Precor 9.23 Service Manual
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Precor 9.23 Service Manual

Precor 9.23 Service Manual

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9.23, 9.27 Treadmill
9.23, 9.27 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.
© 2004 Precor Incorporated
Unauthorized Reproduction and Distribution Prohibited By Law
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  • Page 1 9.23, 9.27 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

    About This Appendix Section One, Things You Should Know. This section includes technical specifications. Read this section, as well as the 9.23, 9.27 Treadmill Owner’s Manual, before you perform the maintenance procedures in this manual. Section Two, Software Features. Precor treadmills are programmed with several diagnostic and setup features.

  • Page 3: Technical Specifications

    9.23, 9.27 Treadmill Technical Specifications Length: 76.5 inches (194.3 cm.) Width: 30.5 inches (77.5 cm.) Height: 55 inches (140 cm.) Running surface: 20 inches by 59 inches (51 cm. by 149.9 cm.) Motor: 2.75 hp. continuous duty DC Speed: 0.5 to 12 mph (0.8 to 19.3 kph)

  • Page 4: Procedure 2.1 - Error Codes And Lower Pca Indicators

    Procedure 2.1 - Error Codes and Lower PCA Indicators Error Codes: The error codes used by the 9.23 and 9.27 treadmills do not conform to Precor standardized error codes and are unique to these models. The 9.23, 9.27 error codes are listed and defined below.
  • Page 5 9.23, 9.27 Treadmill LIMIT - The LIMIT LED indicator will illuminate when too much current is being demanded from the drive motor power controller circuit. If the drive motor’s instantaneous current exceeds 28 amps, the current limit circuit is activated. When current limit is activated the drive motor current and speed can not be increased.
  • Page 6 Press the QUICKSTART to toggle the display to the model number display. The model will be displayed in the time window in the format 23.XX or 27.XX. Press the STOP key to exit this program. Diagram 2.1 - 9.23 Display Safety Key Page 6...

  • Page 7: Procedure 2.3 - Accessing The Upper Pca To Lower Pca Initialization Program

    9.23, 9.27 Treadmill Procedure 2.3 - Accessing the Upper PCA to Lower PCA Initialization Program Warning During this procedure the running belt will be accelerated to the treadmill’s maximum (12.0 mph) speed. Do not stand on the treadmill’s running belt during this procedure.

  • Page 8: Procedure 2.4 - U.s Standard/Metric Selection

    9.23, 9.27 Treadmill Procedure 2.4 - U.S Standard/Metric Selection Note: Only upper software version 2.2 and greater contain the option of selecting U.S. Standard or metric measurements. Within 2 seconds of “power up” press the STOP, INCLINE and SPEED keys sequentially.

  • Page 9: Procedure 2.5 - Documenting Software Problems

    9.23, 9.27 Treadmill Procedure 2.5 - 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. Provide the model number as accessed in Procedure 2.2.
  • Page 10 9.23, 9.27 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 11: Procedure 4.1 - Calibrating The Lift Motor

    9.23, 9.27 Treadmill Procedure 4.1 - Calibrating the Lift Motor Note: This calibration procedure must be performed whenever the lift motor has been replaced or the lift calibration has been disturbed. Set the on/off switch in the “off” position and unplug the AC power cord from the AC outlet.
  • Page 12 9.23, 9.27 Treadmill Set the treadmill in its normal upright position. Set the on/off switch in the “on” position. Place the treadmill in the manual program and operate the incline several times between its minimum and maximum incline positions to ensure that the incline is operating normally throughout its entire range.

  • Page 13: Procedure 4.2 - Adjusting Drive Belt Tension

    9.23, 9.27 Treadmill Procedure 4.2 - Adjusting Drive Belt Tension Set the treadmill on/off switch in the “off” position and unplug the AC power cord from the AC outlet. Remove the hood. Place the drive belt tension gauge on the drive belt as shown in Diagram 4.2.
  • Page 14 9.23, 9.27 Treadmill Diagram 4.3 - Drive Motor Mounting Plug the AC power cord into the AC outlet and set the treadmill circuit breaker in the “on” position. Check treadmill operation per Section 3. Page 14...

  • Page 15: Procedure 5.1 - Troubleshooting The Keypad

    9.23, 9.27 Treadmill Procedure 5.1 - Troubleshooting the Keypad Note: All resistance measurements must be performed with power removed from the treadmill. Performing resistance measurements with voltage applied may damage your ohmmeter. Procedure There are two possible fault modes for the keypad. The key may not function or it may be stuck permanently operated.
  • Page 16 If all of the above measurements are good but a keypad key is still not functioning, replace the upper PCA per Procedure 6.11. If you have performed all of the procedures above and have been unable to correct the problem, call Precor customer support. Page 16...

