Precor Experience 700 line Series Service Manual
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Precor Experience 700 line Series Service Manual

Base, 120 vac and 240 vac
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Service Manual
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Experience
Series 700 line
TRM700-16 Base
Treadmill
120 VAC and 240 VAC

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Summary of Contents for Precor Experience 700 line Series

  • Page 1 Service Manual ™ Experience Series 700 line TRM700-16 Base Treadmill 120 VAC and 240 VAC...

  • Page 2: Table Of Contents

    Contents 1    Introduction General Information Model and Serial Numbers Orientation Covers and Panels Tools Specification Summary Table Understanding bolt grades Parts Lubricants Cleaning Solutions Input Power Requirements CATV RF Cable and Ethernet Requirements Treadmill Placement and Spacing Requirement Safety Guidelines Safety guideline you need to know and follow: 2    Operation Verification Operation Verification Tests.
  • Page 3 How to Access the Service and Diagnostics Menus P10, P20, and P30 consoles P80 consoles P62 and P82 consoles Navigating the Service Menus P10 & P30 consoles P80 and P82 consoles P62 consoles Hardware Validation Service Menu (51765761) P10, P20, and P30 consoles P62, P80, and P82 consoles Club Settings Service Menu (5651565) P10 &...
  • Page 4 Specification Procedure Lift Motor Calibration About Specifications Procedure Lift Platform Assembly Access 5    Replacement Procedures Available Replacement Procedures Covers and Panels Replacement About Hood Cover Replacement Hood Transition Cover Replacement Trim Landing Covers Replacement Trim End Cap Covers Replacement Trim Side Cover Replacement Dash Back Cover Replacement Dash Front Cover Replacement Dash Top and Bottom Cover Replacement...
  • Page 5 About Wire Diagram Procedure E-Stop "Emergency Switch" Replacement About Procedure Motor Controller (MC) Replacement About MC Wire Diagram MC Connector Definition MC Status Light Replacement Procedure Motor Controller Fan Replacement About MC Fan Connector Definition Drive Belt Replacement About Procedure Drive Motor Replacement About Drive Motor Cable Schematic...
  • Page 6 About Procedure Lift Motor Replacement About Specification Lift Motor Fuse Lift motor cable schematic Procedure Lift Platform Replacement About Procedure 6    Troubleshooting About Introduction To Troubleshooting Basic Steps Validate the customer reported issue: Verify the Input Power Condition (Powered units only) Verify that the console is operating correctly Review the Error Log or CPA Event Log for any active error codes Verify (reproduce) the issue.
  • Page 7 Error Log & CPA Event Log About Accessing the Error Log & CPA Event Log Using The Error Log (P10, P20, and P30 consoles) Using the CPA Event Log (P62, P80, and P82 consoles) Active Status Light (ASL) About ASL Overview ASL States ASL Settings and Functions System Troubleshooting Procedures...
  • Page 8 8    Theory of Operation What's New Console Upper PCA and Base Lower PCA Operation Console - Upper PCA board (UPCA) Base - Lower PCA board (LPCA) COMM Communication Interface Cable Active Status Light (ASL) 9    System Wiring Diagram System Wire Diagram Overview System Wire Diagram - Connector Pins COMM Cable Wire Diagram Console Wire Diagram...

  • Page 9: 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 10 1 Introduction See Also "" on the facing page "Safety Guidelines" on page 14 "Operation Verification" on page 16 "Standard Service and Diagnostics Software" on page 18 "Adjustment Procedures" on page 38 "Replacement Procedures" on page 57 "Troubleshooting" on page 152 "Preventive Maintenance" on page 195 "Theory of Operation" on page 203 "Parts Exploded View Diagram &...
  • Page 11 1 Introduction Page 3...

  • Page 12: General Information

    1 Introduction General Information General Information The following information provides general equipment and service information that will help you to use this manual to properly repair and maintain the treadmill. Model and Serial Numbers Model and Serial Numbers Model Numbers The product model number is an alphanumeric code that is comprised of a three character product type designator, a 1 digit product line designator, a one digit console type designator, and a one digit feature level designator.

  • Page 13: Orientation

    1 Introduction General Information Equipment Location The serial number label is located on the hood and frame. Note: Always use the frame label to verify the unit serial number. The hood serial number label may be wrong if the hood was incorrectly replaced with a different tread- mill hood the serial number for that unit will be wrong.

  • Page 14: Covers And Panels

    1 Introduction General Information Covers and Panels Covers and Panels Equipment cover and access panel locations. For cover removal and installation, see "Covers and Panels Replacement" on page 58. Page 6...

  • Page 15: Tools

    • Belt tension gauge – OTC Tools Model #: • Drive Belt tension Gauge (Kent-Moore BT- 6673 33-73-F • 2 Running belt tension gauges (Precor PN: • Polar HRM simulator transmitter (Precor PPP000000020007101) PN: • PPP000000020045101) • 12 " wonder bar •...

  • Page 16: Understanding Bolt Grades

    1 Introduction General Information System Component Specification Drive Belt Tension Used Belt 80-90 lbs (36-41 kgs) Drive Motor fasteners 204 in-lbs (17 ft-lbs, 23 N-m) ammeraal brand running belt tension (gauge/- [[[Undefined variable Spe- percent) cifications.TRM14-Amer- aalRunBeltTension]]] Forbo brand running belt tension (gauge/percent) 3.55 (0.55%)* Deck front fasteners 27-33 in-lbs (3.1-3.7 Nm)

  • Page 17: Parts

    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. There is a copy of the parts Exploded View Diagram and Parts Identification List included in "Parts Exploded View Diagram &...

  • Page 18: Input Power Requirements

    US and Canada power requirements Precor treadmills must be connected to a 20 amp, individual branch circuit that can be shared only with one PVS (Personal Viewing System) display. If you need additional help with the power connections contact your Precor authorized dealer.

  • Page 19: Catv Rf Cable And Ethernet Requirements

    1 Introduction General Information For operator safety and to minimize electrostatic discharge conditions the AC frame ground continuity must also be verified to be a low resistance connection to the AC distribution ground bar. Plugs and Receptacles (US and Canada installations) Country Equipment Voltage Outlet/Plug...
  • Page 20 All communication with our servers is currently done via outgoing (originating from the con- sole) HTTPS sessions. The P80 utilizes to set its clock and for synchronization. At no time is Precor connecting to your network to "push" any data. The P80 initiates all data requests. Community Access Television Network Time Protocol (NTP) is a networking protocol for clock synchronization between computer systems over packet-switched, variable-latency data networks.

  • Page 21: Treadmill Placement And Spacing Requirement

    1 Introduction General Information Treadmill Placement and Spacing Requirement The minimum side to side spacing between treadmills is 20 in (0.5 m) and the minimum front to back spacing is 78 in (2 m). Page 13...

  • Page 22: 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 23 1 Introduction Safety Guidelines Remove jewelry (especially from ears and neck), Tie up long hair, Remove neck ties, and Do not wear loose clothing See Also "Safety Instruction" on page ii "Safety Notices" on page iii Page 15...

  • Page 24: 2    Operation Verification

    2 Operation Verification Operation Verification Tests. 2    Operation Verification This section provides a method to verify that the treadmill is operating correctly and can be returned to service. Do these operation verification tests at the end of a maintenance pro- cedure or whenever it is necessary to ensure that the machine is operating properly. Operation Verification Tests.

  • Page 25: Operational Tests

    2 Operation Verification Operation Verification Tests. BELT SPEED TEST: Select SYSTEM TESTS > BELT TEST and follow prompts to run test HEART RATE TEST: Select HEART RATE TEST and follow prompts to run test 2. Exit Hardware validation Test: On P10, P20, and P30 consoles press the RESET key to exit diagnostics.

  • Page 26: 3    Standard Service And Diagnostics Software

    3    Standard Service and Diagnostics Soft- ware About There are three Standardized Service and Diagnostics menus used across Precor cardio product lines providing equipment usage information, club settings, and machine service dia- gnostic tests: Hardware Validation (5,1,7,6,5,7,6,1) is a set of automated diagnostic tests and hard- ware calibration routines used to troubleshoot and verify machine operation.

  • Page 27: How To Access The Service And Diagnostics Menus

    3 Standard Service and Diagnostics Software How to Access the Service and Diagnostics Menus How to Access the Service and Diagnostics Menus The process to access the service menus vary between console models. Go to section listed below for your particular console to learn how to access the service menus. P10, P20, and P30 consoles Steps: 1.

  • Page 28: P62 And P82 Consoles

    3 Standard Service and Diagnostics Software How to Access the Service and Diagnostics Menus Steps 1. Make sure the P80 is set to the Welcome home page. 2. Press and hold the Pause key while pressing CH up >VOL down > VOL up > CH down: 3.

