Precor C966i Service Manual
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Precor C966i Service Manual

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C956i, C966i (Gen 06) Treadmill
C956i, C966i Treadmill
Warning: This service manual is for use by Precor trained service providers only.
If you are not a Precor Trained Servicer, you must not attempt to service any Precor Product;
Call your dealer for service.
This document contains information required to perform the majority of troubleshooting, and
replacement procedures required to repair and maintain this product.
This document contains general product information, software diagnostic procedures (when
available), preventative maintenance procedures, inspection and adjustment procedures,
troubleshooting procedures, replacement procedures and electrical block and wiring diagrams.
To move directly to a procedure, click the appropriate procedure in the bookmark section to the
left of this page. You may "drag" the separator bar between this page and the bookmark section
to change the size of the page being viewed.
© 2006 Precor Incorporated
Unauthorized Reproduction and Distribution Prohibited By Law
20077-111
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  • Page 1 C956i, C966i Treadmill Warning: This service manual is for use by Precor trained service providers only. If you are not a Precor Trained Servicer, you must not attempt to service any Precor Product; Call your dealer for service. This document contains information required to perform the majority of troubleshooting, and replacement procedures required to repair and maintain this product.

  • Page 2: Section One - Things You Should Know

    Things you Should Know About This Appendix The C956i, C966i (Gen 06) incorporate new drive motor system and display systems. The drive motor is a three phase AC motor. The drive motor controller converts a single phase AC input into three phase motor control.
  • Page 3 C956i, C966i (Gen 06) Treadmill Safety guidelines you should know and follow include: • Read the owner’s manual and follow all operating instructions. • Operate the treadmill on a solid, level surface.Visually check the treadmill before beginning service or maintenance operations. If it is not completely assembled or is damaged in any way, exercise extreme caution while operating and checking the treadmill.
  • Page 4 C956i, C966i (Gen 06) Treadmill General Information For the latest exploded view diagram, part number and part pricing information, visit the Precor dealer website at “www.precor.com/connection. Page 1-4 Page 4...

  • Page 5: Procedure 2.1 - Accessing The Diagnostic Software

    Plug the power cord into the wall outlet, then turn on the treadmill with the circuit breaker. Using the RESET key and the numeric keypad, press keys RESET,5,1,7,6,5,7,6,1, sequentially. Hardware Validation will scroll across the display followed by DISPLAY TEST. Diagram 2.1 - C956i, C966i Treadmill Display Numeric Keypad Back Key OK Key...
  • Page 6 C956i, C966i (Gen 06) Treadmill Press the OK key, the upper most group of LED’s will illuminate on the display. Check the display to ensure that all LED segments are illuminated. Press the OK key four more times to display the remaining LED groups. Check each display group to ensure that all LED segments are illuminated.

  • Page 7: Procedure 2.2 - Displaying Information

    Error Log Procedure Plug the power cord into the wall outlet, then turn on the treadmill with the circuit breaker. With the PRECOR banner scrolling, press the keys RESET,6,5, sequentially. DIAGS-INFORMATION DISPLAY will scroll across the display. Use the keys to move to the desired display shown in the list above.
  • Page 8 C956i, C966i (Gen 06) Treadmill 13. Press the BACK key to exit the U-Boot SW display. 14. U-BASE SW display. This display the installed version of upper PCA software. 15. Press the OK key. The software part number will be displayed as XXXXX-XXX.

  • Page 9: Procedure 2.3 - Setting Club Parameters

    C956i, C966i (Gen 06) Treadmill Procedure 2.3 - Setting Club Parameters This procedure allows you to change the following club settings: • Safety Code • Select Language • Select Units • Set Max Workout Time • Set Max Pause Time •...
  • Page 10 C956i, C966i (Gen 06) Treadmill 14. SET MAX WORKOUT TIME display. Press the OK key. 15. Use the keys to select the maximum time a user can remain in a program. 16. Press the BACK key to exit the set max. workout time display.
  • Page 11 C956i, C966i (Gen 06) Treadmill 36. SET CUSTOM PROGRAM 2 display. Allows programing of the custom program 2. Follow the instructions scrolling on the display to program the custom course. Use the ENTER key to save changes and exit or the BACK to exit without saving changes.

  • Page 12: Procedure 2.4 - Documenting Software Problems

    C956i, C966i (Gen 06) Treadmill Procedure 2.4 - Documenting Software Problems When a problem is found with the software in the upper or lower PCA, record the information listed below. When a problem occurs, record the following information: • Model and serial number •...
  • Page 13 C956i, C966i (Gen 06) Treadmill Section Three - Checking Treadmill Operation This section provides you with a quick method of checking treadmill operation. Check treadmill operation at the end of a maintenance procedure and when it is necessary to ensure that the treadmill is operating properly.

