Precor C932i Service Manual
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Precor C932i Service Manual

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C932i, C946i Treadmill
C932i, C946i 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.
© 2007 Precor Incorporated
Unauthorized Reproduction and Distribution Prohibited By Law
20077-112
Page 1
20039-112

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  • Page 1 C932i, C946i 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

    Section One - Things you Should Know The C932i, C946i incorporate new drive motor system and display systems. The drive motor is a three phase A.C. motor. The drive motor controller converts a single phase A.C. input into three phase motor control.
  • Page 3 C932i, C946i 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 C932i, C946i 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 4...

  • Page 5: Procedure 2.1 - Accessing The Diagnostic Software

    C932i, C946i Treadmill Procedure 2.1 - Accessing the Diagnostic Software The treadmill's diagnostic software consists of the following modes: • Display Test • Keyboard Test • Heart Rate Test • Belt Speed • Incline Procedure Plug the power cord into the wall outlet, then turn on the treadmill with the circuit breaker.
  • Page 6 Pressing a key on the console will cause the representation of that key to go off. Press all of the keys on the console to ensure that all of the keys are functioning. Press and hold the Clear key (C932i) or BA.C.K key (C946i) for 3 seconds, then the key, HEART RATE will be displayed.
  • Page 7 16. Press the Clear key (C932i) or BA.C.K key (C946i) to exit the incline test. 17. If the incline is greater than 0%, AUTOLEVEL will be displayed and the incline will return to 18. Press the RESET key or the CLEAR key (C932i) or the BA.C.K key (C946i) to exit the hardware validation test.

  • Page 8: Procedure 2.2 - Displaying Information

    The hour meter is also used to provide the “time stamp” for the error code log. 10. Press the Clear key (C932i) or BA.C.K key (C946i) then the key, U-BOOT SW will be displayed 11.
  • Page 9 C932i, C946i Treadmill 12. Press the OK key. The software part number will be displayed as XXXXX-XXX. 13. Press the Clear key (C932i) or BA.C.K key (C946i) then the key, U-BASE SW will be displayed. 14. U-BASE SW display. This display the installed version of upper PCA software.

  • Page 10: Procedure 2.3 - Setting Club Parameters

    SELECT LANGUAGE display. Press the OK key. Use the keys to toggle between the available languages. 10. Press the Clear key (C932i) or BA.C.K key (C946i) then the key, SELECT UNITS will be displayed. 11. SELECT UNITS display. Press the OK key.
  • Page 11 32. Use the keys to toggle between ENABLED and DISABLED. 33. Press the Clear key (C932i) or BA.C.K key (C946i) to exit the HIDDEN PROGRAMS or REMOTE SPEED CONTROL display. 34. Press the Clear key (C932i) or BA.C.K key (C946i) to exit the CLUB PARAMETERS program.

  • Page 12: Procedure 2.4 - Documenting Software Problems

    C932i, C946i 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 C932i, C946i 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

    A/D number is in the range of 3055 to 3065 (C932i) or 3010 to 3020 (C946i). If the A/D number is greater than 3055 to 3065 (C932i) or 3010 to 3020 (C946i), operate the incline until the A/D number is in the range of 3055 to 3065 (C932i) or 3010 to 3020 (C946i).
  • Page 15 C932i, C946i Treadmill Plug the line cord into the wall outlet, set the treadmill circuit breaker in the “on” position. 20077-112 Page 15...
  • Page 16 C932i, C946i 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%. 12. Re-install the hood. Page 16...

  • Page 17: Procedure 4.2 - Adjusting Drive Belt Tension

    C932i, C946i 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 18 C932i, C946i 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 18...

  • Page 19: Procedure 4.3 - Treadmill Belt Cleaning

    C932i, C946i Treadmill Procedure 4.3 - Treadmill Belt Cleaning Procedure: First, check for proper operation of the safety stop key. Stand to one side of the treadmill. Insure that the stop key tether is hanging straight down from the stop key and is not wrapped around the handle bars.
  • Page 20 C932i, C946i Treadmill Turn the power off. Place your hands on the towel and push it up and down the length of the running deck several times to clean the deck. Remove the towel. Safety Stop Key Tether It is recommended that this procedure be performed frequently to extend the life of the running belt and running deck.

