Precor C960, C962, C964 Service Manual

C960 Series Commercial Treadmill
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C960, C962, C964 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
C960 Series Commercial Treadmill
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Section One - Things you Should Know
About This Appendix
Section One, Things You Should Know. This section includes technical specifications and a
procedure matrix. Read this section, as well as the owner's manuals shipped with the C960, C962 and C964 Treadmills, before you perform the procedures in this manual.
Section Two, Software Features. Precors C960 Series Treadmills are programmed with several diagnostic and setup features. This section contains the procedures you need to access the diagnostic features on this treadmill.
Section Three, Checking Treadmill Operation. This section provides you with a quick way 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.
Section Four, Inspection and Adjustment Procedures. Perform inspection procedures when a trouble symptom points to a problem and after replacing major components. Many maintenance problems can be fixed by adjusting various treadmill components. This section also provides the step-by-step procedures required to make these adjustments.
Section Five, Troubleshooting Procedures. Diagnostic and troubleshooting procedures are performed when it is necessary to isolate a problem to a particular component.
Section Six, Replacement Procedures. When a component must be replaced, follow the step­by-step procedures included in this section.
Section Seven, Technical Diagrams and Parts Lists. This section includes wiring diagrams and block diagrams for the C960, C962 and C964 Treadmills.
General Information
For the latest exploded view, part number and part pricing information, visit the Precor dealer website at “www.precor.com/Dealer.
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Technical Specifications
Length: 80.5 inches (205 cm.) Width: Handrails 32 inches (81 cm.) Height: 45 inches (114 cm.) Running surface: 61 inches by 20 inches (155 cm. by 51 cm.) Speed: 240 Volts: 0.5 to 15 m.p.h. (0.8 to 24 k.p.h.)
120 Volts: 0.5 to 10 m.p.h. (0.8 to 16 k.p.h.)
(SCR)
120 Volts: 0.5 to 15 m.p.h. (0.8 to 24 k.p.h.), (PWM) Incline: -3% to +15% grade (C962 and C964 only)
0% Fixed grade (C960) Power: 50/60 Hz 120 Vac or 240 Vac Shipping Weight: 502 lbs (226 kg.)
C960 Series Commercial Treadmill
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Serial Number Sequencing
Table 1 identifies the serial number sequences for C960 Series SCR and PWM treadmills.
Table 1. C960 Series Treadmill Serial Number Sequences
SCR Units
If the Model is... And the Voltage The Serial Number
Rating is... Starts With...
C960 120 83 C960 240 84 C962 120 80 C962 240 82 C964 120 81 C964 240 85
PWM Units
If the Model is... And the Voltage The Serial Number
Rating is... Starts With...
C960 240 1N C962 120 1Y C962 240 1P C964 120 1Q C964 240 1R
i Units
If the Model is... And the Voltage The Serial Number
Rating is... Starts With...
C962i 120 3A C962i 240 3B C964i 120 3E C964i 240 3F
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SCR and PWM Upper PCAs
Note:
Upper PCA part number 33663-10X is used on C960s & C962s. Up per PCA part n umb er 3366 2­10X is used on C964s. There are currently three versions of the upper PCA that may be encountered in the field. Versions -101 through 105 were only used on SCR treadmills and have a fixed 11 MHZ clock frequency. Treadmills manufactured starting October 10, 1995 used the version -106. Theses boards could be used on either SCR or PWM treadmills and could be set for either 11 MHZ (SCR) or 16 MHZ (PWM) operation (see diagram 1.1). On August 6, 1997 on version -108 the jumper selection was changed to indicate SCR or PWM (see diagram 1.2).
