Precor 9.45 Service Manual
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Precor 9.45 Service Manual

Precor 9.45 Service Manual

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9.45, 9.45i Treadmill
9.45, 9.45i 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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  • Page 1 9.45, 9.45i 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

    ‘3Y’ and started in production on November 16, 1997. The 9.45i is the only version of the 9.45 that is currently in production. This document will refer to the three versions as follows 9.45 (1Y), 9.45 (2P) and 9.45i (3Y).

  • Page 3: Technical Specifications

    9.45, 9.45i Treadmill Technical Specifications Physical Specifications Length: 71 inches or 180 cm (Extended deck treadmills are 5 inches longer) Width: Handrails 31.5 inches (80 cm) Base 28.5 inches (72 cm) Height: 50 inches (127 cm) Running surface: 53 inches by 18 inches (135 cm by 46 cm)
  • Page 4 It is necessary to watch the display to see if an LED does not light. On 9.45 (1L units) the second routine is the lift test. The lift test takes the lift through each of the critical lift positions. In doing so it tests the performance of the zero switch, upper limit switch, lower limit switch and rotation sensor.
  • Page 5 If you do not wish to trip the circuit breaker, press the ENTER key to exit the diagnostic program. Diagram 2.1 - Display Housing, 9.45 (1Y & 2P) Page 5...
  • Page 6 For the purpose of accessing the various software routines, including the diagnostics program, the display housing keys are hypothetically numbered 1 to 7 from left to right. With the PRECOR M9.45 banner scrolling, press keys RESET,5,1,7,6,5,7,6,1, sequentially (See Diagram 2.2).
  • Page 7 9.45, 9.45i Treadmill 11. The last routine is the circuit breaker trip test. This test checks the ability of the treadmill to trip the circuit breaker under software control. If the STOP key is pressed the trip signal will be sent to the circuit breaker and the circuit will trip, shutting off the treadmill. If you do not wish to trip the circuit breaker, press the ENTER key to exit the diagnostic program.

  • Page 8: Procedure 2.3 - Resetting All User Information

    Procedure Plug the power cord into the wall outlet, then turn on the treadmill with the circuit breaker. With the PRECOR M9.45 or PRECOR M9.45i banner scrolling, press the INCLINE , INCLINE , SPEED , and SPEED keys simultaneously and hold them for approximately five seconds (or until zeros are displayed in the right display windows).
  • Page 9 Plug the power cord into the wall outlet, then turn on the treadmill with the circuit breaker. With the PRECOR M9.45 or PRECOR M9.45i banner scrolling, press any key. At the User ID prompt, select the User IDs to be reset using the SPEED...

  • Page 10: Procedure 2.5 - Displaying The Treadmill Odometer And Error Code Log

    Code Log Procedure Plug the power cord into the wall outlet, then turn on the treadmill with the circuit breaker. On 9.45 (1L or 2P units), with the PRECOR M9.45 banner scrolling, press the ENTER, SPEED and SPEED keys, simultaneously. Continue to hold the keys until the message TREADMILL ODOMETER scrolls across the left display window.
  • Page 11 9.45, 9.45i Treadmill There are five error code log positions. The error code log is displayed and scrolls across the left display window (see Diagram 2.4). Use the SPEED (or INCLINE ) and SPEED (or INCLINE ) keys to scroll through the error code log. The most recent error condition will be displayed in position 1 and the oldest error will be displayed in position 5.

  • Page 12: Procedure 2.6 - Selecting United States Standard Or Metric Units

    Changing the Measurement Standard Press and hold STOP to return the PRECOR M9.45 banner. On 9.45 (1L or 2P units), press the QUICK START and then the SPEED key. Hold both keys for 3–5 seconds, then release. On 9.45 (3Y units), press keys RESET,5,6,7,1, sequentially.
  • Page 13 9.45, 9.45i Treadmill measurement standardUse the SPEED or SPEED keys to select the alternate measurement standard. Press ENTER twice to return to the User ID prompt. Page 13...