  • Page 21: Procedure 5.1 - Troubleshooting The Keypad And Upper Pca

    C932i, C946i 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 22 PCA and the metrics PCA. 11. If you have performed steps 7 - 10 and the metrics PCA still does not illuminate, contact Precor customer support for assistance. 12. Set the treadmill’s on/off switch in the “on” position.
  • Page 23 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 24: Procedure 5.2 - Troubleshooting The Incline System

    C932i, C946i Treadmill Procedure 5.2 - Troubleshooting the Incline System Incline System Description: The incline system on these units consists of an A.C. 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 25 C932i, C946i 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 A.C. line voltage is present, skip to step 12.
  • Page 26 13. If you have performed all of the procedures above and have been unable to correct the problem, call Precor customer service. 14. Set the treadmill’s on/off switch in the “off” position. Remove the incline motor’s connector from the INCLINE connector on the power control module. Visually inspect the incline motor’s wiring and connector for any broken or improperly crimped connections.

  • Page 27: Procedure 5.3 - Troubleshooting Hand Held/Wireless Heart Rate

    C932i, C946i Treadmill Procedure 5.3 - Troubleshooting Hand Held/Wireless 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 unit’s handlebar or from a Polar heart rate chest strap transmitter.
  • Page 28 C932i, C946i Treadmill No hand held reading - Normal chest strap reading Access the diagnostic program (Procedure 3.2). 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 with the opposite hands, right hand on the left handlebar contacts and left hand on the right handlebar contacts.
  • Page 29 C932i, C946i Treadmill No hand held reading - No chest strap reading Access the diagnostic program (Procedure 3.2). Advance to the heart rate display portion of the diagnostic program. Verify that neither a chest strap signal or a hand held signal is being accepted with either a heart rate test transmitter or a chest strap transmitter.

  • Page 30: 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 20 amp A.C. dedicated branch circuit. A 20 amp dedicated branch circuit is defined as: a circuit fed by a 20 amp circuit breaker that feeds a single load and in 120Vac circuits does not share the neutral lead with any other circuit or outlet.
  • Page 31 C932i, C946i 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 32: Procedure 5.5 - Troubleshooting The 3 Phase A.c. Drive Motor System

    2.5Ω. If any of the readings are significantly high or open, replace the drive motor. If you have performed all of the procedures above and have been unable to correct the problem, call Precor customer service. Page 32...
  • Page 33 C932i, C946i Treadmill 10. Connect an A.C. 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 34 C932i, C946i Treadmill Procedure 5.6 - Running Belt & Deck Troubleshooting This procedure is to be used to determine the condition of the running belt and running deck combination. A clamp-on ammeter will be used to measure the treadmill’s A.C. input current under load.
  • Page 35 C932i, C946i Treadmill If the peak A.C. current readings are greater than on a new running belt and deck combination but not approaching 20 amperes, the reading will give you an indication of the running belt and deck combination’s general condition.

  • Page 36: Procedure 6.1 - Replacing The Incline Motor

    C932i, C946i 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 A.C. line cord from the A.C.

  • Page 37: Procedure 6.2 - Replacing The Incline Platform

    C932i, C946i Treadmill Procedure 6.2 - Replacing the Incline Platform Set the treadmill circuit breaker in the “off” position. Remove the A.C. line cord from the A.C. 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 38 C932i, C946i 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, set the on/off switch in the “on” position and thoroughly check it per Section 3.

  • Page 39: Procedure 6.3 - Replacing The Power Control Module

    C932i, C946i Treadmill Procedure 6.3 - Replacing the Power Control Module Set the treadmill’s on/off switch in the “off” position and remove the A.C. line cord from the A.C. outlet. Remove the treadmill’s hood. Disconnect the COMM, INCLINE, INPUT, DB and OUTPUT connectors from the power control module.

  • Page 40: Procedure 6.4 - Replacing Drive Motor

    C932i, C946i 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 A.C. outlet. Remove the hood. Disconnect the drive motor connector from the OUTPUT connector on the power control module.