  • Page 14: Procedure 4.1 - Calibrating The Incline Motor

    C956i, C966i (Gen 06) Treadmill Procedure 4.1 - Calibrating the Incline Motor Set the treadmill circuit breaker in the “off” position and unplug the line cord from the wall outlet. Remove the hood. Place the treadmill on its right side. Remove hitch and clevis pins that secure the incline tube to the incline platform.
  • Page 15 C956i, C966i (Gen 06) Treadmill Check the calibration of the incline system by performing the following steps: Press the INCLINE key until maximum incline is obtained, 15%. Press the INCLINE key to minimum incline is obtained, 0% on C956i treadmills or -3% on C966i treadmills.

  • Page 16: Procedure 4.2 - Adjusting Drive Belt Tension

    C956i, C966i (Gen 06) Treadmill Procedure 4.2 - Adjusting Drive Belt Tension Set the treadmill circuit breaker in the “off” position and unplug the line cord from the wall outlet. Remove the hood. Place the drive belt tension gauge on the drive belt as shown in Diagram 4.2.
  • Page 17 C956i, C966i (Gen 06) Treadmill Diagram 4.3 - Drive Belt Adjustment Re-install the hood. Plug the line cord into the wall outlet and set the treadmill circuit breaker in the “on” position. Check treadmill operation per Section 3. Page 17...

  • Page 18: Procedure 5.1 - Troubleshooting The Keypad And Upper Pca

    C956i, C966i (Gen 06) Treadmill Procedure 5.1 - Troubleshooting the Keypad and Upper PCA Procedure Note The red wire on the cables shown in Diagram 5.1 denotes pin 1. When these cables are inserted into their connectors, the red wire must align with the pin 1 designation on the PCA.
  • Page 19 C956i, C966i (Gen 06) Treadmill With a DC voltmeter, measure between TP1 (+8V) and TP3 (DGND) for 8 Vdc and between TP4 (+5V) and TP3 (DGND) for 5Vdc. See Diagram 5.2. Diagram 5.2 - Metrics PCA, Front View TP1 (+8V)
  • Page 20 21. If the display face has been replaced and the same key is still not functioning, replace the upper PCA. 22. If you have performed steps 18 - 22 and the same key is still not functioning, contact Precor customer support for assistance.

  • Page 21: Procedure 5.2 - Troubleshooting The Incline System

    C956i, C966i (Gen 06) Treadmill Procedure 5.2 - Troubleshooting the Incline System Incline System Description: The incline system on these units consists of an AC line voltage driven incline motor (120 Vac or 240 Vac), and an internal 1 KΩ potentiometer for incline position identification. The incline motor contains two motor windings, one to operate the motor in an “upward”...
  • Page 22 C956i, C966i (Gen 06) Treadmill Diagram 5.4 - Power Control Module Connector Numbering If the incline moves normally skip to step 7. If the display indicates that the incline should be moving and the incline motor does not move and AC line voltage is present, skip to step 12.
  • Page 23 C956i, C966i (Gen 06) Treadmill 12. Set the treadmill’s on/off switch in the “off” position. Visually inspect the incline motor’s wiring and connector for any broken or improperly crimped connections. With an ohmmeter, measure between terminals 1 & 5 and 1 & 6 of the INCLINE connector. Both readings should be approximately 12Ω.

  • Page 24: Procedure 5.3 - Troubleshooting Hand Held Heart Rate

    C956i, C966i (Gen 06) Treadmill Procedure 5.3 - Troubleshooting Hand Held Heart Rate Circuit Description The hand held heart rate system is actually a dual system, that is, it can accept a heart rate signal from either the hand held heart rate contacts on the handlebar or from a Polar heart rate chest strap transmitter.
  • Page 25 C956i, C966i (Gen 06) Treadmill No hand held reading - Normal chest strap reading Set the on/off switch in the “on” position and access the diagnostic program (Procedure 2.1). Advance to the heart rate display portion of the diagnostic program. Verify that a hand held signal is not being accepted by firmly grasping both the right and left hand held contacts.
  • Page 26 C956i, C966i (Gen 06) Treadmill 13. If 5 Vdc is not present, remove the connector from J4 of the heart rate PCA. Measure between the “ground” and “5 Vdc” pins of the connector (just removed from the heart rate PCA) for 5 Vdc. If 5 Vdc is present, replace the heart rate PCA. If the 5 Vdc is not present, measure between the corresponding pins of J17 on the upper PCA (red and black wires).