Diagram 1.1 - UPCA jumpers versions -106 & -107
Diagram 1.2 - UPCA jumpers versions -108 and higher
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Procedure 2.1 - Running the Diagnostic Program (SCR &
PWM Units)
Placing the C962 or C964 Treadmill in diagnostic mode causes the software to perform the following operations:
a Test the LEDs mounted on the upper PCA; b Provide the option of adjusting the lift system; c Provide the option of adjusting the limit switches; d Display the odometer setting in either miles or kilometers; e Display the software version number; f Display the drive motor power bits; g For SCR units (PROM Version 2.08 and earlier), display a prompt allowing you to select
between 110- and 220-volts; and
h Provide a method of checking the operation of the keys on the electronic console.
Procedure
1. Plug the power cord into the wall outlet, then position the safety switch at the green dot. Turn on the treadmill by using the circuit breaker.
2. At the PRESS ENTER FOR PROGRAMS prompt, press and hold the SPEED
T, SPEED S,
and INCLINE
S keys simultaneously or keys RESET,5,1,7,6,5,7,6,1 sequentially on units
with standard access codes. The LED display test is initiated on the electronic co nsole. (The C964 electronic console is shown in Diagram 2.1. Diagram 2.2 is the C962 electronic console. The C960 electronic console is shown in Diagram 2.3).
3. Watch the electronic console as the display test progresses. This test is programmed to display the following LED illumination sequence:
a A horizontal series of dashes appear on the left and right display windows; and b The LEDs to the left of the first column of functions illuminate, followed by the LEDs to
the second and third column.
4. The ADJUST LIFT [YES/DN NO/UP] prompt is displayed. If you wish to adjust the lift...
C960 Series Commercial Treadmill
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THEN... OTHERWISE...
Press any
T key, then continue Press any S key, then skip to Step 6.
with the next step.
Diagram 2.1 - C964 Electronic Display
5. With the message PRESS ENTER WHEN FINISHED displayed on the electronic console, press the INCLINE
S and INCLINE T keys to adjust the slant of the running bed. Press
ENTER when you are finished.
6. The LIMIT SWITCH [YES/DN NO/UP] prompt is displayed. If you wish to check the limit switches...
THEN... OTHERWISE...
Press any T key, then continue Press any S key, then skip to Step 9. with the next step.
7. Watch the electronic console. If the three limit switches are adjusted co rrectly, t he followin g series of messages is displayed on the electronic console:
GOING TO FIFTEEN PERCENT AT FIFTEEN PERCENT GOING TO UPPER LIMIT GOING TO NEG THREE PERCENT AT NEGATIVE THREE PERCENT GOING TO LOWER LIMIT GOING TO ZERO
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Diagram 2.2 - C962 Electronic Display
Diagram 2.3 - C960 Electronic Display
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8. If all of the messages listed in Step 7 are displayed on the electronic console...
THEN... OTHERWISE...
The treadmill lift switches are Press RESET to return to the PRESS calibrated correctly, press ENTER ENTER FOR PROGRAMS prompt, to continue. then calibrate the lift systems
described in Procedure 4.1.
Note:
Some newer versions of software display the odometer as a separate function. Refer to procedure 2.4 for these units.
9. The electronic console displays the odometer reading. With the MILE NNNNN or
KILOMETER NNNNN message displayed, press ENTER.
Note:
NNNNN represents the number of miles (or kilometers) travelled on the running belt. The mileage is recorded on the upper PCA. If a new upper PCA is installed in the treadmill, the odometer reading will be zero.
10. The electronic console displays the version number of the PROM. With the VERSION N.N message displayed, press ENTER.
Note:
N.N represents the version number of the PROM currently installed on the upper PCA.
11. The electronic console displays the drive motor power bits. With the POWER BITS NNN message displayed, press ENTER.
IMPORTANT
Step 12 applies only to SCR units (PROM Version 2.08 and earlier).
12. Press ENTER to display the CHOOSE MOTOR [220/DN 110/UP] prompt. If you are servicing a 110-volt treadmill, press any
S key, then continue with the next step. If you are
servicing a 240-volt unit, press any
T key.