  • Page 29: Navigating The Service Menus

    3 Standard Service and Diagnostics Software Navigating the Service Menus Steps 1. Make sure the P82 is set to the Welcome home page. 2. Press and hold the VOL down key while pressing CH up >CH down > CH down > CH 3.

  • Page 30: P80 And P82 Consoles

    3 Standard Service and Diagnostics Software P62 consoles CONSOLE KEY FUNCTION/DESCRIPTION Up/Down Moves up and down through the current menu. Selects the current menu item or confirms settings. BACK/CLEAR • Returns to the previous menu level without saving changes. • Hold Back to exit the Display test. PAUSE •...

  • Page 31: Hardware Validation Service Menu (51765761)

    3 Standard Service and Diagnostics Software Hardware Validation Service Menu (51765761) CONSOLE KEY FUNCTION/DESCRIPTION Softkey controls Use your finger to touch the on-screen softkey controls (OK. START, STOP, etc.) or to select a menu item. Scroll Up/Dwn Use your finger to select while swiping your finger Up/Dwn to scroll through menu lists.
  • Page 32 3 Standard Service and Diagnostics Software Hardware Validation Service Menu (51765761) DIAGNOSTIC TEST DESCRIPTION TEST DISPLAY TEST Tests the console LEDs. Successively press the OK key to verify each group of LEDs and verify that all LEDs illuminate. Press Back to exit the test.

  • Page 33: P62, P80, And P82 Consoles

    3 Standard Service and Diagnostics Software Hardware Validation Service Menu (51765761) DIAGNOSTIC TEST DESCRIPTION TEST • A/D - lift motor incline position potentiometer A/D number. • SEC - UP/DWN command response delay between the UPCA LPCA • Glitches - Momentary failures in the A/D potentiometer output. If there are more than 50 Glitches, the lift motor should be replaced.

  • Page 34: Club Settings Service Menu (5651565)

    3 Standard Service and Diagnostics Software Club Settings Service Menu (5651565) SYSTEM TESTS TEST DESCRIPTION TEST Tests belt operating condition in 0.1 speed increments Test parameters: • AMPS IN: Treadmill input Current. • VOLTS IN: Treadmill input Voltage • VBUSS: Treadmill internal buss Voltage •...

  • Page 35: P10 & P30 Consoles

    3 Standard Service and Diagnostics Software Club Settings Service Menu (5651565) On non-touchscreen consoles (P10, P20, and P30), Club Settings is used to manage and cus- tomize workout limit parameters. On touchscreen consoles (P62, P80, and P82), Club Set- tings menu provides access to four main submenus: the About menu, the Equipment Usage menu, the System Settings menu, and the Maintenance menu.

  • Page 36: P62, P80, And P82 Console

    3 Standard Service and Diagnostics Software Club Settings Service Menu (5651565) CLUB PARAMETER DESCRIPTION HIDDEN PROGRAMS Either enabled or disabled*, the setting allows the unit to access specialized fitness tests designed for police, fire fighters and the military. Default: disabled REMOTE SPEED Not used.
  • Page 37 3 Standard Service and Diagnostics Software Club Settings Service Menu (5651565) Information about the machine hardware, software, and error event codes. ABOUT MENU DESCRIPTION CPA Event Log menu: About > CPA Event Log The CPA Event Log contains all console and base error diagnostic messages and error codes including network connectivity inform- ation, OEM test codes, and maintenance error codes.

  • Page 38: Equipment Usage Menu

    3 Standard Service and Diagnostics Software Club Settings Service Menu (5651565) ABOUT MENU DESCRIPTION server address Machine Type menu: About > Machine Type Specifies the detected machine type: TRED, AMT, EFX. Equipment Usage menu menu: Club Settings (5,6,5,1,5,6,5) > Equipment Usage Information about the usage of the machine.
  • Page 39 ®     » Preva Server menu: System Settings > Connectivity> Network Con- figuration Specifies Precor Preva server URL (na.preva.com). Display menu menu: Club Settings (5,6,5,1,5,6,5) > System Settings > Dis- play Console default display configuration settings: language, units, standby delay, .browser and news reader on/off.
  • Page 40 3 Standard Service and Diagnostics Software Club Settings Service Menu (5651565) SYSTEM SETTINGS DESCRIPTION MENU Range: ON/OFF Default: ON Show (enable) the Browser app.     » News Reader menu: System Settings > Display > News Reader Range: ON/OFF Default: ON Show (enable) the News Reader app. TV Settings menu menu: Club Settings (5,6,5,1,5,6,5) >...
  • Page 41 Sets Auto Stop to On or Off.     » Register Equipment menu: System Settings > Workout Limits > Register Equip- ment GUI interface to register equipment with Precor.Preva Business Suite "PBS" (requires PBS user name and password, location code, base serial number, & friendly name of the unit).

  • Page 42: Maintenance Menu

    3 Standard Service and Diagnostics Software Club Settings Service Menu (5651565) Maintenance menu menu: Club Settings (5,6,5,1,5,6,5) > Maintenance Information about the machine operating status and running belt condition and maintenance. MAINTENANCE DESCRIPTION MENU Recommended Action menu: Maintenance > Recommended Action menu Range: Good, Inspect •...

  • Page 43: Information Display

    3 Standard Service and Diagnostics Software Information Display (65) MAINTENANCE DESCRIPTION MENU Yellow Solid: Indicates an error has occurred, was self-corrected and the machine can be used. The fault can be cleared. Yellow Pulsing There is a current non-recoverable fault con- dition, there is a loss of a major function and the machine id out- of-service.
  • Page 44 3 Standard Service and Diagnostics Software Information Display (65) METRIC DESCRIPTION MAINT COUNTER Hours remaining until maintenance is required (initializes to 250 hrs, estimated hours for 1 month use). Press/Hold the PAUSE/RESET key to reset the counter. U-BOOT SW The console Upper Boot software version information. U-BASE SW The console Upper Base software version information.

  • Page 45: P62, P80, And P82 Consoles

    3 Standard Service and Diagnostics Software Information Display (65) P62, P80, and P82 consoles The P62, P80, and P82 consoles do not support the Information Display service menu (6,5). On P62, P80, and P82 consoles, the Information Display (6,5) type data is located in Club Settings (5,6,5,1,5,6,5) service menu, see the P62, P80, and P82 console "Club Settings Ser- vice Menu (5651565)"...

  • Page 46: 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 47: Drive Belt Tension And Alignment Adjustment

    4 Adjustment Procedures Drive Belt Tension and Alignment Adjustment Drive Belt Tension and Alignment Adjustment About This procedure provides instruction to verify and make adjustments to the Drive Belt alignment and tension. The Drive Belt alignment and tension should be verified anytime the Drive Belt is removed or when unusual belt noises are heard during normal operation.
  • Page 48 4 Adjustment Procedures Drive Belt Tension and Alignment Adjustment Drive Belt tension adjustment Belt tension adjustment is an iterative process that requires removing the Drive Belt for each incremental tension adjustment. The process entails: making a belt tension measurement, removing the Drive Belt from the motor pulley, changing the motor position to adjust the belt tension.
  • Page 49 4 Adjustment Procedures Drive Belt Tension and Alignment Adjustment 3. Verify that the Drive Belt tension is within New or Used Drive Belt tension Verification Belt Tension specification: a. If the belt tension is not within the belt Verification Belt Tension specification; continue procedure to adjust tension to the tension Calibration Belt Tension spe- cification.
  • Page 50 4 Adjustment Procedures Drive Belt Tension and Alignment Adjustment CAUTION: Only make small incremental changes to motor position per tension adjustment. Do not over tension the belt which could cause damage to the belt or motor pulley mechanism. 6. Re-tighten the four motor mount fasteners and torque to specification 204 in-lbs (17 ft- lbs, 23 N-m).

  • Page 51: Running Belt Tension And Tracking Adjustment

    Tools 5/16" Hex Key (QTY 2) Belt tension gauges (Precor pn PPP000000020007101) Note: Proper tensioning of the belt requires the use of two tensioning gauges, Pre- cor part number PPP000000020007101. Specification...

