Precor GEN06 Series C952 Service Manual
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Precor GEN06 Series C952 Service Manual

Precor GEN06 Series C952 Service Manual

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Service Manual

TRM10/GEN06 Treadmill
120 VAC and 240 VAC

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Summary of Contents for Precor GEN06 Series C952

  • Page 1: Service Manual

    Service Manual TRM10/GEN06 Treadmill 120 VAC and 240 VAC...

  • Page 2: Table Of Contents

    Contents 1    Introduction General Information Orientation Tools Parts Lubrication Cleaning Solutions Electrical Requirements Safety Guidelines Safety guideline you need to know and follow: 2    Operation Verification Operation Verification Procedure Operation Verification Checklist 3    Standard Service Software About Service Access Codes Accessing the Service Software Navigating the Service Software Menus Hardware Validation - Diagnostic Tests (51765761) Club Parameter - Settings (5651565)
  • Page 3 Procedure Running Belt Tension and Tracking Adjustment About Procedure 5    Replacement Procedures Available Replacement Procedures Auto Stop Magnet Replacement About Procedure Auto Stop Sensor Replacement About Procedure Circuit Breaker Replacement About Procedure Drive Belt Replacement About Procedure Drive Motor Replacement About Procedure Drive Roller Replacement About...
  • Page 4 Incline Lift Platform Replacement About Procedure Input Module Replacement About Procedure Line Filter Replacement About Procedure Power Control Module Replacement About Procedure Power Cord Replacement About Procedure Running Belt and Deck Replacement About Procedure Take Up Roller Replacement About Procedure 6    Troubleshooting About Introduction to Treadmill Troubleshooting...
  • Page 5 Error Log System Troubleshooting Procedures Available Troubleshooting Procedures Auto Stop Troubleshooting Tripped Circuit Breaker Communications Error Troubleshooting No Power to the Console Troubleshooting Drive Motor System Troubleshooting E-Stop Not Communicating Heart Rate Monitor Troubleshooting Incline System Troubleshooting Input Power and Machine Controls Troubleshooting Running Belt and Deck Troubleshooting Tripped Circuit Breaker 7    Preventive Maintenance...
  • Page 6 Copyright Appendix B : Notices and Safety Trademarks Intellectual Property Warranty Safety Instruction Safety Notices (Undefined variable: TRM700-16Base.ServiceManualTitle)

  • Page 7: 1    Introduction

    1 Introduction 1    Introduction If you are not a Precor certified servicer, you must not attempt to service any Precor Product. Call your dealer for service information. WARNING: This service documentation is for use by Precor certified servicer pro- viders only. Personal injury can result from electrical shock and/or mechanical moving parts.
  • Page 8 1 Introduction "Troubleshooting" on page 68 "Theory of Operation" on page 103 (Undefined variable: TRM700-16Base.ServiceManualTitle)

  • Page 9: General Information

    Parts IMPORTANT: Always purchase OEM replacement parts and hardware from Precor. If you use parts not approved by Precor, you could void the Precor Limited Warranty. Use of parts not approved by Precor may cause injury. Exploded View Diagram and Parts List There is a copy of the parts Exploded View Diagram and Parts Identification List included in "Parts"...

  • Page 10: Lubrication

    1 Introduction General Information most current parts information including the Exploded View Diagram and Parts Identification List . Precor Connect Partner website Exploded View Diagram and Parts list, see "Parts" on page 111. Lubrication Use only synthetic lubricants such as Mobile 1 Synthetic grease or Super Lube with Teflon.
  • Page 11 1 Introduction General Information Dedicated Branch Circuit It is required that the treadmill be connected to and operated on a dedicated 20 amp AC branch circuit. A Dedicated Branch Circuit is defined as a circuit fed by a single circuit breaker feeding a single load, with a single non-shared neutral providing a return line.

  • Page 12: Safety Guidelines

    1 Introduction Safety Guidelines Safety Guidelines WARNING: Only Precor certified servicers and technicians are permitted to service Precor products. Personal injury can result from electrical shock and/or mechanical moving parts. Safety guideline you need to know and follow: Read and follow all Warning notices to protect yourself from personal injury.
  • Page 13 1 Introduction Safety Guidelines Remove neck ties, and Do not wear loose clothing See Also "Safety Instruction" on page ii "Safety Notices" on page ii (Undefined variable: TRM700-16Base.ServiceManualTitle)

  • Page 14: 2    Operation Verification

    2 Operation Verification Operation Verification Procedure 2    Operation Verification This section provides a method of verifying the TRM10/GEN06 Treadmill Base operation. Check the treadmill operation at the end of a maintenance procedure and when it is necessary to ensure that the treadmill is operating properly. "Operation Verification Procedure"...