  • Page 27: Procedure 5.4 - Troubleshooting The External A.c. Power Source

    Procedure 5.4 - Troubleshooting the External A.C. Power Source It is extremely important that any Precor treadmill be connected to and operated on a dedicated 20 amp A.C. circuit. A 20 amp dedicated circuit is defined as: a circuit fed by a 20 amp circuit breaker that feeds a single load.
  • Page 28 C956i, C966i (Gen 06) Treadmill The circuit breaker correctly feeds a single A.C. outlet but the neutral is common between several A.C. outlets. The common neutral lead must be removed from treadmill’s A.C. outlet and a new neutral lead from the treadmill’s A.C. outlet to the A.C. neutral distribution bar must be added.

  • Page 29: Procedure 5.5 - Troubleshooting The 3 Phase Ac Drive Motor System

    C956i, C966i (Gen 06) Treadmill Procedure 5.5 - Troubleshooting the 3 Phase AC Drive Motor System Circuit Description The power control module converts single phase 120Vac or 240Vac into three phase variable frequency current for the AC drive motor. The motor speed is controlled by controlling the frequency of the drive motor current.
  • Page 30 C956i, C966i (Gen 06) Treadmill 10. Connect an AC voltmeter between terminals 4 & 5 of the OUTPUT connector on the power control module. See Diagrams 5.3 and 5.4. Set the treadmill’s on/off switch in the “on” position. Press the QUICK START key. If the power control module is supplying output, you will momentarily read approximately 55 Vac.

  • Page 31: Procedure 6.1 - Replacing The Incline Motor

    C956i, C966i (Gen 06) Treadmill Procedure 6.1 - Replacing the Incline Motor Note: The replacement incline motor must be calibrated prior to installation (See Procedure 4.1). Set the treadmill’s circuit breaker in the “off” position and remove the AC line cord from the AC outlet.

  • Page 32: Procedure 6.2 - Replacing The Incline Platform

    C956i, C966i (Gen 06) Treadmill Procedure 6.2 - Replacing the Incline Platform Set the treadmill circuit breaker in the “off” position. Remove the AC line cord from the AC outlet. Carefully, lay the treadmill on its side. Remove the hitch pin and clevis pin that fastens the incline motor tube to the incline platform.
  • Page 33 C956i, C966i (Gen 06) Treadmill Diagram 6.2 - Incline Mounting Pin Fasten the incline tube to the incline platform with the clevis pin and hitch pin removed in step 3. Set the treadmill in its upright position and thoroughly check it per Section 3.

  • Page 34: Procedure 6.3 - Replacing The Power Control Module

    C956i, C966i (Gen 06) Treadmill Procedure 6.3 - Replacing the Power Control Module Set the treadmill’s on/off switch in the “off” position and remove the AC line cord from the AC outlet. Remove the treadmill’s hood. Disconnect the COMM, INCLINE, INPUT, DB and OUTPUT connectors from the power control module.

  • Page 35: Procedure 6.4 - Replacing Drive Motor

    C956i, C966i (Gen 06) Treadmill Procedure 6.4 - Replacing Drive Motor Set the treadmill’s on/off switch in the “off” position and unplug the treadmill’s line cord from the AC outlet. Remove the hood. Disconnect the drive motor connector from the OUTPUT connector on the power control module.

  • Page 36: Procedure 6.5 - Replacing The Circuit Breaker

    C956i, C966i (Gen 06) Treadmill Procedure 6.5 - Replacing the Circuit Breaker Set the treadmill circuit breaker in the “off” position and unplug the treadmill’s line cord from the AC outlet. Remove the treadmill’s hood. Remove the two screws that fastens the AC input panel to the frame,. See Diagram 6.4.
  • Page 37 C956i, C966i (Gen 06) Treadmill Remove the two screws retaining the circuit breaker and remove the circuit breaker. Reference the label on the replacement circuit breaker and set the circuit breaker in its mounting position with the “LINE” side of the breaker facing the input module and the “LOAD”...

  • Page 38: Procedure 6.6 - Replacing The Line Filter

    C956i, C966i (Gen 06) Treadmill Procedure 6.6 - Replacing the Line Filter Set the treadmill circuit breaker in the “off” position and unplug the treadmill’s line cord from the AC outlet. Remove the treadmill’s hood. Remove the two screws that fastens the AC input panel to the frame,. See Diagram 6.4.

  • Page 39: Procedure 6.7 - Replacing The Line Cord

    C956i, C966i (Gen 06) Treadmill Procedure 6.7 - Replacing the Line Cord Set the treadmill circuit breaker in the “off” position and unplug the treadmill’s line cord from the AC outlet. Remove the treadmill’s hood. Remove the two screws that fastens the AC input panel to the frame,. See Diagram 6.4.

