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GEN06 Series C952
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Precor GEN06 Series C952, TRM10 Series, GEN06 Series C966, GEN06 Series C954, GEN06 Series C956 Service Manual

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Page 1
Service Manual
TRM10/GEN06 Treadmill
120 VAC and 240 VAC
Page 2
Contents
1Introduction 1
General Information 3
Orientation 3
Tools 3
Parts 3
Lubrication 4
Cleaning Solutions 4
Electrical Requirements 4
Safety Guidelines 6
Safety guideline you need to know and follow: 6
2Operation Verification 8
Operation Verification Procedure 8
Operation Verification Checklist 9
3Standard Service Software 10
4Adjustment Procedures 20
About 21
Procedure 21
About 24
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Procedure 24
About 26
Procedure 26
5Replacement Procedures 29
About 30
Procedure 30
About 32
Procedure 32
About 34
Procedure 34
About 36
Procedure 36
About 40
Procedure 40
About 42
Procedure 42
About 46
Procedure 46
About 48
Procedure 48
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About 51
Procedure 51
About 53
Procedure 53
About 55
Procedure 55
About 57
Procedure 57
About 59
Procedure 59
About 61
Procedure 61
About 66
Procedure 66
6Troubleshooting 68
Validate a customer reported issue: 68
Basic Steps 68
About 70
Viewing Error Codes 71
Troubleshooting with Error Codes 71
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Available Troubleshooting Procedures 74
Auto Stop Troubleshooting 75
Tripped Circuit Breaker 78
Communications Error Troubleshooting 81
No Power to the Console Troubleshooting 82
Drive Motor System Troubleshooting 83
E-Stop Not Communicating 86
Heart Rate Monitor Troubleshooting 87
Incline System Troubleshooting 89
Input Power and Machine Controls Troubleshooting 90
Running Belt and Deck Troubleshooting 91
Tripped Circuit Breaker 93
7Preventive Maintenance 96
8Theory of Operation 103
About 103
Consoles 103
Treadmill Base Operation 104
System Diagrams 110
System Block Diagram - 120 VAC 110
System Wiring Diagram 110
9Parts 111
Exploded View Diagram 112
Parts Identification List 117
Appendix A : Edition Information i
Edition i
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Copyright i
Appendix B : Notices and Safety ii
Trademarks ii
Intellectual Property ii
Warranty ii
Safety Instruction ii
Safety Notices ii
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1 Int roduction

1Introduction
If you are not a Precor certified servicer, you must not attempt to service any Precor Product. Call your dealer for service information.
WARNING: This service documentation is for use by Precor certified servicer pro-
viders only. Personal injury can result from electrical shock and/or mechanical moving parts.
This service manual applies to the following treadmill models:
l GEN06 series treadmill: The GEN-06 treadmill base is defined as any treadmill pro-
duced between April 2006 and April 2011. GEN-06 Treadmills include the following models; C952, C954, C956, and C966.
l TRM10 series treadmill: The TRM10 treadmill base is defined as any treadmill pro-
duced after April 2011 and is configured with a Pxx series console. All of the base and console combinations are part of the "Experience" line of products.
This document contains information required to perform troubleshooting and replacement pro­cedures required to repair and maintain this equipment including: general product information, software diagnostic procedures, preventative maintenance procedures, inspection and adjust­ment procedures, troubleshooting procedures, replacement procedures and system block and wiring diagrams.
Separate Base/Console Service Manuals
This document provides information to service the equipment base independent of the installed console. For console service documentation, refer to the particular console service manual.
Additional Documentation
There is also an online web version if you have internet access at: Online Service Manual
See Also
"General Information" on page3
"Safety Guidelines" on page6
"Operation Verification" on page8
"Standard Service Software" on page10
"Preventive Maintenance" on page96
"Adjustment Procedures" on page20
"Replacement Procedures" on page29
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"Troubleshooting" on page68
"Theory of Operation" on page103
1 Int roduction
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1 Int roduction

General Information

General Information
The following information provides general equipment and service information that will help you to use this manual to properly repair and maintain the treadmill.

Orientation

The equipment orientation (front, right, left, back) used in manual is referenced to a user stand­ing on the equipment facing the console.

Tools

General set of service and repair tools.
l US and Metric Hex Key set l Standard and Philips screw driver set l US SAE and Metric Wrench set l DVM Multimeter l Torque wrench l Crank Puller (recommended Park Tool CCP-22) l US SAE and Metric socket set l Belt Tension Gauge (recommended Kent-Moore BT-33-73-
F)
l Running belt tension gauge
(pn PPP00000002000710

Parts

IMPORTANT: Always purchase OEM replacement parts and hardware from Precor. If you use parts not approved by Precor, you could void the Precor Limited Warranty. Use of parts not approved by Precor may cause injury.
Exploded View Diagram and Parts List
There is a copy of the parts the "Parts" on page111 chapter that you can use as a quick reference. It is recommended that
you go to the servicer partners Precor Connect (or Precor Connection) website to view the
Exploded View Diagram
and
Parts Identification List
included in
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1 Int roduction
General Information
most current parts information including the
List
.
l
Precor Connect Partner website
Exploded View Diagram
and
Parts Identification
Exploded View Diagram and Parts list, see "Parts" on page111.
.

Lubrication

Use only synthetic lubricants such as Mobile 1 Synthetic grease or Super Lube with Teflon. Use of unapproved lubricants, cleaners, or solvents may void the bike warranty.
CAUTION: Do not apply any lubricants or wax to the deck and belt. Do not use Wax
Blast, silicon sprays, or other applied lubricants. The use of these lubricants will quickly degrade the low-friction surface of the deck.
CAUTION: Do not use petroleum based lubricants on mechanical components such
as the lift, as this may result in degradation of nylon gearing mechanisms. Use only syn­thetic lubricants such as "Super Lube with Teflon" or "Mobile One Synthetic" grease (RED).
Use of unapproved lubricants, cleaners, or solvents may void the treadmill warranty.

Cleaning Solutions

Wipe down equipment with recommended cleaning solution. Use dry cloth to remove residue solution.
l General: 1 oz. mild soap (Simple Green) to 30 oz. water.
l Console and PVS: a diluted solution of one part 91% Isopropyl alcohol to one part
water.
CAUTION: Do not use acidic cleaners and do not spray directly onto the equipment
surfaces.

Electrical Requirements

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1 Int roduction
General Information
Dedicated Branch Circuit
It is required that the treadmill be connected to and operated on a dedicated 20 amp AC branch circuit. A Dedicated Branch Circuit is defined as a circuit fed by a single circuit breaker feeding a single load, with a single non-shared neutral providing a return line. A treadmill oper­ating from a non-dedicated branch circuit or a circuit breaker of less than 20 amps capacity will not have the necessary power to operate normally under higher load conditions.
120 Vac Systems
120 VAC distribution systems utilize a single pole circuit breaker (power lead) and a neutral lead connected to a common neutral (ground) bar. The AC. safety ground (green wire) is con­nected to a separate ground bar in the distribution system.
If it is determined that any of the above electrical conditions are in question, please consult with a qualified electrician to make appropriate circuit changes.
CAUTION: The treadmill requires a 20-amp individual branch circuit grounded per
NEC (National Electric Code) guidelines or local region electric code.
IMPORTANT: If the AC circuit feeding a treadmill is found to be a non-dedicated branch circuit or a circuit equipped with a capacity of less than 20 amps, the AC circuit must be corrected before any reliable Troubleshooting can be performed. More importantly, a non-dedicated branch circuit may constitute a safety hazard to the tread­mill operator .
Input Power
Nominal 120 VAC models
l Operating voltage: 90 VAC to 132 VAC.
l Frequency: 47 65 Hz
Nominal 240 AC Models
l Rated Operating voltage: 180 VAC - 264 VAC.
NOTE: An Internal operating voltage range of 180 – 275 VAC with reduced per-
formance is allowed.
l Frequency: 47-65 Hz
Frame Ground
For operator safety and to minimize electrostatic discharge conditions the AC frame ground continuity must also be verified to be a low resistance connection to the AC distribution ground bar.
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1 Int roduction

Safety Guidelines

Safety Guidelines
WARNING: Only Precor certified servicers and technicians are permitted to service
Precor products. Personal injury can result from electrical shock and/or mechanical moving parts.

Safety guideline you need to know and follow:

l Read and follow all Warning notices to protect yourself from personal injury.
l Read and follow all Caution notices to prevent damage to the equipment.
l Read the owner’s manual and follow all operating instructions.
l Operate the equipment on a solid, level surface.
l Visually check the equipment before beginning service or maintenance operations. If it
is not completely assembled or is damaged in anyway, do not attempt to operate the equipment.
l Never place liquids on any part of the equipment while performing service.
l To prevent electrical shock, keep all electrical components away from water and other
liquids.
l Do not use accessory attachments that are not recommended by the manufacturer.
Non-OEM accessories can cause injuries.
l Do not stand or climb on the handlebars, display enclosure or cover.
l On a self-powered unit, it will either be necessary to either equip the unit with the
optional external power supply or have an assistant pedal on the unit while voltage measurements are being taken. Because of the danger of working on the unit while it is in motion using the optional external power supply is strongly recommended.
l On ATM units when the stairarms are in motion; the generator will operate and produce
potentially hazardous voltages even when the battery is disconnected.
l On AMT units with Cardio Theater PVS units will have external power supply and
coaxial cable routed through the bottom of the unit to the top of the display console. Cord management must be maintained
l On ATM units, a pinching hazard exists when the unit is operated. It is possible to ser-
iously pinch a finger. The AMT can be mechanically locked by inserting a screwdriver through the primary sheave and frame.
l On treadmills, removing the hood exposes high voltage components and potentially dan-
gerous machinery. Exercise extreme caution when you perform maintenance pro­cedures with the hood removed.
When servicing the equipment:
l During service operations you will be very close to moving machinery and voltage bear-
ing components:
o
Remove jewelry (especially from ears and neck),
o
Tie up long hair,
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o
Remove neck ties, and
o
Do not wear loose clothing
See Also
"Safety Instruction" on pageii
"Safety Notices" on pageii
1 Int roduction
Safety Guidelines
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2 Operation Verificat ion

Operation Verification Procedure

2Operation Verification
This section provides a method of verifying the TRM10/GEN06 Treadmill Base operation. Check the treadmill operation at the end of a maintenance procedure and when it is necessary to ensure that the treadmill is operating properly.
"Operation Verification Procedure" below
"Operation Verification Checklist" on the facing page
Operation Verification Procedure
Perform these tests to verify operation of the unit.
1. Plug the power cord into the wall outlet and switch the power switch to the "ON" pos­ition.
2. Press and hold the RESET key for a minimum of 6 seconds, if errors are logged, the error log will be displayed. Make note of all logged error codes and odometer reading. The odometer reading can help you determine the age and relevance of the error. Note that on P80 consoles, go to the error event log to view logged errors, see "Access-
ing the Service Software" on page10.
3. Clear the error log; select a logged error and then hold down the QUICK START key until the error is deleted.
4. Enter the Hardware Validation Test by entering access code 5,1,7,6,5,7,6,1:
a. Press either the STOP, PAUSE or RESET buttons and then enter
5,1,7,6,5,7,6,1 Note: For P80 consoles, refer to "Accessing the Service Software" on page10.
5. Select and run the Display Test, the Keypad Test, and the Heart Rate Test, Verify that each test is successfully completed with the following results:
l LEDs light
l Keys all function
l Heart rate is acquired and displayed
6. Enter the Machine Tests submenu and run the Belt Speed Test and the Incline Test. Verify following results:
l Running belt operates from minimum to maximum speed.
l Incline moves up and down and the A/D value is approximately 6000+/-500 at 0%
incline.
7. Press the RESET key to exit diagnostics. On P80 consoles, press Back to exit dia­gnostic and return to the Home page.
8. Operate the unit in the Manual program. Adjust the speed of the running belt to 2–3 mph. Operate the treadmill for at least 5 minutes while walking on the unit.
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2 Operation Verificat ion

Operation Verification Checklist

9. Concentrate on the feel of the running belt, the sound of the drive motor and rollers. Be on the alert for unusual noises, smells or vibrations.
10. Observe the LED’s on the console. Make sure that each LED lights as the information corresponding to that LED is displayed on the console.
11. Press the INCLINE UP key while viewing the console. Confirm that the running deck inclines and the incline indicator increments to 15% as the INCLINE UP key is con­tinually pressed.
12. Press the INCLINE DOWN key while viewing the console. Confirm that the running deck returns to a level position and the incline indicator decrements to 0% as the INCLINE DOWN key is pressed. (Depending on the software configuration of the con­sole, the lowest level of incline can be either 0% or -3%).
13. While the running belt is in motion, press the STOP button and verify the running belt stops.
14. Restart the running belt and while the running belt is in motion, pull the ESTOP cord and verify the running belt stops.
15. Press and hold the RESET key for a minimum of 6 seconds and view the error log again. This time check for any NEW error codes that may have resulted from the veri­fication tests. Repair any new error codes and repeat the verification tests. Note that on P80 consoles, go to the Event Log page to view logged errors, see
"Accessing the Service Software" on page10.
Operation Verification Checklist
Use this checklist to track that the verification procedure tests were successfully completed and that the treadmill operation has been verified:
Check, record, and then clear any errors in the error log. Verify that all LEDs function properly during the Hardware Validation tests. Verify that all keys on the keypad function properly during the Hardware Val-
idation tests. Verify that the heart rate functions normally and displays a valid heart rate.
Verify the running belt drive system functions properly throughout the minimum to maximum range of control. All drive system components (deck, belts, rollers, IFT) are free of excessive noise, vibrations, or smells. Verify the Incline A/D value is approximately 6000+/-500 at 0% incline, the incline operates within the complete range of the lift when the UP or DOWN keys are pressed and is free of excessive noise or vibrations. Verify the STOP button stops the running belt from moving.
Verify that pulling the ESTOP cord stops the running belt from moving. Check for any new error codes that may have been logged in the error log during
operation verification of the treadmill.
.
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3 Standard Service Software