  • Page 17: Procedure 5.2 - Troubleshooting The Lift System

    9.23, 9.27 Treadmill Procedure 5.2 - Troubleshooting the Lift System Lift System Description: The lift system on these units consists of an AC line voltage driven lift motor (120 Vac), and an internal 10 KΩ potentiometer for lift position identification. The lift motor contains two motor windings, one to operate the motor in an “upward”...
  • Page 18 Procedure 6.1. 12. If you have performed all of the procedures above and have been unable to correct the problem, call Precor customer support. 13. Remove Jk3 connector from the lower PCA, refer to Diagram 5.2. With an ohmmeter, measure between pins 1 and 3 of JK3 (red and black wires).
  • Page 19 17. If the measurements in step 16 are still significantly incorrect, replace the incline motor per Procedure 6.1. 18. If you have performed all of the procedures above and have been unable to correct the problem, call Precor customer support. Page 19...

  • Page 20: Procedure 5.3 - Troubleshooting The Speed Sensor

    If the measurements in step 5 are now correct, replace the drive roller. If the measurements are still incorrect, replace the speed sensor per Procedure 6.4. If you have performed all of the procedures above and have been unable to correct the problem, call Precor customer support. Page 20...

  • Page 21: Procedure 5.4 - The Display Does Not Illuminate

    9.23, 9.27 Treadmill Procedure 5.4 - The Display does not Illuminate Set the on/off switch in the “off” position and insert the AC power cord into a 120 Vac outlet. The on/off switch should illuminate. If the on/off switch illuminates skip to step 5. If the on/off switch does not illuminate continue with step 2.
  • Page 22 9.23, 9.27 Treadmill Diagram 5.5 - Circuit Breaker and On/Off Switch Circuit Breaker On/Off Switch Reset Button AC Power Cord Page 22...
  • Page 23 PCA JK1 connector. If the reading is still 0 Vdc or significantly low, replace the interconnect cable. If the reading is now correct, replace the upper PCA. 17. If you have performed all of the procedures above and have been unable to correct the problem, call Precor customer support. Page 23...

  • Page 24: Procedure 5.5 - Troubleshooting The Safety Key Circuit

    9.23, 9.27 Treadmill Procedure 5.5 - Troubleshooting the Safety Key Circuit Note: The safety key switch is a reed switch that is operated by a magnet on the safety key. If the safety key circuit is not functioning correctly the display will not illuminate and the treadmill can not be operated.

  • Page 25: Procedure 5.6 - Troubleshooting The Drive Motor System

    9.23, 9.27 Treadmill Procedure 5.6 - Troubleshooting the Drive Motor System Note: The drive motor controller is a PWM (pulse width modulated) system. The system incorporates current limit (set at 28 amps of drive motor current). The lower PCA has several LED indicators to depict lower PCA status.
  • Page 26 14. If the drive motor does not function normally with the bypass cable installed, replace the lower PCA per Procedure 6.5. 15. If you have performed all of the procedures above and have been unable to correct the problem, call Precor customer support. Page 26...

  • Page 27: Procedure 5.7 - Troubleshooting The External A.c. Power Source

    Procedure 5.7 - Troubleshooting the External A.C. Power Source It is extremely important that any Precor treadmill be connected to and operated on a dedicated 15 amp A.C. circuit. A 15 amp dedicated circuit is defined as: a circuit fed by a 15 amp circuit breaker that feeds a single load.
  • Page 28 9.23, 9.27 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 6.1 - Replacing The Incline Motor

    9.23, 9.27 Treadmill Procedure 6.1 - Replacing the Incline Motor Set the on/off switch in the “off” position and remove the AC power cord from the AC outlet. Remove the treadmill’s hood. Disconnect the JK3 and JK4 cables from the lower PCA. Disconnect the incline motor’s frame ground (green wire) from the frame.

  • Page 30: Procedure 6.2 - Replacing The Incline Platform

    9.23, 9.27 Treadmill Procedure 6.2 - Replacing the Incline Platform Set the treadmill’s on/off switch in the “off” position. Remove the AC power cord from the AC outlet. Carefully, lay the treadmill on either it’s left or right side. Remove the bolt that fastens the incline motor to the lift platform. Care must be taken throughout this procedure to not allow the incline motor’s lift tube to rotate.
  • Page 31 9.23, 9.27 Treadmill Install the rubber bumpers on the replacement lift platform with the hardware removed in step 6. Install both wheels on the replacement lift platform with the hardware removed in step 5. Set the replacement lift platform in its mounting position and fasten it with the hardware removed in step 4.

  • Page 32: Procedure 6.3 - Replacing The Lower Pca

    9.23, 9.27 Treadmill Procedure 6.3 - Replacing the Lower PCA Note: If the lower PCA is replaced, the upper PCA to lower PCA initialization procedure (Procedure 2.3) must be performed to ensure proper operation. Set the treadmill’s on/off switch in the “off” position and remove the AC power cord from the AC outlet.

  • Page 33: Procedure 6.4 - Replacing The Speed Sensor

    9.23, 9.27 Treadmill Procedure 6.4 - Replacing the Speed Sensor Set the treadmill’s on/off switch in the “off” position. Remove the AC power cord from the AC outlet. Disconnect the JK2 connector from the lower PCA, refer to Diagram 5.2.