  • Page 52: Procedure

    4 Adjustment Procedures Running Belt Tension and Tracking Adjustment Procedure CAUTION: 1) The tracking adjustments should only be done in 1/4 turn increments. 2) ONLY use the right side tension bolt to adjust tracking. 3) ONLY use hand tools to adjust tracking. Running belt tension adjustment Review entire procedure before starting.
  • Page 53 4 Adjustment Procedures Running Belt Tension and Tracking Adjustment Note: It is not necessary to remove the adjustment bolts. Loosen bolts until the take- up roller adjustment cassette touches the frame. No further loosening is required. If the bolt is removed, remove the trim end cap cover and reinstall the bolt. CAUTION: Only use hand tools to adjust tension.
  • Page 54 4 Adjustment Procedures Running Belt Tension and Tracking Adjustment 8. Attach a running belt tension gauge on each side of the running belt opposite each other. Place the gauges so that the trim landing mounting brackets do not interfere with the gauge movement.
  • Page 55 4 Adjustment Procedures Running Belt Tension and Tracking Adjustment 11. Remove the tension gauges. Running belt tracking adjustment Review entire procedure before starting. 1. Connect the power cord and switch the power ON. 2. Start the treadmill and set the speed to 3 mph (5 kph). 3.
  • Page 56 4 Adjustment Procedures Running Belt Tension and Tracking Adjustment 4. Increase the speed to 6 mph (10 kph) verify tracking, then increase the speed to 9 mph (14 kph) verify tracking, and finally increase the speed to 12 mph (19 kph) and verify tracking.

  • Page 57: 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 any time the lift motor is replaced, the lift motor fuse fails, or any incline system component is replaced.
  • Page 58 4 Adjustment Procedures Lift Motor Calibration b. Front lift motor access method, go to "Front lift platform assembly access" on page 55. WARNING: Keep hands and appendages clear of the incline platform assembly before switching power ON. Switching power ON will cause the incline platform to move to the level "0"...
  • Page 59 4 Adjustment Procedures Lift Motor Calibration b. If the distance is NOT within the specified limit, continue procedure and calibrate the lift motor assembly. Lift motor calibration adjustment 4. Disconnect the extension tube from the lift platform weldment mounting bracket by removing the hitch pin and clevis pin.

  • Page 60: Lift Platform Assembly Access

    4 Adjustment Procedures Lift Motor Calibration 6. Reinstall the extension tube into the lift platform mounting bracket and secure using the hitch pin and clevis pin. It may be necessary to slightly rotate the extension tube to align the clevis pin mounting holes. Choose an adjustment direction that will minimize the change to the extension tube calibration distance.
  • Page 61 4 Adjustment Procedures Lift Motor Calibration Side lift platform assembly access This method accesses the lift platform assembly and connected hardware by laying the tread- mill on its side. Laying the treadmill on its side 1. Toggle the power switch from OFF to ON. This will reset the incline level to "0" (the incline level "Home"...
  • Page 62 4 Adjustment Procedures Lift Motor Calibration 3. If not already removed, remove the Hood cover "Hood Cover Replacement" on page 60. 4. Clear the area of any obstructions or items that could damage or be damaged as the treadmill is tipped on its side. 5.
  • Page 63 4 Adjustment Procedures Lift Motor Calibration Front lift platform assembly access This method accesses the lift platform assembly and connected hardware from the front of the treadmill by raising and supporting the treadmill front frame weldment. Raising and supporting the treadmill 1.
  • Page 64 4 Adjustment Procedures Lift Motor Calibration WARNING: Keep hands and appendages clear of the incline platform assembly before switching power ON. Switching power ON will cause the incline platform to move to the level "0" Home position. 1. Access the service menu (51765761) and select the INCLINE TEST. Increase the incline level enough to lift the treadmill frame off the supports.

  • Page 65: 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 install system components. Available Replacement Procedures "Covers and Panels Replacement" on the next page "Power Cord Replacement" on page 77 "ON/OFF SW Circuit Breaker Replacement" on page 79 "ASL PCA Replacement"...

  • Page 66: Covers And Panels Replacement

    5 Replacement Procedures Covers and Panels Replacement Covers and Panels Replacement About These procedure provides instruction to remove and install the TRM covers and panels. Cover Remove/lnstall Procedure Hood Cover "Hood Cover Replacement" on page 60 Hood Transition Cover "Hood Transition Cover Replacement" on page 61 Trim Landing Covers "Trim Landing Covers Replacement"...
  • Page 67 5 Replacement Procedures Covers and Panels Replacement Cover Remove/lnstall Procedure page 76 Page 59...

  • Page 68: Hood Cover Replacement

    5 Replacement Procedures Covers and Panels Replacement Click link to open procedure instructions. Hood Cover Replacement Hood Cover Replacement Description Hood Cover Removal Instructions 1. Remove the four #3 Phillips hood cover screw fasteners. Retain fastener hardware for installation. 2. Grasp the lower edge of the hood cover and pull outwards while lifting to release the tab clip fasteners.

  • Page 69: Hood Transition Cover Replacement

    5 Replacement Procedures Covers and Panels Replacement Hood Transition Cover Replacement Hood Transition Cover Replacement Description Hood Transition Cover - left Hood Transition Cover - right Removal Instructions Repeat procedure for both the left and right covers. 1. Remove the hood cover, see "Hood Cover Replacement"...
  • Page 70 5 Replacement Procedures Covers and Panels Replacement 2. Repeat procedure for both left and right covers. 3. Replace the hood cover, see "Hood Cover Replacement" on page 60. Page 62...

  • Page 71: Trim Landing Covers Replacement

    5 Replacement Procedures Covers and Panels Replacement Trim Landing Covers Replacement Trim Landing Covers Replacement Description Trim Landing Cover- left Trim Landing Cover - right Trim End Cap - left Trim End Cap - right Removal Instructions The same procedure applies to both the left and right trim landing covers.
  • Page 72 5 Replacement Procedures Covers and Panels Replacement 1. Loosen the #2 Phillips trim end cap ( left, right) keeper block screw fastener to relax tension on the trim landing rear tab clip. Do not remove the keeper block fastener or the keeper block will fall from the inside cover mount. The trim end cap will need to be removed to reinstall the keeper block.
  • Page 73 5 Replacement Procedures Covers and Panels Replacement 1. Install by sliding the cover over the landing trim mounting clips from the back towards the front while pressing down on the cover top. Continue the process until all the landing mount clips lock in place. 2.

  • Page 74: Trim End Cap Covers Replacement

    5 Replacement Procedures Covers and Panels Replacement Trim End Cap Covers Replacement Trim End Cap Covers Replacement Description Trim End Cap - left Trim End Cap - right Removal Instructions Repeat procedure for both the left and right end cap covers. 1.
  • Page 75 5 Replacement Procedures Covers and Panels Replacement 4. Pull the cover away from the frame to release the cover tabs and remove. 5. Repeat the same removal procedure to remove both the left or right trim end cap covers. Installation Instructions Repeat procedure for both the left and right covers.

  • Page 76: Trim Side Cover Replacement

    5 Replacement Procedures Covers and Panels Replacement Trim Side Cover Replacement Trim Side Cover Replacement Description Trim Side Cover - left Trim Side Cover - right Removal Instructions Repeat the removal procedure for both the left or right side trim covers. 1.
  • Page 77 5 Replacement Procedures Covers and Panels Replacement mounts to remove the cover. Installation Instructions Repeat procedure for both the left and right covers. 1. Mount the trim side cover bottom rim flange onto the bottom of the five anchor mounts making sure to fit the rim flange alignment cutout (located at the bottom rear of the cover) into the rear white anchor bracket.

  • Page 78: Dash Back Cover Replacement

    5 Replacement Procedures Covers and Panels Replacement Dash Back Cover Replacement Dash Back Cover Replacement Description Dash Back Cover Dash Front Cover Removal Instructions 1. Remove the back cover . Start by removing the bottom three #3 Phillips screw fasten- ers first and then the remaining four top screws.

  • Page 79: Dash Front Cover Replacement

    5 Replacement Procedures Covers and Panels Replacement Dash Front Cover Replacement Dash Front Cover Replacement Description Dash Front Cover Removal Instructions 1. Remove the back cover , see "Covers and Panels Replacement" on page 58. 2. Remove the console, refer to the treadmill assembly guide (700 Line Treadmill Assembly Guide P/N 304387-101).

  • Page 80: Dash Top And Bottom Cover Replacement

    5 Replacement Procedures Covers and Panels Replacement Dash Top and Bottom Cover Replacement Dash Top and Bottom Replacement Description Dash Top Cover Dash Bottom Cover E-Stop Switch Assy Removal Instructions 1. Remove the two #3 Phillips screw fasteners from the dash assy bottom cover Retain fastener hardware for installation.
  • Page 81 5 Replacement Procedures Covers and Panels Replacement 3. Remove the dash bottom cover .from between the dash assembly weldment cross member and HHHR bar. Page 73...
  • Page 82 5 Replacement Procedures Covers and Panels Replacement Installation Instructions 1. Install the dash bottom cover .into position between the dash assembly weldment cross member and HHHR bar. Page 74...
  • Page 83 5 Replacement Procedures Covers and Panels Replacement 2. Reinstall the E-Stop switch onto the dash top cover and secure using the four #2 Philips fasteners. Make sure the interface cable electrical (red/black, white/black) con- nections are correctly attached and secure. 3.