  • Page 14: Procedure 2.7 - Determining Software Version Numbers

    Plug the power cord into the wall outlet, then turn on the treadmill with the circuit breaker. On 9.45 (1L or 2P units), with the PRECOR M9.45 banner scrolling, press the ENTER key. On 9.45 (3Y units), with the PRECOR M9.45 banner scrolling, press keys RESET,5,1,7,6,5,7,6,1, sequentially.

  • Page 15: Procedure 2.8 - 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 16 9.45, 9.45i 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 17: Procedure 4.1 - Calibrating The Lift Limit Switches, 9.45 (1L)

    9.45, 9.45i Treadmill Procedure 4.1 - Calibrating the Lift Limit Switches, 9.45 (1L) WARNING Always turn off the circuit breaker and unplug the treadmill before you remove the treadmill hood. If the treadmill is not already at zero percent incline, press any key when the CALIBRATE LIFT PRESS ANY KEY prompt is displayed.
  • Page 18 9.45, 9.45i Treadmill If the distances recorded in the previous step are equal to within 1/4"... THEN... OTHERWISE... Skip to Step 17. Continue with the next step. At the PRESS ENTER FOR PROGRAMS prompt, press and hold the ENTER key.
  • Page 19 9.45, 9.45i Treadmill Diagram 4.2 -Switch Mounting Bracket Assembly Lower Limit Switch Zero Switch Actuator Upper Limit Switch Lift Capacitor Page 19...
  • Page 20 9.45, 9.45i Treadmill WARNING When power is applied to the treadmill, the wires connected to the upper and lower limit switches carry 120 volts (or 240 volts if you are servicing a 240-volt treadmill). Turn off the treadmill and unplug the power cord from the wall outlet before you perform the following steps.

  • Page 21: Procedure 4.2 - Calibrating The Lift Motor, 9.45 (2P Or 3Y)

    9.45, 9.45i Treadmill Procedure 4.2 - Calibrating the Lift Motor, 9.45 (2P or 3Y) Turn off the treadmill with the circuit breaker, then unplug the treadmill from the wall outlet. Remove the hood. Place the treadmill on its right side. Remove the bolt and nut that secure the lift tube to the lift platform.

  • Page 22: Procedure 5.1 - Troubleshooting The Keypad And Upper Pca

    9.45, 9.45i 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 23 9.45, 9.45i 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 24: Procedure 5.2 - Troubleshooting The Heart Rate System

    9.45, 9.45i Treadmill Procedure 5.2 - Troubleshooting the Heart Rate System If the HEART RATE indicator does not blink with your heart beat when you perform Procedure 2.1, the problem may be either the heart rate receiver assembly or the chest strap assembly.
  • Page 25 Plug the power cord into the wall outlet, then turn on the treadmill with the ON/OFF switch. If necessary use conductive spray (Precor part number 37364-101) to ensure good contact between the chest strap transmitter and the user, put on the heart rate chest strap transmitter.Enter the diagnostics program per Procedure 2.1 or 2.2.

  • Page 26: Procedure 5.3 - Troubleshooting The Lift System

    9.45, 9.45i Treadmill Procedure 5.3 - Troubleshooting the Lift System, 9.45 Units) 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 27 (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 28 9.45, 9.45i Treadmill 10. Measure the voltage between the red wire (term. 4 of J3) and the black wire (term 1 of J3). The voltage should read a constant 5 Vdc. If the voltage is 0 or significantly lower than 5 Vdc, disconnect the rotation sensor connector from the lower PCA.
  • Page 29 9.45, 9.45i Treadmill Procedure 5.4 - Troubleshooting the Lift System, 9.45 (2P & 3Y Units) System Description The lift system is powered by a 120 Vac lift motor that uses two independent motors windings. One motor winding operates the motor in an upward direction and the other motor winding operates the motor in a downward direction.
  • Page 30 9.45, 9.45i Treadmill Remove the P2 connector from the lower board. Using an ohmmeter, measure between terminals 1 and 3 of P2, between terminals 1 and 2 of P2 and between terminals 2 and 3 of P2. The measurements should be approximately 14.5Ω, 14.5Ω and 29Ω, respectively. If any of the measurements are significantly low, replace the lift motor.