  • Page 15: Operation Verification Checklist

    2 Operation Verification Operation Verification Checklist 9. Concentrate on the feel of the running belt, the sound of the drive motor and rollers. Be on the alert for unusual noises, smells or vibrations. 10. Observe the LED’s on the console. Make sure that each LED lights as the information corresponding to that LED is displayed on the console.

  • Page 16: 3    Standard Service Software

    3    Standard Service Software About Standard access codes are used across Precor cardio product lines to access a set of com- mon service software functional modes used to retrieve equipment product and usage inform- ation, manage club settings, and hardware maintenance validation/diagnostic test software.
  • Page 17 3 Standard Service Software Accessing the Service Software software. Standard, P10, and P30 Consoles To access the service software: Press either the STOP, PAUSE, or RESET key. Sequentially type in the service access code using the numeric keypad. NOTE: The access code must be correctly and quickly entered or the process will abort.
  • Page 18 3 Standard Service Software Accessing the Service Software Press either the STOP, PAUSE, or RESET key. Sequentially type in the service access code using the following control keys to rep- resent an equivalent numeric value: 1 = Workouts key 5 = Enter key 6 = Up key 7 = Down key NOTE: The access code must be correctly and quickly entered or the process will...

  • Page 19: Navigating The Service Software Menus

    3 Standard Service Software Navigating the Service Software Menus To access the Hardware Validation (5,1,7,6,5,7,6,1) diagnostic test page:  Select System Settings ( Settings page) >System Test ( System Settings page) > opens Diagnostic tests and hardware calibration page. Navigating the Service Software Menus Console hardkeys and softkeys used to navigate the service software menus.
  • Page 20 3 Standard Service Software Hardware Validation - Diagnostic Tests (51765761) DIAGNOSTIC TEST DESCRIPTION TEST Press the back button to exit this test. Tests the belt speed in 0.1 mph increments showing the required Input Belt Test Voltage, Input Current to the treadmill, the Output Voltage, and Drive Motor current at each speed.

  • Page 21: Club Parameter - Settings (5651565)

    3 Standard Service Software Club Parameter - Settings (5651565) DIAGNOSTIC TEST DESCRIPTION TEST Numeric Backlight Tests the backlight level on the speed and incline parameter displays. Test Numeric Display Tests the speed and incline numeric indicators. Test Heart Rate Test Tests the Hands ON/OFF Status, Raw and Filtered pulse values.
  • Page 22 3 Standard Service Software Club Parameter - Settings (5651565) CLUB PARAMETER DESCRIPTION SET METRICS Default: none DEFAULT Sets a metric that may be of specific importance to the specific facil- ity or fitness trainer. The selected metric will scroll across the screen at regular intervals during the workout.
  • Page 23 3 Standard Service Software Club Parameter - Settings (5651565) SYSTEM SETTINGS DESCRIPTION MENU LANGUAGE Sets the default language for all workouts on this machine. Lan- guage for single use workouts can still be set by the user from the workout options. SET UNITS Range: U.S, Metric Default: U.S.

  • Page 24: Information Display

    3 Standard Service Software Information Display (65) SYSTEM SETTINGS DESCRIPTION MENU REGISTER Used to register the P80 after Connectivity interface has been con- EQUIPMENT figured and established. MANAGE SETTINGS Used to save your equipment settings to a USB flash drive, or to import settings from a USB flash drive.
  • Page 25 3 Standard Service Software Information Display (65) METRIC DESCRIPTION TIP: You can quickly access the Error log by holding down the PAUSE key. Will show the STUCK KEY message when there are no logged error codes. Standard, P80 consoles: The P80 does not support service access code 65. The equipment usage, SW, and Error Log information is accessed from various submenus on the Settings page (access code 51765761).

  • Page 26: 4    Adjustment Procedures

    4 Adjustment Procedures Available Adjustment Procedures 4    Adjustment Procedures Adjustment procedures provide you with the step-by-step adjustment instructions to bring sys- tems and components into specification. Perform the adjustment procedures whenever a trouble symptom points to a particular component and after a major component is removed/re- placed.

  • Page 27: Drive Belt Tension & Alignment Adjustment

    4 Adjustment Procedures Drive Belt Tension & Alignment Adjustment Drive Belt Tension & Alignment Adjustment About This procedure provides instruction to verify and make adjustments to the Drive Belt tension. The Drive Belt tension should be verified anytime the drive belt is removed or replaced. NOTE: This procedure assumes that the drive belt has been installed and seated onto the drive roller and drive motor pulleys.
  • Page 28 4 Adjustment Procedures Drive Belt Tension & Alignment Adjustment 3. Verify that the tension measurement is within the Range Limit specification, see Drive Belt Tension Specification table. Note that there is a separate Range Limit specification for New and Used belt installations. a.
  • Page 29 4 Adjustment Procedures Drive Belt Tension & Alignment Adjustment a. If the tension is not within specification, repeat the adjustment process. b. If the tension is within specification, continue procedure. 8. Torque the drive motor mount bolts to 204 in-lbs (17 ft-lbs, 23 N-m). 9.