  • Page 84: Side Arm Upper/Lower Covers Replacement

    5 Replacement Procedures Covers and Panels Replacement Side Arm Upper/Lower Covers Replacement Side Arm Upper/Lower Covers Replacement This procedure replaces the left/right upper and lower side arm covers. Description Lower Side Arm Cover - right Upper Side Arm Cover - left Removal Instructions Repeat procedure for both the left and right upper and lower side arm covers.

  • Page 85: Power Cord Replacement

    5 Replacement Procedures Power Cord Replacement Power Cord Replacement About This procedure provides instruction to replace the power cord. Description Power Entry Assembly Power Cord ON/OFF SW Circuit Breaker Procedure Review entire procedure before starting. Removal Instructions 1. Switch the power OFF and unplug the power cord.
  • Page 86 5 Replacement Procedures Power Cord Replacement 1. Remove the hood cover, see "Hood Cover Replacement" on page 60. 2. Use a 1/4" socket to loosen the right side power cord cable clamp fastener. Then loosen the inner cable clamp fastener until the clamp can be slide over the power cord plug. Then disconnect and remove the power cord.

  • Page 87: On/Off Sw Circuit Breaker Replacement

    5 Replacement Procedures ON/OFF SW Circuit Breaker Replacement ON/OFF SW Circuit Breaker Replacement About This procedure provides instruction to replace the ON/OFF SW Circuit Breaker. The Power Entry Assembly located in the front of the treadmill under the frame weldment cross member contains the Power Cord Inlet Assembly, the ON/OFF SW Circuit Breaker, and PCA board.

  • Page 88: Wire Diagram

    5 Replacement Procedures ON/OFF SW Circuit Breaker Replacement Wire Diagram Power Entry Assembly wire diagram. Procedure Review entire procedure before starting. Page 80...
  • Page 89 5 Replacement Procedures ON/OFF SW Circuit Breaker Replacement Description Power Entry Assembly Bracket Power Cord Inlet Assembly ON/OFF SW Circuit Breaker ASL PCA ASL PCA Bracket Removal Instructions 1. Switch the power OFF and unplug the power cord. TIP: For easier access, raise the incline to maximum before removing power. Access the service Hardware Validation (51765761) and use the CROSSRAMP/INCLINE Test to raise the incline and then remove power.
  • Page 90 5 Replacement Procedures ON/OFF SW Circuit Breaker Replacement 2. Remove the hood cover, see "Hood Cover Replacement" on page 60. 3. Remove the four #3 Phillips fasteners and remove the Power Entry Assembly bracket . Hold the bracket while removing to prevent wire cable damage. Retain fastener hardware for installation.

  • Page 91: Asl Pca Replacement

    5 Replacement Procedures ASL PCA Replacement ASL PCA Replacement About This procedure provides instruction to replace the PCA board. The Power Entry Assembly located in the front of the treadmill under the frame weldment cross member contains the Power Cord Inlet Assembly, the ON/OFF SW Circuit Breaker, and the ASL PCA board.

  • Page 92: Procedure

    5 Replacement Procedures ASL PCA Replacement Procedure Review entire procedure before starting. Page 84...
  • Page 93 5 Replacement Procedures ASL PCA Replacement Description Power Entry Assembly Bracket Power Cord Inlet Assembly ON/OFF SW Circuit Breaker ASL PCA ASL PCA Bracket Removal Instructions 1. Switch the power OFF and unplug the power cord. TIP: For easier access, raise the incline to maximum before removing power. Access the service Hardware Validation (51765761) and use the CROSSRAMP/INCLINE Test to raise the incline and then remove power.
  • Page 94 5 Replacement Procedures ASL PCA Replacement 2. Remove the hood cover, see "Hood Cover Replacement" on page 60. 3. Remove the four #3 Phillips fasteners and remove the Power Entry Assembly bracket . Hold the bracket while removing to prevent wire cable damage. Retain fastener hardware for installation.
  • Page 95 5 Replacement Procedures ASL PCA Replacement 1. Reinstall the ASL PCA board onto the ASL PCA Bracket . Securely snap the ASL PCA board into position on the bracket. 2. Reinstall the ASL PCA Bracket by pressing the tabs into the mounting slots on the Power Entry Assembly Bracket 3.

  • Page 96: E-Stop "Emergency Switch" Replacement

    5 Replacement Procedures E-Stop "Emergency Switch" Replacement E-Stop "Emergency Switch" Replacement About This procedure provides instruction to replace the E-Stop "Emergency Stop Switch". Procedure Review entire procedure before starting. Removal and Installation procedures 1. The removal and installation procedures are included in the Dash Top and Bottom Cover Removal/Installation procedure, see "Dash Top and Bottom Replacement"...

  • Page 97: Motor Controller (Mc) Replacement

    5 Replacement Procedures Motor Controller (MC) Replacement Motor Controller (MC) Replacement About This procedure provides instruction to replace the Motor Controller The Motor Controller (MC), is located in the Drive Motor compartment at the front of the tread- mill under the hood cover. Description Motor Controller (MC) Lift Motor...

  • Page 98: Mc Wire Diagram

    5 Replacement Procedures Motor Controller (MC) Replacement MC Wire Diagram Page 90...

  • Page 99: Mc Connector Definition

    5 Replacement Procedures Motor Controller (MC) Replacement MC Connector Definition MC I/O connectors The MC interface input/output connectors are located on the front and back sides of the MC housing. Page 91...
  • Page 100 5 Replacement Procedures Motor Controller (MC) Replacement Page 92...
  • Page 101 5 Replacement Procedures Motor Controller (MC) Replacement MC connector pin definitions CONN NAME Description INPUT MC AC INPUT PWR EARTH GROUND AC LINE 1- LINE AC LINE AC LINE 2- NEUTRAL MOTOR DRIVE MOTOR AC PWR OUT MOTOR PHASE W MOTOR PHASE V MOTOR PHASE U MOTOR PHASE W...
  • Page 102 5 Replacement Procedures Motor Controller (MC) Replacement CONN NAME Description D_RESET DRIVE MOTOR THERMAL SWITCH THERMAL SWITCH SENSE THERMAL SWITCH SENSE DBTH DYNAMIC BRAKE RESISTER THERMAL SWITCH THERMAL SWITCH SENSE THERMAL SWITCH SENSE LIFT LIFT MOTOR PWR OUT & CONTROL BLK - POTENTIOMETER RED - POTENTIOMETER WHITE - MOTOR COMMON...
  • Page 103 5 Replacement Procedures Motor Controller (MC) Replacement MC Fan Motor Connector The fan motor interface cable connector is located under the MC top cover. Note: For MC Fan replacement, see "Motor Controller Fan Replacement" on page 100. Component Description Fan motor Black (24V GND) Yellow (Fault signal) Red (+24 Vdc) Page 95...

  • Page 104: Mc Status Light

    5 Replacement Procedures Motor Controller (MC) Replacement MC Status Light The MC status light is located on the left side of the MC housing. ASL State DESCRIPTION Green Normal operation. Yellow Indicates a fault condition has occured, refer to the error log for more information. The MC may continue to operate after a fault reset or there may be an internal MC fault that needs to be corrected before the MC will operate.

  • Page 105: Replacement Procedure

    5 Replacement Procedures Motor Controller (MC) Replacement Replacement Procedure Review entire procedure before starting. Removal Instructions 1. Switch the power OFF and unplug the power cord. 2. Remove the hood cover, see "Hood Cover Replacement" on page 60. 3. Facing the front of the treadmill, remove the two right side 5/16" hex fasteners and then loosen the two left side 5/16"...
  • Page 106 5 Replacement Procedures Motor Controller (MC) Replacement 4. Carefully raise front and rear of MC as needed to disconnect the attached interface cable connectors, see "Motor Controller (MC) Replacement" on page 89 Note: The COMM connector contacts have an application of dielectric grease to ensure proper electrical contact.
  • Page 107 5 Replacement Procedures Motor Controller (MC) Replacement 2. Reinstall the MC by sliding the left side base flanges under the two left preinstalled loosened fasteners. Then install the two right side fasteners and fully tighten all four fasteners. 3. Route cables and secure using the frame cable clamps. Recheck all cable MC con- nections and make sure that the cables have freedom of movement and clear of any frame or component edges that could pinch or damage the cable wires.

