Precor C932 Service Manual
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Precor C932 Service Manual

Precor C932 Service Manual

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C932, C932i, C934, C936i Treadmill
C932, C932i, C934, C936i 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.
© 2004 Precor Incorporated
Unauthorized Reproduction and Distribution Prohibited By Law
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  • Page 1 C932, C932i, C934, C936i 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.

  • Page 2: Section One - Things You Should Know

    Section Seven, Technical Diagrams and Parts Lists. This section includes wiring diagrams, and block diagrams for the treadmills. General Information For the latest exploded view diagram, part number and part pricing information, visit the Precor dealer website at “www.precor.com/connection”. Page 2...

  • Page 3: Technical Specifications

    C932, C932i, C934, C936i Treadmill Technical Specifications Physical Specifications Length: 79 inches (201 cm.) Width: 33.5 inches (85 cm.) Height: 55 inches (140 cm.) Running surface: 20 inches by 57 inches (51 cm. by 145 cm.) Motor: 3.0 hp. continuous duty DC Speed: 0.5 to 11 mph (0.8 to 18 kph)

  • Page 4: Procedure 2.1 - Accessing The Hardware Validation Program

    Plug the power cord into the wall outlet, then turn on the treadmill with the circuit breaker. Press keys RESET,5,1,7,6,5,7,6,1, sequentially. For C932 and C932i treadmills, skip to step 30. For C934 and C936i treadmills, continue with step 5. The display will momentarily read DISPLAY and then alternately illuminate every LED on the display.
  • Page 5 C932, C932i, C934, C936i Treadmill The display will momentarily read KEYBOARD. 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.
  • Page 6 LED positions to ensure that all of the LED’s are functioning. 31. Press either the RESET or SELECT key to continue to the keyboard test. Diagram 2.2 - C932 Treadmill Display Key # 7 Key # 1...
  • Page 7 C932, C932i, C934, C936i Treadmill 32. The display will scroll KEYBOARD TEST. The display will have a representation of every key on the keyboard including the STOP key. Press each key on the keyboard to ensure that all keys are functioning normally. Tug on the safety key lanyard, to ensure that the STOP key will activate.
  • Page 8 C932, C932i, C934, C936i Treadmilll 47. It is suggested that you perform this test on a treadmill known to be in excellent operating condition. Note the values displayed at a fixed power bit reading (as set by the SPEED keys) and your body weight. Those values may then be used to benchmark the operation of treadmills you are diagnosing.
  • Page 9 Plug the power cord into the wall outlet, then turn on the treadmill with the circuit breaker. Press the keys RESET,6,5, sequentially. For C932 and C932i treadmills, skip to step 19. For C934 and C936i treadmills, continue with step 4.
  • Page 10 C932, C932i, C934, C936i Treadmilll 15. The errors will be displayed as; 1: ERXX 16. The arrows keys will allow you to scroll through the log. 17. When the QUICK START key is held for 2 seconds the message CLEAR? will be displayed.

  • Page 11: Procedure 2.3 - Accessing The Club Setting Program

    Plug the power cord into the wall outlet, then turn on the treadmill with the circuit breaker. With the banner scrolling, press keys RESET,5,6,5,1,5,6,5, sequentially For C932 and C932i treadmills, skip to step 16. For C934 and C936i treadmills, continue with step 4.
  • Page 12 C932, C932i, C934, C936i Treadmilll 11. Use the keys to scroll through the possible range of maximum workout times (1 min. to 99 min. or no limit). 12. Press the ENTER key to select the currently displayed maximum workout time or the STOP key to leave the original maximum workout time selected.
  • Page 13 C932, C932i, C934, C936i Treadmill 27. Press the SELECT key to select the currently scrolling maximum pause time and to continue to the next selection. 28. The display will scroll SELECT MAX COOL DOWN TIME. The currently displayed maximum cool down time will then be scrolled (0 to 99 min. or no limit). Use the keys to select the desired maximum cool downtime.

  • Page 14: Procedure 2.4 - Documenting Software Problems

    C932, C932i, C934, C936i Treadmilll 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 15 C932, C932i, C934, C936i 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 16: Procedure 4.1 - Calibrating The Lift Motor

    C932, C932i, C934, C936i Treadmilll 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 17 C932, C932i, C934, C936i 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 18: Procedure 4.2 - Adjusting Drive Belt Tension

    C932, C932i, C934, C936i Treadmilll 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 19 C932, C932i, C934, C936i Treadmill Re-install the hood per Procedure 6.11. Diagram 4.3 - Drive Belt Adjustment Drive Motor Mounting Bolt 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 20: Procedure 5.1 - Troubleshooting The Keypad And Upper Pca

    C932, C932i, C934, C936i Treadmilll 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 21 C932, C932i, C934, C936i Treadmill Carefully, lift the display housing front panel off of the display housing backing plate. Disconnect the heart rate cable and stop switch cable from the upper PCA. Disconnect the keypad connector from the upper PCA. See Diagram 5.2.
  • Page 22 C932, C932i, C934, C936i Treadmilll 16. If one or more keys do not function correctly, either the keypad (display housing) or upper PCA could be defective. Replace the display and repeat step 14. If the display housing did not correct the problem, re-install the original display housing and replace the upper PCA.

  • Page 23: Procedure 5.2 - Troubleshooting The Lift System

    C932, C932i, C934, C936i 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), 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 24 C932, C932i, C934, C936i Treadmilll Insert the treadmill’s line in the AC outlet and set the circuit breaker in the “on” position. Set the treadmill in the manual program and press the LIFT key. If the lift motor operates normally, test treadmill operation per Section 3. If the lift motor still does not operate, retest the lift fuse per steps 2 &...
  • Page 25 C932, C932i, C934, C936i Treadmill 14. If the resistance readings in step 13 are normal, replace the lower logic PCA per Procedure 6.3. 15. If you have performed all of the procedures above and have been unable to correct the problem, call Precor customer service.