  • Page 30: Lift Motor Calibration

    4 Adjustment Procedures Lift Motor Calibration Lift Motor Calibration About This procedure provides instruction to verify and calibrate the Lift Motor and incline system. The Lift Motor calibration should be verified anytime the Lift Motor circuit breaker fails or is replaced or any incline system component is replaced.
  • Page 31 4 Adjustment Procedures Lift Motor Calibration 6. Re-Install the actuator tube into the incline platform mounting bracket. It may be neces- sary to slightly rotate the actuator tube to align the clevis pin mounting holes. Choose the adjustment direction that will minimize the change to the actuator tube reference dis- tance.

  • Page 32: Running Belt Tension And Tracking Adjustment

    4 Adjustment Procedures Running Belt Tension and Tracking Adjustment Running Belt Tension and Tracking Adjustment About This procedure provides instructions to verify and make adjustments to the running belt ten- sion and tracking alignment. The running belt tension and tracking should be verified anytime the running belt alignment is not centered or the running belt is replaced.
  • Page 33 4 Adjustment Procedures Running Belt Tension and Tracking Adjustment NOTE: Setting the gauge to a 3 reference value centers the gauge head travel allow- ing +/- movement without impeding travel. 1. Alternately tighten the right and left take-up roller mounting bolts in increments of 0.2% so that the roller is evenly tensioned to the final 0.55% (dial 3.55) specification as fol- lows: a.
  • Page 34 4 Adjustment Procedures Running Belt Tension and Tracking Adjustment 2. Increase the speed to 9 mph (14 kph) and then 12 mph (19 KPH) making sure that the tracking remains centered, make small adjustments as needed. 3. Verify that the treadmill is level, adjust as necessary. 4.

  • Page 35: 5    Replacement Procedures

    5 Replacement Procedures Available Replacement Procedures 5    Replacement Procedures Replacement procedures provide you with the step-by-step instructions to remove and replace system components. Available Replacement Procedures "Auto Stop Magnet Replacement" on the next page "Auto Stop Sensor Replacement" on page 32 "Circuit Breaker Replacement" on page 34 "Drive Belt Replacement"...

  • Page 36: Auto Stop Magnet Replacement

    Contact PRECOR customer service for repair or replacement. 1. Set the treadmill circuit breaker to OFF and unplug the treadmill’s power cord.
  • Page 37 5 Replacement Procedures Auto Stop Magnet Replacement 7. Align the replacement magnet on the running deck and then secure the magnet to the running deck using the two push fasteners. 8. 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.

  • Page 38: Auto Stop Sensor Replacement

    Contact PRECOR customer service for repair or replacement. 1. Set the treadmill circuit breaker to OFF and unplug the treadmill’s power cord.
  • Page 39 5 Replacement Procedures Auto Stop Sensor Replacement 7. Reconnect the Auto Stop Cable to the Auto Stop Sensor Assembly. 8. Replace front hood and side step cover. 9. Connect power cord and Switch the input power ON. 10. Verify the Auto Stop function by doing the Auto Stop diagnostics test, see "Hardware Validation - Diagnostic Tests (51765761)"...

  • Page 40: Circuit Breaker Replacement

    5 Replacement Procedures Circuit Breaker Replacement Circuit Breaker Replacement About This procedure provides instruction to remove and replace the ON/OFF Circuit Breaker. Procedure Review entire procedure before starting. 1. Set the treadmill circuit breaker to OFF and unplug the treadmill’s power cord from the AC outlet.
  • Page 41 5 Replacement Procedures Circuit Breaker Replacement LOAD side of the circuit breaker facing the AC line filter. Install the circuit breaker using the previously removed fasteners. 8. Install wire connections as follows for the 120 VAC and 240 VAC models: a.

  • Page 42: Drive Belt Replacement

    About This procedure provides instruction to remove and replace the Drive Belt. CAUTION: 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 run- ning belt tension. Improper tensioning of the belt will lead to premature running belt wear, premature driver roller bearing failure and premature Take Up Roller bearing failure.
  • Page 43 5 Replacement Procedures Drive Belt Replacement 7. Use the drive belt to help lift the roller out of the mounting bracket and then remove the belt off the drive roller pulley, Remove the belt from the treadmill. Drive Belt Installation 8.
  • Page 44 5 Replacement Procedures Drive Belt Replacement 12. Adjust the right drive roller mounting bolt so that the right drive roller shaft to frame cross beam distance equals the left side reference distance. This adjustment will make sure that the drive roller is positioned parallel and square to the front of the frame. 13.
  • Page 45 5 Replacement Procedures Drive Belt Replacement Tension and Tracking Adjustment" on page 26 procedure. 16. Replace the belt guard cover ensuring the tabs are firmly locked into position on the Take Up Roller shaft, see "End Cap & Belt Guard Cover Replacement" on page 46.