  • Page 108: Motor Controller Fan Replacement

    5 Replacement Procedures Motor Controller Fan Replacement Motor Controller Fan Replacement About This procedure provides instruction to replace the Motor Controller ) Fan. MC Fan Connector Definition The fan motor interface cable connector is located under the MC top cover. Component Description Fan motor...
  • Page 109 5 Replacement Procedures Motor Controller Fan Replacement Component Description Yellow (Fault_signal) Red (+24 VDC) Page 101...
  • Page 110 5 Replacement Procedures Motor Controller Fan Replacement Review entire procedure before starting. Removal Instructions 1. Switch the power OFF and unplug the power cord. 2. Remove the MC, see "Motor Controller (MC) Replacement" on page 89. 3. Use a #2 Philips screwdriver to remove the MC top cover screw fastener.
  • Page 111 5 Replacement Procedures Motor Controller Fan Replacement 3. Reinstall the fan grill onto the fan and secure with the four screw fasteners. 4. Reconnect the fan power cable and install the top cover onto the MC housing. Make sure that the power cable is not pinched or damaged while snapping the top cover into the housing tabs.
  • Page 112 5 Replacement Procedures Motor Controller Fan Replacement 7. P10, P20, and P30 consoles a. Clear the Error Log of any stored error codes: Hold down PAUSE to access the Error Log > select OK to view error codes, and then hold down QUICK START to clear the Error Log of all error codes.

  • Page 113: Drive Belt Replacement

    5 Replacement Procedures Drive Belt Replacement Drive Belt Replacement About This procedure provides instruction to remove and install the Drive Belt Procedure Review entire procedure before starting. Removal Instructions 1. Switch the power OFF and unplug the power cord. 2. Remove the hood cover, see "Covers and Panels Replacement"...
  • Page 114 5 Replacement Procedures Drive Belt Replacement 4. Relax the running belt tension by loosening the left and right 5/16" hex key tension adjustment bolts. Alternately loosen the left and right adjustment bolts in 1/4 turn incre- ments to evenly remove left and right tension. Only use hand tools and not power tools which can easily over or under tension the belt causing damage to the belt and/or take- up roller tension mechanism.
  • Page 115 5 Replacement Procedures Drive Belt Replacement 6. Remove the left side Dust Guard #3 Phillips screw fastener. Retain fastener hardware for installation. 7. Remove the left and right Drive Roller Keepers (one #3 Phillips screw per keeper). Retain fastener hardware for installation. 8.
  • Page 116 5 Replacement Procedures Drive Belt Replacement Page 108...
  • Page 117 5 Replacement Procedures Drive Belt Replacement Installation Instructions 1. Lift the left side of the Dust Guard enough to install the Drive Belt over the Dust Guard. 2. Lift the Drive Roller enough to place the Drive Belt onto the Drive Roller pulley. Reinstall the Drive Roller into the left and right mounting brackets.
  • Page 118 5 Replacement Procedures Drive Belt Replacement 1. Reinstall the left and right Drive Roller Keepers and secure using the #3 screw fasten- ers (one fastener per Keeper). 2. Center and square the running belt on the Drive and Take-up Rollers. Tension the run- ning belt to specification, see "Running Belt Tension and Tracking Adjustment"...
  • Page 119 5 Replacement Procedures Drive Belt Replacement TIP: Use (turn) the Drive Motor flywheel to make it easier to turn the motor pulley and help walk the belt onto or off the Drive Motor and Drive Roller pulleys. 4. Reinstall the left side Dust Guard #3 Phillips fastener and fully tighten. 5.

  • Page 120: Drive Motor Replacement

    5 Replacement Procedures Drive Motor Replacement Drive Motor Replacement About This procedure provides instruction to replace the Drive Motor. The Drive Motor is located in the Drive Motor compartment at the front of the treadmill under the hood cover. Description Drive Motor Page 112...

  • Page 121: Drive Motor Cable Schematic

    5 Replacement Procedures Drive Motor Replacement Drive Motor Cable Schematic Procedure Review entire procedure before starting. Removal Instructions 1. Switch the power OFF and unplug the power cord. 2. Remove the hood cover, see "Hood Cover Replacement" on page 60. 3. Disconnect the Motor Controller "MTH" and "MOTOR" electrical connections: a.
  • Page 122 5 Replacement Procedures Drive Motor Replacement 4. Use a 5/16" socket (or nut driver) to remove the Drive Motor static bleed resistor ground wire (Orange wire). Retain fastener hardware for installation. 5. Use tape or marker to make a motor base position reference mark. This reference mark will be used to help position the replacement motor installation position.
  • Page 123 5 Replacement Procedures Drive Motor Replacement 7. Remove the four 1/2" hex head bolts, plastic top hat washers, and bottom washers fastener hardware. Remove the drive motor. Retain fastener hardware for installation. Installation Instructions 1. Install the replacement Drive Motor into the motor isolation tray and secure using the four 1/2"...
  • Page 124 5 Replacement Procedures Drive Motor Replacement 2. Reconnect the motor static bleed resistor ground wire and secure using the 5/16 " hex head fastener. Fully tighten the fastener to ensure good electrical contact with the frame weldment. WARNING: Static electric shock hazard. Make sure the motor static bleed resistor ground wire is securely connected to the frame.
  • Page 125 5 Replacement Procedures Drive Motor Replacement CAUTION: Take your time and be careful when reconnecting the MC cable con- nectors. Many of the connector contacts are small and can be easily damaged if incorrectly inserted into the MC connector. 4. Reinstall the MC by sliding the left side base flange under the two left preinstalled loosened fasteners.
  • Page 126 5 Replacement Procedures Drive Motor Replacement 7. Connect the power cord and switch the power ON. 8. Verify the Drive Belt alignment and tension to specification. see "Drive Belt Tension and Alignment Adjustment" on page 39. 9. Reinstall the hood cover, see "Hood Cover Replacement"...

  • Page 127: Drive Roller Replacement

    5 Replacement Procedures Drive Roller Replacement Drive Roller Replacement About This procedure provides instruction to remove and replace the Drive Roller. Procedure Review entire procedure before starting. Removal Instructions 1. Switch the power OFF and unplug the power cord. 2. Remove the hood cover, see "Covers and Panels Replacement"...
  • Page 128 5 Replacement Procedures Drive Roller Replacement CAUTION: Only use hand tools to adjust tension. Power tools can easily over and/or under tension causing damage to the belt and/or tension hardware mechanism. 4. Remove the two #3 Phillips screws and two 7/16" hex head fasteners and remove the Dust Guard .
  • Page 129 5 Replacement Procedures Drive Roller Replacement 7. Loosen the Take-up Roller tension adjustment bolts enough to allow the freedom of movement required to lift the Drive Roller from the mounting brackets. Slide the Drive Roller through the running belt and remove. Page 121...
  • Page 130 5 Replacement Procedures Drive Roller Replacement Installation Instructions 1. Place the Drive Roller thru the Running Belt and then set the Roller back into position in the mounting brackets. 2. Reinstall the left and right Roller Keepers and secure using the #3 screw fasteners (one fastener per Keeper).
  • Page 131 5 Replacement Procedures Drive Roller Replacement 3. Center and square the running belt onto the Take-up and Drive rollers and tension to specification, see "Running Belt Tension and Tracking Adjustment" on page 43. Do not verify tracking or apply power at this step in the process, the running belt tracking will be verified after the Drive Belt is installed.

  • Page 132: Take-Up Roller Replacement

    5 Replacement Procedures Take-up Roller Replacement Take-up Roller Replacement About This procedure provides instruction to remove and replace the Take-up Roller. Procedure Review entire procedure before starting. Removal Instructions 1. Switch the power OFF and unplug the power cord. 2. Remove the hood cover, see "Covers and Panels Replacement"...
  • Page 133 5 Replacement Procedures Take-up Roller Replacement 4. Continue to loosen the Take-up roller tension bolts enough to allow the freedom of movement required to lift the Take-up roller from the mounting brackets. Lift the Take- up roller while removing from the inside of the running belt. Make sure the Take-up roller does not drag across the deck surface.
  • Page 134 5 Replacement Procedures Take-up Roller Replacement 2. Set the Take-up roller into the left and right mounting brackets. 3. Connect the power cord and switch the ON/OFF circuit breaker to ON. 4. Center and square the running belt between the Drive and Take-up rollers. Tension to specification and verify tracking, see "Running Belt Tension and Tracking Adjustment"...
  • Page 135 5 Replacement Procedures Take-up Roller Replacement 6. Do the Operation Verification tests (see "Operation Verification" on page 16) and return to service. Page 127...