  • Page 41: Procedure 6.5 - Replacing The Circuit Breaker

    C932i, C946i 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 A.C. outlet. Remove the treadmill’s hood. Remove the two screws that fastens the A.C. input panel to the frame,. See Diagram 6.4.
  • Page 42 C932i, C946i 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 43: Procedure 6.6 - Replacing The Line Filter

    C932i, C946i 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 A.C. outlet. Remove the treadmill’s hood. Remove the two screws that fastens the A.C. input panel to the frame,. See Diagram 6.4.

  • Page 44: Procedure 6.7 - Replacing The Line Cord

    C932i, C946i 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 A.C. outlet. Remove the treadmill’s hood. Remove the two screws that fastens the A.C. input panel to the frame,. See Diagram 6.4.

  • Page 45: Procedure 6.8 - Replacing The Input Module

    C932i, C946i 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 A.C. outlet. Remove the treadmill’s hood. Remove the two screws that fasten the A.C. input panel to the frame. See Diagram 6.4.

  • Page 46: Procedure 6.9 - Replacing The End Cap Or Belt Guard

    C932i, C946i 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 A.C. 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 47 C932i, C946i Treadmill Diagram 6.8 - Belt Guard Mounting Notch Belt Guard 20077-112 Page 47...

  • Page 48: Procedure 6.10 - Replacing The Upper Pca

    C932i, C946i 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 A.C. outlet. The PCA’s in the display are static sensitive. They can be damaged if proper static prevention equipment is not used.
  • Page 49 C932i, C946i Treadmill The display face snaps onto the display with six tabs. One of the tabs is behind the HR PCA. The HR PCA snaps into its mounting. Press its tabs downward and remove the HR PCA from its mounting.

  • Page 50: Procedure 6.11 - Replacing The Metrics Pca

    C932i, C946i 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 A.C. outlet. The PCA’s in the display are static sensitive. They can be damaged if proper static prevention equipment is not used.
  • Page 51 C932i, C946i Treadmill 15. Snap the display cap into place on the display. 16. Replace the display back cover by sliding the lower portion of the cover over the targas, then press the cover into place. Fasten the cover with the hardware removed in step 3.

  • Page 52: Procedure 6.12 - Replacing The D-Pad Assembly

    C932i, C946i 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 A.C. outlet. The PCA’s in the display are static sensitive. They can be damaged if proper static prevention equipment is not used.
  • Page 53 C932i, C946i Treadmill 15. Snap the display cap into place on the display. 16. Replace the display back cover by sliding the lower portion of the cover over the targas, then press the cover into place. Fasten the cover with the hardware removed in step 3.

  • Page 54: Procedure 6.13 - Replacing The Hr Pca

    C932i, C946i 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 A.C. outlet. The PCA’s in the display are static sensitive. They can be damaged if proper static prevention equipment is not used.

  • Page 55: Procedure 6.14 - Replacing The Display Face

    C932i, C946i 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 A.C. outlet. The PCA’s in the display are static sensitive. They can be damaged if proper static prevention equipment is not used.
  • Page 56 C932i, C946i 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 57: Procedure 6.15 - Drive Roller Replacement

    C932i, C946i Treadmill Procedure 6.15 - Drive Roller Replacement Note: Two running belt gauges, Precor part number 20007-101, are required. It is important that this procedure be followed to maintain correct drive belt and running belt tension. Over tensioning the belt will lead to premature running belt wear, premature driver roller bearing failure and premature take up roller bearing failure.
  • Page 58 C932i, C946i Treadmill Place the drive belt on the new drive roller and use as a handle to slide the drive roller through the running belt and into place. Hand tighten both drive roller mounting bolts. Make sure the running belt is in the center of the deck, the spacing should be the same on each side of the running belt to the edge of the running deck.
  • Page 59 C932i, C946i Treadmill Walk the drive belt onto the drive roller pulley by rotating the drive motor flywheel. Be sure the belt is fully seated in the grooves of both pulleys and correctly aligned. A drive belt tension gauge should read 100-120 pounds. The drive belt de-tension after use. A range of 80-90 pounds after the belt has been installed for a while is acceptable.
  • Page 60 C932i, C946i Treadmill 11. Carefully move the running belt so that you can see the dials easily while tightening the take up roller mounting bolts. Tighten the take up roller mounting bolts alternately in order to evenly tighten the running belt. Tighten bolts until the gauges read .55%, which is five and 1/2 lines past the number 3.