  • Page 46: Drive Motor Replacement

    5 Replacement Procedures Drive Motor Replacement Drive Motor Replacement About This procedure provides instruction to remove and replace the Drive Motor. Procedure Review entire procedure before starting. 1. Switch the input power OFF and unplug the power cord. 2. Remove the front hood. 3.
  • Page 47 5 Replacement Procedures Drive Motor Replacement 7. Set the replacement drive motor onto the frame. Align the motor mount plate to the ref- erence position marks, insert and tighten the four mounting bolts to the torque 204 in-lbs (17 ft-lbs, 23 N-m). 8.

  • Page 48: Drive Roller Replacement

    About This procedure provides instruction to remove and replace the Drive Roller. CAUTION: 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 run- ning belt tension. Improper tensioning of the belt will lead to premature running belt wear, premature driver roller bearing failure and premature Take Up Roller bearing failure.
  • Page 49 5 Replacement Procedures Drive Roller Replacement 6. Use the drive belt to help lift the roller out of the mounting bracket and then remove the belt off the drive roller pulley, 7. Remove the drive roller. Installing the drive roller 8.
  • Page 50 5 Replacement Procedures Drive Roller Replacement 13. Adjust the right drive roller mounting bolt so that the right drive roller shaft to frame cross beam distance equals the left side reference distance. This adjustment will make sure that the drive roller is positioned parallel and square to the front of the frame. 14.
  • Page 51 5 Replacement Procedures Drive Roller Replacement Tension and Tracking Adjustment" on page 26 procedure. 17. Replace the belt guard cover ensuring the tabs are firmly locked into position on the Take Up Roller shaft (see "End Cap & Belt Guard Cover Replacement" on the next page).

  • Page 52: End Cap & Belt Guard Cover Replacement

    5 Replacement Procedures End Cap & Belt Guard Cover Replacement End Cap & Belt Guard Cover Replacement About This procedure provides instruction to remove and replace the End Cap and belt guard cov- ers. Procedure Review entire procedure before starting. 1.
  • Page 53 5 Replacement Procedures End Cap & Belt Guard Cover Replacement 4. To remove the belt guard, press inwards on the belt guard to remove the belt guard tabs from the Take Up Roller mounts. Slide the belt guard off of the treadmill. 5.

  • Page 54: Incline Lift Motor Replacement

    5 Replacement Procedures Incline Lift Motor Replacement Incline Lift Motor Replacement About This procedure provides instruction to remove and replace the Lift Motor. Procedure Review entire procedure before starting. Calibrate the replacement Lift Motor prior to installation 2. Switch the input power OFF. 3.
  • Page 55 5 Replacement Procedures Incline Lift Motor Replacement 9. Switch the input power OFF and unplug the power cord. Remove the Lift Motor . 10. Access the Lift Motor from the bottom by carefully laying the treadmill on its side. TIP: If the Lift Motor will raise the treadmill to maximum, you can access the Lift Motor from the front.
  • Page 56 5 Replacement Procedures Incline Lift Motor Replacement 16. Connect the frame ground wire to the treadmill frame, Make sure to route the cable using the frame cable clips to secure the able in position. Securely tighten the mounting screw to ensure very good electrical connectivity. 17.

  • Page 57: Incline Lift Platform Replacement

    5 Replacement Procedures Incline Lift Platform Replacement Incline Lift Platform Replacement About This procedure provides instruction to remove and replace the Incline Platform. Procedure Review entire procedure before starting. 1. Switch the treadmill power to OFF and unplug the power cord. 2.
  • Page 58 5 Replacement Procedures Incline Lift Platform Replacement 8. Install the actuator tube into the incline platform mounting bracket. Hold the jack screw from turning while inserting the actuator tube into the mounting bracket. Secure with clevis and hitch pins. 9. If the Lift Motor actuator tube has turned during the installation process (which changes the incline reference gap distance) re-calibrate the Lift Motor, see "Lift Motor Cal- ibration"...

  • Page 59: Input Module Replacement

    5 Replacement Procedures Input Module Replacement Input Module Replacement About This procedure provides instruction to remove and replace the AC Input Module. Procedure Review entire procedure before starting. 1. Set the treadmill circuit breaker to OFF and unplug the treadmill’s power cord from the AC outlet.
  • Page 60 5 Replacement Procedures Input Module Replacement 9. Set the AC input module in its mounting position with the side with two terminals facing the circuit breaker and install using the previously removed fasteners. 10. Re-connect the AC input module blue wire to terminal N, the brown wire to terminal L and the green/yellow wire to terminal E.

