Precor C944 Service Manual
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Precor C944 Service Manual

Precor C944 Service Manual

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C944 Treadmill
C944 Treadmill
Warning: This service manual is for use by Precor trained service providers only.
If you are not a Precor Trained Servicer, you must not attempt to service any Precor Product;
Call your dealer for service.
This document contains information required to perform the majority of troubleshooting, and
replacement procedures required to repair and maintain this product.
This document contains general product information, software diagnostic procedures (when
available), preventative maintenance procedures, inspection and adjustment procedures,
troubleshooting procedures, replacement procedures and electrical block and wiring diagrams.
To move directly to a procedure, click the appropriate procedure in the bookmark section to the
left of this page. You may "drag" the separator bar between this page and the bookmark section
to change the size of the page being viewed.
© 2003 Precor Incorporated
Unauthorized Reproduction and Distribution Prohibited By Law
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Summary of Contents for Precor C944

  • Page 1 C944 Treadmill Warning: This service manual is for use by Precor trained service providers only. If you are not a Precor Trained Servicer, you must not attempt to service any Precor Product; Call your dealer for service. This document contains information required to perform the majority of troubleshooting, and replacement procedures required to repair and maintain this product.

  • Page 2: Section One - Things You Should Know

    About This Appendix Section One, Things You Should Know. This section includes technical specifications. Read this section, as well as the C944 Treadmill Owner’s Manual, before you perform the maintenance procedures in this manual. Section Two, Software Features. Precor’s C944 Treadmill is programmed with several diagnostic and setup features.

  • Page 3: Technical Specifications

    C944 Treadmill Technical Specifications Physical Specifications Length: 76 inches (193 cm) Width: Handrails 31.5 inches (80 cm) Base 28.5 inches (72 cm) Height: 44 inches (112 cm) Running surface: 53 inches by 18 inches (135 cm by 46 cm) Motor:...

  • Page 4: Procedure 2.1 - Accessing The Diagnostic Software

    Procedure Plug the power cord into the wall outlet, then turn on the treadmill with the circuit breaker. With the PRECOR C944 banner scrolling, press the SPEED , SPEED and INCLINE keys simultaneously or keys RESET,5,1,7,6.5.7.6,1, sequentially on units with standard access codes (see Diagram 2.1).
  • Page 5 C944 Treadmill Diagram 2.1. C944 Treadmill Display With the ADJUST LIFT banner scrolling, press the INCLINE keys. The running deck will incline when the INCLINE key is pressed and decline as the INCLINE key is pressed. The running deck will stop moving when the key is released. After the INCLINE keys are pressed, the message, PRESS ENTER WHEN FINISHED will scroll by.
  • Page 6 C944 Treadmill THEN... OTHERWISE... Press RESET to return to the PRESS The treadmill lift switches are calibrated correctly, press ENTER ENTER FOR PROGRAMS prompt, to continue. then calibrate the lift systems described in Procedure 4.1. Note: Software revision changes can only be made by replacing the currently installed PROM. The revision of the software does not change by resetting the system.
  • Page 7 C944 Treadmill 12. Press each key listed below. Verify that each single dot expands to four dots as the appropriate key is pressed. ENTER Expands the far left dot. INCLINE Expands the second dot from the left. INCLINE Expands the third dot from the left.

  • Page 8: Procedure 2.2 - Displaying The Treadmill Odometer

    The odometers get updated at the end of the course. If a user shuts off the unit while in the middle of a course, the odometer will not be updated and the user will have essentially lost the mileage for that session. Pressing RESET displays the PRECOR C944 banner and accumulates the mileage.

  • Page 9: Procedure 2.3 - Changing Club Settings

    This selection is used to artificially limit the maximum speed the treadmill can attain when a user is working out.The C944 Treadmill can attain an absolute maximum speed of 12.0 MPH (20.0 KPH) for PWM units and 10.0 MPH (16.0 KPH) for SCR units. This speed selec- tion mode cannot exceed these speeds, but rather speeds may be selected that are lower than these maximums.
  • Page 10 Selecting Maximum Workout Speed For PWM treadmills, the maximum workout speed limit is between either 1 and 12 MPH or 1 and 20 KPH. Maximum workout speed limits for SCR C944 treadmills range between 1 and 10 MPH or 1 and 16 KPH.

  • Page 11: Procedure 2.4 - Documenting Software Problems

    If you isolated the problem to either the PROM, upper PCA, or lower PCA, include the information you recorded with the malfunctioning PROM or PCA when you ship it to Precor. When a problem occurs, record the following information: •...
  • Page 12 C944 Treadmill Section Three - Checking Treadmill Operation This section provides you with a quick method of checking treadmill operation. Check treadmill operation at the end of a maintenance procedure and when it is necessary to ensure that the treadmill is operating properly.