13. The electronic console displays the NO KEYS message. Press each of the keys listed in the left column of Table 2.1. Verify that the message across from each function key name is displayed on the electronic console as the key is pressed.
Note:
The messages displayed in the right column are displayed as the keys are pressed. The message NO KEYS is displayed after each key is pressed.
14. When the NO KEYS message is displayed after you test the QUICK START/SET PACER key, press RESET to return to the PRESS ENTER FOR PROGRAMS prompt.
15. Turn off the treadmill with the circuit breaker, then unplug the power cord from the wall
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outlet.
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Table 2.1 - Electronic Console Key Test
KEY TO BE PRESSED MESSAGE TO BE VERIFIED
Left CHANGE Key CHANGE 1 Middle CHANGE Key CHANGE 2 Right CHANGE Key CHANGE 3 ENTER ENTER INCLINE t INCLINE DOWN INCLINEs INCLINE UP STOP/PAUSE STOP SPEED t SPEED DOWN SPEED s SPEED UP QUICK START/SET PACER SET PACER
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Procedure 2.2 - Running the Diagnostic Program (i Units)
Placing the C962i or C964i Treadmill in diagnostic mode causes the software to perform the following operations:
a Test the LEDs mounted on the upper PCA; b Provide the option of calibrating the lift system; c Display the drive motor power bits; d Display and test the heart rate function; e Display the error code log; f Provide a method of checking the operation of the keys on the electronic console; g Test the circuit breaker trip function.
Procedure
1. Plug the power cord into the wall outlet, then position the safety switch at the green dot. Turn on the treadmill by using the circuit breaker.
2. At the PRESS ENTER FOR PROGRAMS prompt, press keys RESET,5,1,7,6,5,7,6,1 sequentially. The LED display test is initiated prompt on the electronic console. (The C964i electronic console is shown in Diagram 2.4. The C962i electronic console is shown in Diagram 2.5).
3. Watch the electronic console as the display test progresses. This test is programmed to illuminate every LED on the display. It is necessary to watch the test as it proceeds to determine if an LED does not illuminate. Press the ENTER key to proceed to the next test.
4. The lift calibration setup will be available if required. If you need to calibrate the lift proceed with step 5, otherwise, press the ENTER key, go to step 6 and choose RECALIBRATE NO.
5. Using the INCLINE
S and INCLINE T keys set the treadmill so that the distance from the
bottom front corner of the treadmill frame is 4.3 inches ± .05 inch. When the position is set press the ENTER key. In step 6 of this procedure, choose RECALIBRATE YES.
6. You will be offered the to choice to either recalibrate the lift or to proceed without recalibrating the lift. Press one of the
S keys to recalibrate the lift or one of the T keys to
proceed without recalibrating the lift.
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Diagram 2.4 - C964i Electronic Display
Diagram 2.5 - C962i Electronic Display
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7. The power bits will be displayed. The power bits indicate how much power is being applied to the drive motor. The power bit reading is a combination of the speed selected and the load applied to the treadmill. The power bit reading can be used to help determine bed and belt wear. To display power bits, press the SPEED
S key. Observe that the power bit
reading will increase when the speed is increased and/or the load is increased. Press the ENTER to continue to the next test.
8. Heart rate will be displayed. Either a heart rate test transmitter or chest strap transmitter may be used. The heart rate will be displayed. Press the ENTER key to proceed to th e next test.
9. The error code log will be displayed. Use the
st keys to scroll through the log. Position 1 will
contain the most recent error logged and error 5 will contain the oldest error logged. If more than five errors have been logged, the most recent error will be entered into position 1, and all of the existing errors will be pushed down one position. The error that was in position 5 will be lost. If you wish to clear the error code log, press the QUICK START key. Press the ENTER key to proceed to the next test.
10. The keypad test will be displayed. Press each of the keys on the display panel, the display will indicate which key was pressed. This test will also check safety switch operation.
11. The next test is the circuit breaker trip test. While the keypad test is still displayed, press and hold the STOP key. After a few seconds the circuit breaker will trip.