  • Page 61: Line Filter Replacement

    5 Replacement Procedures Line Filter Replacement Line Filter Replacement About This procedure provides instruction to remove and replace the AC Line Filter. Procedure Review entire procedure before starting. 1. Set the treadmill circuit breaker to OFF and unplug the treadmill’s power cord from the AC outlet.
  • Page 62 5 Replacement Procedures Line Filter Replacement 8. Re-attach wire connections as follows for the 120 VAC and 240 VAC models: a. On 120 Vac and 240 Vac treadmills, connect the blue wire from the power control module to the L1 terminal on the LOAD side of the AC line filter and the brown wire from the power control module to the L2 terminal on the LOAD side of the AC line filter.

  • Page 63: Power Control Module Replacement

    5 Replacement Procedures Power Control Module Replacement Power Control Module Replacement About This procedure provides instruction to remove and replace the Power Control Module (IFT Drive). Procedure Review entire procedure before starting 1. Switch the input power OFF and remove power cord. 2.
  • Page 64 5 Replacement Procedures Power Control Module Replacement 6. Install and tighten the four mounting screws. 7. Reconnect the COMM, INCLINE, INPUT, DB and OUTPUT connectors. The mating connectors are keyed to insure proper contact pin alignment and fit. 8. Reinstall the hood. 9.

  • Page 65: Power Cord Replacement

    This procedure provides instruction to remove and replace the power cord. CAUTION: Use only Precor OEM power cords. Do not remove or otherwise bypass the 3-prong plug with an adapter to use a non-grounded outlet. Do not plug the unit into a power transformer in an attempt to adjust the voltage requirements.
  • Page 66 5 Replacement Procedures Power Cord Replacement 5. Remove the fasteners that retain the AC power cord clamp and remove the clamp. Keep fasteners for replacement installation. 6. Disconnect the AC power cord from the input module. 7. Feed the end of the replacement AC power cord that mates with the input module through its hole in the frame and firmly insert it into the input module.

  • Page 67: Running Belt And Deck Replacement

    About This procedure provides instruction to remove and replace the Running Belt. CAUTION: 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 run- ning belt tension. Improper tensioning of the belt will lead to premature running belt wear, premature driver roller bearing failure and premature Take Up Roller bearing failure.
  • Page 68 5 Replacement Procedures Running Belt and Deck Replacement 10. Slide the running belt off the deck and discard. Remove and keep the deck mounting inserts. 11. If the deck has already been flipped (flipped surface is used), discard and replace with new deck.
  • Page 69 5 Replacement Procedures Running Belt and Deck Replacement 19. Check the alignment of the magnet and the auto stop assembly, see "Auto Stop Sensor Replacement" on page 32. 20. Tighten and torque the Deck mounting bolts to 150 in-lbs (17 N-m). 21.
  • Page 70 5 Replacement Procedures Running Belt and Deck Replacement 27. Repeat the process on walking on the right side of the belt. 28. Repeat the process walking on the left side of the belt. NOTE: It may be necessary to override the treadmill auto-stop function. 29.
  • Page 71 5 Replacement Procedures Running Belt and Deck Replacement 31. Clean up any loose wax from the deck sides and frame. 32. Verify treadmill operation (see "Operation Verification" on page 8) and return to service. .See Also "Adjustment Procedures" on page 20 "Running Belt Tension and Tracking Adjustment" on page 26 (Undefined variable: TRM700-16Base.ServiceManualTitle)

  • Page 72: Take Up Roller Replacement

    About This procedure provides instruction to remove and replace the Take Up Roller. CAUTION: 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 run- ning belt tension. Improper tensioning of the belt will lead to premature running belt wear, premature driver roller bearing failure and premature Take Up Roller bearing failure.
  • Page 73 5 Replacement Procedures Take Up Roller Replacement 7. Tension the running belt to specification and verify tracking, see "Running Belt Tension and Tracking Adjustment" on page 26. 8. Replace the belt guard cover ensuring the tabs are firmly locked into position on the Take Up Roller shaft, see "End Cap &...

  • Page 74: 6    Troubleshooting

    6    Troubleshooting 6    Troubleshooting About This section contains troubleshooting information to help you identify, isolate, and resolve com- ponent and system issues. Troubleshooting issues is an investigative process that utilizes audio/visual cues, error code information (if available), system/component troubleshooting procedures, and experience to fix the problem.
  • Page 75 6    Troubleshooting If the treadmill does not switch ON or trips the circuit breaker, see .Troubleshoot- ing Tripped Breakers), If the console does not power up, see Troubleshooting Console Power. Verify that the console is operating correctly. Run the Display, and Keypad diagnostic tests (see "Hardware Validation - Diagnostic Tests (51765761)"...

  • Page 76: Standard Error Codes

    Standard Error Codes About There is a set of standard error codes implemented across Precor exercise equipment. Error codes are system generated error codes designed to detect and report fault conditions. Each error code is associated with a particular system or component fault condition. The main- tenance software monitors error code event conditions, when a fault is detected, the error code is stored in the Error Log along with the event mileage, hours, and motor current.