  • Page 31: Procedure 5.5 - Troubleshooting The External A.c. Power Source

    Procedure 5.5 - 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 32 9.45, 9.45i 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 33: Procedure 6.1 - Replacing The Scr (1L Units)

    9.45, 9.45i Treadmill Procedure 6.1 - Replacing the SCR (1L Units) Diagrams 6.1 and 6.2, illustrate the components underneath the hood. Removing the SCR Remove the hood as described in Procedure 5.1 of the Residential Treadmill Service Manual. Disconnect the wires from the SCR terminals listed in Table 945-4.
  • Page 34 9.45, 9.45i Treadmill Replacing the SCR Coat the mounting surface of the SCR with a thin coat of thermal compound. Position the SCR at its mounting location. The treadmill frame is used a a heat sink for the SCR. Therefore, it is critical that the SCR is in full contact with the frame.

  • Page 35: Procedure 6.2 - Replacing The Terminal Block (1L Units)

    9.45, 9.45i Treadmill Procedure 6.2 - Replacing the Terminal Block (1L Units) WARNING Always turn off the circuit breaker and unplug the treadmill before you remove the treadmill hood. Removing the Terminal Block Remove the hood as described in Procedure 5.1 of the Residential Treadmill Service Manual.

  • Page 36: Procedure 6.3 - Replacing The Lift Motor, Rotation Sensor Or Magnet Hub (1L Units)

    9.45, 9.45i Treadmill Procedure 6.3 - Replacing the Lift Motor, Rotation Sensor or Magnet Hub (1L Units) Remove the magnet hub and rotation sensor bracket from the defective lift motor and mount them on the new lift motor. Unless the magnet and/or rotation sensor are defective, do not remove them from their mounting positions on the magnet hub and sensor bracket.
  • Page 37 9.45, 9.45i Treadmill Diagram 6.3 - Lift Motor Components (1Y Units) Lift Motor Rotation Sensor Rotation Sensor Bracket Magnet 10. Choose one: If... Then... Otherwise... You are replacing the Continue with the next Skip to Step 14 magnet step Removing and Replacing the Magnet 11.
  • Page 38 9.45, 9.45i Treadmill 14. Choose one: If... Then... Otherwise... You are replacing the Continue with the next Skip to Step 18 rotation sensor step 15. Remove the screw and washer that secure the rotation sensor to the sensor bracket (see Diagram 6.3).
  • Page 39 9.45, 9.45i Treadmill Note: The original nuts used to mount the lift motor are Kep nuts, which do not require a separate washer. If you do not use Kep nuts to mount the lift motor, use washers when you mount the lift motor to the treadmill frame.

  • Page 40: Procedure 6.4 - Replacing The Limit Switches, Actuator Shaft Or Switch Bracket (1L Units)

    9.45, 9.45i Treadmill Procedure 6.4 - Replacing the Limit Switches, Actuator Shaft or Switch Bracket (1L Units) The three limit switches and the actuator shaft are mounted on the switch bracket (see Diagram 6.4). WARNING Always turn off the circuit breaker and unplug the treadmill before you remove the treadmill hood.
  • Page 41 9.45, 9.45i Treadmill Diagram 6.4 - Limit Switch Mounting (1Y Units) Lower Limit Switch Zero Sense Switch Switch Bracket Upper Limit Switch Switch Actuator Lift Capacitor Actuator Shaft 10. Remove the two screws and washers that secure the limit switch to the switch bracket (See Diagram 6.4).
  • Page 42 9.45, 9.45i Treadmill Removing and Replacing the Switch Bracket 17. Remove the socket head screws and washers that secure the switch bracket to the lift motor platform. Set aside the switch bracket. 18. Position the switch bracket at its mounting location.
  • Page 43 9.45, 9.45i Treadmill 29. Connect the red wires disconnected in Step 3 to the limit switch terminals. 30. Choose one: If... Then... Otherwise... You are replacing more Continue with the next Skip to Step 38 than one limit switch step (to replace the...