  • Page 61: Procedure 6.16 - Take Up Roller Replacement

    C932i, C946i Treadmill Procedure 6.16 - Take Up Roller Replacement Note: Two running belt gauges, Precor part number 20007-101, are required. It is important that this procedure be followed to maintain correct drive belt and running belt tension. Over tensioning the belt will lead to premature running belt wear, premature driver roller bearing failure and premature take up roller bearing failure.
  • Page 62 C932i, C946i Treadmill bracket. Using a measuring tape, measure the distance from the front of the left side drive roller shaft to the front of the frame cross beam and make note of that measurement. Tighten the right side drive roller bolt until it measures the same distance as the left side drive roller, shaft to frame.
  • Page 63 C932i, C946i Treadmill 13. Remove both gauges from the running belt. Running Belt Tracking Adjustment 14. Place a reference point on the deck right next to one edge of the running belt so that any side to side movement can be observed, a white grease marker works well. Start the treadmill and set the speed to 1 mph.

  • Page 64: Procedure 6.17 - Running Belt And/Or Deck Replacement

    C932i, C946i Treadmill Procedure 6.17 - Running Belt and/or Deck Replacement Note: Two running belt gauges, Precor part number 20007-101, are required. It is important that this procedure be followed to maintain correct drive belt and running belt tension. Over tensioning the belt will lead to premature running belt wear, premature driver roller bearing failure and premature take up roller bearing failure.
  • Page 65 C932i, C946i Treadmill Remove the four bolts and the retaining plates that hold the deck to the frame. Lift the deck and running belt up and away from the treadmill. Remove both drive roller mounting bolts releasing the tension evenly on both sides.
  • Page 66 C932i, C946i Treadmill If the deck has already been flipped replace it with a new deck. Make sure that the new deck surface is clear of debris. Ensure the new deck is installed with the inserts on the bottom of the deck.
  • Page 67 C932i, C946i Treadmill 10. Slide the running deck back into position over the running deck pivot bracket. Align the bottom plate and pivot bracket holes with the running deck bolt holes. Replace the plates and the running deck mounting bolts removed in step 7. Only hand tighten the bolts at this time.
  • Page 68 C932i, C946i Treadmill 13. Tighten the bolts so the deck is secure. Torque the bolts to 150 inch pounds. 14. Make sure the running belt is in the center of the deck, the spacing should be the same on each side of the running belt to the edge of the running deck.
  • Page 69 C932i, C946i Treadmill 16. Walk the drive belt onto the drive roller pulley by rotating the drive motor flywheel. Be sure the belt is fully seated in the grooves of both pulleys and correctly aligned. A drive belt tension gauge should read 100-120 pounds.
  • Page 70 C932i, C946i Treadmill 17. Move the running belt so that the seam is underneath the treadmill. Place a running belt tension gauge on each side of the running belt parallel from each other. The gauges have a fixed side and a movable side.
  • Page 71 C932i, C946i Treadmill drifting stops. The adjustments should only be done in 1/4 turn increments. NOTE: ONLY use the right side take up roller mounting bolt to adjust tracking. 21. Increase the speed to 3 mph for a minute, then 6 mph, 9 mph and finally 12 mph, making any small adjustments as needed.
  • Page 72 C932i, C946i Treadmill Wiring Diagram 7.1 - C932i, C946i 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 72...
  • Page 73 C932i, C946i Treadmill Block Diagram 7.2 - C932i, C946i 120 Vac 20077-112 Page 73...
  • Page 74 C932i, C946i Treadmill Wiring Diagram 7.3 - C932i, C946i 240 Vac Stop Switch Ω Page 74...
  • Page 75 C932i, C946i Treadmill Block Diagram 7.4 - C932i, C946i 240 Vac 20077-112 Page 75...

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