  • Page 77: Viewing Error Codes

    6    Troubleshooting Viewing Error Codes Error codes are viewed in the service software Information Display Error Log (see "Error Log" page 73). There are 2 methods to access the Error Codes: :"Error Log" on page 73: Access the Information Display (6,5) and select Error Log. Quick Access: Press and hold the Reset/Pause key for a minimum of 6 seconds will directly access the Error Log and show any stored error codes.
  • Page 78 6    Troubleshooting The Issues and Symptom information Troubleshooting and repair information Using Error Codes to troubleshoot 1. Access the service software "Error Log" on the next page Information Display to view any current or past error code events. 2. Go to the Error Code Troubleshooting Guide, look up the error code and follow the troubleshooting information...

  • Page 79: Error Log

    6    Troubleshooting Error Log Error Log: access the Information Display (6,5) > select Error Log "Standard Error Codes" on page 70 are stored in memory in a First-In Last-Out basis, the new- est error code is stored in the number one position pushing any current error codes down one position.

  • Page 80: System Troubleshooting Procedures

    6    Troubleshooting System Troubleshooting Procedures System troubleshooting procedures provide information and procedures to help you troubleshoot and repair treadmill issues. Available Troubleshooting Procedures "Auto Stop Troubleshooting " on the next page "Tripped Circuit Breaker" on page 93 "Communications Error Troubleshooting" on page 81 "No Power to the Console Troubleshooting"...

  • Page 81: Auto Stop Troubleshooting

    2. Check the treadmill to ensure the Auto Stop hardware is installed. If the Auto Stop hardware is not installed, contact Precor customer support to see if your treadmill is compatible for the Auto Stop or arrange the installation of the Auto Stop hardware.
  • Page 82 Contact PRECOR customer service for repair or replacement. 6. The Auto Stop system consists of a magnet holder mounted to the right front corner of the deck and a Hall Effect sensor mounted to the drive roller bracket of the frame.
  • Page 83 If the voltage does not change, replace the Auto Stop Sensor. 12. If you have completed all the previous steps and Auto Stop will still not function cor- rectly, contact Precor Customer Support. See Also "System Troubleshooting Procedures" on page 74...

  • Page 84: Tripped Circuit Breaker

    OFF the wall breaker. If more than one treadmill loses power, the treadmills are on the same breaker. If YES, advise the customer to have their facility wiring upgraded per Precor spe- cifications.
  • Page 85 AC receptacle. If AC line voltage is present then the treadmills are sharing neutral lines. If YES, advise customer to have their facility wiring upgraded per Precor spe- cifications, and then continue with step 2. If NO, continue troubleshooting.
  • Page 86 6    Troubleshooting If YES, it is likely that there is a shorted component (line filter, lower control module) or faulty/shorted wiring. If NO, continue with the following steps. Does the treadmill power up, but trips the breaker after the motor is started? If YES, it is likely that there is a bad roller or bad drive motor.

  • Page 87: Communications Error Troubleshooting

    6    Troubleshooting Communications Error Troubleshooting Go to the error log and note any occurrences of the error codes related to communications issues. Related Error Codes Communications error codes: 30 through 33. Refer to the Error Code Troubleshooting Guide for error code description and troubleshooting information.

  • Page 88: No Power To The Console Troubleshooting

    6    Troubleshooting No Power to the Console Troubleshooting Applies To: P10, P20, or P30 consoles only. This procedure only applies to treadmill powered consoles. 1. Verify that the treadmill input power is correct, see "Tripped Circuit Breaker" on page 93. 2. Remove the treadmill hood and measure the AC voltage at the input side of the line fil- ter.

  • Page 89: Drive Motor System Troubleshooting

    6    Troubleshooting Drive Motor System Troubleshooting About Occasionally, there may be issues with the proper operation of the drive system that do not generate error codes. This troubleshooting procedure is intended troubleshoot the 3-phase Drive Motor System. If there is a drive motor system Error code from 20 through 29 in the error log, go to the Error Code Troubleshooting Guide, see the Error Code Troubleshooting Guide, for troubleshooting...
  • Page 90 OUTPUT connector on the power control module. If proper con- nection is not being achieved, replace the drive motor connector. 9. If you have performed all of the procedures above and have been unable to correct the problem, call Precor customer support. (Undefined variable: TRM700-16Base.ServiceManualTitle)
  • Page 91 6    Troubleshooting See Also "System Troubleshooting Procedures" on page 74 (Undefined variable: TRM700-16Base.ServiceManualTitle)

  • Page 92: E-Stop Not Communicating

    6    Troubleshooting E-Stop Not Communicating The error 37 is generated by the upper PCA in the console when the lower control module gets into an E-Stop state and the upper PCA in the console did not know about it. The system uses pin 8 of the data cable to communicate E-Stop states between the console and the lower control module.

