

This manual identifies some of the most frequent system breakdowns of the series 800 treadmills

and describes the diagnostic procedures in order to eliminate breakdowns and return the system to

its correct functioning.

It refers principally to the troubleshooting of the 800 series.

WARNING:

Before resolving any treadmill breakdowns one must check that the connector located at the base

of the right handle has been correctly screwed in during the installation phase.

The incorrect closure of the connector’s ring nut could cause contact with some pins and not with

others. This could create breakdown symptoms as described below.

Service Manual 800 series Rev. 1/01.07.2019

2 - System breakdowns and diagnostic procedures

WARNING:

Before undertaking any maintenance procedure, the service technicians must take the following

precautions:

1) Use tools with insulated handles

2) Wear personal protective clothing and equipment, such as insulated gloves and shoes,

3) Switch off the equipment (ON/OFF switch to "0") and remove the plug from the outlet.

The following table lists the most frequent system breakdowns and associates the symptoms with

various diagnostic procedures.

Symptom

Diagnostic Procedure

Par

The treadmill does not raise or fall

Diagnosis of the inclination subsystem

The treadmill does not rotate (does not move)

Diagnosis of the velocity subsystem

The treadmill does not turn on

(the belt does not elevate and it does not rotate)

Diagnosis of the power subsystem

The treadmill is not regularly sliding

Diagnosis of the sliding subsystem

3 - Diagnosis of inclination subsystem

This procedure, whose flow chart is described in the next paragraph, takes into consideration the

possible causes of the inclination subsystem’s breakdown starting from the most probable and

listing descending order those with least probability.

Possible breakdown factors:

1. Transmission of the command from the PC to the treadmill

2. Fuse on filter board and control board

3. End run micro-switches

4. Power board

5. Elevation motor

Service Manual 800 series Rev. 1/01.07.2019

not OK

Not OK

not OK

Not OK

not OK

3.1 - Flow chart for the diagnosis of inclination subsystem

3.5 Substitution RS 232

cable

Stop

Start

3.2 Transmission

check

3.3 Connection check

Stop

3.4 RS 232 cable check

3.6 Inclination check

3.9 Control board

imput check

3.10 Filter board and

control board fuse check

3.12 Test of the limit

switch

Send the treadmill to

the manufacturer

3.8 Removal of the hood

3.7 Treadmill check

Stop

3.11 Test control board

and elevation motor

elevaz.

3.13 Test of 0% limit

switch

3.14 Substitution of the

control board

3.15 Substitution of the

elevation motor

Service Manual 800 series Rev. 1/01.07.2019

3.2 - Transmission check

The trial consists in verifying whether the command (of elevation or of rotation) correctly reaches

the treadmill. It requires the use of software installed on a personal computer in order to send the

command to the treadmill.

If the transmission of the command does not work, the software should show an error message.

Consequently, if the error message shows on the PC, it means that the transmission check is not

OK. Should this not occur, the transmission check should be considered OK.

Note: Unfortunately not all software on all PC’s have the possibility of determining whether the

command reached the treadmill in the correct manner, and therefore in these cases, one should

consider the check not OK, even in the absence of error messages.

3.3 - Connection check

With this check one must verify whether the connectors of the RS232 cable are properly inserted in

the ports of the PC and of the treadmill. It requires the manual verification of the positioning of the

connectors and possible reinsertion of them.

After this verification, one must send a new command (of elevation or of rotation) to the treadmill

and verify if the treadmill responds accordingly or not. If the treadmill correctly executes the

command it means that the connection check is OK, otherwise not OK.

3.4 - RS232 cable check

This check consists of the verification that the connection cable RS232 between the PC and the

treadmill is intact. It requires a visual trial, checking that the cable has not undergone damage and

that it is immune from cuts, tears, or crushing.

If the cable appears in a good state the check of the cable RS232 is OK, otherwise not OK.

3.5 - Substitution of RS232 cable

Essential tools:

•Screwdriver

Essential replacement parts:

•RS232 serial cable

This very simple procedure requires removal of the RS232 cable disconnecting the cable from the

ports and then substituting it with a new cable.

Service Manual 800 series Rev. 1/01.07.2019

3.6 - Inclination check

In order to execute the elevation check it is obviously necessary that the treadmill is under tension

and should the hood be open, it is necessary to act very carefully. To apply tension, with the cover

open, the following operations must be executed, in order:

1) block the security contact in the closet position(Fig.1)

2) connect the power plug

3) main switch to the ON position

WARNING:

At this moment, the machine is under tension and you are advised to act very carefully in order to

avoid accidental contact with the parts under tension.

The elevation check can be performed utilizing the software from the PC in order to send an

elevation command to the treadmill. If the treadmill elevates itself in the proper way after the

command is given, the elevation check is considered OK; otherwise not OK.

After the execution of the check and given that one must still work on the treadmill with the cover

open, it is recommended to remove the tension following these steps:

1) Switch OFF the treadmill

2) Unplug the power plug

3.7 - Treadmill check

Essential tools:

•RAM Serial Tester

This check is executed utilizing an instrument called a “RAM Serial Tester” (CERST), which is

able to send elevation and rotation commands to the treadmill.

The objective of this check is to verify the behaviour of the treadmill in reaction to commands

received from the “Serial Tester”.

If the treadmill exhibits the correct behaviour, one must hypothesize that the cause of the

malfunctioning is external and must be researched on the PC software that prepares the structure of

the commands, or on the system which transmits commands.

When the serial tester receives power, the display shows the velocity and inclination information.

The instrument has four buttons with the following functions:

START/STOP: activates and deactivates the treadmill

VEL/INC : moves the cursor on the display and allows the selection of velocity or inclination

UP () : increases by 0.5 the velocity or inclination

DOWN () : decreases by 0.5 the velocity or inclination

The “Serial tester” device is also provided with an RS232 plug for the connection to the treadmill.

When one presses the Start/Stop, Up or Down buttons, the serial tester sends the corresponding

command to the treadmill.

Service Manual 800 series Rev. 1/01.07.2019

The reception of the command by the treadmill is signalled by a change in the symbol on the lower

right hand part of the display, that goes from > (greater) to < (lesser) or vice versa.

The check is executed by disconnecting the PC connector from the RS232 port and connecting the

serial tester. Once the serial tester and the treadmill are turned on, it is possible to utilize the various

buttons of the serial tester to send commands to the treadmill, thereby observing its behaviour.

If the treadmill acts correctly based on the commands received, the check is considered OK;

otherwise not OK.

3.8 - Removal of hood

Necessary tools:

•Philips screwdriver

•Screwdriver

In order to remove the motor hood cover, the following steps must be taken, in the order indicated:

1) Switch OFF the treadmill by main switch

2) unplug the power plug

3) unscrew the screws of the RS232 connector on the hood and remove the connector

4) remove the hood by unscrewing the four screws found at its base

5) re-insert the connector in the serial port RS232 on the motor box

Should the hood come off prior to having executed operations 1) and 2), a security switch will

interrupt the power to the treadmill. The main switch will remain under tension and the warning

light will remain on to signal the operator that it’s necessary to follow the operations listed above in

1) and 2).

3.9 –Control board input check

Tools needed:

•5,5 mm wrench

•hook or elastic restraint safety switch

Remove the protective cover of the control board placed under the engine of elevation with 5,5mm

wrench.

Attach the hook to the safety restraint (Fig.1-4), switch ON the treadmill by main switch and verify

visually that the light-emitting diodes DL1, DL2 and DL3 on the control board are lit (Fig.2-3).

If these diodes are lit, the test is OK, otherwise it is not OK.

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