  • Page 34: Procedure 6.5 - Replacing Drive Motor

    9.23, 9.27 Treadmill Procedure 6.5 - Replacing Drive Motor Set the treadmill’s on/off switch in the “off” position and remove the treadmill’s power cord from the AC outlet. Remove the hood. The drive motor and flywheel are balanced as a matched pair. Since the flywheel is balanced to a specific motor, flywheels should not be removed from one motor and installed on a different motor.
  • Page 35 9.23, 9.27 Treadmill Connect the black wire removed in step 3 to the T4 (M-) terminal of the lower PCA, the red wire removed in step 3 to the T3 (M+) terminal of the lower PCA and the green -yellow lead to its frame ground termination.

  • Page 36: Procedure 6.6 - Replacing The Circuit Breaker

    9.23, 9.27 Treadmill Procedure 6.6 - Replacing the Circuit Breaker Set the treadmill’s on/off switch in the “off” position and remove the treadmill’s power cord from the AC outlet. Disconnect both red leads from the circuit breaker. Refer to diagram 5.5.

  • Page 37: Procedure 6.7 - Replacing The On/Off Switch

    9.23, 9.27 Treadmill Procedure 6.7 - Replacing the On/Off Switch Set the treadmill’s on/off switch in the “off” position and remove the treadmill’s power cord from the AC outlet. Remove the treadmill’s hood. Remove the red, re-black, white and black wires from the on/off switch.
  • Page 38 9.23, 9.27 Treadmill Connect the white wire from the AC power cord to the lower left had terminal of the on/off switch, the black wire from the AC power cord to the lower right hand terminal of the on/off switch, the red wire from the circuit breaker to the upper left hand terminal of the on./off switch and the red-black wire from the lower PCA to the upper right hand terminal of on/off switch.

  • Page 39: Procedure 6.8 - Replacing The Drive Motor Brushes

    9.23, 9.27 Treadmill Procedure 6.8 - Replacing the Drive Motor Brushes Set the treadmill’s on/off switch in the “off” position and remove the treadmill’s power cord from the AC outlet. Remove the treadmill’s hood. Unsnap both brush covers (front and rear of the drive motor) from the drive motor. Refer to Diagram 6.8.

  • Page 40: Procedure 6.9 - Replacing The Prom

    Note: If the lower PCA is replaced, the upper PCA to lower PCA initialization procedure (Procedure 2.3) must be performed to ensure proper operation. Anti-static kits (part number 20024-101) can be ordered from Precor. The PROM and the associated printed circuit assembly (PCA) are static sensitive. Anti- static devices must be used and all anti-static precautions must be followed during this procedure.
  • Page 41 9.23, 9.27 Treadmill Notch PLCC44 Notch Perform Procedure 2.3, upper PCA to lower PCA initialization. Page 41...

  • Page 42: Procedure 6.10 - Replacing The Console With Keypad

    9.23, 9.27 Treadmill Procedure 6.10 - Replacing the Console with Keypad Note: The keypad is furnished as part of the console, the console must be replaced when a replacement keypad is required. Set the treadmill’s on/off switch in the “off” position and remove the treadmill’s power cord from the AC outlet.
  • Page 43 9.23, 9.27 Treadmill Remove the five screws that fasten the upper PCA to the console and remove the upper PCA from the console. 10. Set the upper PCA in its mounting position in the replacement console and fasten it with the hardware removed in step 9.

  • Page 44: Procedure 6.11 - Replacing The Upper Pca

    9.23, 9.27 Treadmill Procedure 6.11 - Replacing the Upper PCA Note: If the lower PCA is replaced, the upper PCA to lower PCA initialization procedure (Procedure 2.3) must be performed to ensure proper operation. Set the treadmill’s on/off switch in the “off” position and remove the treadmill’s power cord from the AC outlet.

  • Page 45: Procedure 6.12 - Replacing The Interconnect Cable

    9.23, 9.27 Treadmill Procedure 6.12 - Replacing the Interconnect Cable Set the treadmill’s on/off switch in the “off” position and remove the treadmill’s power cord from the AC outlet. Remove the treadmill’s hood. Remove the four screws that fasten the backplate to the rear of the console and remove the backplate.

  • Page 46: Procedure 6.13 - Replacing The Safety Key Switch

    9.23, 9.27 Treadmill Procedure 6.13 - Replacing the Safety Key Switch Set the treadmill’s on/off switch in the “off” position and remove the treadmill’s power cord from the AC outlet. Remove the six screws that fasten the safety switch cover to the console and remove the safety switch cover.

  • Page 47: Wiring Diagram 7.1 - 9.23, 9.27 Treadmills

    9.23, 9.27 Treadmill Wiring Diagram 7.1 - 9.23, 9.27 Treadmills Page 47...

  • Page 48: Block Diagram 7.2 - 9.23, 9.27 Treadmills

    9.23, 9.27 Treadmill Block Diagram 7.2 - 9.23, 9.27 Treadmills Page 48...

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