Precor C966 Serivce Manual
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Precor C966 Serivce Manual

Precor C966 Serivce Manual

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C966 Treadmill
C966 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 C966

  • Page 1 C966 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 About This Appendix Section One, Things You Should Know. This section includes technical specifications. Read this section, as well as the C966 Treadmill Owner’s Manual, before you perform the maintenance procedures in this manual. Section Two, Software Features. Precor’s C966 Treadmills are programmed with several diagnostic and setup features.

  • Page 3: General Information

    C966 Treadmill General Information For the latest exploded view diagram, part number and part pricing information, visit the Precor dealer website at “www.precor.com/Dealer. Technical Specifications Physical Specifications Length: 84 inches (213 cm.) Width: Handrails 36.75 inches (93 cm.) Base 33.75 inches (86 cm.) Height: 57 inches (145 cm.)

  • Page 4: Procedure 2.1 - Accessing The Diagnostic Software

    The keys on the display are hypothetically numbered 1 to 7 from left to right. See Diagram 2.1. The STOP is key number 4 and is located directly below the QUICK START key. With the PRECOR banner scrolling, press keys RESET,5,1,7,6,5,7,6,1, sequentially. The display test will be initiated.
  • Page 5 C966 Treadmill The keyboard test will place two dots on the display for each key on the display, including the numeric keypad. Pressing a key will cause the upper of the two dots associated with the key to go out. Test all of the keys in this manner. Tug on the safety key lanyard, to ensure that the STOP key is operating normally.
  • Page 6 C966 Treadmill 22. This test is valuable in diagnosing treadmill response to load conditions. As load is increased, the power bits are kept at a constant value (as set via the SPEED keys) and the current and belt speed will vary proportionately to the load.

  • Page 7: Procedure 2.2 - Displaying Information

    Procedure Plug the power cord into the wall outlet, then turn on the treadmill with the circuit breaker. With the PRECOR banner scrolling, press the keys RESET,6,5, sequentially. The odometer display will be initiated. The treadmill’s odometer will be displayed as 1234567 MPH or 1234567 KPH depending on club settings (See Procedure 2.3).
  • Page 8 C966 Treadmill 11. The arrows keys will allow you to scroll through the log. When the first unused position is reached in the log, the message NO MORE ERRORS will be displayed. 12. If you wish to clear the error log of all existing errors, follow the procedure in step 13.

  • Page 9: Procedure 2.3 - Selecting Club Settings

    C966 Treadmill Procedure 2.3 — Selecting Club Settings This procedure allows you to change the following club settings: • Language • Measurement Units • Maximum Speed • Maximum Workout Time • Maximum Pause Time • Cool Down Time • Fitness Test Enable/Disable •...
  • Page 10 C966 Treadmill 10. Use the keys to scroll through the possible range of maximum speeds. 11. Press the ENTER key to select the currently displayed maximum speed or the STOP key to leave the original maximum speed selected. Select Maximum Workout Time 12.
  • Page 11 C966 Treadmill 23. Press the ENTER key to select the currently display or the STOP key to leave the original display. Modify Custom Courses 24. The prompt MODIFY CUSTOM COURSE 1 will be displayed. The currently stored custom course will then be displayed. The left most column of the course blinks, indicating that it is the column selected for modification.

  • Page 12: Procedure 2.4 - Documenting Software Problems

    C966 Treadmill Procedure 2.4 — Documenting Software Problems When a problem is found with the software in the upper or lower PCA, record the information listed below. When a problem occurs, record the following information: • Model and serial number •...
  • Page 13 C966 Treadmill Section Three — Checking Treadmill Operation This section provides you with a quick method of checking treadmill operation. Check treadmill operation at the end of a maintenance procedure and when it is necessary to ensure that the treadmill is operating properly.

  • Page 14: Procedure 4.1 - Calibrating The Lift Motor

    C966 Treadmill Procedure 4.1 — Calibrating the Lift Motor Set the treadmill circuit breaker in the “off” position and unplug the line cord from the wall outlet. Remove the hood. Place the treadmill on it’s right side. Remove hitch and clevis pins that secure the lift tube to the lift platform.
  • Page 15 C966 Treadmill Plug the power cord into the wall outlet, set the treadmill circuit breaker in the “on” position. Press keys RESET, 5,1,7,6,5,7,6,1, sequentially to enter the diagnostics routine. Refer to Procedure 2.1 and advance to the lift test. When the lift calibration number is displayed on...