  • Page 136: Running Belt And Deck Replacement Procedure

    This procedure provides instruction to remove and replace the Running Belt and Deck. There are two different running belt brands and deck combinations available for use on Precor treadmills; Ammerall Beltech and Fobo brand running belts; Ammeraal Beltech and Forbo brand running belts.
  • Page 137 5 Replacement Procedures Running Belt and Deck Replacement Procedure Removal Instructions 1. Switch the power OFF and unplug the power cord. 2. Remove the hood cover, see "Covers and Panels Replacement" on page 58, and left/right Trim Landing covers, see "Covers and Panels Replacement" on page 58.
  • Page 138 5 Replacement Procedures Running Belt and Deck Replacement Procedure TIP:Avoid applying downward pressure on the bolts while removing. Pressing down on the bolts can push the nuts out of the pivot housing .reinstall the nut into the pivot housing if this occurs. 6.
  • Page 139 5 Replacement Procedures Running Belt and Deck Replacement Procedure 7. Carefully lift the deck and belt out of the treadmill frame. 8. Remove the running belt from the deck and discard. A new deck surface must be used with each new belt replacement. a.
  • Page 140 5 Replacement Procedures Running Belt and Deck Replacement Procedure 2. Reinstall the Deck/Belt into the treadmill frame. Make sure to verify that the bottom of the belt is not caught on any frame weldment brackets (GFX cushion brackets) or other frame hardware that could impede belt movement.
  • Page 141 5 Replacement Procedures Running Belt and Deck Replacement Procedure 4. Reinstall the four 5/32" hex key bolt and washer rear deck fasteners, torque to 50-55 in- lbs (5.6-(6.2 Nm). These fasteners attach to the left and right rear deck pivot assemblies. The 1/2" fastener nuts are press fit into the bottom of the deck pivot housing.
  • Page 142 5 Replacement Procedures Running Belt and Deck Replacement Procedure 5. Reinstall the Drive Roller, see "Drive Roller Replacement" on page 119. 6. Reinstall the Take-up Roller, see "Take-up Roller Replacement" on page 124. 7. Center and square the running belt onto the Take-up and Drive rollers, tension the belt to specification and verify the belt tracking, see "Running Belt Tension and Tracking Adjustment"...

  • Page 143: Lift Motor Replacement

    5 Replacement Procedures Lift Motor Replacement Lift Motor Replacement About This procedure provides instruction to remove and replace the Lift Motor. Specification System Component Specification Lift Motor Calibration Distance* 1 1/8 in - 1 3/16 in (2.8 cm - 3.0 cm) Note: * Calibration distance is specified at incline level 0.

  • Page 144: Lift Motor Cable Schematic

    5 Replacement Procedures Lift Motor Replacement Lift motor cable schematic Procedure Removal Instructions Review entire procedure before starting. 1. Remove the hood cover, see "Hood Cover Replacement" on page 60. 2. You can access the lift motor jackscrew in one of two methods: 1) by raising the tread- mill providing access from the front of the treadmill or 2) by laying the treadmill on its Page 136...
  • Page 145 5 Replacement Procedures Lift Motor Replacement side. This procedure uses the front access method. If you do not have supports avail- able, then use the alternative side access method, see "Side lift platform assembly access" on page 53 procedure. Note: You can also access the jackscrew by laying the treadmill on its side, see "Side lift platform assembly access"...
  • Page 146 5 Replacement Procedures Lift Motor Replacement TIP: Remove the MC fasteners so that the MC module can be raised to allow easy access to disconnect and connect the connectors. 8. Remove the lift motor ground wire (GRN or GRN/YEL) from the frame chassis ground screw fastener.
  • Page 147 5 Replacement Procedures Lift Motor Replacement 10. Remove the lift motor actuator housing mount hitch pin and clevis pin fastener from the frame pan mounting bracket. Hold the lift motor while removing fasteners and carefully remove from the treadmill. Page 139...
  • Page 148 5 Replacement Procedures Lift Motor Replacement Installation Instructions Lift motor calibration 1. Lay replacement lift motor on the floor in front of treadmill. Connect the the lift motor interface cable to the MC "LIFT" connector. Page 140...
  • Page 149 5 Replacement Procedures Lift Motor Replacement 2.  Connect the power cord and switch the power from OFF to ON. This will set the lift motor to the calibration reference incline level "0". 3. Switch the power OFF and unplug the power cord. 4.
  • Page 150 5 Replacement Procedures Lift Motor Replacement 7. Place the extension tube into the lift platform mounting bracket and secure using the hitch pin and clevis pin. It may be necessary to slightly rotate the extension tube to align the clevis pin mounting holes. Choose an adjustment direction that will minimize the change to the extension tube calibration distance.
  • Page 151 5 Replacement Procedures Lift Motor Replacement 8. Connect the lift motor I/O cable MC "LIFT" connector. Route cable and secure in the frame routing cable clamp. Connect the ground wire (GRN or GRN/YEL) to the chassis ground screw and fully tighten. Page 143...
  • Page 152 5 Replacement Procedures Lift Motor Replacement 9. If the MC was loosened or removed, install the MC and secure fasteners, see "Motor Controller (MC) Replacement" on page 89. Remove blocking and lower treadmill Note: If you used the side access method, then refer to the "Side lift motor jackscrew access"...
  • Page 153 5 Replacement Procedures Lift Motor Replacement 14. Reinstall the hood cover, see "Hood Cover Replacement" on page 60., . 15. Verify the treadmill incline operation from minimum to maximum levels.Make sure that there are no active Incline function related error codes. 16.

  • Page 154: Lift Platform Replacement

    5 Replacement Procedures Lift Platform Replacement Lift Platform Replacement About This procedure provides instruction to remove and replace the Lift Platform. Procedure Removal Instructions Review entire procedure before starting. 1. Remove the hood cover, see "Hood Cover Replacement" on page 60. 2.
  • Page 155 5 Replacement Procedures Lift Platform Replacement Note: You can alternatively access the lift platform assembly by laying the treadmill on its side, see "Side lift platform assembly access" on page 53 pro- cedure. 5. Access the service menu (51765761) and select INCLINE TEST. Use the incline con- trol to set the incline level to 14.
  • Page 156 5 Replacement Procedures Lift Platform Replacement Do not allow the lift motor extension tube to move. Make sure the lift motor extension tube does not rotate on the jackscrew during removal and remains at the same position for installation. Use tape to mark the extension tube position on the jackscrew .
  • Page 157 5 Replacement Procedures Lift Platform Replacement 9. Remove right lift platform pivot hitch pin. Remove left lift platform pivot hitch pin and spacer. Carefully push the right and left clevis pins outward enough to allow the lift plat- form to be removed. Retain fastener hardware for installation. Installation Instructions 1.
  • Page 158 5 Replacement Procedures Lift Platform Replacement 2. Place the extension tube into the lift platform mounting bracket and secure using the hitch pin and clevis pin. It may be necessary to slightly rotate the extension tube to align the clevis pin mounting holes. If the extension tube has been rotated during or after it was removed, recalibrate the lift motor prior to installation, see "Lift Motor Calibration"...
  • Page 159 5 Replacement Procedures Lift Platform Replacement 1. Connect the power cord and switch the power ON. Be aware that switching the power ON will cause the incline platform to move and return to the level "0" position. If you are using the side access method, see "Side lift platform assembly access"...

  • Page 160: 6    Troubleshooting

    6 Troubleshooting About 6    Troubleshooting About This section contains troubleshooting information to help you identify, isolate, and resolve com- ponent and system issues. Review the Introduction To Troubleshooting section below to learn about the troubleshooting process, troubleshooting best practices, and other pertinent information that will help you effi- ciently troubleshoot issues and return the equipment to service.

  • Page 161: Verify The Input Power Condition (Powered Units Only)

    You can then refer to Error Code Troubleshooting Guide to help resolve the issue. Also, when calling Precor cus- tomer service for assistance, refer to the Error Log or CPA Event Log for additional inform- ation to help the representative resolve the issue.

  • Page 162: Perform Hardware Validation Diagnostic Tests

    6 Troubleshooting Basic Steps Perform hardware validation diagnostic tests Access the Hardware Validation Diagnostic Tests service mode and run any related tests that might help isolate the cause of the issue, see "Hardware Validation Service Menu (51765761)" on page 23. These tests will help identify good and failed components. Resolve any resulting failures.

  • Page 163: 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-...

  • Page 164: Viewing Error Codes (Error Log & Event Log)

    6 Troubleshooting Standard Error Codes Viewing Error Codes (Error Log & Event Log) Error event codes are logged, stored, and viewed in either the Error Log or CPA Event Log menus depending on the console model, see Error Log & CPA Event Log: P10, P20, and P30: access Information Display (6,5) >...

  • Page 165: Error Log & Cpa Event Log

    You can then refer to Error Code Troubleshooting Guide to help resolve the issue. Also, when calling Precor cus- tomer service for assistance, refer to the Error Log or CPA Event Log for additional inform- ation to help the representative resolve the issue.