  • Page 13: Procedure 4.1 - Calibrating The Lift Limit Switches

    THEN . . . OTHERWISE . . . Skip to Step 17. Continue with the next step. With the PRECOR C944 banner scrolling, press the SPEED , SPEED and INCLINE keys simultaneously or keys 4,5,1,7,6.5.7.6,1, sequentially on units with standard access codes.
  • Page 14 C944 Treadmill Diagram 4.1 - Measuring the Side Rail With the ADJUST LIFT prompt displayed, press either the INCLINE INCLINE key to move the lift. The message PRESS ENTER WHEN FINISHED is displayed on the electronic console. If the distance measured at the front of the side rail is larger than the distance measured at the back of the side rail .
  • Page 15 C944 Treadmill sense switch . . . THEN . . . OTHERWISE . . . The zero sense switch is calibrated The switch bracket must be adjusted; correctly; skip to Step 16. continue with the next step. WARNING When power is applied to the treadmill, the wires connected to the upper and lower limit switches carry 110 volts (or 220 volts if you are servicing a 220-volt treadmill).
  • Page 16 C944 Treadmill Diagram 4.2 - Limit Switch Bracket Lower Limit Switch Actuator Zero Sense Switch Upper Limit Switch Note: The zero sense switch can be actuated if the center of the wheel is slightly above or slightly below the widest point of the switch actuator. However, for best results, adjust the position of the zero sense switch as described in the following step.
  • Page 17 C944 Treadmill 13. If the center of the wheel on the zero sense switch is above the widest point of the switch actuator . . . THEN . . . OTHERWISE . . . Move the switch bracket down until...

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

    C944 Treadmill Procedure 5.1 - Troubleshooting the Keypad and Upper PCA If the function keys on the electronic console are unresponsive, the problem may be either the upper PCA or keypad. This troubleshooting procedure gives you the information you need to determine which of these components is malfunctioning.
  • Page 19 C944 Treadmill Table 5.1 - Voltage Test Points (Function Keys Not Pressed) Place the positive lead of the The voltmeter should read... voltmeter on... Pin 3 of J3 5 Vdc ± 500 mVdc Pin 4 of J3 5 Vdc ± 500 mVdc Pin 5 of J3 5 Vdc ±...

  • Page 20: Procedure 5.2 - Troubleshooting The Lift System

    C944 Treadmill Procedure 5.2 - Troubleshooting the Lift System Lift System Description: The lift system on these units consists of an AC line voltage driven lift motor (120 Vac or 240 Vac), a hall effect rotation sensor and three position location switches. The lift system orients itself by locating the zero sense switch when the treadmill is powered up.
  • Page 21 (240 VAC units), replace the lift capacitor. If you have performed all of the above procedures and have been unable to correct the problem, call Precor Customer Support. Typically, when the lift is able to physically move but causes a lift error, the problem is in the lift position identification system (rotation sensor and zero sense switch).
  • Page 22 Try substituting the lower PCA first, the ribbon cable second and the upper PCA third. If you have performed all of the above procedures and have been unable to correct the problem, call Precor Customer Support. Page 22...

  • Page 23: Procedure 5.3 - Troubleshooting The Speed Sensor

    Try substituting the ribbon cable first, the upper PCA second and the lower PCA third. If you have performed all of the above procedures and have been unable to correct the problem, call Precor Customer Support. Page 23...

  • Page 24: Procedure 5.4 - Troubleshooting The External A.c. Power Source

    Procedure 5.4 - Troubleshooting the External A.C. Power Source It is extremely important that any Precor treadmill be connected to and operated on a dedicated 20 amp A.C. circuit. A 20 amp dedicated circuit is defined as: a circuit fed by a 20 amp circuit breaker that feeds a single load.
  • Page 25 C944 Treadmill The circuit breaker correctly feeds a single A.C. outlet but the neutral is common between several A.C. outlets. The common neutral lead must be removed from treadmill’s A.C. outlet and a new neutral lead from the treadmill’s A.C. outlet to the A.C. neutral distribution bar must be added.