About

3Standard Service Software
About
Standard access codes are used across Precor cardio product lines to access a set of com­mon service software functional modes used to retrieve equipment product and usage inform­ation, manage club settings, and hardware maintenance validation/diagnostic test software. Each mode is assigned a unique service access code that is entered into the console to begin the functional mode. There are three functional modes: Hardware Validation, Club Para­meters, and Information Display:
l Hardware Validation is a set of functional diagnostic tests used to troubleshoot and
verify proper operation.
l Club Parameters also referred to as Club Settings are used manage and configure the
usage of the machine.
l Information Display provides information about the equipment usage, hardware, soft-
ware, and error log data.
The user interface, available information, settings, etc. will vary based on the console model ­base configuration. Make sure to use the information and instructions for your particular con­sole application. Consoles that support standard service access codes include:
• Standard Consoles • P30 console
• P10 consoles • P80 console
• P20 console

Service Access Codes

The following table lists the standard service access codes and associated functional mode.
SERVICE
ACCESS CODE SERVICE MODE FUNCTION
5,1,7,6,5,7,6,1 Hardware Validation Diagnostic tests.
5,6,5,1,5,6,5 Club Parameters Configure machine and workout
parameter limits.
‡
6,5
Information Display
Note:‡Access code 65 not used on the P80, use access code 51765761.
‡
View usage, SW, and Error Log information.

Accessing the Service Software

The process to access the service code functional mode varies between console models. Go to instructions listed below for your particular console to learn how to access the service
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software.
Standard, P10, and P30 Consoles
3 Standard Service Software
Accessing the Service Software
To access the service software:
l Press either the STOP, PAUSE, or RESET key.
l Sequentially type in the service access code using the numeric keypad.
NOTE: The access code must be correctly and quickly entered or the process will
abort. Restart the process from the beginning if this occurs.
P20 Consoles
To access the service software:
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3 Standard Service Software
Accessing the Service Software
l Press either the STOP, PAUSE, or RESET key.
l Sequentially type in the service access code using the following control keys to rep-
resent an equivalent numeric value:
1 = Workouts key 5 = Enter key 6 = Up key 7 = Down key
NOTE: The access code must be correctly and quickly entered or the process will
abort. Restart the process from the beginning if this occurs.
P80 Consoles
To access the service software:
l Make sure the P80 is set to the Welcome home page.
l Press and continue holding down the PAUSE key while pressing the Volume and
Channel Up/Down keys in the following sequence ("X" pattern) to open the service soft­ware login page:
Press/hold PAUSE while selecting CH Up > Vol Down > Vol Up > CH Down
NOTE: Keep the keypad entry interval to greater than 1 second between key presses. Key press interval speed faster than 1 second may result in an unsuccessful login. .
l Successful login will open the service access login page. Use the touch-screen keypad
to type in the service access code > Continue to open the functional mode software.
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3 Standard Service Software

Navigating the Service Software Menus

o
To access the Hardware Validation (5,1,7,6,5,7,6,1) diagnostic test page: Select System Settings ( > opens
Diagnostic tests and hardware calibration
Settings
page) >System Test (
page.
System Settings
page)
Navigating the Service Software Menus
Console hardkeys and softkeys used to navigate the service software menus.
Standard, P10, P20, & P30 consoles:
The service software is organized in a sequential top-menu sub-menu architecture with instruc­tions shown on the workout information display. Use the console keys to navigate and select service mode operations.
CONSOLE KEY FUNCTION/DESCRIPTION
Up/Down Moves up and down through the current menu. OK Selects current menu item or confirms setting. BACK/CLEAR
PAUSE • Exits service mode
• Returns to the previous menu level without saving changes.
• Hold Back to exit the Display test.
• Press and hold PAUSE will open the Error Log or show the "Stuck Key" message when there are no logged errors.
P80 series consoles:
The P80 uses the touch-screen to view, navigate, and perform the diagnostic tests. Follow on­screen prompts to access and complete tests.

Hardware Validation - Diagnostic Tests (51765761)

Service Access Code: 5,1,7,6,5,7,6,1 (see "Service Access Codes" on page10)
The set of available diagnostic tests will vary based on console model. Select console model to view the available diagnostic tests.
Standard, P10, P20, & P30 consoles:
DIAGNOSTIC
TEST
Display Test
Keypad Test
PVS Key Test Heart Rate Test
Tests the console LEDs. Successively press the OK key to verify each group of LEDs and verify that all LED's illuminate. Press Back to exit the test.
An illuminated LED map of the function keys will be shown. Press each indi­vidual key and verify that the corresponding LED extinguishes. Press and hold BACK to exit the test
Not used, OEM test.
Tests the unfiltered, filtered, and pulse values. Grasp the grips to test the hand held heart rate. Use a Polar heart rate simulator to test the wireless heart rate.
TEST DESCRIPTION
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3 Standard Service Software
Hardware Validation - Diagnostic Tests (51765761)
DIAGNOSTIC
TEST
TEST DESCRIPTION
Press the back button to exit this test.
Belt Test
Tests the belt speed in 0.1 mph increments showing the required Input Voltage, Input Current to the treadmill, the Output Voltage, and Drive Motor current at each speed.
Auto Stop Test
Tests the Auto Stop function showing the averaged foot plants and exerciser "is detected"/ "is not detected" function. Foot plant averaging delay resets with each speed change.
Incline Test
Tests the incline & Decline function. Allows you to verify the A/D number at any incline level and the number of Glitches (communication time between the LPCA and UPCA).
Stop Key Test
Tests the Stop Key function for P10 and P30 console s.
Test procedure prompts to press the Stop Button, then disconnect and recon­nect the Lanyard E-Stop, and then press Stop to reset and exit the test.
P80 Series Consoles:
On P80 consoles, Diagnostic Tests are located on the Diagnostic tests and hardware cal­ibration page:
l Access code 51765761
l select System Settings
l Select System Tests
l Opens Diagnostic tests and hardware calibration page, select test from menu.
DIAGNOSTIC
TEST
TEST DESCRIPTION
Auto Stop Test Tests the Auto Stop function showing the averaged foot plants and exerciser
"is detected"/ "is not detected" function. Foot plant averaging delay resets with each speed change.
Belt Speed Test Tests the belt speed by stepping the speed in 0.1 mph increments and show-
ing the required drive motor current.
Incline Test Tests the incline & Decline function. Allows you to verify the A/D number at
any incline level and the number of Glitches (communication time between the LPCA and UPCA).
USB Test Shows detected USB devices.
Touchscreen Test Use finger to draw line across touch-screen. Select Finish to exit.
Touchscreen Cal­ibration
Touch the cross points on the touch screed to proceed through the calibration procedure.
Backlight Test Tests the console LEDs. Successively press the OK key to verify each group
of LEDs and verify that all LED's illuminate. Press Back to exit the test.
RGB Test Test the touch-screen RGB colors. Touch screen to advance through the red,
green, blue, and white colors.
Speaker Test Tests speakers.
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3 Standard Service Software

Club Parameter - Settings (5651565)

DIAGNOSTIC
TEST
Numeric Backlight Test
Numeric Display Test
Heart Rate Test Tests the Hands ON/OFF Status, Raw and Filtered pulse values. Grasp the
Tests the backlight level on the speed and incline parameter displays.
Tests the speed and incline numeric indicators.
touch grips to test the hand held heart rate. Use a Polar heart rate simulator to test the wireless heart rate.
TEST DESCRIPTION
Club Parameter - Settings (5651565)
Service Access Code: 5, 6, 5, 1, 5, 6, 5 (see "Service Access Codes" on page10)
Club Parameters or Club Settings are used to manage and configure the usage of the machine. Select a console model to view the available club parameters.
Standard, P10, P20, & P30 consoles:
CLUB PARAMETER DESCRIPTION
SAFETY CODE
(Treadmill only)
SELECT LANGUAGE
SET UNITS Range: U.S, Metric
SET MAX WORKOUT TIME
SET MAX PAUSE TIME
SET COOL DOWN TIME
Range: Enable/Disable Default:Disabled Enable or disable* the Safety Code. When enabled, the setting
requires a password "1234" to be entered to start the unit. Default:English Sets the default language for all workouts on this machine. Lan-
guage for single use workouts can still be set by the user from the workout options.
Default: U.S. Sets units of measure to US standard* or Metric. Range: 1 to 240 min, NO LIMIT Default: 60 min Sets the maximum allowable user workout time per session. Range: 1 to 120 sec Default: 120 sec Sets how long the equipment remains in a paused banner during a
workout before resetting. Range:1 to 5 min Default: 5 min Sets the amount of time that a cool down period will occur at the
end of every workout. Factory default is 5 minutes. Settable in 1 minute increments.
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Club Parameter - Settings (5651565)
CLUB PARAMETER DESCRIPTION
SET METRICS DEFAULT
Default: none Sets a metric that may be of specific importance to the specific facil-
ity or fitness trainer. The selected metric will scroll across the screen at regular intervals during the workout.
SET SPEED LIMIT Range: Unit max allowable speed
Default: 12 mph (19 kph) Sets the maximum speed the user can set the unit to.
SET INCLINE LIMIT Range: unit max incline
Default: 15% Sets the maximum user incline value.
HIDDEN PROGRAMS Default: disabled
Either enabled or disabled*, the setting allows the unit to access specialized fitness tests designed for police, fire fighters and the military.
REMOTE SPEED
Not supported.
CONTROL
AUTO STOP CONFIGURE (Treadmill only)
SET CUSTOM PROGRAM 1/2
*
Sets the Auto Stop setting to ON* or OFF. ON brings treadmill to gradual stop.
Range: ON/OFF Default: OFF Create a customized workout program (residential use).
Note:* not available on all models.
3 Standard Service Software
P80 Series Consoles:
The P80 Club parameters include additional configuration parameters for TV, internet con­nectivity, and Preva Net functionality. Refer to the Owner's manual for the complete descrip­tion of available Club parameters.
The P80 Club parameters are located on System Settings page:
l Access code 51765761.
l Select System Settings.
l Select form the list of available System Setting menus.
SYSTEM SETTINGS
MENU
CONNECTIVITY set­tings
Connectivity settings allow you to configure or provides inform­ation about the equipment’s network connection.
DISPLAY settings Display settings allow you to configure the, Measurement units,
Standby Mode Delay, Internet Browser Access, and Preva® Net Panel.
SELECT Default:English
DESCRIPTION
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3 Standard Service Software
Club Parameter - Settings (5651565)
SYSTEM SETTINGS
DESCRIPTION
MENU
LANGUAGE Sets the default language for all workouts on this machine. Lan-
guage for single use workouts can still be set by the user from the workout options.
SET UNITS Range: U.S, Metric
Default: U.S. Sets units of measure to US standard* or Metric.
STANBY MODE
DELAY
Range: sec Default: sec Specifies wait time starting Standby mode.
INTERNET ACCESS Range: YES/NO
Default: YES Sets internet access connectivity.
PREVA NET PANEL Range: YES/NO
Default: YES
Sets internet access connectivity. TV SETTINGS TV SETTINGS configure the television channels. WORKOUT LIMITS set-
WORKOUT LIMITS page, select System Settings > Workout Limits.
tings
MAXIMUM WORKOUT DURATION
Range: 1 to 240 min, NO LIMIT Default: 60 min Sets the maximum allowable user workout time per session.
MAXIMUM PAUSE Range: 1 to 300 sec
Default: 30 sec Sets how long the equipment remains in a paused banner during
a workout before resetting.
SUMMARY TIME OUT
MAXIMUM SPEED
(Treadmill only)
Range: 1 to 120 sec
Default: 60 sec
Sets the time out to view the Workout Summary data.
Range: Unit max allowable speed Default: 12 mph (19 kph) Sets the maximum speed the user can set the unit to.
MAXIMUM INCLINE (Treadmill only)
Range: unit max incline Default: 15% Sets the maximum user incline value.
AUTO STOP (Treadmill only)
Range: ON/OFF Default: ON Sets the Auto Stop setting to ON* or OFF. ON brings treadmill to
gradual stop.
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3 Standard Service Software

Information Display (65)