  • Page 93: Heart Rate Monitor Troubleshooting

    6    Troubleshooting Heart Rate Monitor Troubleshooting Hand Held Heart Rate Does Not Work 1. Place your hands on the HHHR (Hand Held Heart Rate) contacts, making full contact with both top and bottom contacts for at least 15 seconds. a. If the unit displays a heart rate, no problem exists. b.
  • Page 94 6    Troubleshooting Wireless Heart Rate Does Not Work 1. Verify wireless heart rate with a known good chest strap transmitter or test transmitter. If the heart rate reading is erratic, incorrect, or absent, continue. NOTE: It may be necessary to lean in closer to the console at first to allow receiver to begin to acquire a heart rate signal.

  • Page 95: Incline System Troubleshooting

    Operation of lift motor for testing: Most Precor treadmills require the running belt to be moving to operate the lift. For this reason it is recommended that the servicer use the "Hardware Validation" - Machine Tests (see "Hard-...

  • Page 96: Input Power And Machine Controls Troubleshooting

    6    Troubleshooting Input Power and Machine Controls Troubleshooting Errors in this section cover either input power (error 15 & 16) conditions, Console controls (error 5 & 80-83), or processor/memory (error 9 & 11) conditions. These are errors that although they are valid to the proper function of the machine, are not part of a specific treadmill base system (lift system, drive system, deck &...

  • Page 97: Running Belt And Deck Troubleshooting

    6    Troubleshooting Running Belt and 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 AC input current under load. The AC input current is a direct indication of the load being placed on the treadmill.
  • Page 98 6    Troubleshooting previously flipped. See Procedure, Running Belt and/or Deck Replacement (on page 101) for running belt and running deck replacement. 4. If the average AC 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 99: Tripped Circuit Breaker

    OFF the wall breaker. If more than one treadmill loses power, the treadmills are on the same breaker. If YES, advise the customer to have their facility wiring upgraded per Precor spe- cifications.
  • Page 100 AC receptacle. If AC line voltage is present then the treadmills are sharing neutral lines. If YES, advise customer to have their facility wiring upgraded per Precor spe- cifications, and then continue with step 2. If NO, continue troubleshooting.
  • Page 101 6    Troubleshooting If YES, it is likely that there is a shorted component (line filter, lower control module) or faulty/shorted wiring. If NO, continue with the following steps. Does the treadmill power up, but trips the breaker after the motor is started? If YES, it is likely that there is a bad roller or bad drive motor.

  • Page 102: 7    Preventive Maintenance

    Precor recommended preventative maintenance schedule. Always pur- chase replacement parts and hardware from Precor. If you use parts not approved by Precor, you could void the Precor Limited Warranty. Use of parts not approved by Pre- cor may cause injury.
  • Page 103 7 Preventative Maintenance Maintenance Schedule Daily Task Instruction water. Clean the running belt top surface. Clean the top surface of the running belt with a soft dry or damp cloth using an approved cleaner. Clean the running belt and deck. Clean the running belt and deck, see "Running Belt and Deck Cleaning Procedure"...
  • Page 104 7 Preventative Maintenance Maintenance Schedule Weekly Task Instruction (parameter controls, HHR, Stop key. etc.). Note:  1). Perform test with incline set to maximum level and power OFF and power cord dis- connected. Monthly Perform the following maintenance tasks every month. Monthly Task Instruction Verify the Safety clip is attached to the Pull on the lanyard attached to the Safety clip...

  • Page 105: Running Belt And Deck Cleaning Procedure

    7 Preventative Maintenance Running Belt and Deck Cleaning Procedure Quarterly Task Instruction Verify the running belt tension, Verify the running belt tension, alignment and tracking, alignment, and tracking. see "Running Belt Adjustment" procedure. Verify the drive motor belt tension. Verify the drive motor belt tension and adjust as neces- sary, see "Drive Motor Belt Tension Adjustment"...
  • Page 106 7 Preventative Maintenance Running Belt and Deck Cleaning Procedure c. Once the running belt is moving, push the SAFETY STOP key. d. Ensure the running belt stops moving, then reset the SAFETY STOP key. e. Turn the power switch to OFF. The ON/OFF switch is located at the front of the treadmill.
  • Page 107 7 Preventative Maintenance Running Belt and Deck Cleaning Procedure CAUTION: You have approximately 3 seconds before the treadmill running belt begins to move after pressing Quick Start. Ensure you are in the proper position. WARNING: Press the safety stop key if the towel becomes loose to prevent it from being pulled into the treadmill’s rollers.
  • Page 108 7 Preventative Maintenance Running Belt and Deck Cleaning Procedure 7. Grasp both sides of the towel and run it up and down the length of the belt several times to clean the top of the deck. 8. Remove the towel from beneath the belt. 9.