  • Page 16: Procedure 4.2 - Adjusting Drive Belt Tension

    C966 Treadmill Procedure 4.2 — Adjusting Drive Belt Tension Set the treadmill circuit breaker in the “off” position and unplug the line cord from the wall outlet. Remove the hood. Place the drive belt tension gauge on the drive belt as shown in Diagram 4.2.
  • Page 17 C966 Treadmill Diagram 4.3 - Drive Belt Adjustment Drive Motor Mounting Bolt Re-install the hood. Plug the line cord into the wall outlet and set the treadmill circuit breaker in the “on” position. Check treadmill operation per Section 3. Page 17...

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

    C966 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. The keys on this unit are touch sensitive keys. It is necessary to use the keypad diagnostics to troubleshoot the key functions.
  • Page 19 The display housing front panel is equipped with the keypad. 10. If you have performed all of the procedures above and have been unable to correct the problem, call Precor customer service. 11. Access the diagnostics program per procedure 2.1. If the key(s) necessary to access the diagnostic program is not functioning, skip to step 14.

  • Page 20: Procedure 5.2 - Troubleshooting The Speed Sensor

    C966 Treadmill Procedure 5.2 — Troubleshooting the Speed Sensor Note: The speed sensor is a hall effect sensor that emits a pulse when a flywheel lobe passes between it’s transmitter and receiver. The speed control circuit processes the pulse train emitted by the speed sensor.
  • Page 21 Try substituting the lower logic PCA first then the upper PCA, if necessary. If you have performed all of the above procedures and have been unable to correct the problem, call Precor Customer Support. Page 21...

  • Page 22: Procedure 5.3 - Troubleshooting Hand Held Heart Rate

    C966 Treadmill Procedure 5.3 — Troubleshooting Hand Held Heart Rate Circuit Description The hand held heart rate system is actually a dual system, that is, it can accept a heart rate signal from either the hand held heart rate contacts on the unit’s handlebar or from a Polar heart rate chest strap transmitter.
  • Page 23 C966 Treadmill Set the on/off switch in the “off” position and remove the display housing. Verify the internal chest strap setting is set as shown in Diagram 5.4. Verify that a ferrite bead is installed on the heart rate PCA to upper PCA cable.
  • Page 24 C966 Treadmill 15. Set the on/off switch in the “off” position. Refer to Diagram 5.4 for the following measurements. With an ohmmeter measure between the “lower right contact” pin on the J1 connector and the lower right hand held heart rate contact on the handlebar. The reading should be 1 Ω...
  • Page 25 C966 Treadmill 25. Set the on/off switch in the “off” position, and remove the spare jumper from J14 of the heart rate PCA. Re-locate all potential sources of radiation. Set the on/off switch in the “on” position and repeat the procedure in step 6.

  • Page 26: 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 27 C966 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 28: Procedure 5.5 - Troubleshooting The Lift System

    C966 Treadmill Procedure 5.5 - Troubleshooting the Lift System Lift System Description: The lift system on these units consists of an AC line voltage driven lift motor (120 Vac), and an internal 1 KΩ potentiometer for lift position identification. The lift motor contains two motor windings, one to operate the motor in an “upward”...
  • Page 29 12. If you have performed all of the procedures above and have been unable to correct the problem, call Precor customer service. 13. Set the treadmill’s circuit breaker in the “off” position and remove the AC line cord from the AC outlet.
  • Page 30 15. If you have performed all of the procedures above and have been unable to correct the problem, call Precor customer service. 16. Set the treadmill’s circuit breaker in the “off” position and remove the AC line cord from the AC outlet.

  • Page 31: Procedure 6.1 - Replacing The Lift Motor

    C966 Treadmill Procedure 6.1 — Replacing the Lift Motor Note: The replacement lift motor must be calibrated prior to installation. The lower PCA bracket assembly must be removed to gain access to the lift motor. The defective lift motor is then removed and the calibrated replacement lift motor is installed.