SYSTEM SETTINGS
MENU
REGISTER EQUIPMENT
MANAGE SETTINGS Used to save your equipment settings to a USB flash drive, or to
Note:* not available on all models.
Used to register the P80 after Connectivity interface has been con­figured and established.
import settings from a USB flash drive.
DESCRIPTION
Information Display (65)
Service Access Code: 6, 5 (see "Service Access Codes" on page10)
Information Display provides information about the equipment usage, hardware, software, and error log data. . Select console model to view the available information and data.
Standard, P10, P20, & P30 consoles:
METRIC DESCRIPTION
ODOMETER Displays the total number of accumulated miles on the unit.
This value is stored in the upper PCA in the console so if the PCA is replaced the accumulated miles would start again from "0".
HOUR METER Displays the total number of hours that the unit took to
accumulate unit miles. This value is stored in the upper PCA in the console so if
that PCA is replaced the hours of use would start again from "0".
BELT RATING Displays a belt rating from 10 (best) to 0 (worst). Reset-
table to 10 by holding QuickStart.
U-BOOT SW Displays the software part number and current version
installed in the upper PCA (console). This is the unit spe­cific console software.
LOWER SW Displays the current version of software loaded in the
Machine Controller.
METRICS BOARD SW Displays the current version of software loaded in the met-
rics board.
SER NUMBER Displays the model and serial number of the equipment.
The base serial number can be set here using the WinCSAFE computer software. The factory default is NONE.
USAGE LOG Displays the type of workout programs the users are
accessing most frequently.
"Error Log" on page73 • Displays the number of times each workout has been
used and displays the associated cumulative minutes.
• Displays the user preferences in workout selection.
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3 Standard Service Software
Information Display (65)
METRIC DESCRIPTION
TIP: You can quickly access the Error log by holding down
the PAUSE key. Will show the STUCK KEY message when there are no logged error codes.
Standard, P80 consoles:
The P80 does not support service access code 65. The equipment usage, SW, and Error Log information is accessed from various submenus on the Settings page (access code
51765761).
l Access code 5,1,7,6,5,7,6,1.
l Select SETTINGS menu for the desired information.
SETTINGS
(Informality menus)
INFORMATION
ABOUT ABOUT menu provide basic equipment information includ-
ing:
model/serial numbers, SW pn/version network connectivity heart rate information
Event Log, select to open Error Log History Table
EQUIPMENT USAGE Provided equipment usage information includes:
Cumulative Workout Seconds Cumulative Workout Distance
Cumulative Workouts Sessions Last Workout Start Date Time
Last Workout End Date Time SOFTWARE DOWNLOADS Enable auto-software downloading. REFLASHING Reflash CPA, MFE, or GUI software. AVAILABLE UPDATES Software update notification. CURRENT USER Current user name and role.
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4 Adjustment Procedures

Available Adjustment Procedures

4Adjustment Procedures
Adjustment procedures provide you with the step-by-step adjustment instructions to bring sys­tems and components into specification. Perform the adjustment procedures whenever a trouble symptom points to a particular component and after a major component is removed/re­placed.
Available Adjustment Procedures
."Drive Belt Tension & Alignment Adjustment" on the facing page
"Running Belt Tension and Tracking Adjustment" on page26
"Lift Motor Calibration" on page24
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4 Adjustment Procedures

Drive Belt Tension & Alignment Adjustment

Drive Belt Tension & Alignment Adjustment

About

This procedure provides instruction to verify and make adjustments to the Drive Belt tension. The Drive Belt tension should be verified anytime the drive belt is removed or replaced.
NOTE:This procedure assumes that the drive belt has been installed and seated
onto the drive roller and drive motor pulleys.

Procedure

Review entire procedure before starting.
Drive Belt Tension Verification
2. Switch the input power OFF and unplug the power cord.
3. Remove the front hood.
Drive Belt Alignment
4. Verify the drive belt alignment. Make sure that the drive belt is aligned parallel to the frame rail. Measure the belt to frame rail distance at the drive roller pulley and at the drive motor pulley. If the measurements are not the same, adjust the belt position on the drive motor pulley to match the drive roller belt distance.
CAUTION: Improper drive belt alignment will cause damage and/or break the drive
belt.
2. Place the belt tension gauge onto the drive belt.
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4 Adjustment Procedures
Drive Belt Tension & Alignment Adjustment
3. Verify that the tension measurement is within the Range Limit specification, see
Belt Tension Specification
table. Note that there is a separate Range Limit specification
Drive
for New and Used belt installations.
a. If the belt tension is not within the Range Limit specification; Re-tension to the
OEM specification, go to Drive Belt Tension Adjustment procedure below.
b. If the belt tension is within the Range Limit specification; Reinstall all covers,
verify treadmill operation (see Operation Verification), and return to service.
Drive Belt Tension Specification
Belt Condition Tension Range Limit
New 105 lbs +/- 10 (48 kgs +/- 4.5) 95-115 lbs (43-52 kgs)
Used 85 lbs +/- 5 (39 kgs +/- 2) 80-90 lbs (36-41 kgs)
Drive Belt Tension Adjustment
Belt tension is adjusted by moving the drive motor position (forward or rearward) in an iterative process until the belt tension meets specification.
4. Remove the drive belt. It is recommended that you walk the belt off the smaller drive motor pulley.
5. Loosen the drive motor mount bolts, slightly move the drive motor either forward or rear­ward as required to increase or decrease the belt tension. Re-tighten the bolts.
6. Re-install the drive belt. It is recommended that you walk the drive belt onto the larger drive roller pulley.
7. Measure and verify that the belt tension meets the Tension specification, see
Tension Specification
table. Note that there is a separate specification for New and
Used belt installations:
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Drive Belt
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4 Adjustment Procedures
Drive Belt Tension & Alignment Adjustment
a. If the tension is not within specification, repeat the adjustment process.
b. If the tension is within specification, continue procedure.
8. Torque the drive motor mount bolts to 204 in-lbs (17 ft-lbs, 23 N-m).
9. Plug in the power cord and switch the input power ON.
10. Run the treadmill speed at 3 mph for 1 minute.
11. Switch the power OFF and disconnect power.
12. Measure and verify that the tension measurement is within the Range Limit spe­cification, see
Drive Belt Tension Specification
table. Note that there is a separate
Range Limit specification for New and Used belt installations.
a. If the belt tension is not within the Range Limit specification, repeat the tension
adjustment procedure.
b. If the belt tension is within the Range Limit specification, continue procedure.
13. Re-install hood.
14. Connect and Switch the input power ON.
15. Verify operation and return to service.
.See Also
"Adjustment Procedures" on page20
"Drive Motor Replacement" on page40
"Drive Belt Replacement" on page36
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4 Adjustment Procedures

Lift Motor Calibration

Lift Motor Calibration

About

This procedure provides instruction to verify and calibrate the Lift Motor and incline system. The Lift Motor calibration should be verified anytime the Lift Motor circuit breaker fails or is replaced or any incline system component is replaced.

Procedure

Review entire procedure before starting.
1. Toggle the treadmill circuit breaker from OFF to ON. The treadmill will begin to auto­reset the running deck incline to the 0% incline level "Home" position (This is the Lift Motor calibration reference position).
WARNING:Be aware that switching power ON will cause the Lift Motor actuator to
auto-reset moving the incline actuator and platform. Keep clear of incline system components.
2. Set the treadmill circuit breaker to OFF and disconnect the power cord.
3. Access the Lift Motor actuator tube in one of the following methods:
a. From the bottom by carefully laying the treadmill on its side
b. From the front by connecting power and raising the treadmill to maximum incline
and resting the frame base onto blocks securely placed under the front corners of the frame (removes weight from the incline platform and Lift Motor actuator tube). Switch power OFF and unplug the power cord.
4. Disconnect the actuator tube from the incline platform mounting bracket by removing the hitch pin and clevis pin.
5. Set the actuator reference gap (distance between the top of the actuator tube (or nut) to the bottom of the Lift Motor housing) to [[[Undefined variable Gen­eral.TRM10ActuatorRefGap]]]. Firmly hold the jack screw from turning and rotate the actuator tube to adjust the reference distance.
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4 Adjustment Procedures
Lift Motor Calibration
6. Re-Install the actuator tube into the incline platform mounting bracket. It may be neces­sary to slightly rotate the actuator tube to align the clevis pin mounting holes. Choose the adjustment direction that will minimize the change to the actuator tube reference dis­tance. Hold the jack screw from turning while adjusting the actuator tube.
7. Return the treadmill to the upright position or remove support blocks.
8. Level the Treadmill.
9. Install the hood.
10. Connect the power cord and set the treadmill circuit breaker to ON.
11. Verify the treadmill incline operation through the full range of motion. Do the "Hardware
Validation - Diagnostic Tests (51765761)" on page13 - INCLINE TEST diagnostic test.
12. Verify treadmill operation (see "Operation Verification" on page8) and return to service.
.See Also
"Replacement Procedures" on page29
"Incline Lift Motor Replacement" on page48
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4 Adjustment Procedures

Running Belt Tension and Tracking Adjustment

Running Belt Tension and Tracking Adjustment

About

This procedure provides instructions to verify and make adjustments to the running belt ten­sion and tracking alignment. The running belt tension and tracking should be verified anytime the running belt alignment is not centered or the running belt is replaced.
NOTE:Proper tensioning of the belt requires the use of two tensioning gauges, Pre-
cor part number PPP000000020007101....

Procedure

Review entire procedure before starting.
Running Belt Tension adjustment
1. Remove the front hood, and left/right side step covers.
2. Remove the drive motor belt from the drive roller pulley. . If is recommended that you walk the belt off the smaller drive motor pulley.
NOTE:The drive motor belt must be removed to properly adjust the running belt ten-
sion.
3. Remove tension from the rear take-up roller. Alternately loosen the left and right bolts to equally remove the belt tension.
4. Center the running belt and make sure that it is squarely positioned from the front drive roller to rear Take Up Roller.
5. Move the running belt so that the seam is positioned underneath the treadmill.
6. Attach a running belt tension gauge on each side of the running belt opposite each other.
7. Slide the gauge head to set the dial needle to a coarse setting of 3. You can then rotate the gauge dial face to fine tune the needle to precisely 3.
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4 Adjustment Procedures
Running Belt Tension and Tracking Adjustment
NOTE:Setting the gauge to a 3 reference value centers the gauge head travel allow-
ing +/- movement without impeding travel.
1. Alternately tighten the right and left take-up roller mounting bolts in increments of 0.2% so that the roller is evenly tensioned to the final 0.55% (dial 3.55) specification as fol­lows:
a. Tighten the right bolt to dial setting 3.2, then the left bolt to 3.2.
b. Tighten the right bolt to dial setting 3.4, then the left bolt to 3.4
c. Tighten the right bolt to dial setting 3.55 (0.55%), then the left bolt to 3.55 (0.55%)
2. Remove the tension gauges.
3. Re-install the drive belt .Install by walking the belt onto the larger drive roller pulley. Make sure that the belt alignment is parallel to the frame rail, see "" on page23.
Running Belt Tracking Adjustment
4. Start the treadmill and set the speed to 3 mph (5 kph).
5. Observe and verify that the running belt tracking remains centered, adjust as required:
a. If the belt starts to drift toward the right, slowly turn the right side Take Up Roller
mounting bolt clockwise in ¼ turn increments until the drifting stops.
b. If the belt starts to drift toward the left, slowly turn the right side Take Up Roller
bolt counterclockwise in ¼ turn increments until the drifting stops.
NOTE:1) The tracking adjustments should only be done in 1/4 turn increments.
2) ONLY use the right side Take Up Roller mounting bolt to adjust tracking.
3) ONLY use hand tools to adjust tracking.
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4 Adjustment Procedures
Running Belt Tension and Tracking Adjustment
2. Increase the speed to 9 mph (14 kph) and then 12 mph (19 KPH) making sure that the tracking remains centered, make small adjustments as needed.
3. Verify that the treadmill is level, adjust as necessary.
4. Verify the running belt/deck surfaces are clean.
5. Replace all covers.
6. Verify treadmill operation (see "Operation Verification" on page8) and return to service.
.See Also
"Adjustment Procedures" on page20
"Running Belt and Deck Replacement" on page61
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5 Replacement Procedures

Available Replacement Procedures

5Replacement Procedures
Replacement procedures provide you with the step-by-step instructions to remove and replace system components.
Available Replacement Procedures
"Auto Stop Magnet Replacement" on the next page
"Auto Stop Sensor Replacement" on page32
"Circuit Breaker Replacement" on page34
"Drive Belt Replacement" on page36
"Drive Motor Replacement" on page40
"Drive Roller Replacement" on page42
"End Cap & Belt Guard Cover Replacement" on page46
"Input Module Replacement" on page53
"Incline Lift Motor Replacement" on page48
"Incline Lift Platform Replacement" on page51
"Input Module Replacement" on page53
"Line Filter Replacement" on page55
"Power Control Module Replacement" on page57
"Power Cord Replacement" on page59
"Running Belt and Deck Replacement" on page61
"Take Up Roller Replacement" on page66
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5 Replacement Procedures

Auto Stop Magnet Replacement

Auto Stop Magnet Replacement

About

This procedure provides instruction to remove and replace the Auto Stop Magnet.