12. The diagnostics program is now complete.
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Procedure 2.3 - Selecting Club Settings
Selecting United States standard units causes information to be displayed in feet and pounds. Information is displayed in meters and kilograms if metric units are selected.
Procedure
1. Plug the power cord into the wall outlet, then position the safety switch at the green dot. Turn on the treadmill by using the circuit breaker.
2. At the PRESS ENTER FOR PROGRAMS prompt, press and hold all three CHANGE keys simultaneously or keys RESET,5,6,5,1,5,6,5 sequentially on units with standard access codes until the CHOOSE UNITS [YES/DN NO/UP] prompt is displayed.
3. Use any
S or T key to select either the U. S. Standard or Metric measurement system.
4. With the MAX SPEED prompt displayed, use the
S or T keys to designate a workout speed
limit. Press ENTER when the desired speed appears.
Note:
For 110-volt treadmills, the maximum workout speed limit is between either 1 and 10 MPH or 1 and 16 KPH. Maximum workout speed limits for 220-volt treadmills range between 1 and 12 MPH or 1 and 20 KPH.
5. With the MAX WORKOUT prompt displayed, use the
S or T keys to designate a workout
time limit between 10 and 240 minutes. Press ENTER when the desired time appears.
IMPORTANT
On PWM C960 Series Treadmills, you may choose either English, Spanish, German or French language options.
6. The MODIFY CUSTOM prompt is displayed. If you plan to customize the program...
THEN... OTHERWISE...
Press any
T key, then press Press any S key, then press ENTER
ENTER to return to the PRESS tto return to the PRESS ENTER FOR ENTER FOR PROGRAMS prompt. PROGRAMS prompt.
Note:
Instructions for designing custom courses are provided in the C964 Owner's Manual.
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Procedure 2.4 - Displaying the Odometer
Note:
Some older versions of software display the odometer as part of the diagnostics program. Refer to procedure 2.1 for these units.
1. To access the odometer press the RESET key to return to the start up point, if necessary. Press keys Speed
S and Incline S, simultaneously or keys RESET,6,5 sequentially. The
odometer will displayed in either miles or kilometers depending on club setting selection. Refer to procedure 2.3.
2. Press the Enter key. The hours in use will be displayed.
3. Press the Enter key. The software version will be displayed.
4. Press the Enter key to exit.
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Procedure 2.5 - Determining Software Version Numbers
Software version numbers are invaluable for tracking and identifying problems and staying aware of changes to the operation and features of the product. Software version numbers will usually appear as two digits separated by a decimal.
Procedure
1. Plug the power cord into the wall outlet, then position the safety switch at the green dot. Turn on the treadmill by using the circuit breaker.
2. On older software versions access the diagnostics as in procedure 2.1. On newer software versions enter the odometer program as in procedure 2.4
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Procedure 2.6 - Documenting Software Problems
When a problem is found with either the software or upper or lower PCAs, record th e information listed below. 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:
Model and serial number
Software version number Determine the version number of the PROM mounted on the upper PCA as described in
Procedure 2.5 or by looking at the label on the PROM. See Diagram 2.6
Program number running when the problem occurred
A description of: a What happened or failed to happen. b The action taken by the user just before the problem occurred. c Problem-related information (such as how far into the program the problem occurred,
the work level being used when the problem occurred, etc.).
The frequency of occurrence.
Diagram 2.6 - Prom
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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.
Procedure
1. Plug the power cord into the wall outlet, then turn on the treadmill with the circuit breaker.
2. Place the treadmill in Manual Mode. Adjust the speed of the running belt to 2–3 m.p.h. Operate the treadmill for at least 5 minutes.
a Concentrate on the feel of the running belt and the sound of the drive motor and rollers.