  • Page 32: Procedure 6.2 - Replacing The Lift Platform

    C966 Treadmill Procedure 6.2 — Replacing the Lift Platform Set the treadmill circuit breaker in the “off” position. Remove the AC line cord from the AC outlet. Remove the treadmill hood. Carefully, lay the treadmill on it’s right side. Remove the hitch pin and clevis pin that fastens the lift motor tube to the lift platform. While the lift tube is not fastened to the lift platform, care must be taken to not allow the lift tube to rotate.
  • Page 33 C966 Treadmill Diagram 6.2 - Lift Pin Removal Allen Wrench Lift Pin Pull the left hand (upper) lift pin out of the treadmill frame in the same manner as in step 5. Remove the lift platform from the treadmill. Remove both wheels from the lift platform and re-mount them on the replacement lift platform.

  • Page 34: Procedure 6.3 - Replacing The Speed Sensor

    C966 Treadmill Procedure 6.3 — Replacing the Speed Sensor Set the treadmill circuit breaker in the “off” position. Remove the AC line cord from the AC outlet. Disconnect the plug from the J2 connector on the lower logic PCA. Rotate the flywheel so that the speed sensor is between flywheel lobes.
  • Page 35 C966 Treadmill 11. Set the treadmill circuit breaker in the “on” position and check treadmill operation per Procedure 3. Page 35...

  • Page 36: Procedure 6.4 - Replacing Drive Motor

    C966 Treadmill Procedure 6.4 — Replacing Drive Motor Set the treadmill circuit breaker in the “off” position and unplug the treadmill’s line cord from the AC outlet. Remove the hood. The drive motor and flywheel are balanced as a matched pair. Since the flywheel is balanced to a specific motor, flywheels should not be removed from one and installed on a different motor.
  • Page 37 C966 Treadmill 15. Re-install the hood. 16. Check treadmill operation per Procedure 3. Page 37...

  • Page 38: Procedure 6.5 - Replacing The Circuit Breaker

    C966 Treadmill Procedure 6.5 — Replacing the Circuit Breaker Set the treadmill circuit breaker in the “off” position and unplug the treadmill’s line cord from the AC outlet. Diagram 6.4 — Circuit Breaker Mounting Panel Disconnect all of the wiring from the circuit breaker.
  • Page 39 C966 Treadmill Set the circuit breaker mounting panel in it’s mounting position. Fasten the circuit breaker mounting panel to the treadmill using the screws removed in step 2. Check treadmill operation per Section 3. Page 39...

  • Page 40: Procedure 6.6 - Replacing The Line Filter

    C966 Treadmill Procedure 6.6 — Replacing the Line Filter Set the treadmill circuit breaker in the “off” position and unplug the treadmill’s line cord from the AC outlet. Remove the four screws that fasten the circuit breaker mounting plate to the treadmill. See Diagram 6.10 or 6.11.

  • Page 41: Procedure 6.7 - Replacing The Line Cord

    C966 Treadmill Procedure 6.7 — Replacing the Line Cord Set the treadmill circuit breaker in the “off” position and unplug the treadmill’s line cord from the AC outlet. These units are equipped with a detachable line cord. Loosen the line cord clamping screw.

  • Page 42: Procedure 6.8 - Replacing The Drive Motor Cooling Fan

    C966 Treadmill Procedure 6.8 — Replacing the Drive Motor Cooling Fan Set the treadmill circuit breaker in the “off” position and unplug the treadmill’s line cord from the AC outlet. Remove the hood. Remove the drive motor per Procedure 6.4, steps 2-8.

  • Page 43: Procedure 6.9 - Replacing The Drive Motor Brushes

    C966 Treadmill Procedure 6.9 — Replacing the Drive Motor Brushes Set the treadmill circuit breaker in the “off” position and unplug the treadmill’s line cord from the AC outlet. Remove the hood. Remove the drive motor per Procedure 6.4, steps 2-6.

  • Page 44: Procedure 6.10 - Replacing The Lower Pca

    C966 Treadmill Procedure 6.10 — Replacing the Lower PCA Set the treadmill circuit breaker in the “off” position. Remove the AC line cord from the AC outlet. Note the routing and tie down points of all of the wiring coming into the lower PCA. This information will be required after the replacement lower PCA has been installed.

  • Page 45: Procedure 6.11 - Replacing The Prom

    C966 Treadmill Procedure 6.11 - 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 46 C966 Treadmill Wiring Diagram 7.1 — C966-120 Vac Page 46...
  • Page 47 C966 Treadmill Wiring Diagram 7.2 — C966-240 Vac Page 47...
  • Page 48 C966 Treadmill Block Diagram 7.3 — C966 120 Vac Page 48...
  • Page 49 C966 Treadmill Block Diagram 7.4 — C966 240 Vac Page 49...

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