  • Page 40: Procedure 6.8 - Replacing The Input Module

    C956i, C966i (Gen 06) Treadmill Procedure 6.8 - Replacing the Input Module Set the treadmill circuit breaker in the “off” position and unplug the treadmill’s line cord from the AC outlet. Remove the treadmill’s hood. Remove the two screws that fastens the AC input panel to the frame,. See Diagram 6.4.

  • Page 41: Procedure 6.9 - Replacing The End Cap Or Belt Guard

    C956i, C966i (Gen 06) Treadmill Procedure 6.9 - Replacing the End Cap or Belt Guard Set the treadmill circuit breaker in the “off” position and unplug the treadmill’s line cord from the AC outlet. Remove the four screws (2 lower screws, each side) that retain the end cap. Do Not loosen or move the take up roller mounting/adjustment bolts.
  • Page 42 C956i, C966i (Gen 06) Treadmill Diagram 6.8 - Belt Guard Mounting Notch Belt Guard Page 1-42 Page 42...

  • Page 43: Procedure 6.10 - Replacing The Upper Pca

    C956i, C966i (Gen 06) Treadmill Procedure 6.10 - Replacing the Upper PCA Set the treadmill circuit breaker in the “off” position and unplug the treadmill’s line cord from the AC outlet. The PCA’s in the display are static sensitive. They can be damaged if proper static prevention equipment is not used.
  • Page 44 C956i, C966i (Gen 06) Treadmill Press the four display face tabs outwards and disengage the display face from the display. Disconnect the stop switch cable from the upper PCA and remove the display face from the display. Disconnect the Metrics cable, D-pad cable and the keypad cable from the upper PCA. See Diagram 5.1.

  • Page 45: Procedure 6.11 - Replacing The Metrics Pca

    C956i, C966i (Gen 06) Treadmill Procedure 6.11 - Replacing the Metrics PCA Set the treadmill circuit breaker in the “off” position and unplug the treadmill’s line cord from the AC outlet. The PCA’s in the display are static sensitive. They can be damaged if proper static prevention equipment is not used.
  • Page 46 C956i, C966i (Gen 06) Treadmill 16. Replace the display back cover with the hardware removed in step 3. 17. Check treadmill operation per Section 3. Page 1-46 Page 46...

  • Page 47: Procedure 6.12 - Replacing The D-Pad Assembly

    C956i, C966i (Gen 06) Treadmill Procedure 6.12 - Replacing the D-Pad Assembly Set the treadmill circuit breaker in the “off” position and unplug the treadmill’s line cord from the AC outlet. The PCA’s in the display are static sensitive. They can be damaged if proper static prevention equipment is not used.
  • Page 48 C956i, C966i (Gen 06) Treadmill 16. Replace the display back cover with the hardware removed in step 3. 17. Check treadmill operation per Section 3 Page 1-48 Page 48...

  • Page 49: Procedure 6.13 - Replacing The Hr Pca

    C956i, C966i (Gen 06) Treadmill Procedure 6.13 - Replacing the HR PCA Set the treadmill circuit breaker in the “off” position and unplug the treadmill’s line cord from the AC outlet. The PCA’s in the display are static sensitive. They can be damaged if proper static prevention equipment is not used.

  • Page 50: Procedure 6.14 - Replacing The Display Face

    C956i, C966i (Gen 06) Treadmill Procedure 6.14 - Replacing the Display Face Set the treadmill circuit breaker in the “off” position and unplug the treadmill’s line cord from the AC outlet. The PCA’s in the display are static sensitive. They can be damaged if proper static prevention equipment is not used.
  • Page 51 C956i, C966i (Gen 06) Treadmill 15. The red wire in the Metrics and D-pad cables indicate pin 1. Align the red wire in the Metrics and D-pad cables with the pin 1 markings on the upper PCA. Connect the Metrics, D-pad and keypad cables to the upper PCA.
  • Page 52 C956i, C966i (Gen 06) Treadmill Wiring Diagram 7.1 - C956i, C966i 120 Vac Input GRIPS Module METRICS Circuit Breaker D-PAD Line Filter Stop Switch Upper INPUT COMM Power Control Module Incline 100Ω INCLINE Motor Drive OUTPUT Motor Page 1-52 Page 52...
  • Page 53 C956i, C966i (Gen 06) Treadmill Block Diagram 7.2 - C956i, C966i 120 Vac Page 53...
  • Page 54 C956i, C966i (Gen 06) Treadmill Wiring Diagram 7.3 - C956i, C966i 240 Vac Stop Switch Ω Page 1-54 Page 54...
  • Page 55 C956i, C966i (Gen 06) Treadmill Block Diagram 7.4 - C956i, C966i 240 Vac Page 55...

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