Be on the alert for unusual noises, smells, or vibrations.
b. On SCR units, measure and log the AC input current under loaded and unloaded con-
ditions. On PWM units, log the power bits under loaded and unloaded conditions.
c Observe the Leds on the electronic console. Make sure that each LED lights as the
information corresponding to that LED is displayed on the electronic console.
3. Press the STOP key. When the treadmill comes to a stop, view the electronic console as the treadmill scans time, speed, distance and percent.
Note:
If you are servicing a C960 Treadmill, skip Steps 4 and 5.
4. Press the INCLINE
S key while viewing the electronic console. Confirm that the treadmill
inclines and the incline display increments to twelve percent as the INCLINE
S key is
pressed.
5. Press the INCLINE
T key while viewing the electronic console. Confirm that the running bed
returns to a level position and the incline display decrements to minus three percent as the INCLINE
T key is pressed.
6. Return the treadmill to 0% incline and turn off the treadmill with the circuit breaker, then unplug the treadmill from the wall outlet.
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Procedure 4.1 - Calibrating the Lift Assembly on C962 &
C964 SCR & PWM Units
WARNING
Always turn off the circuit breaker and unplug the treadmill before you remove the treadmill hood.
1. If the treadmill is not already at zero percent incline, press any key when the CALIBRATE LIFT PRESS ANY KEY prompt is displayed.
2. Using the ruler, measure the distance between the floor and the top of the front and back ends of the side rail (see Diagram 4.1).
Note:
The distance between the floor and the top of the front end of the side rail should be 11 inches.
Diagram 4.1 - Measuring the Ends of the Side Rail
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3. If the distances recorded in the previous step are equal to within 1/4 inch...
THEN... OTHERWISE...
Skip to Step 17. Continue with the next step.
4. At the PRESS ENTER FOR PROGRAMS prompt, press and hold the ENTER key.
5. Press ENTER when the display test starts.
6. With the ADJUST LIFT [YES/DN NO/UP] prompt displayed, press any
T key. The
message PRESS ENTER WHEN FINISHED is displayed on the electronic console.
7. If the distance measured at the front of the side rail is larger than the distance measured at the back of the side rail...
THEN... OTHERWISE...
Press the INCLINE
T key until Press the INCLINE S key until the
the front and back treadmill front and back treadmill measurements measurements are equal; then are equal; then press RESET. press RESET.
8. 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 Commercial Treadmill Service Manual.
9. Remove the hood.
10. Check the position of the zero sense switch in relation to the switch actuator (see Diagram
4.2).
11. If the widest point of the switch actuator is lined up with the center of the wheel on the zero 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.
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Diagram 4.2 - Limit Switch Bracket Assembly
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). Turn off the treadmill and unplug the power cord from the wall outlet before you perform the following steps.
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12. Loosen the socket head bolts and washers that secure the switch bracket to the lift platform (see Diagram 4.2).
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.
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 Move the switch bracket up until the the widest part of the actuator is widest part of the actuator is centered centered on the wheel on the zero on the wheel on the zero sense switch; sense switch; then continue with then continue with the next step. the next step.
14. Tighten the socket head bolts and washers that secure the switch bracket to the lift platform.
15. Replace the hood
16. Check the operation of the treadmill as described in Section 3 of this appendix.
IMPORTANT
If the electronic console displays the diagnostic message LIFT ERROR PRESS STOP when you incline or decline the running bed to its maximum limits, repeat this procedure.
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Procedure 4.2 - Calibrating the Lift Assembly on C962i &
C964i Treadmills
Note:
On April 20, 2000 the C962i and C964i treadmills were equipped with a lift utilizing an internal lift potentiometer. Use the calibration procedure in steps 1-4 for units manufactured prior to April 20,
2000. For units manufactured after March 26, 2000, skip to step 5.
1. Enter the diagnostics program by pressing keys RESET,5,1,7,6,5,7,6,1, sequentially. Proceed to the lift calibration portion of the diagnostics routine.