Procedure

Review entire procedure before starting.
CAUTION: Do not place the Auto Stop Magnet on or near a steel structure. If the
magnet assembly comes in contact with a steel structure and then pulled away from the steel structure, the magnet can become dislodged from the magnet assembly housing. Contact PRECOR customer service for repair or replacement.
1. Set the treadmill circuit breaker to OFF and unplug the treadmill’s power cord.
2. Remove the front hood.
3. Remove the left and right trim strips from the treadmill deck.
4. Remove the four mounting bolts and two top plates that fasten the running deck to the pivot bracket at the back of the treadmill. Keep fasteners for installation.
5. Pull the running deck out from the right side of the treadmill just far enough to expose the front right edge of the running deck, see "" on page3.
6. Pry out the two push fasteners from the deck using a flat head screw driver and remove the Auto Stop Magnet. Keep fasteners for installation.
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5 Replacement Procedures
Auto Stop Magnet Replacement
7. Align the replacement magnet on the running deck and then secure the magnet to the running deck using the two push fasteners.
8. Slide the running deck back into position over the running deck pivot bracket. Align the bottom plate and pivot bracket holes with the running deck bolt holes. Insert and tighten deck mounting bolts.
9. Check the alignment of the magnet and the auto stop assembly, see "Auto Stop Sensor
Replacement" on the next page.
10. Replace the trim strips and front hood.
11. Connect the power cord and Switch the input power ON.
12. Verify the Auto Stop function by doing the Auto Stop diagnostics test, see "Hardware
Validation - Diagnostic Tests (51765761)" on page13.
13. Verify treadmill operation per ""Operation Verification Procedure" on page8" and return to service.
.See Also
"Replacement Procedures" on page29
"Running Belt and Deck Replacement" on page61
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5 Replacement Procedures

Auto Stop Sensor Replacement

Auto Stop Sensor Replacement

About

This procedure provides instruction to remove and replace the Auto Stop Sensor.

Procedure

Review entire procedure before starting.
CAUTION: Do not place the Auto Stop Magnet on or near a steel structure. If the
magnet assembly comes in contact with a steel structure and then pulled away from the steel structure, the magnet can become dislodged from the magnet assembly housing. Contact PRECOR customer service for repair or replacement.
1. Set the treadmill circuit breaker to OFF and unplug the treadmill’s power cord.
2. Remove the front hood and right side step cover.
3. Unplug the Auto Stop Cable from the Auto Stop assembly.
4. The Auto Stop Sensor assembly has round alignment tabs that match the holes of the treadmill frame support. With one hand grasp the side of the Auto Stop Sensor assembly that is closest to the outside of the treadmill and apply pressure toward the run­ning deck. With your other hand push on each alignment tab from the inside of the frame mounting holes. The Auto Stop Assembly should disengage from the frame.
5. Position the replacement Auto Stop assembly with the cable connector facing to the right side of the treadmill. Slide the Auto Stop assembly over the treadmill frame support and push down until the round tabs align with the holes in the support. The round tabs will snap into the treadmill frame mounting holes securing the Auto Stop assembly in place.
6. Check the alignment of the magnet and the Auto Stop assembly. The magnet and the Auto Stop assembly each have an alignment mark on the top of their housings. The magnet mark and the Auto Stop mark should align and the gap should be approximately 3/16 of an inch between the housings. A 3/16 hex key can be used as a feeler gauge to set the correct gap. If the gap or alignment are off adjust the running deck until the mag­net and auto housing are properly aligned, see "Auto Stop Magnet Replacement" on
page30.
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5 Replacement Procedures
Auto Stop Sensor Replacement
7. Reconnect the Auto Stop Cable to the Auto Stop Sensor Assembly.
8. Replace front hood and side step cover.
9. Connect power cord and Switch the input power ON.
10. Verify the Auto Stop function by doing the Auto Stop diagnostics test, see "Hardware
Validation - Diagnostic Tests (51765761)" on page13.
11. Verify treadmill operation per ""Operation Verification Procedure" on page8" and return to service.
.See Also
"Replacement Procedures" on page29
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5 Replacement Procedures

Circuit Breaker Replacement

Circuit Breaker Replacement

About

This procedure provides instruction to remove and replace the ON/OFF Circuit Breaker.

Procedure

Review entire procedure before starting.
1. Set the treadmill circuit breaker to OFF and unplug the treadmill’s power cord from the AC outlet.
2. Remove the treadmill’s hood.
3. Remove the two screws that fasten the AC input panel to the frame. Keep fasteners for replacement installation.
4. Disconnect the wiring from the circuit breaker (2 blue wires on 120 Vac treadmills or 2 blue and 2 brown wires on 240 Vac treadmills) Note: The figure below is showing a 240 volt configuration.
5. Incline the AC input panel from the frame and rotate it to expose the AC input circuit breaker screws.
6. Remove the two screws and remove the circuit breaker. Keep fasteners for replace­ment installation.
7. Reference the label on the replacement circuit breaker and install the circuit breaker in its mounting position with the LINE side of the breaker facing the input module and the
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5 Replacement Procedures
Circuit Breaker Replacement
LOAD side of the circuit breaker facing the AC line filter. Install the circuit breaker using the previously removed fasteners.
8. Install wire connections as follows for the 120 VAC and 240 VAC models:
a. 120 VAC: On 120 Vac treadmills connect the blue wire from the input module to
the LINE terminal on the circuit breaker and the blue wire from the AC line filter to the LOAD terminal on the circuit breaker.
b. 240 VAC: On 240 Vac treadmills connect the blue wire from the input module to
the upper LINE terminal on the circuit breaker and the blue wire from the AC line filter to the upper LOAD terminal on the circuit breaker. Connect the brown wire from the input module to the lower LINE terminal on the circuit breaker and the brown wire from the AC line filter to the lower LOAD terminal on the circuit breaker.
9. Set the AC input panel in its mounting position and install using the previously removed fasteners.
10. Plug in the power cord and Switch the input power ON.
11. Verify treadmill operation per ""Operation Verification Procedure" on page8 and return to service.
.See Also
"Replacement Procedures" on page29
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5 Replacement Procedures

Drive Belt Replacement

About

This procedure provides instruction to remove and replace the Drive Belt.
CAUTION: Two running belt gauges, Precor part number 20007-101, are required.
It is important that this procedure be followed to maintain correct drive belt and run­ning belt tension. Improper tensioning of the belt will lead to premature running belt wear, premature driver roller bearing failure and premature Take Up Roller bearing failure.

Procedure

Review entire procedure before starting.
Drive Belt Removal
2. Switch the input power OFF and unplug the power cord.
Drive Belt Replacement
3. Remove the front hood.
4. Remove running belt tension by alternately loosening the left and right Take Up Roller mounting/adjustment bolts, but do not remove the mounting bolts, see "Running Belt
Tension and Tracking Adjustment" on page26.
5. Walk the drive belt off the smaller drive motor pulley. Remove pulley off the drive roller pulley.
6. Alternately loosen and remove the left and right drive roller mounting bolts.
TIP: You can put a reference mark on the right drive roller mounting bracket to
identify the current drive roller shaft position for re installation.
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5 Replacement Procedures
Drive Belt Replacement
7. Use the drive belt to help lift the roller out of the mounting bracket and then remove the belt off the drive roller pulley, Remove the belt from the treadmill.
Drive Belt Installation
8. Place the replacement drive belt onto the drive roller pulley and use the drive belt to help lower and slide the drive roller into the roller mounting bracket. Hand tighten the left and right drive roller mounting bolts.
9. Position the running belt on the rollers so that it is centered and sets square on the deck from the front drive roller to the rear Take Up Roller.
10. Alternately tighten the left and right drive roller mounting bolts to evenly tighten the roller until the left mounting bolt reaches the left mount stop. The left mounting bracket stop sets the roller reference position and the right bolt is used to make final position adjust­ments. Fully tighten the left mounting bolt against the bracket stop position.
11. Using a measuring tape, measure the distance from the front of the left drive roller shaft to the front of the frame cross beam. Record this reference distance.
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5 Replacement Procedures
Drive Belt Replacement
12. Adjust the right drive roller mounting bolt so that the right drive roller shaft to frame cross beam distance equals the left side reference distance. This adjustment will make sure that the drive roller is positioned parallel and square to the front of the frame.
13. Install the drive belt onto the drive motor pulley and walk the drive belt onto the larger drive roller pulley.
14. Verify the drive belt alignment and set tension to specification, see "Drive Belt Tension &
Alignment Adjustment" on page21 procedure.
15. Set the running belt tension to specification and verify tracking, see "Running Belt
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5 Replacement Procedures
Drive Belt Replacement
Tension and Tracking Adjustment" on page26 procedure.
16. Replace the belt guard cover ensuring the tabs are firmly locked into position on the Take Up Roller shaft, see "End Cap & Belt Guard Cover Replacement" on page46.
17. Replace the end cap, see "End Cap & Belt Guard Cover Replacement" on page46.
18. Replace the hood cover.
19. Verify treadmill operation per "Operation Verification" and return to service.
.See Also
"Replacement Procedures" on page29
"Adjustment Procedures" on page20
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5 Replacement Procedures

Drive Motor Replacement

Drive Motor Replacement

About

This procedure provides instruction to remove and replace the Drive Motor.

Procedure

Review entire procedure before starting.
1. Switch the input power OFF and unplug the power cord.
2. Remove the front hood.
3. Disconnect the drive motor power cable connector from the OUTPUT connector on the power control module.
TIP: Remove the MC fasteners so that the MC module can be raised to allow easy
access to disconnect and connect the I/O connectors.
4. Remove the drive belt. It is recommended that you walk the belt off the smaller drive motor pulley.
5. Mark the outline of the current motor mounting plate which will be used as a reference position when you install the replacement motor.
6. Remove the four drive motor mounting bolts. Keep bolts for replacement installation.
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5 Replacement Procedures
Drive Motor Replacement
7. Set the replacement drive motor onto the frame. Align the motor mount plate to the ref­erence position marks, insert and tighten the four mounting bolts to the torque 204 in-lbs (17 ft-lbs, 23 N-m).
8. Re-install the drive belt. It is recommended that you walk the drive belt onto the larger drive roller pulley.
9. Connect the drive motor connector from the OUTPUT connector on the power control module.
10. Verify that the drive belt is properly seated and aligned, see "" on page23 procedure.
11. Verify the drive belt tension is within specification and adjust as necessary, see "Drive
Belt Tension & Alignment Adjustment" on page21
12. Re-install hood.
13. Plug in the power cord and Switch the input power ON.
14. Verify treadmill operation per ""Operation Verification Procedure" on page8" and return to service.
.See Also
"Replacement Procedures" on page29
"Drive Belt Tension & Alignment Adjustment" on page21
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5 Replacement Procedures

Drive Roller Replacement

Drive Roller Replacement

About

This procedure provides instruction to remove and replace the Drive Roller.
CAUTION: Two running belt gauges, Precor part number 20007-101, are required.
It is important that this procedure be followed to maintain correct drive belt and run­ning belt tension. Improper tensioning of the belt will lead to premature running belt wear, premature driver roller bearing failure and premature Take Up Roller bearing failure.

Procedure

Review entire procedure before starting.
1. Switch the input power OFF and unplug the power cord.
2. Remove the front hood.
3. Relax the running belt tension by alternately loosening the left and right Take Up Roller mounting/adjustment bolts, but do not remove the mounting bolts.
4. Walk the drive belt off the smaller drive motor pulley. Remove pulley off the drive roller pulley.
5. Alternately loosen and remove the left and right drive roller mounting bolts.
TIP: Before loosening the mounting bolts, you can put a reference mark on the right
drive roller mounting bracket to identify the current drive roller shaft position used later for re installation.
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5 Replacement Procedures
Drive Roller Replacement
6. Use the drive belt to help lift the roller out of the mounting bracket and then remove the belt off the drive roller pulley,
7. Remove the drive roller.
Installing the drive roller
8. Insert the replacement drive roller through the running belt. Use running belt to help lower and slide the drive roller into the mounting bracket.
9. Insert the replacement drive roller through the running belt. Place the drive belt onto the drive roller pulley and use the drive belt to help lower and slide the drive roller into the roller mounting bracket. Hand tighten the left and right drive roller mounting bolts.
10. Position the running belt on the rollers so that it is centered and sets square on the deck from the front drive roller to the rear Take Up Roller.
11. Alternately tighten the left and right drive roller mounting bolts to evenly tighten the roller until the left mounting bolt reaches the left mount stop. The left mounting bracket stop sets the roller reference position and the right bolt is used to make final position adjust­ments. Fully tighten the left mounting bolt against the bracket stop position.
12. Using a measuring tape, measure the distance from the front of the left drive roller shaft to the front of the frame cross beam. Record this reference distance.
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5 Replacement Procedures
Drive Roller Replacement
13. Adjust the right drive roller mounting bolt so that the right drive roller shaft to frame cross beam distance equals the left side reference distance. This adjustment will make sure that the drive roller is positioned parallel and square to the front of the frame.
14. Install the drive belt onto the drive motor pulley and walk the drive belt onto the larger drive roller pulley.
15. Verify the drive belt alignment and set tension to specification, see "Drive Belt Tension &
Alignment Adjustment" on page21 procedure.
16. Set the running belt tension to specification and verify tracking, see "Running Belt
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Drive Roller Replacement
Tension and Tracking Adjustment" on page26 procedure.
17. Replace the belt guard cover ensuring the tabs are firmly locked into position on the Take Up Roller shaft (see "End Cap & Belt Guard Cover Replacement" on the next
page).
18. Replace the end cap (see "End Cap & Belt Guard Cover Replacement" on the next
page).
19. Replace the hood cover.
20. Verify treadmill operation (see "Operation Verification" on page8) and return to service.
.See Also
"Replacement Procedures" on page29
"Adjustment Procedures" on page20
"Running Belt and Deck Replacement" on page61
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5 Replacement Procedures

End Cap & Belt Guard Cover Replacement

End Cap & Belt Guard Cover Replacement

About

This procedure provides instruction to remove and replace the End Cap and belt guard cov­ers.