  • Page 109: 8    Theory Of Operation

    8 Theory of Operation About 8    Theory of Operation About The treadmill is comprised of two basic system blocks, the console provides the user interface and operational controls. It contains the Upper PCA board which sends the control input information to the base. The base contains and uses the Lower PCA board to execute received operational commands.

  • Page 110: Treadmill Base Operation

    8 Theory of Operation Treadmill Base Operation (Lower PCA "LPCA") which then performs the actual machine function. The two processors communicate via a serial data stream. When the user makes a request via a machine control or the keypad, the console processor communicates the command to the processor in the lower electronics module.
  • Page 111 8 Theory of Operation Treadmill Base Operation 120V and 240V configurations in the United States. CAUTION: The treadmill requires a 20-amp individual branch circuit grounded per NEC (National Electric Code) guidelines or local region electric code. 120v power, when measured from hot to neutral, should read between 90 and 132v. 240v power, when measured from hot to neutral should read between 180 and 264v.
  • Page 112 8 Theory of Operation Treadmill Base Operation speed of an AC motor is controlled by frequency, there is no need for a speed sensor. The 3 phase AC motor generates enough torque to provide continuous duty run time. The 3 phase voltage amplitude of all three input AC sine waves is the same at any given time which allows the torque to be applied smoothly throughout the rotation of the motor.
  • Page 113 8 Theory of Operation Treadmill Base Operation Auto Stop The Auto Stop feature monitors up and down movement of the deck. The deck motion indic- ates a user is present. The lack of motion indicates that a user is not present. If the running belt is moving and the Auto Stop does not detect motion from the running deck, the Auto Stop fea- ture will stop the motion of the running belt.
  • Page 114 8 Theory of Operation Treadmill Base Operation In order to turn the motor in forward and reverse directions, the AC motor has 2 separate wind- ings, one for up and one for down direction. The AC-1 input has a continuous connection to the center / common connection of the motor winding.
  • Page 115 8 Theory of Operation Treadmill Base Operation It is important to note that since the potentiometer is mechanically connected to the internal gearing of the motor, it would be highly unlikely for a lift motor to go out of calibration without having physical damage to the potentiometer mechanism.

  • Page 116: System Diagrams

    9 System Diagrams System Diagrams System Diagrams System Block Diagram - 120 VAC See Also "Theory of Operation" on page 103. System Wiring Diagram This document provides service documentation for the following treadmill models: 20031 142nd Ave. NE P.O.Box 7202 Woodinville, WA. 98072-4002 Ph: 1-800-347-4404 (Undefined variable: TRM700-16Base.ServiceManualTitle)

  • Page 117: 9    Parts

    IMPORTANT: Always purchase OEM replacement parts and hardware from Precor. If you use parts not approved by Precor, you could void the Precor Limited Warranty. Use of parts not approved by Precor may cause injury. "Exploded View Diagram" on the next page "Parts Identification List"...

  • Page 118: Exploded View Diagram

    9 System Diagrams Exploded View Diagram Exploded View Diagram Page 1 of 5 (Undefined variable: TRM700-16Base.ServiceManualTitle)
  • Page 119 9 System Diagrams Exploded View Diagram Page 2 of 5 (Undefined variable: TRM700-16Base.ServiceManualTitle)
  • Page 120 9 System Diagrams Exploded View Diagram Page 3 of 5 (Undefined variable: TRM700-16Base.ServiceManualTitle)
  • Page 121 9 System Diagrams Exploded View Diagram Page 4 of 5 (Undefined variable: TRM700-16Base.ServiceManualTitle)
  • Page 122 9 System Diagrams Exploded View Diagram Page 5 of 5 (Undefined variable: TRM700-16Base.ServiceManualTitle)

  • Page 123: Parts Identification List

    9 System Diagrams Parts Identification List Parts Identification List Parts LIst (Undefined variable: TRM700-16Base.ServiceManualTitle)
  • Page 124 9 System Diagrams Parts Identification List (Undefined variable: TRM700-16Base.ServiceManualTitle)
  • Page 125 9 System Diagrams Parts Identification List (Undefined variable: TRM700-16Base.ServiceManualTitle)
  • Page 126 No part of this manual may be reproduced in any form or by any means (including electronic storage and retrieval or translation into a foreign language) without prior agreement and writ- ten consent from Precor Incorporated as governed by United States and international copy- right laws.

  • Page 127: Safety Instruction

    Precor shall not be liable for errors or for incid- ental or consequential damages in connection with the furnishing, use, or performance of this document or of any information contained herein.
  • Page 128 B Appendix B: Notices and Safety instructions. Warning WARNING notice denotes a hazard. It calls attention to an operating procedure, practice, or the like that, if not correctly performed or adhered to, could result in per- sonal injury or death. Do not proceed beyond a WARNING notice until the indicated conditions are fully understood.

This manual is also suitable for:

Trm10 seriesGen06 series c966Gen06 series c954Gen06 series c956

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