  • Page 26: Procedure 6.1 - Replacing The Lift Motor, Rotation Sensor Or Magnet Hub

    C944 Treadmill Procedure 6.1 - Replacing the Lift Motor, Rotation Sensor or Magnet Hub Note: If you need to replace a lift motor that utilizes a hall effect rotation sensor, remove the magnet hub and rotation sensor bracket from the defective lift motor and mount them on the new lift motor.
  • Page 27 C944 Treadmill Diagram 6.1 - Exploded view of the Lift Motor (with Rotation Sensor) Lift Motor Rotation Sensor Mounting Bracket Rotation Sensor Magnet Hub Magnet Page 27...
  • Page 28 C944 Treadmill Replacing the Magnet 10. Remove the set screw that secures the magnet to the magnet hub. Discard the magnet. Note: When you position the magnet in the magnet hub, place the north pole towards the center of the magnet hub.
  • Page 29 C944 Treadmill Replacing the Lift Motor 23. Extend the lift motor actuator 1/2” by turning the magnet hub. Note: To extend the lift motor actuator faster, place a screwdriver shaft in the lower mounting hole of the lift motor and rotate the lift motor tube.

  • Page 30: Procedure 6.2 - Replacing The Limit Switches, Actuator Shaft Or Switch Bracket

    C944 Treadmill Procedure 6.2 - Replacing the Limit Switches, Actuator Shaft or Switch Bracket Note: The limit switches and the actuator shaft are mounted on the switch bracket (see Diagram 4.2). WARNING Always turn off the circuit breaker and unplug the treadmill before you remove the treadmill hood.
  • Page 31 C944 Treadmill Removing the Down Limit Switch Carefully remove the black wires from the down limit switch. Remove the screws and washers that secure the limit switch to the switch bracket (see Diagram 4.2). If you are removing the zero sense switch...
  • Page 32 C944 Treadmill 11. If you are removing the actuator shaft or switch bracket... THEN... OTHERWISE... Continue with the next step. Skip to Step 26. Removing the Actuator Shaft and Switch Actuator 12. Remove the screw that secures the switch actuator to the actuator shaft. Set aside the screw and switch actuator.
  • Page 33 C944 Treadmill 22. Position the shoulder screw removed in Step 13 through the actuator block and into the base of the lift platform. 23. Tighten the shoulder screw that connects the actuator shaft and actuator block to the lift platform.
  • Page 34 C944 Treadmill THEN... OTHERWISE... Continue with the next step. Skip to Step 38. Replacing the Zero Sense Switch 35. Position the limit switch at its mounting location. 36. Replace the screws and washers that secure the limit switch to the switch bracket.

  • Page 35: Procedure 6.3 - Replacing The Lift Motor Capacitor

    Loosen the screw and nut on the capacitor mounting bracket. Note: If you are servicing a 240-volt C944 treadmill, use a phillips screwdriver to loosen and tighten the screw on the capacitor mounting bracket. Remove the capacitor from the mounting bracket.

  • Page 36: Procedure 6.4 - Replacing The Lift Platform

    C944 Treadmill Procedure 6.4 - Replacing the Lift Platform WARNING Always turn off the circuit breaker and unplug the treadmill before you remove the treadmill hood. Removing the Lift Platform Turn off the treadmill with the circuit breaker, then unplug the power cord from the wall outlet.
  • Page 37 C944 Treadmill Replacing the Lift Platform With the treadmill still on its left side, position the lift platform at its mounting position. Replace the two bolts and nuts that secure the lift platform to the treadmill frame. Note: The original nuts used to mount the lift platform are Kep nuts, which do not require a separate washer.

  • Page 38: Procedure 6.5 - Replacing The Prom

    C944 Treadmill Procedure 6.5 - Replacing the PROM Anti-static kits (part number 20024-101) can be ordered from Precor. The PROM and the associated printed circuit assembly (PCA) are static sensitive. Anti- static devices must be used and all anti-static precautions must be followed during this procedure.
  • Page 39 C944 Treadmill Wiring Diagram 7.1 - C944 SCR 120 Vac Page 39...
  • Page 40 C944 Treadmill Block Diagram 7.2 - C944 SCR 120 Vac Page 40...
  • Page 41 C944 Treadmill Wiring Diagram 7.3 - C944 SCR 240 Vac Blue Snubber Blue Brown Black Black Page 41...
  • Page 42 C944 Treadmill Block Diagram 7.4 - C944 SCR 240 Vac Page 42...
  • Page 43 C944 Treadmill Wiring Diagram 7.5 - C944 PWM 120 Vac F1 Lift Fuse 2A Slow Blow Page 43...
  • Page 44 C944 Treadmill Block Diagram 7.6 - C944 PWM 120 Vac Page 44...
  • Page 45 C944 Treadmill Wiring Diagram 7.7 - C944 PWM 240 Vac F1 Lift Fuse 2A Slow Blow Page 45...
  • Page 46 C944 Treadmill Block Diagram 7.8 - C944 PWM 240 Vac Page 46...

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