Procedure

Review entire procedure before starting.
1. Switch the input power OFF and unplug power cord.
2. Remove the four screws (2 lower screws, each side) that retain the end cap. Keep fasteners for installation. DO NOT loosen or move the Take Up Roller mount­ing/adjustment bolts. Doing so will change the running belt’s tension and alignment.
3. To remove the end cap, slide the end cap off of the treadmill.
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End Cap & Belt Guard Cover Replacement
4. To remove the belt guard, press inwards on the belt guard to remove the belt guard tabs from the Take Up Roller mounts. Slide the belt guard off of the treadmill.
5. To install the belt guard, slide the replacement belt guard into place so that the tabs on the belt guard engage in both Take Up Roller mounts.
6. To install the rear guard, slide the end cap into place so that the tabs on the end cap engage in the notches in the running belt trim strips.
7. Secure end cap with fasteners.
See Also
"Replacement Procedures" on page29
"Running Belt and Deck Replacement" on page61
"Take Up Roller Replacement" on page66
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5 Replacement Procedures

Incline Lift Motor Replacement

Incline Lift Motor Replacement

About

This procedure provides instruction to remove and replace the Lift Motor.

Procedure

Review entire procedure before starting.
Calibrate the replacement Lift Motor prior to installation
2. Switch the input power OFF.
3. Remove the front hood.
4. Lay the replacement Lift Motor in front of the treadmill allowing room for the actuator/ jack screw to freely move up and down.
5. Disconnect the Lift Motor power cable connector from the Power Control Module INCLINE connector and connect the replacement Lift Motor power cable.
TIP: Remove the MC fasteners so that the MC module can be raised to allow easy
access to disconnect and connect the I/O connectors.
6. Toggle the treadmill circuit breaker from OFF to ON. The treadmill will begin to auto­reset the actuator to the 0% incline level "Home" position (This is the Lift Motor cal­ibration reference position).
WARNING:Be aware that the Lift Motor actuator will begin to auto-calibrate caus-
ing movement to the Lift Motor actuator when power is applied to the treadmill.
7. Switch the treadmill power to OFF and unplug the power cord.
8. Set the actuator 0% incline reference gap (distance between the top of the actuator tube (or nut) to the bottom of the Lift Motor housing). Firmly hold the jack screw from turning and rotate the actuator tube to adjust the reference distance.
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9. Switch the input power OFF and unplug the power cord.
5 Replacement Procedures
Incline Lift Motor Replacement
Remove the Lift Motor
.
10. Access the Lift Motor from the bottom by carefully laying the treadmill on its side.
TIP:If the Lift Motor will raise the treadmill to maximum, you can access the Lift
Motor from the front. Connect power and raise the treadmill to maximum incline and resting the frame base onto blocks securely placed under the front corners of the frame (removes weight from the incline platform and Lift Motor actuator tube). Switch power OFF and unplug the power cord.
11. Disconnect the ground wire (green with yellow stripe) from the l frame. Keep screw for motor installable.
12. Remove the lift actuator tube from the lift platform, remove the hitch pin and clevis pin.
13. Remove the Lift Motor actuator housing from the frame mounting bracket. Grasp the Lift Motor and remove the Lift Motor housing mount hitch pin and clevis pin. Remove the Lift Motor from the treadmill
Install the Lift Motor
.
NOTE:Be careful to not allow the actuator tube nut to turn during the installation
process. This will cause the actuator reference gap to change.
14. Set the calibrated Lift Motor housing into the frame mounting bracket, replace the upper clevis pin and secure with the hitch pin. Be careful to not turn the actuator tube or jack screw while installing the motor.
15. Install the actuator tube into the incline platform mounting bracket. It may be necessary to slightly rotate the actuator tube to align the clevis pin mounting holes. Choose the adjustment direction that will minimize the change to the actuator tube reference dis­tance. Hold the jack screw from turning while adjusting the actuator tube.
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Incline Lift Motor Replacement
16. Connect the frame ground wire to the treadmill frame, Make sure to route the cable using the frame cable clips to secure the able in position. Securely tighten the mounting screw to ensure very good electrical connectivity.
17. Connect the Lift Motor connector to the INCLINE connector on the power control mod­ule. Make sure to route and use the frame cable clips to safely secure the cable away from the jack screw.
18. Connect the Lift Motor connector to the LIFT connector on the motor control module. Make sure to route and use the frame cable clips to safely secure the cable away from the jack screw.
19. Return the treadmill to the upright position.
20. Level the Treadmill.
21. Install the hood.
22. Plug in the power cord and Switch the input power to ON.
23. Verify the treadmill incline operation through the full range of motion. Do the "Hardware
Validation - Diagnostic Tests (51765761)" on page13 - INCLINE TEST diagnostic test.
24. Verify treadmill operation (see "Operation Verification" on page8) and return to service.
See Also
"Replacement Procedures" on page29
"Lift Motor Calibration" on page24
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5 Replacement Procedures

Incline Lift Platf orm Replacement

Incline Lift Platform Replacement

About

This procedure provides instruction to remove and replace the Incline Platform.

Procedure

Review entire procedure before starting.
1. Switch the treadmill power to OFF and unplug the power cord.
2. Remove the front hood.
3. Access the incline platform by carefully laying the treadmill on its side.
4. Disconnect the Lift Motor actuator tube from the incline platform mounting bracket by removing the hitch pin and clevis pin. Keep fasteners for installation.
NOTE:Be careful to not allow the actuator tube to turn during the removal/in-
stallation process. This will cause the actuator reference gap to change and will require recalibration of the Lift Motor, see "Lift Motor Calibration" on page24.
5. Remove the left and right incline platform hitch pins from the frame mounting brackets and removal the platform. Keep fasteners for installation.
6. Remove the wheels from the old incline platform and reinstall them on the replacement incline platform.
7. Set the replacement incline platform in it mounting position. Align the key in the incline mounting pin with the key way in the frame and slide the incline mounting pins into place. Secure mounting pins with the hitch pins.
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Incline Lift Platf orm Replacement
8. Install the actuator tube into the incline platform mounting bracket. Hold the jack screw from turning while inserting the actuator tube into the mounting bracket. Secure with clevis and hitch pins.
9. If the Lift Motor actuator tube has turned during the installation process (which changes the incline reference gap distance) re-calibrate the Lift Motor, see "Lift Motor Cal-
ibration" on page24.
10. Return the treadmill to the upright position.
11. Level the treadmill.
12. Install hood and all removed covers and trim.
13. Connect the power cord and Switch the input power to ON.
14. Verify the treadmill incline operation through the full range of motion. Do the "Hardware
Validation - Diagnostic Tests (51765761)" on page13 - INCLINE TEST diagnostic test.
15. Verify treadmill operation (see "Operation Verification" on page8) and return to service.
See Also
"Replacement Procedures" on page29
"Lift Motor Calibration" on page24
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5 Replacement Procedures

Input Module Replacement

Input Module Replacement

About

This procedure provides instruction to remove and replace the AC Input Module.

Procedure

Review entire procedure before starting.
1. Set the treadmill circuit breaker to OFF and unplug the treadmill’s power cord from the AC outlet.
2. Remove the treadmill’s hood.
3. Remove the two screws that fasten the AC input panel to the frame. Keep fasteners for replacement installation.
4. Incline the AC input panel from the frame and rotate it to expose the AC line cord clamp screws and input module screws
5. .Remove the mounting screws and remove the AC power cord clamp. Keep fasteners for replacement installation
6. Disconnect the AC line cord from the input module.
7. Disconnect the wiring from the AC input module (1 blue wire, 1 brown wire and 1 green/yellow wire).
8. Remove the mounting screws and remove the AC input module. Keep fasteners for replacement installation:
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Input Module Replacement
9. Set the AC input module in its mounting position with the side with two terminals facing the circuit breaker and install using the previously removed fasteners.
10. Re-connect the AC input module blue wire to terminal N, the brown wire to terminal L and the green/yellow wire to terminal E.
11. Insert the AC line cord firmly into the input module. Set the AC line cord clamp in its mounting position and fasten it with the previously removed fasteners.
12. Reinstall hood.
13. Plug in the power cord and Switch the input power ON.
14. Verify treadmill operation per ""Operation Verification Procedure" on page8" and return to service.
.See Also
"Replacement Procedures" on page29
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5 Replacement Procedures

Line Filter Replacement

Line Filter Replacement

About

This procedure provides instruction to remove and replace the AC Line Filter.

Procedure

Review entire procedure before starting.
1. Set the treadmill circuit breaker to OFF and unplug the treadmill’s power cord from the AC outlet.
2. Remove the treadmill’s hood.
3. Remove the two screws that fasten the AC input panel to the frame. Keep fasteners for replacement installation.
4. Disconnect the wiring from the circuit breaker (2 blue wires on 120 Vac treadmills or 2 blue and 2 brown wires on 240 Vac treadmills) Note: The figure below is showing a 240 volt configuration.
5. Lift the AC input panel from the frame and rotate it to expose the AC input circuit breaker screws.
6. Remove the two screws and remove the circuit breaker. Keep fasteners for replace­ment installation.
7. Set the replacement AC line filter in its mounting position with the three terminals facing the circuit breaker and secure with previously removed screws.
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Line Filter Replacement
8. Re-attach wire connections as follows for the 120 VAC and 240 VAC models:
a. On 120 Vac and 240 Vac treadmills, connect the blue wire from the power control
module to the L1 terminal on the LOAD side of the AC line filter and the brown wire from the power control module to the L2 terminal on the LOAD side of the AC line filter.
b. On 120 Vac treadmills, connect the blue wire from the input module to the L1 ter-
minal on the LINE side of the AC line filter, the brown wire from the circuit breaker to the L2 terminal on the LINE side of the AC line filter and the green/yellow wire to the (non-insulated) terminal mounted directly on the line filter case.
c. On 240 Vac treadmills, connect the blue wire from the circuit breaker to the L1 ter-
minal on the LINE side of the AC line filter, the brown wire from the circuit breaker to the L2 terminal on the LINE side of the AC line filter and the green/yellow wire to the (non-insulated) terminal mounted directly on the line filter case.
9. Set the AC input panel in its mounting position and install using the previously removed fasteners.
10. Plug in the power cord and Switch the input power ON.
11. Verify treadmill operation per ""Operation Verification Procedure" on page8" and return to service.
.See Also
"Replacement Procedures" on page29
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5 Replacement Procedures

Power Control Module Replacement

Power Control Module Replacement

About

This procedure provides instruction to remove and replace the Power Control Module (IFT Drive).

Procedure

Review entire procedure before starting
1. Switch the input power OFF and remove power cord.
2. Remove the front hood.
3. Disconnect the COMM, INCLINE, INPUT, DB and OUTPUT connectors from the power control module.
4. Remove the four screws that mount the power control module. Keep fasteners for installation.
5. Set the replacement power control module in its mounting position.
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Power Control Module Replacement
6. Install and tighten the four mounting screws.
7. Reconnect the COMM, INCLINE, INPUT, DB and OUTPUT connectors. The mating connectors are keyed to insure proper contact pin alignment and fit.
8. Reinstall the hood.
9. Pug in the power cord and Switch the input power ON.
10. Verify treadmill operation (see Operation Verification) and return to service.
See Also
"Replacement Procedures" on page29
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5 Replacement Procedures

Power Cord Replacement

Power Cord Replacement

About

This procedure provides instruction to remove and replace the power cord.
CAUTION: Use only Precor OEM power cords. Do not remove or otherwise bypass
the 3-prong plug with an adapter to use a non-grounded outlet. Do not plug the unit into a power transformer in an attempt to adjust the voltage requirements. Failure to follow these instructions might damage the unit and void the Precor Limited War­ranty.
CAUTION: The treadmill requires a 20-amp individual branch circuit grounded per
NEC (National Electric Code) guidelines or local region electric code.

Procedure

Review entire procedure before starting.
1. Set the treadmill circuit breaker to OFF and unplug the treadmill’s power cord from the AC outlet.
2. Remove the treadmill’s hood.
3. Remove the two screws that fasten the AC input panel to the frame. Keep fasteners for replacement installation.
4. Lift the AC input panel from the frame and rotate it to expose the AC power cord clamp screws.
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5 Replacement Procedures
Power Cord Replacement
5. Remove the fasteners that retain the AC power cord clamp and remove the clamp. Keep fasteners for replacement installation.
6. Disconnect the AC power cord from the input module.
7. Feed the end of the replacement AC power cord that mates with the input module through its hole in the frame and firmly insert it into the input module.
8. Set the AC power cord clamp in its mounting position and install using the previously removed fasteners.
9. Set the AC input panel in its mounting position and install using the previously removed fasteners.
10. Plug in the power cord and Switch the input power ON.
11. Verify treadmill operation per ""Operation Verification Procedure" on page8" and return to service.
.See Also
"Replacement Procedures" on page29
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5 Replacement Procedures

Running Belt and Deck Replacement

Running Belt and Deck Replacement

About

This procedure provides instruction to remove and replace the Running Belt.
CAUTION: Two running belt gauges, Precor part number 20007-101, are required.
It is important that this procedure be followed to maintain correct drive belt and run­ning belt tension. Improper tensioning of the belt will lead to premature running belt wear, premature driver roller bearing failure and premature Take Up Roller bearing failure.