  • Page 166: Using The Error Log (P10, P20, And P30 Consoles)

    6 Troubleshooting Error Log & CPA Event Log error codes, select the error code and press/hold the QUICK START key until the "NO ERRORS" message shows. P62, P80, and P82: Access Hardware Validation (5,1,7,6,5,7,6,1) > select About > CPA Event Log Note: ...
  • Page 167 6 Troubleshooting Error Log & CPA Event Log code that can be used along with the Error Code Troubleshooting Guide to help resolve the issue. Typical CPA Event Log data: Error Code Data Event Time & Date Stamp Error Code Number Error Code Description...

  • Page 168: Active Status Light (Asl)

    6 Troubleshooting Active Status Light (ASL) Active Status Light (ASL) (Only applies to machines that support the feature) About The Active Status Light (ASL) is a service and maintenance status light located on the front lower center of the front hood cover. The ASL provides a visual indication of the machine oper- ational status.

  • Page 169: Asl States

    6 Troubleshooting Active Status Light (ASL) The console UPCA determines the ASL state using inputs from the error log and main- tenance counter. During active operation (workout in progress) or during the pause state, the console transmits the ASL state to the lower control board (LPCA Only direct error code and maintenance counter data is used to determine the current machine ASL state.

  • Page 170: Asl Settings And Functions

    6 Troubleshooting Active Status Light (ASL) ASL State DESCRIPTION servicing or replacement. Ellipticals: The maintenance counter starts at 1000 hours and counts down the active use hours to 0. When the counter reaches zero hours, the ASL will begin pulsing blue indicating preventative maintenance is due.
  • Page 171 6 Troubleshooting Active Status Light (ASL) The "OFF" setting effectively disables the ASL "blue pulsing" state without affecting the yellow or pulsing yellow fault states. When set to OFF, the Maintenance Reminder counter continues counting down the miles (or hours) remaining which can be viewed in the service access menu, see "View- ing the current ASL state"...
  • Page 172 6 Troubleshooting Active Status Light (ASL) to solid blue. P10, P20, and P30 consoles: 1. Access Information Display (6,5) > select MAINT COUNTER > OK. 2. Press/Hold the QUICKSTART key, the "HOLD TO RESET MAINTENANCE COUNTER" message will show, continue holding down QUICKSTART for 3 sec until the maintenance counter is reset to [[[Undefined variable TRM700- 16Base.MaintCounter]]].
  • Page 173 6 Troubleshooting Active Status Light (ASL) Note: Clearing the CPA Event Log does NOT clear the error codes from the Event Log. Page 165...

  • Page 174: System Troubleshooting Procedures

    6 Troubleshooting System Troubleshooting Procedures System Troubleshooting Procedures System Troubleshooting procedures provide information and procedures to help you troubleshoot and repair treadmill system issues . Available System Troubleshooting Procedures "Tripped Circuit Breaker" on the facing page "Input Power Troubleshooting" on page 171 "Console Power Troubleshooting"...

  • Page 175: Tripped Circuit Breaker

    If more than one treadmill loses power, the treadmills are on the same breaker: If YES, advise the customer to have the facility wiring upgraded to provide one individual branch circuit outlet per machine, see Precor specifications, see ."" on page 10.
  • Page 176 6 Troubleshooting System Troubleshooting Procedures CAUTION: The treadmill requires a 20-amp individual branch circuit grounded per NEC (National Electric Code) guidelines or local region electric code. Measure the AC input voltage with the treadmill running and no exerciser on the belt "unloaded."...
  • Page 177 System Troubleshooting Procedures line, and ground line. Have a certified electrician verify the treadmill is powered from an individual branch circuit: If YES, advise customer to have their facility wiring upgraded per Precor spe- cifications. If NO, continue Troubleshooting. CAUTION: The treadmill requires a 20-amp individual branch circuit grounded per NEC (National Electric Code) guidelines or local region electric code.
  • Page 178 6 Troubleshooting System Troubleshooting Procedures See Also "System Troubleshooting Procedures" on page 166 Page 170...

  • Page 179: Input Power Troubleshooting

    6 Troubleshooting System Troubleshooting Procedures Input Power Troubleshooting The machine requires reliable stable input power for proper operation. Poor input power issues such as low/high line voltage levels, incorrect or unstable frequency, intermittent power, power spikes, etc, can cause machine operating issues. The following error codes are related to poor input power issues: Related Error Codes RELATED...
  • Page 180 6 Troubleshooting System Troubleshooting Procedures Troubleshooting Procedure Review the machine Error Log or Event Log and note any one of the possible related error codes. Then use the Error Code and Troubleshooting Guide to learn about these error codes and procedures to troubleshoot and repair the issue, see Error Code Troubleshooting Guide.

  • Page 181: Console Power Troubleshooting

    6 Troubleshooting System Troubleshooting Procedures Console Power Troubleshooting Machine powered consoles (Standard, P10, P20, and P30). 1. Using a multimeter, verify that the facility outlet AC voltage is within required limits, see "" on page 10. a. If NO, ask facility to have an electrician check the power panel circuit breaker and outlet power.
  • Page 182 6 Troubleshooting System Troubleshooting Procedures a. If NO, replace the line filter. b. If YES, continue troubleshooting. 4. Replace the unit console and COMM cable with known good parts. Switch the power ON, does the test console power-up? a. If NO, replace the unit.

  • Page 183: Communications Error Troubleshooting

    6 Troubleshooting System Troubleshooting Procedures Communications Error Troubleshooting Errors 30 through 33 all indicate the loss of communications or erratic communications between the Upper PCA "UPCA " and the Lower PCA "LPCA ". The main reason for a general communication error is a faulty interconnect cable, either it is not connected securely, or it has become damaged.
  • Page 184 6 Troubleshooting System Troubleshooting Procedures Page 176...

  • Page 185: Machine Controls Troubleshooting

    6 Troubleshooting System Troubleshooting Procedures Machine Controls Troubleshooting Applies To: P30 consoles The main symptoms caused by bad machine incline and speed controls are lack of control for incline and speed (treadmills) or resistance and crossramp (ellipticals & AMTs). Machine con- trol error codes will occur when the machine controls no longer provide reliable mechanical inputs to the console machine control software.
  • Page 186 6 Troubleshooting System Troubleshooting Procedures See Also "System Troubleshooting Procedures" on page 166 Page 178...

  • Page 187: Auto Stop Troubleshooting

    6 Troubleshooting System Troubleshooting Procedures Auto Stop Troubleshooting Apple To: TRM800-14, TRM700-16 and later treadmill models This troubleshooting procedure only applies to TRM800-14, TRM700-16 and later treadmill models that utilize software and drive motor current input to manage the auto stop function. For early production models like the TRM10 treadmill that utilize mechanical magnetic sensor input to manage the auto stop function, refer to the Error Code Troubleshooting Guide...

  • Page 188: E-Stop Not Communicating Troubleshooting

    6 Troubleshooting System Troubleshooting Procedures E-Stop not Communicating Troubleshooting An error 37 may occur after an E-STOP event. If the E-STOP event is not successfully cleared in the lower PCA and the upper display believes the E-STOP has been cleared, a error 37 will occur.

  • Page 189: Heart Rate Monitor Troubleshooting

    6 Troubleshooting System Troubleshooting Procedures Heart Rate Monitor Troubleshooting Hand Held Heart Rate Does not Work 1. Place your hands on the handlebar HHHR (Hand Held Heart Rate) hand held pulse sensors, making full contact with both top and bottom pulse sensors for at least 15 seconds.
  • Page 190 6 Troubleshooting System Troubleshooting Procedures 8. Verify that the HHHR handlebar pulse sensor cable is not damaged and that it is cor- rectly installed. Verify the four HHHR PCA pulse sensor input connector pins ( left top, left lower , right top , and right lower) are attached to their respective handlebar pulse sensor terminal, (see HHHR PCA schematic below).
  • Page 191 6 Troubleshooting System Troubleshooting Procedures Note: It may be necessary to temporarily move closer to the console to allow the receiver to acquire the heart rate transmitter signal. 3. Identify possible sources of wireless signals that are transmitting in close proximity to the machine that may cause HHHR transmitter signal interference.