2. Use the INCLINE
S and INCLINE T keys to set the distance between the front, bottom
corner of the frame to the floor at 4.3 inches ± 0.05 inch. See diagram 4.3. After the 4.3 inch distance has been set, press the ENTER key. At the message PRESS UP TO RECALIBRATE / PRESS DOWN FOR NO RECALIBRATION, press one of the
S keys.
3. Exit the diagnostics program.
4. Check the rear bottom corners of the frame. If the rear corners of the frame do not measure
4.3 inches to the floor, adjust the rear feet accordingly. If the rear feet need to be adjusted more than 1 inch, the treadmill should be relocated to a more level location.
Note:
It is important that the lift is calibrated first (steps 1 & 2) before the rear height is adjusted.
Diagram 4.3 - Lift Calibration Dimensions
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5. Set the on/off switch in the off position. Lay the treadmill on its left side.
6. Remove the bolt that fastens the lower end of the lift motor to the lift platform.
7. Set the on/off switch in the on position. Enter the diagnostics program by pressing keys RESET,5,1,7,6,5,7,6,1, sequentially. Proceed to the lift calibration portion of the diagnostics routine.
8. Using the INCLINE
S and INCLINE T keys, set the lift calibration number to 78.
9. Exit the diagnostics program and set the on/off switch in the off position. Taking care not to rotate the lift motor drive screw, rotate the lift motor tube until the measurement between th e lift motor frame and the top of the lift tube is 1-7/8 inches. See Diagram 4.4.
Diagram 4.4 - Lift Motor Calibration
10. Fasten the lift motor tube to the lift platform with the bolt removed in step 6. Do not rotate the lift tube any more than is necessary to align the lift tube mounting hole with the lift platform mounting hole.
11. Set the treadmill in an upright position. The distance from the front of the treadmill to the floor should be 4.3 inches. See Diagram 4.3.
12. Check the rear bottom corners of the frame. If the rear corners of the frame do not measure
4.3 inches to the floor, adjust the rear feet accordingly. If the rear feet need to be adjusted more than 1 inch, the treadmill should be relocated to a more level location.
1-7/8
Lift Motor Drive Screw
Lift Motor Tube
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Procedure 4.3 - Inspecting and Adjusting Safety Switch
Alignment
WARNING
Always turn off the circuit breaker and unplug the treadmill before you remove the treadmill hood.
Inspecting the Alignment of the Safety Switch
1. Turn off the treadmill with the circuit breaker, then unplug the power cord from the wall outlet.
2. Attach the safety clip to your clothing at waist level, then watch the safety switch as you step backwards.
Note:
Do not attach the safety clip too securely.
3. If the safety switch tripped before the safety clip came off your clothing...
THEN... OTHERWISE...
The safety switch is adjusted Continue with the next step. correctly; skip to Step 15
Adjusting the Alignment of the Safety Switch
4. Remove the screws that secure the display housing to the display housing mounting plate.
5. Place your right hand on the two right upper display housing mounting tabs. Place your left hand on the left tabs.
6. Push the right tabs towards the right targa upright and the left tabs towards the left targa upright, while lifting the display housing from the mounting plate. Support the display housing on the front handrails.
7. Loosen the screws and nuts that secure the safety limit switch to the switch mounting bracket (see Diagram 4.5).
8. Slide the safety switch away from the cam.
9. Tighten the screws and nuts that secure the safety limit switch to the switch mounting bracket.
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Diagram 4.5 - Safety Switch Assembly
10. Line up the tabs on the display housing with the holes on the display housing mounting plate.
11. Gently press the display housing onto the mounting plate until the tabs are pushed into the holes.
12. Attach the safety clip to your clothing at waist level, then watch the safety switch as you step backwards.
13. If the safety switch tripped before the safety clip came off your clothing...
THEN... OTHERWISE...
The safety switch is adjusted correctly; Return to Step 5. continue with the next step.
14. Replace the three screws that secure the upper display housing to the display housing mounting plate.
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