Procedure

Review entire procedure before starting.
1. Switch the input power OFF and unplug the power cord.
2. Remove the front hood.
3. Remove the end cap and belt guard covers (see "End Cap & Belt Guard Cover Replace-
ment" on page46).
4. Remove the left and right deck trim covers
5. Remove the Take Up Roller, see "Take Up Roller Replacement" on page66.
6. Remove the Drive Roller, see "Drive Roller Replacement" on page42.
7. Remove the four mounting bolts and the roller guard that hold the deck to the frame.
8. Lift the deck and running belt up and away from the treadmill.
9. If installed, remove the Auto Stop magnet from the deck, see "Auto Stop Magnet
Replacement" on page30.
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5 Replacement Procedures
Running Belt and Deck Replacement
10. Slide the running belt off the deck and discard. Remove and keep the deck mounting inserts.
11. If the deck has already been flipped (flipped surface is used), discard and replace with new deck. Re-install the deck mounting inserts.
12. If the deck has not be flipped (flipped surface is new), flip deck and re-install the deck mounting inserts into the used side of the deck surface.
13. The new running belt will have a directional arrow placed on the inside of the belt. The arrow indicates the correct direction of travel. Slip the running belt onto the deck with the arrow pointing in the direction of travel.
CAUTION: Incorrectly installed running belt direction will cause the belt to wear pre-
maturely.
14. Carefully place the deck with running belt onto the deck.
15. Reinstall the Auto Stop Magnet on the right front corner of the deck, see "Auto Stop
Magnet Replacement" on page30.
16. Slide the take up roller though the running belt and install in the frame mounting bracket. Hand tighten the mounting bolts into the take up roller shaft.
17. Align the bottom plate and pivot bracket holes with the running deck bolt holes. Replace the roller guard, install and hand tighten the deck mounting bolts.
18. Verify that the spacing on all four corners is the same, adjust as necessary.
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5 Replacement Procedures
Running Belt and Deck Replacement
19. Check the alignment of the magnet and the auto stop assembly, see "Auto Stop Sensor
Replacement" on page32.
20. Tighten and torque the Deck mounting bolts to 150 in-lbs (17 N-m).
21. Reinstall the Drive Roller and Drive Belt, see "Drive Roller Replacement" on page42.
22. Reinstall the Take Up Roller, see "Take Up Roller Replacement" on page66.
23. Tension and verify the running belt tracking, see "Running Belt Tension and Tracking
Adjustment" on page26.
24. Replace the belt guard cover ensuring the tabs are firmly locked into position on the Take Up Roller shaft, see "End Cap & Belt Guard Cover Replacement" on page46.
25. Replace the end cap, see "End Cap & Belt Guard Cover Replacement" on page46.
New Deck break-in
26. Straddle the running belt and set the speed to 3 mph (5 kph). While holding the treadmill handles, walk onto the middle of the running belt starting from the back walking to the front and returning to the back. Repeat walking process 4 times.
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5 Replacement Procedures
Running Belt and Deck Replacement
27. Repeat the process on walking on the right side of the belt.
28. Repeat the process walking on the left side of the belt.
NOTE:It may be necessary to override the treadmill auto-stop function.
29. Stop the treadmill and step off the belt.
30. Set the treadmill to the maximum speed and run for 3 minutes.
NOTE:This process helps to remove excess wax from the belt.
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31. Clean up any loose wax from the deck sides and frame.
5 Replacement Procedures
Running Belt and Deck Replacement
32. Verify treadmill operation (see "Operation Verification" on page8) and return to service.
.See Also
"Adjustment Procedures" on page20
"Running Belt Tension and Tracking Adjustment" on page26
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5 Replacement Procedures

Take Up Roller Replacement

Take Up Roller Replacement

About

This procedure provides instruction to remove and replace the Take Up Roller.
CAUTION: Two running belt gauges, Precor part number 20007-101, are required.
It is important that this procedure be followed to maintain correct drive belt and run­ning belt tension. Improper tensioning of the belt will lead to premature running belt wear, premature driver roller bearing failure and premature Take Up Roller bearing failure.

Procedure

Review entire procedure before starting.
1. Switch the input power OFF and unplug the power cord.
2. Remove the front hood.
3. Remove the end cap and belt guard covers (see "End Cap & Belt Guard Cover Replace-
ment" on page46.
4. Remove the left and right deck trim covers.
Removal Instructions
5. Remove running belt tension by alternately loosening the left and right Take Up Roller mounting/adjustment bolts. Remove the mounting bolts, lift and slide the Take Up Roller out of the running belt.
Installation Instructions
6. Slide the new Take Up Roller through the running belt and slide into position. Evenly hand tighten the left and right Take Up Roller mounting bolts a few turns only.
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5 Replacement Procedures
Take Up Roller Replacement
7. Tension the running belt to specification and verify tracking, see "Running Belt Tension
and Tracking Adjustment" on page26.
8. Replace the belt guard cover ensuring the tabs are firmly locked into position on the Take Up Roller shaft, see "End Cap & Belt Guard Cover Replacement" on page46.
9. Replace the end cap (see "End Cap & Belt Guard Cover Replacement" on page46).
10. Replace the hood cover.
11. Verify treadmill operation (see Operation Verification) and return to service.
.See Also
"Replacement Procedures" on page29
"Running Belt Tension and Tracking Adjustment" on page26
"Running Belt and Deck Replacement" on page61
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6Troubleshooting

6Troubleshooting

About

This section contains troubleshooting information to help you identify, isolate, and resolve com­ponent and system issues.
Troubleshooting issues is an investigative process that utilizes audio/visual cues, error code information (if available), system/component troubleshooting procedures, and experience to fix the problem.
Start by reviewing the “Introduction to Troubleshooting” topic which will give you a systematic approach to resolving an issue.
Information to help troubleshoot issues
l System and Component Troubleshooting procedures
l Error Codes (see “Error Code Troubleshooting Guide”)
l Service Bulletins
IMPORTANT: Error Code description and Troubleshooting information is contained in the
Error Code Troubleshooting Guide
, see Error Code Guide.pdf.
However, not all system issues will create an error code event. For these types of issues you will use audible and visual indicators in conjunction with the Diagnostic Tests to troubleshoot and resolve the issue.

Introduction to Treadmill Troubleshooting

Validate a customer reported issue:

Always validate and confirm a customer reported failed condition. The failure that is reported may differ from your observations as a trained technician. Many reported failure are not true failures and can be fixed without a customer visit. Make sure the unit power is connected and switched ON. Question the customer about the issue for other possible simple solutions. After confirming this is a real failure, continue with fix the issue.

Basic Steps

Troubleshooting Basic Steps
to troubleshoot and
Review the entire
Troubleshooting Basic Steps
information before starting the troubleshooting process. These steps are intended to help you systematically troubleshoot and fix treadmill fail­ures.
l Verify input Power; always begin by verifying the input power is connected and
switched "ON". Also make sure the input power is within the specified power limits ("General Information" on page3). Poor quality, intermittent, or out-of-spec input power will cause operational failures.
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6Troubleshooting
o
If the treadmill does not switch ON or trips the circuit breaker, see .Troubleshoot­ing Tripped Breakers),
o
If the console does not power up, see Troubleshooting Console Power.
l Verify that the console is operating correctly. Run the Display, and Keypad diagnostic
tests (see "Hardware Validation - Diagnostic Tests (51765761)" on page13). Note any failures.
NOTE:Keep in mind that if a key on the keypad does not function, the lower control
module will not receive a user initiated request for action. In this case the cause for the failure would not be in the lower portion of the unit, and no errors will be logged.
l Check the Error Log ("Information Display (65)" on page18) to learn about any current
or past logged error code events. The error log history will often provide vital information that will lead to the source causing the issue. Record all listed error log code information and odometer reading. Then clear the error log by pressing and holding the "Quick Start" key.
NOTE:Not all failures trigger an error code event. You will need to use the Diagnostic
Tests and audio/visual observation to identify the cause (component or system) of the issue. Review the list of troubleshooting procedures for possible related issues and troubleshooting information.
l Verify the issue. Run the unit in normal user mode to verify if the reported failure reoc-
curs, is a repeatable or intermittent type failure. Make note of any additional obser­vations (noises, vibrations, etc.) that occur at the time of the failure.
NOTE: It is important to keep in mind that some issues are weight (load) related. You
may need to increase the exerciser weight to reproduce the failure.
l Verify the running belt speed and incline operation. Run the Belt, Incline, and Auto Stop
diagnostic tests, (see "Hardware Validation - Diagnostic Tests (51765761)" on
page13). Note any failures.
l Verify that the Club Settings are not causing the issue. If a failure is observed in user
mode but passes the hardware validation diagnostic tests, this could be an indication that one of the club parameters has been incorrectly set.
l Return to the error log to verify all current error codes. This will verify if the original error
codes are reoccurring and if there are any new error code issues. Do not disregard the original recorded error code/odometer information that was previously cleared. The issue may be mileage related, review the odometer history to verify if the error event is related to mileage intervals.
NOTE:If there is no logged error codes and the issue persists, you will need to use
observable and audible indicators to identify the source of the failure. Browse the list of available troubleshooting procedures for related troubleshooting information.
l Verify if there are any related service bulletins that may fix this issue. If no service bul-
letin exists for this issue, continue with the troubleshooting steps for the system that is failing (Power & Control, Drive Motor System, Incline System, Communication, Belt & Deck, Auto Stop, or Heart Rate).
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6Troubleshooting
See Also
"Standard Error Codes" below
"Standard Error Codes" below
"Error Log" on page73
"System Troubleshooting Procedures" on page74

Standard Error Codes

About

There is a set of standard error codes implemented across Precor exercise equipment. Error codes are system generated error codes designed to detect and report fault conditions. Each error code is associated with a particular system or component fault condition. The main­tenance software monitors error code event conditions, when a fault is detected, the error code is stored in the Error Log along with the event mileage, hours, and motor current.
Error code numbers range from 01 to 99. There are also a small number of alpha and alpha­numeric codes. Most error codes are grouped into numeric ranges to help easily identify com­mon system issues. However not all error codes follow these guideline. Refer to the Error
Code Troubleshooting Guide for a complete list of error codes and troubleshooting inform-
ation.
IMPORTANT: Error Code description and Troubleshooting information is contained in the
Error Code Troubleshooting Guide
, see Error Code Guide.pdf.
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6Troubleshooting

Viewing Error Codes

Error codes are viewed in the service software Information Display Error Log (see "Error Log"
on page73). There are 2 methods to access the Error Codes:
l :"Error Log" on page73: Access the Information Display (6,5) and select Error Log.
l Quick Access: Press and hold the Reset/Pause key for a minimum of 6 seconds will
directly access the Error Log and show any stored error codes. If there are no stored error codes, the STUCK KEY message will be shown.

Troubleshooting with Error Codes

Getting Started
You will need a copy of the “ error codes including the code description, related issues/symptoms, troubleshooting and repair information, click Error Code Troubleshooting Guide.
IMPORTANT: Error Code description and Troubleshooting information is contained in the
Error Code Troubleshooting Guide
The
Error Code Troubleshooting Guide
l The error code description
Error Code Troubleshooting Guide
, see Error Code Guide.pdf.
contains the following information:
” to learn Information about the
l The affected system components
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6Troubleshooting
l The Issues and Symptom information
l Troubleshooting and repair information
Using Error Codes to troubleshoot
1. Access the service software "Error Log" on the next page Information Display to view any current or past error code events.
2. Go to the Error Code Troubleshooting Guide, look up the error code and follow the troubleshooting information
See Also
"Error Log" on the next page
"Troubleshooting" on page68
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Error Log

Error Log: access the Information Display (6,5) > select Error Log
"Standard Error Codes" on page70 are stored in memory in a First-In Last-Out basis, the new-
est error code is stored in the number one position pushing any current error codes down one position. When the memory is full, the oldest error code is pushed off the stack and removed from memory.
IMPORTANT: Error Code description and Troubleshooting information is contained in the
Error Code Troubleshooting Guide
The Error Log shows the stored error codes listed in sequential order starting with the newest error code (always the number 1 error code) to the oldest logged error (highest error code number).
A detected fault will trigger an error code event to be logged. However, when multiple instances of the same error code event occur within the same Hour or Odometer reading, only the first occurrence will be logged. Either a change to the Mileage or Odometer, or a different intervening error code is logged must occur before the same repeating error code is logged again.
, see Error Code Guide.pdf.
NOTE:Multiple repeating instances of the same error code event occurring during
the same Hour or Odometer reading will only be logged as a single error code event.
Error Log Data
The Error Log includes the following information:
l Error Log table number (1 is always the newest error code event)
l Error Code Number
l Mileage
l Hours
l Motor Current.
See Also
"General Information" on page3
"Troubleshooting" on page68
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System Troubleshooting Procedures

System troubleshooting procedures provide information and procedures to help you troubleshoot and repair treadmill issues.