  • Page 26: Procedure 5.3 - Troubleshooting The Speed Sensor

    C932, C932i, C934, C936i Treadmilll Procedure 5.3 - 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 27 C932, C932i, C934, C936i Treadmill Measure the voltage between terminal 1 of J3. (red wire) and terminal 4 of J3 (black wire) on the lower PCA, see Diagram 5.2. The voltage should read approximately 5 Vdc. If the voltage is missing or significantly low, disconnect the speed sensor plug from the lower PCA.

  • Page 28: 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 29 C932, C932i, C934, C936i 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 30: Procedure 6.1 - Replacing The Lift Motor

    C932, C932i, C934, C936i Treadmilll Procedure 6.1 - Replacing the Lift Motor Note: The replacement lift motor must be calibrated prior to installation. The defective lift motor is then removed and the calibrated replacement lift motor is installed. If the incline is at 0%, skip to step 3.

  • Page 31: Procedure 6.2 - Replacing The Lift Platform

    C932, C932i, C934, C936i 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.
  • Page 32 C932, C932i, C934, C936i Treadmilll Diagram 6.2 - Treadmill Frame Trim Frame Trim Lift Platform Mounting Pin Front Check treadmill operation per Procedure 3. Page 32...

  • Page 33: Procedure 6.3 - Replacing The Lower Pca

    C932, C932i, C934, C936i Treadmill Procedure 6.3 - Replacing the Lower PCA Set the treadmill circuit breaker in the “off” position. Remove the AC line cord from the AC outlet. Disconnect the lower PCA drive motor connector from the drive motor. Disconnect Both lift motor connectors, the speed sensor connector, the drive motor fan connectors, the lower PCA fan connector and the AC input wires from the lower PCA.
  • Page 34 C932, C932i, C934, C936i Treadmilll 10. Feed the three pin lift motor connector through the grommet in the lower PCA bracket and insert it in the J7 connector of the lower PCA. 11. Insert the large lift motor connector in the J1 connector of the lower PCA.

  • Page 35: Procedure 6.4 - Replacing The Speed Sensor

    C932, C932i, C934, C936i Treadmill Procedure 6.4 - 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 J3 connector on the lower PCA.
  • Page 36 C932, C932i, C934, C936i Treadmilll Feed the speed sensor connector through the grommet in the lower PCA bracket and insert it in the J3 connector of the lower PCA. 10. Slowly rotate the flywheel to ensure that the flywheel lobes do not contact the speed sensor.

  • Page 37: Procedure 6.5 - Replacing Drive Motor

    C932, C932i, C934, C936i Treadmill Procedure 6.5 - 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 38 C932, C932i, C934, C936i Treadmilll 16. Check treadmill operation per Procedure 3. Page 38...

  • Page 39: Procedure 6.6- Replacing The Circuit Breaker

    C932, C932i, C934, C936i Treadmill Procedure 6.6- Replacing the Circuit Breaker Set the treadmill circuit breaker in the “off” position and unplug the treadmill’s line cord from the AC outlet. Remove the sheet metal screw that is approximately in the center of the treadmill dress panel.
  • Page 40 C932, C932i, C934, C936i Treadmilll Check treadmill operation per Section 3. Page 40...

  • Page 41: Procedure 6.7 - Replacing The Line Filter

    C932, C932i, C934, C936i Treadmill Procedure 6.7 - 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 sheet metal screw that is approximately in the center of the treadmill dress panel.

  • Page 42: Procedure 6.8 - Replacing The Line Cord

    C932, C932i, C934, C936i Treadmilll Procedure 6.8 - Replacing the Line Cord Set the treadmill circuit breaker in the “off” position and unplug the treadmill’s line cord from the AC outlet. Remove the sheet metal screw that is approximately in the center of the treadmill dress panel.

  • Page 43: Procedure 6.9 - Replacing The Drive Motor Cooling Fan

    C932, C932i, C934, C936i Treadmill Procedure 6.9 - 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 brown and blue wires from the drive motor cooling fan.

  • Page 44: Procedure 6.10 - Replacing The Drive Motor Brushes

    C932, C932i, C934, C936i Treadmilll Procedure 6.10 - 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 screws that retain the drive motor brush cover. Carefully, remove the heavy paper cover from the brush access opening.
  • Page 45 C932, C932i, C934, C936i Treadmill Replace the hood per Procedure 6.11. 10. Check treadmill operation per Procedure 3. Page 45...

  • Page 46: Procedure 6.11 - Removing And Replacing The Hood

    C932, C932i, C934, C936i Treadmilll Procedure 6.11 - Removing and Replacing the Hood Set the treadmill circuit breaker in the “off” position and unplug the treadmill’s line cord from the AC outlet. Remove the four bolts that mount the hood the treadmill. Note that only two front bolts utilize flat washers Remove the hood from the treadmill.

  • Page 47: Procedure 6.12 - Replacing The Prom

    C932, C932i, C934, C936i 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 48 C932, C932i, C934, C936i Treadmilll Wiring Diagram 7.1 - C932, C932i C934, C936i Lower J2-1 J2-2 AC Line Cord 120 VAC Units Only Page 48...
  • Page 49 C932, C932i, C934, C936i Treadmill Block Diagram 7.2 - C932, C932i, C934, C936i Page 49...

This manual is also suitable for:

C932iC936iC934

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