  • Page 44: Procedure 6.5 - Replacing The Lift Motor Capacitor (1L Units)

    9.45, 9.45i Treadmill Procedure 6.5 - Replacing the Lift Motor Capacitor (1L Units) WARNING Always turn off the circuit breaker and unplug the treadmill before you remove the treadmill hood. Removing the Lift Motor Capacitor Remove the hood. Remove the black and red wires from the lift motor capacitor terminals.

  • Page 45: Procedure 6.6 - Replacing The Transformer (1L Units)

    9.45, 9.45i Treadmill Procedure 6.6 - Replacing the Transformer (1L Units) Removing the Transformer Remove the hood as described in Procedure 5.1 of the Residential Treadmill Service Manual. Disconnect the wires from the transformer terminals listed in Table 6.2. Table 6.2 - Transformer Connections...

  • Page 46: Procedure 6.7 - Replacing The Speed Sensor (1L Units)

    9.45, 9.45i Treadmill Procedure 6.7 - Replacing the Speed Sensor (1L Units) WARNING Always turn off the circuit breaker and unplug the treadmill before you begin maintenance operations. Removing the Speed Sensor Remove the hood. Disconnect the speed sensor wire assembly from the lower PCA.
  • Page 47 9.45, 9.45i Treadmill Inspect and adjust the gap between the speed sensor and flywheel as described in Procedure 3.4 of the Residential Service Manual. Check the operation of the treadmill as described in Section Three in the appendix of the treadmill you are servicing, then replace the hood.
  • Page 48 9.45, 9.45i Treadmill Procedure 6.8 - Replacing the Speed Sensor (2P & 3Y Units) WARNING Always turn off the circuit breaker and unplug the treadmill before you remove the treadmill hood. Removing the Speed Sensor Remove the hood. Disconnect the speed sensor wire assembly from the lower PCA.
  • Page 49 9.45, 9.45i Treadmill Connect the speed sensor wire assembly to the lower PCA. Inspect and adjust the gap between the speed sensor and flywheel as described in Procedure 3.4 of the Residential Treadmill Service Manual. Check the operation of the treadmill as described in Section Three of this appendix, then replace the hood.

  • Page 50: Procedure 6.9 - Replacing The Lift Platform

    9.45, 9.45i Treadmill Procedure 6.9 - Replacing the Lift Platform Removing the Lift Platform Turn off the treadmill with the circuit breaker, then unplug the power cord from the wall outlet. WARNING Before continuing with this procedure, review the Warning and Caution statements listed in Section One of the Residential Treadmill Service Manual.
  • Page 51 9.45, 9.45i Treadmill Diagram 6.7 - Lift Platform Lift Motor 1L Units Only Lift Platform 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.
  • Page 52 9.45, 9.45i Treadmill Procedure 6.10 - Replacing the Target Label (2P & 3Y Units) WARNING Always turn off the circuit breaker and unplug the treadmill before you remove the treadmill hood. Removing the Target Label Remove the hood. CAUTION The speed sensor is mounted on the motor casing. Exercise caution when you remove and replace the flywheel.
  • Page 53 9.45, 9.45i Treadmill Procedure 6.11 - Replacing the Lift Motor (2P & 3Y Units) WARNING Always turn off the circuit breaker and unplug the treadmill before you remove the treadmill hood. Removing the Lift Motor Remove the hood. Disconnect the lift motor wiring assembly from the lower PCA.

  • Page 54: Procedure 6.12 - Replacing The Prom

    9.45, 9.45i Treadmill Procedure 6.12 - 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 55: Wiring Diagram 7.1 - 9.45 1L Unit

    9.45, 9.45i Treadmill Wiring Diagram 7.1 - 9.45 1L Unit Page 55...

  • Page 56: Block Diagram 7.2 - 9.45 1L Units

    9.45, 9.45i Treadmill Block Diagram 7.2 - 9.45 1L Units Page 56...
  • Page 57 9.45, 9.45i Treadmill Wiring Diagram 7.3 - 9.45 2P & 3Y Units Page 57...
  • Page 58 9.45, 9.45i Treadmill Block Diagram 7.4 - 9.45 2P & 3Y Units Page 58...

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