Available Troubleshooting Procedures

l "Auto Stop Troubleshooting " on the next page
l "Tripped Circuit Breaker" on page93
l "Communications Error Troubleshooting" on page81
l "No Power to the Console Troubleshooting" on page82
l "Drive Motor System Troubleshooting" on page83
l "E-Stop Not Communicating" on page86
l "Heart Rate Monitor Troubleshooting" on page87
l "Incline System Troubleshooting" on page89
l "Input Power and Machine Controls Troubleshooting" on page90
l "Running Belt and Deck Troubleshooting" on page91
See Also
"Troubleshooting" on page68
"Standard Error Codes" on page70
"Error Log" on the previous page
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Auto Stop Troubleshooting

This procedure will provide troubleshooting steps for the Auto Stop feature
Related Error Codes
Auto Stop error codes: 60, 61.
Refer to the Error Code Troubleshooting Guide for error code description and troubleshooting information.
Procedure:
1. If the Console message is "Temporarily Out of Order" on the P80 console or "Please use another Treadmill" on the P10, P20, or P30 console go
Tests
below.
2. Check the treadmill to ensure the Auto Stop hardware is installed.
l If the Auto Stop hardware is not installed, contact Precor customer support to see
if your treadmill is compatible for the Auto Stop or arrange the installation of the Auto Stop hardware.
Run Hardware Validation
3. Verify that the Auto Stop cable is plugged into the correct port in the console. The con­nector for the Auto Stop is the same number of pins as the connector for the heart rate grips, and you need to make sure that they were not reversed.
a. If the cables were reversed, swap the connectors and re-test.
b. If the cables were correctly connected, continue
4. If the Auto Stop hardware is installed, access the club settings and check if the Auto Stop feature is enabled. If it is not enabled, enable the feature, see "Club Parameter -
Settings (5651565)" on page15.
Run Hardware Validation Tests
5. Access the service access software Hardware Validation Tests (see "Hardware Val-
idation - Diagnostic Tests (51765761)" on page13 and select the Auto Stop test. If the
feature is enabled the P80 Auto Stop sensor test will count the number of times the mag­net crosses the sensor. The P10, P20, or P30 consoles will display USER DETECTED if motion is detected from the running deck or NO USER DETECTED if no motion is detected from the running deck. If the unit passes this test or a USER DETECTED mes­sage is displayed and the Auto Stop feature does not function contact Precor Customer Support. If the Auto Stop did not pass the test continue troubleshooting.
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CAUTION: Do not place the Auto Stop Magnet on or near a steel structure. If the
magnet assembly comes in contact with a steel structure and then pulled away from the steel structure, the magnet can become dislodged from the magnet assembly housing. Contact PRECOR customer service for repair or replacement.
6. The Auto Stop system consists of a magnet holder mounted to the right front corner of the deck and a Hall Effect sensor mounted to the drive roller bracket of the frame. Check the alignment and gap (3/16") between the Auto Stop magnet holder and the Auto Stop sensor. If the alignment and gap are not correct, it may be necessary to loosen the deck and adjust so that the magnet is gapped and positioned properly rel­ative to the sensor. Reference Procedure, Replacing the Auto Stop Magnet. If the align­ment and the gap between the Auto Stop magnet holder and the Auto Stop sensor are correct continue with step 9.
7. The Auto Stop sensor will display a green blinking LED visible next to the connector, indicating that power is being applied to the sensor board. The LED does not tell you if the voltage is correct, just that it is present. If the LED is not lit or if LED is lit continue with the next step.
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8. The connector has 3 wires (red, black, and green), which can be metered for troubleshooting. Unplug the Auto Stop connector from the Auto Stop Sensor.
9. Place the meter red lead to the red wire and black lead to the black wire of the Auto Stop connector. The meter should indicate 5 volts +/- 0.1 volt. If 5 volts is present continue with the next step.
10. If the 5 volts is not present of significantly low temporarily replace the Auto Stop cable with a known good cable and repeat step 10. If the 5 volts is not present or the voltage is still significantly low replace the console or upper PCA. If 5 volts is present permanently replace the Auto Stop cable.
NOTE: The running belt does not need to be moving for this test.
11. With the Auto Stop connector plugged into the Auto Stop sensor place the meter red lead to the green wire and black lead to the black wire. The meter should indicate 5 volts +/- 0.1volt. While monitoring this voltage, have someone step onto the deck and bounce up and down. The voltage between the black and green wires should fluctuate between bounces. If the voltage does not change, replace the Auto Stop Sensor.
12. If you have completed all the previous steps and Auto Stop will still not function cor­rectly, contact Precor Customer Support.
See Also
"System Troubleshooting Procedures" on page74
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Tripped Circuit Breaker

Troubleshooting a tripped treadmill ON/OF circuit breaker or facility outlet circuit breaker. Review the electrical requirements, see "General Information" on page3.
It is extremely important to know whether it is the treadmill circuit breaker or the facility wall out­let circuit breaker that trips. It is also extremely important to know when the breaker trip occurs, choose one of the following trip events:
l Immediately on power up
l After the belt starts but before the exerciser walks onto the belt
l After the exerciser walks onto the belt.
If the facility outlet circuit breaker trips
l Measure the facility wall outlet voltage. If the is approximately 0 VAV, the wall breaker
has tripped.
l Inspect the power cord, if damaged, replace the line cord. If the line cord is not damaged
continue with the following steps.
l Verify whether there is more than one treadmill on the same outlet circuit breaker. This
will be especially evident if two or more treadmills shutdown at the same time. To verify if multiple treadmills are sharing the same wall breaker, manually switched OFF the wall breaker. If more than one treadmill loses power, the treadmills are on the same breaker.
o
If YES, advise the customer to have their facility wiring upgraded per Precor spe­cifications.
o
If NO, continue troubleshooting.
IMPORTANT: If the AC circuit feeding a treadmill is found to be a non-dedicated branch circuit or a circuit equipped with a capacity of less than 20 amps, the AC circuit must be corrected before any reliable Troubleshooting can be performed. More importantly, a non-dedicated branch circuit may constitute a safety hazard to the tread­mill operator .
l Verify the wall outlets do not share neutral wiring and that each wall outlet is on an indi-
vidual branch circuit. An individual branch circuit will have its own load line, neutral line and ground line. To verify that the treadmill is not on an individual branch circuit use an AC voltmeter measure from the hot contact of one AC receptacle to the neutral contact of another AC receptacle. If AC line voltage is present then the treadmills are sharing neutral lines.
o
If YES, advise customer to have their facility wiring upgraded per Precor spe­cifications, and then continue to step 5.
o
If NO, continue troubleshooting
CAUTION: The treadmill requires a 20-amp individual branch circuit grounded per
NEC (National Electric Code) guidelines or local region electric code.
l Measure the AC input voltage with the treadmill unloaded (running belt moving, with no
one walking on the running belt) and then again while loaded (someone walk­ing/running on the belt). The difference between the two states should be no more than
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about 6 volts RMS, and ideally less.
o
If the voltage variance is more than 6 volts RMS, the distance the branch circuit wire are runs maybe very long or may have used smaller diameter wire. Recom­mend to the club that they should consult with an electrician if this is suspected.
o
If NO, continue troubleshooting.
l Weight overloading is the most frequent cause of treadmill shutting down. Overloading
is most often caused by excess deck/belt friction, but can be made worse by line voltage conditions. This condition happens more often with heavier runners, but never walkers. In high exerciser clubs (10 hours or more of use per day), the decks/belts will wear out much faster than at other locations, sometimes in months rather than years. It is often accompanied by error codes 27, 28, or 29, see "Troubleshooting the 3 Phase AC Drive Motor System."
If the Treadmill ON/OFF circuit breaker is tripped:
l Verify the wall outlets do not share neutral wiring and that each wall outlet is on an indi-
vidual branch circuit. An individual branch circuit will have its own load line, neutral line and ground line. To verify that the treadmill is not on an individual branch circuit use an AC voltmeter measure from the hot contact of one AC receptacle to the neutral contact of another AC receptacle. If AC line voltage is present then the treadmills are sharing neutral lines.
o
If YES, advise customer to have their facility wiring upgraded per Precor spe­cifications, and then continue with step 2.
o
If NO, continue troubleshooting.
CAUTION: The treadmill requires a 20-amp individual branch circuit grounded per
NEC (National Electric Code) guidelines or local region electric code.
l Verified that a long distance branch run has inadequate gauge wire.
o
If YES, advise customer to have their facility wiring upgraded per Precor spe­cifications.
o
If NO, continue troubleshooting.
l Verify the input line voltage; Low line voltage for the U.S. is any voltage below 108VAC,
measured while the treadmill circuit breaker is switched "ON" and the running belt is stopped. For international, low line voltage is anything below 200 VAC while the tread­mill circuit breaker is switched "ON" and the running belt is stopped. Measure the line voltage with the treadmill circuit breaker is switched "ON", and the running belt is stopped. Record the voltage. Then measure the voltage again using the instantaneous voltage drop using the min/max function on your volt meter while someone is running on the treadmill at 7.0 MPH or higher.
o
If any measurement is below 108VAC (US) or 200 VAC (International), advise the customer to have their facility wiring inspected by an electrician.
o
If the measurements are at or above 108VAC (US) or 200VAC (International), continue troubleshooting.
l Does the treadmill trip its breaker immediately on power up?
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o
If YES, it is likely that there is a shorted component (line filter, lower control module) or faulty/shorted wiring.
o
If NO, continue with the following steps.
l Does the treadmill power up, but trips the breaker after the motor is started?
o
If YES, it is likely that there is a bad roller or bad drive motor.
o
If NO, continue with the following steps.
l Does the drive motor start up fine, but trips the breaker after an exerciser walks/runs on
the running belt?
o
If YES, Overloading is the most frequent cause of treadmill shutting down. Over­loading is most often caused by excess deck/belt friction, but can be made worse by line voltage conditions. The overloading condition happens more often with heavier runners, but never walkers. In high exerciser clubs (10 hours or more of use per day), the decks/belts will wear much faster than at other locations, some­times in months rather than years. It is often accompanied by error codes 27, 28, or 29. Perform an amp draw test in the "Running Belt and Deck Troubleshooting"
on page91 procedure.
See Also
"System Troubleshooting Procedures" on page74
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Communications Error Troubleshooting

Go to the error log and note any occurrences of the error codes related to communications issues.
Related Error Codes
Communications error codes: 30 through 33.
Refer to the Error Code Troubleshooting Guide for error code description and troubleshooting information.
Procedure
Refer to the Error Code Troubleshooting Guide.
See Also
"System Troubleshooting Procedures" on page74
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No Power to the Console Troubleshooting

Applies To: P10, P20, or P30 consoles only.
This procedure only applies to treadmill powered consoles.
1. Verify that the treadmill input power is correct, see "Tripped Circuit Breaker" on
page93.
2. Remove the treadmill hood and measure the AC voltage at the input side of the line fil­ter. Verify that line voltage is present when the breaker switch is turned on.
a. If NO, replace the breaker switch.
b. If Yes, continue troubleshooting.
3. Measure the AC voltage at the output side of the line filter. Verify that line voltage is present when the breaker switch is turned on.
a. If NO, Replace the line filter.
b. If Yes, continue troubleshooting.
4. Use a known good console and communication cable. Plug the test console and test communications cable into the suspect treadmill lower control module (IFT drive). Does the test console power up?
a. If NO, replace the lower control module (IFT drive).
b. If Yes, continue troubleshooting.
4. If the test console powered up, re-connect the test communications cable from the test console to the original console. Does the original console power up?
a. If Yes, replace the Communications Cable.
b. If No, replace the upper PCA.
CAUTION: Swapping a lower control module from a good unit into a bad unit could
damage the lower control module from the good unit. If the control module that is being swapped may have a defect and could damage components in the good unit.
See Also
"System Troubleshooting Procedures" on page74
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Drive Motor System Troubleshooting

About
Occasionally, there may be issues with the proper operation of the drive system that do not generate error codes. This troubleshooting procedure is intended troubleshoot the 3-phase Drive Motor System.
If there is a drive motor system Error code from 20 through 29 in the error log, go to the Error Code Troubleshooting Guide, see the Error Code Troubleshooting Guide, for troubleshooting information.
If there are no errors in the error log, yet the drive system appears to have an issue (such as jit­tery motion) then continue the troubleshooting procedure.
Related Error Codes
Drive system error codes: 20 through 29.
Refer to the Error Code Troubleshooting Guide for error code description and troubleshooting information.
Procedure
Lower Control Module OUTPUT power Check
NOTE:When taking voltage readings of the AC drive motor, the readings may not
seem accurate because of the frequencies being used, however, they are indicative of the presence of drive motor voltage and relative frequency changes.
1. If the drive motor starts when you force the running belt to move and the drive motor runs rough, jump to the will not start, continue with the next step.
2. If the drive motor does not start, the lower control module will only apply voltage for a couple of seconds before it shuts down. Therefore the voltage readings in the following step must be taken within the first couple of seconds after the treadmill is instructed to start the running belt. (A multi-meter with a hold feature is recommended)
3. Connect an AC voltmeter between terminals 4 (red) & 5 (white) of the OUTPUT con­nector on the lower control module. Set the treadmill ON/OFF switch to the ON position. Press the QUICK START key. If the lower control module is supplying output, you will momentarily read some value of AC voltage. Make a note of the voltage and set the treadmill ON/OFF switch to the OFF position.
4. Set the treadmill ON/OFF switch to the OFF position. Repeat the previous AC voltage measurement between terminals 4 (red) & 6 (black) of the OUTPUT connector as the previous step. Voltage should read the same value as the OUTPUT pins 4 and 5. Set the treadmill ON/OFF switch to the OFF position.
Drive Motor Winding Check
procedure below. If the drive motor
5. Set the treadmill ON/OFF switch to the OFF repeat the previous AC voltage meas­urement between terminals 5 (white) & 6 (black) of the OUTPUT connector on the lower control module. The voltage should read the same value as the OUTPUT pins 4 and 5. Set the treadmill’s ON/OFF switch to the OFF position.
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6. If one or more of the previous OUTPUT voltage readings are not present, replace the lower control module. If the voltage readings are present, continue with the next step.
Drive Motor Winding Check
CAUTION: All resistance measurements must be performed with power removed
from the machine. Performing the resistance measurements with voltage applied tho the circuit can damage the muftimeter.
7. Set the treadmill’s ON/OFF switch to the OFF position. Disconnect the drive motor con­nector from the OUTPUT connector on the power control module. With an ohmmeter, measure between terminals 4 (red) & 5 (white), 4 (red) & 6 (black) and 5 (white) & 6 (black) of the drive motor connector. Each reading should be approximately 2.5 ohms. If any of the readings are significantly high or open, replace the drive motor.
8. If the ohm readings are correct, inspect the female terminals of the drive motor con­nector. Verify that they are not spread beyond the point of making good connection with the male pins on the OUTPUT connector on the power control module. If proper con­nection is not being achieved, replace the drive motor connector.
9. If you have performed all of the procedures above and have been unable to correct the problem, call Precor customer support.
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See Also
"System Troubleshooting Procedures" on page74
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E-Stop Not Communicating