  • Page 192: Drive Motor System Troubleshooting

    6 Troubleshooting System Troubleshooting Procedures Drive Motor System Troubleshooting About This procedure applies to 3-phase drive motor systems. Occasionally, there may be issues or failures of the drive system that do not generate error codes. This procedure provides addi- tional information to troubleshoot and repair these types of issues. 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...
  • Page 193 6 Troubleshooting System Troubleshooting Procedures Troubleshooting Procedure Motor Controller module "MC " output power test 1. Switch treadmill ON/OFF switch to OFF Disconnect the Drive Motor cable Motor con- nector from the Motor Controller "MOTOR" connector. 2. Set the multimeter to measure AC voltage. Switch the treadmill ON/OFF switch to ON. Press the QUICK START key and immediately measure the voltage between the red wire (pin 4) &...
  • Page 194 6 Troubleshooting System Troubleshooting Procedures 3. Repeat the AC voltage measurement between the MC MOTOR connector red wire (pin 4) & the black wire (pin 6). The measured voltage should be the approximately the same value as the previously measured red wire (pin 4) & white wire (pin 5) voltage. Set the treadmill ON/OFF switch to the OFF position.
  • Page 195 #45750-3111 (recommended MOLEX pn 0457503112 crimp tool). If the connector can- not be repaired, replace the Drive Motor. 8. If you have performed all of the procedures above and have been unable to correct the problem, call Precor customer support. See Also "System Troubleshooting Procedures" on page 166...

  • Page 196: Incline Lift System Troubleshooting

    6 Troubleshooting System Troubleshooting Procedures Incline Lift System Troubleshooting The incline Lift system consists of an AC voltage driven lift motor (120 Vac or 240 Vac) and an internal 1 K ohm potentiometer for lift position monitoring. The first step in troubleshooting the lift system is to review the error log for any lift system error codes.

  • Page 197: Error Code 40 "No Lift Motion Detected

    6 Troubleshooting System Troubleshooting Procedures Lift motor schematic "Lift Platform Replacement" on page 146 Procedure 1. Switch the input power OFF. Visually inspect the lift motor cable wires for damage (torn insulation, bare wires, shorted/open wires, etc.) and MC module connectors for any damaged pins, shorted pins, or improperly crimped connections.

  • Page 198: Possible Fault Causes

    6 Troubleshooting System Troubleshooting Procedures Possible Fault Causes: Lift motor cable connector pins damaged or not properly seated (plugged in) Damaged lift motor windings. Lift platform is physically jammed and unable to move. Lift fuse is blown (open). Bad MC lift motor control circuitry. 1.
  • Page 199 6 Troubleshooting System Troubleshooting Procedures can cause the lift platform to jam which in turn can cause a blown lift fuse (see Lift motion in only one direction step). 5. Verify the lift motor capacitor. The lift capacitor is mounted inside the lift motor. If the lift capacitor is shorted, the lift fuse will blow (open).
  • Page 200 6 Troubleshooting System Troubleshooting Procedures i. Move the incline below 15% to allow room for lift upward travel. Disconnect the MC LIFT connector and connect an AC voltmeter between terminals 4 (white) & 7 (red) of the MC LIFT connector (see lift motor schematic). Select the manual program mode and press the INCLINE UP control.

  • Page 201: Running Belt Troubleshooting

    6 Troubleshooting System Troubleshooting Procedures Running Belt Troubleshooting The TRM700/800 series treadmill provide the following diagnostic tools to help isolate and resolve running belt issues: Belt Rating parameter that indicates the condition of the running belt. Diagnostics Belt Speed Test can be used to monitor the drive motor load current (Higher than typical motor current indicates a worn belt/deck condition) On P62, P80, and P82 consoles, the Club Setting >...
  • Page 202 6 Troubleshooting System Troubleshooting Procedures P62, P80, and P82 consoles: Club Settings (5,6,5,1,5,6,5) > Maintenance menu > Belt Rating 2. Do the troubleshooting instruction for the current Belt Rating number: Belt Rating 2 thru 10: 1. Clean the belt and deck, see "Running Belt and Deck Cleaning Procedure"...

  • Page 203: 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 204 7 Preventative Maintenance Maintenance Schedule Daily Task Description Unusual noises Worn or frayed power cords. Worn, damaged, missing safety lanyards or clips. Any other indication that the equipment may be in need of service. Important: If you determine that the equipment needs service, disconnect all power connections (television, Ethernet, and power) and move the equipment away from the exercise area.
  • Page 205 7 Preventative Maintenance Maintenance Schedule Weekly Task Description and power cord disconnectged: Verify that the power cord is Verify that the power cord is not damaged, pinched, ‡ ‡ not damaged coiled, or positioned under the machine Vacuum and clean floor area Vacuum and use damp mop to clean floor area under- underneath equipment neath equipment.
  • Page 206 7 Preventative Maintenance Maintenance Schedule Monthly Task Instruction floor underneath the tread- area under the front cover. Be careful not to bring the nozzle mill to close to any electronic circuit boards. Clean and lubricate the lift Clean and lubricate the lift motor jackscrew with an motor jackscrew (Inline approved grease, see""...
  • Page 207 7 Preventative Maintenance Maintenance Schedule Semi-Annual Maintenance Perform the following maintenance tasks every 6 months: Semiannual Task Instruction Clean and lubricate the Lift Motor Raise the Incline to maximum, Switch the input jackscrew. power OFF, and unplug the power cord. Clean the jackscrew and apply approved grease, see ""...

  • Page 208: Running Belt And Deck Cleaning Procedure

    7 Preventative Maintenance Running Belt and Deck Cleaning Procedure Running Belt and Deck Cleaning Procedure Review the entire procedure before beginning. 1. Verify the proper operation of the safety Stop key. a. Stand to one side of the treadmill – Do not stand or allow others to stand on the treadmill running belt during this procedure.
  • Page 209 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 210 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 211: 8    Theory Of Operation

    8 Theory of Operation What's New 8    Theory of Operation What's New The TRM700-16 features and differences from previous generation TRMs including: Updated self lubricating running belt with no wax deck No Dynamic Brake Resister (DBR Redesigned dash and arms Service/maintenance Active Status Light (ASL Supports the P30, P62, and P82 consoles TRM700-16 and TRM800-14 use common base platform...

  • Page 212: Base - Lower Pca Board (Lpca)

    8 Theory of Operation Console Upper PCA and Base Lower PCA Operation Base - Lower PCA board (LPCA) The base Lower PCA (LPCA ) receives machine control commands from the console and dir- ectly executes the commands to control the braking, lift operation, and power ON/OFF. The LPCA also monitors error conditions and sends the detected error event code information to the console.
  • Page 213 8 Theory of Operation Page 205...

  • Page 214: 9    System Wiring Diagram

    9 System Wiring Diagram 9    System Wiring Diagram System Wire Diagram Overview Page 206...

  • Page 215: System Wire Diagram - Connector Pins

    9 System Wiring Diagram System Wire Diagram - Connector Pins Page 207...

  • Page 216: Comm Cable Wire Diagram

    9 System Wiring Diagram COMM Cable Wire Diagram COMM Cable Wire Diagram COMM Cable Wire Diagram Page 208...

  • Page 217: Console Wire Diagram

    9 System Wiring Diagram Console Wire Diagram Console Wire Diagram Console Wire Diagram Page 209...

  • Page 218: Power Entry Assemble Wire Diagram

    9 System Wiring Diagram Power Entry Assemble Wire Diagram Power Entry Assemble Wire Diagram Power Entry Assembly Wire Diagram Page 210...

  • Page 219: 10    Parts Exploded View Diagram & Parts List

    Precor Connect Partner website 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. Page 211...

  • Page 220: Exploded View Diagram

    10 Parts Exploded View Diagram & Parts List Exploded View Diagram Exploded View Diagram Page 212...
  • Page 221 10 Parts Exploded View Diagram & Parts List Exploded View Diagram Page 213...
  • Page 222 10 Parts Exploded View Diagram & Parts List Exploded View Diagram Page 214...
  • Page 223 10 Parts Exploded View Diagram & Parts List Exploded View Diagram Page 215...
  • Page 224 10 Parts Exploded View Diagram & Parts List Exploded View Diagram Page 216...
  • Page 225 10 Parts Exploded View Diagram & Parts List Exploded View Diagram Page 217...
  • Page 226 10 Parts Exploded View Diagram & Parts List Exploded View Diagram Page 218...

  • Page 227: Parts List

    10 Parts Exploded View Diagram & Parts List Parts List Parts List Continue to view the hard copy version. Page 219...
  • Page 228 10 Parts Exploded View Diagram & Parts List Parts List Page 220...
  • Page 229 10 Parts Exploded View Diagram & Parts List Parts List Page 221...

  • Page 230: Appendix A : Edition Information

    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 231: Appendix B : Notices And Safety

    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 232: Safety Notices

    B Appendix B: Notices and Safety Safety Notices Warning and Caution notices indicate an activity that could be dangerous and cause personal injury and/or equipment damage if not adhered to. Always follow Warning and Caution instruc- tions. 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.

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