The error 37 is generated by the upper PCA in the console when the lower control module gets into an E-Stop state and the upper PCA in the console did not know about it. The system uses pin 8 of the data cable to communicate E-Stop states between the console and the lower control module.
Related Error Codes
E-Stop error code: 37.
Refer to the Error Code Troubleshooting Guide for error code description and troubleshooting information.
Procedure
Refer to the Error Code Troubleshooting Guide for error code description and troubleshooting information.
See Also
"System Troubleshooting Procedures" on page74
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Heart Rate Monitor Troubleshooting

Hand Held Heart Rate Does Not Work
1. Place your hands on the HHHR (Hand Held Heart Rate) contacts, making full contact with both top and bottom contacts for at least 15 seconds.
a. If the unit displays a heart rate, no problem exists.
b. If the unit does not display a heart rate value within this time, continue with next
step.
2. Set the ON/OFFswitch to the OFF position, wait 10 seconds, then set the ON/OFF switch to the on position and repeat step 1.
a. If the HHHR functions correctly, then the processor on the HR board was in a
"latched-up" condition, and cycling the power cleared the condition.
b. If the HHHR does not function correctly, continue with step 3.
3. Verify that the HHHR board has the correct operating voltage. Connect a voltmeter to VCC and Ground on the Power/Signal connector. The voltage should read between 4.5 and 5 Vdc.
4. Verify the wiring of the HHHR contacts (top left, bottom left, top right, bottom right) go to the proper pin on the Grip/Contact connector, that none of the lines are shorted,
a. If NO, Correct the wiring error.
b. If Yes, Continue.
5. Verify that the grip connections are free of corrosion.
a. If NO, replace the corroded HHHR grips.
b. If Yes, continue.
6. Verify that there is a ferrite bead around the cable from the HHHR board to the upper PCA. (GEN-06 treadmill only)
7. Verify that the unit does not display a heart rate with only one hand on a grip. This would indicate static damage, and require replacement of the heart rate board.
8. If the above procedures do not correct the problem, replace the heart rate board.
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Wireless Heart Rate Does Not Work
1. Verify wireless heart rate with a known good chest strap transmitter or test transmitter. If the heart rate reading is erratic, incorrect, or absent, continue.
NOTE: It may be necessary to lean in closer to the console at first to allow receiver to
begin to acquire a heart rate signal.
2. Verify that the HHHR board has the correct operating voltage. Connect a voltmeter to VCC and Ground on the Power/Signal connector. The voltage should read between 4.5 and 5.5 Vdc.
3. Identify other sources of wireless interference signals in close proximity to the unit (such as Wi-Fi networks, cordless phones, etc.).
NOTE: Wi-Fi network is transmitting in close proximity to the treadmill the heart rate
system MAY pick it up. Using an ohmmeter, verify that upper and lower PCAs have a good electrical path to chassis ground.
4. If the preceding procedures do not correct the problem, replace the heart rate board.
5. Possible sources of interference signals include, but not limited to:
l Wi-Fi Network Routers
l Cordless Telephones
l Cell Phones
l Electronic Dog Fences
l Garage Door Remotes
l Noisy AC feeds
l Florescent light ballasts
See Also
"System Troubleshooting Procedures" on page74
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Incline System Troubleshooting

The incline system consists of an AC line voltage driven lift motor (120VAC or 240VAC), and an internal 1 K W (Ohms) potentiometer for lift position monitoring. It is important when you start to troubleshoot the lift system to determine if the problem is due to an inability to move the lift, or an inability to monitor the lift position.
Related Error Codes
Incline system error codes: 40 through 45.
Refer to the Error Code Troubleshooting Guide for error code description and troubleshooting information.
Procedure
Determine whether you need to troubleshoot the AC voltages going to the motor windings, or if you need to troubleshoot the DC voltages and/or ohm readings from the potentiometer. The error log will help determine which is causing the issue.
Check the error log for INCLINE system error codes, press and hold the reset key for at least 6 seconds to access the error log.
If there is an error code for a lift system error logged (Error 40 through 45), go to the Error
Code Troubleshooting Guide and follow the troubleshooting information.
CAUTION: All resistance measurements must be performed with power removed
from the machine. Performing the resistance measurements with voltage applied tho the circuit can damage the muftimeter.
Operation of lift motor for testing:
Most Precor treadmills require the running belt to be moving to operate the lift. For this reason it is recommended that the servicer use the "Hardware Validation" - Machine Tests (see "Hard-
ware Validation - Diagnostic Tests (51765761)" on page13) to verify lift operation.
See Also
"System Troubleshooting Procedures" on page74
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Input Power and Machine Controls Troubleshooting

Errors in this section cover either input power (error 15 & 16) conditions, Console controls (error 5 & 80-83), or processor/memory (error 9 & 11) conditions. These are errors that although they are valid to the proper function of the machine, are not part of a specific treadmill base system (lift system, drive system, deck & belt system, etc…). Follow the steps for error code 5, 9, 12, 15, 16, 80, 81, 82, or 83 on the following pages.
Related Error Codes
l Input Power: 15,16,
l MachineControls: 5, 80-85.
l Processor Memory; 9:11.
Refer to the Error Code Troubleshooting Guide for error code description and troubleshooting information.
Procedure
Refer to the
Error Code Troubleshooting Guide
.
See Also
"System Troubleshooting Procedures" on page74
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Running Belt and Deck Troubleshooting

This procedure is to be used to determine the condition of the running belt and running deck combination.
A clamp-on ammeter will be used to measure the treadmill’s AC input current under load. The AC input current is a direct indication of the load being placed on the treadmill. Treadmill load­ing consists of several factors, the user’s weight, treadmill speed and condition of the running belt and running deck.
The AC input current measurements should be performed at 7-8mph. and 0% incline. Because the loading varies with the user’s weight, you should perform the AC input current measurement test on a new running belt and deck combination. That will provide you with a benchmark reading to account for your individual weight.
Because the AC input current reading will pulse between a high value (during foot plant) and a low reading (between foot plants) we suggest the use of an analog clamp-on ammeter. An analog ammeter makes it very easy to see the AC current pulses. The refresh rate on digital ammeters may make it difficult to see the rapid current peaks unless the digital ammeter is equipped with a peak hold feature.
Procedure
1. Remove the treadmill’s motor cover and place the A.C clamp-on ammeter on the brown wire from the A.C. input module (or A.C. power cord) to the circuit breaker (ON/OFF switch). See the illustration below.
2. Set the treadmill’s speed at 7-8 mph and the incline at 0%. Walk on the treadmill and observe the average A.C. current reading. Typical average A.C. current reading on a new running belt and deck should average between 8 to 12 amperes. Note that a digital meter could measure peak amps as high as 20 amps, even on a new belt and deck.
3. If the average current reading approaches 20 amperes, the running belt should be replaced. The running deck should be flipped or replaced if the running deck has been
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previously flipped. See Procedure, Running Belt and/or Deck Replacement (on page
101) for running belt and running deck replacement.
4. If the average AC current readings are greater than on a new running belt and deck combination but not approaching 20 amperes, the reading will give you an indication of the running belt and deck combination’s general condition.
NOTE: Repeat the amp draw test after replacing a running belt and deck. Damage to
the lower control module can occur if the unit had been run in an overload/high current condition for prolonged periods of time. This type of damage would not generate an error code, but would cause the breaker to trip intermittently. An amp draw test will catch this condition.
See Also
"System Troubleshooting Procedures" on page74
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Tripped Circuit Breaker

Troubleshooting a tripped treadmill ON/OF circuit breaker or facility outlet circuit breaker. Review the electrical requirements, see "General Information" on page3.
It is extremely important to know whether it is the treadmill circuit breaker or the facility wall out­let circuit breaker that trips. It is also extremely important to know when the breaker trip occurs, choose one of the following trip events:
l Immediately on power up
l After the belt starts but before the exerciser walks onto the belt
l After the exerciser walks onto the belt.
If the facility outlet circuit breaker trips
l Measure the facility wall outlet voltage. If the is approximately 0 VAV, the wall breaker
has tripped.
l Inspect the power cord, if damaged, replace the line cord. If the line cord is not damaged
continue with the following steps.
l Verify whether there is more than one treadmill on the same outlet circuit breaker. This
will be especially evident if two or more treadmills shutdown at the same time. To verify if multiple treadmills are sharing the same wall breaker, manually switched OFF the wall breaker. If more than one treadmill loses power, the treadmills are on the same breaker.
o
If YES, advise the customer to have their facility wiring upgraded per Precor spe­cifications.
o
If NO, continue troubleshooting.
IMPORTANT: If the AC circuit feeding a treadmill is found to be a non-dedicated branch circuit or a circuit equipped with a capacity of less than 20 amps, the AC circuit must be corrected before any reliable Troubleshooting can be performed. More importantly, a non-dedicated branch circuit may constitute a safety hazard to the tread­mill operator .
l Verify the wall outlets do not share neutral wiring and that each wall outlet is on an indi-
vidual branch circuit. An individual branch circuit will have its own load line, neutral line and ground line. To verify that the treadmill is not on an individual branch circuit use an AC voltmeter measure from the hot contact of one AC receptacle to the neutral contact of another AC receptacle. If AC line voltage is present then the treadmills are sharing neutral lines.
o
If YES, advise customer to have their facility wiring upgraded per Precor spe­cifications, and then continue to step 5.
o
If NO, continue troubleshooting
CAUTION: The treadmill requires a 20-amp individual branch circuit grounded per
NEC (National Electric Code) guidelines or local region electric code.
l Measure the AC input voltage with the treadmill unloaded (running belt moving, with no
one walking on the running belt) and then again while loaded (someone walk­ing/running on the belt). The difference between the two states should be no more than
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6Troubleshooting
about 6 volts RMS, and ideally less.
o
If the voltage variance is more than 6 volts RMS, the distance the branch circuit wire are runs maybe very long or may have used smaller diameter wire. Recom­mend to the club that they should consult with an electrician if this is suspected.
o
If NO, continue troubleshooting.
l Weight overloading is the most frequent cause of treadmill shutting down. Overloading
is most often caused by excess deck/belt friction, but can be made worse by line voltage conditions. This condition happens more often with heavier runners, but never walkers. In high exerciser clubs (10 hours or more of use per day), the decks/belts will wear out much faster than at other locations, sometimes in months rather than years. It is often accompanied by error codes 27, 28, or 29, see "Troubleshooting the 3 Phase AC Drive Motor System."
If the Treadmill ON/OFF circuit breaker is tripped:
l Verify the wall outlets do not share neutral wiring and that each wall outlet is on an indi-
vidual branch circuit. An individual branch circuit will have its own load line, neutral line and ground line. To verify that the treadmill is not on an individual branch circuit use an AC voltmeter measure from the hot contact of one AC receptacle to the neutral contact of another AC receptacle. If AC line voltage is present then the treadmills are sharing neutral lines.
o
If YES, advise customer to have their facility wiring upgraded per Precor spe­cifications, and then continue with step 2.
o
If NO, continue troubleshooting.
CAUTION: The treadmill requires a 20-amp individual branch circuit grounded per
NEC (National Electric Code) guidelines or local region electric code.
l Verified that a long distance branch run has inadequate gauge wire.
o
If YES, advise customer to have their facility wiring upgraded per Precor spe­cifications.
o
If NO, continue troubleshooting.
l Verify the input line voltage; Low line voltage for the U.S. is any voltage below 108VAC,
measured while the treadmill circuit breaker is switched "ON" and the running belt is stopped. For international, low line voltage is anything below 200 VAC while the tread­mill circuit breaker is switched "ON" and the running belt is stopped. Measure the line voltage with the treadmill circuit breaker is switched "ON", and the running belt is stopped. Record the voltage. Then measure the voltage again using the instantaneous voltage drop using the min/max function on your volt meter while someone is running on the treadmill at 7.0 MPH or higher.
o
If any measurement is below 108VAC (US) or 200 VAC (International), advise the customer to have their facility wiring inspected by an electrician.
o
If the measurements are at or above 108VAC (US) or 200VAC (International), continue troubleshooting.
l Does the treadmill trip its breaker immediately on power up?
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