Precor TRM10/GEN06 Service Manual

TRM10/ GEN06 TREADMILL BASE

Service Manual

20039-165 REV A04

PRECOR CUSTOMER SUPPORT

Contents

Section 1 - About This Document ........................................................................................... 5

Section 2 - General Information ............................................................................................. 6

GEN-06/ TRM10 Treadmill Base ......................................... 6

Lubricants ........................................................... 6

Electrical Requirements .............................................. 6

Section 3 - Safety Guidelines ................................................................................................... 8

Section 4 - Operation Verification .......................................................................................... 9

Operation Verification ............................................... 9

Procedure ................................................................................................................................ 9

Operation Verification Checklist .................................... 11

Section 5 - Standardized Service Access Codes ................................................................... 12

Service Access Codes ................................................ 12

Accessing the Service Software ...................................... 12

P80 Console ........................................................................................................................... 13

Access Code Table ................................................... 14

P20 Console Service Software Access ................................. 15

Hardware Validation - Diagnostic Tests (51765761) ................... 16

Club Parameter - Settings (5651565) ................................. 17

Information Display (65) ............................................ 18

Section 6 - Theory Of Operation ........................................................................................... 19

Consoles ............................................................ 19

Basic operation of a console ............................................................................................. 19

Consoles that could appear on the GEN-06 / TRM10 Treadmill Base ........................ 20

Console To Base Communication ....................................... 22

Treadmill Base Operation ............................................ 23

Power Entry ............................................................................................................................ 23

Lower Electronics Module .................................................................................................. 24

AC Drive Motor Controller .................................................................................................. 25

Auto-Stop ............................................................................................................................... 27

AC Lift System – Motion Control ........................................................................................ 28

AC Lift System – Position Monitoring ................................................................................. 30

Section 7 - TRM Base Troubleshooting Procedures ........................................................... 31

Introduction to Treadmill Troubleshooting ........................... 31

Troubleshooting Tripped Breakers .................................... 31

If the unit trips the wall breaker: ........................................................................................ 32

If the Treadmill breaker (power switch) is tripped: ......................................................... 33

Troubleshooting No Power to the Console ............................. 35

Standardized Error Codes ............................................ 36

Error Codes ............................................................................................................................ 38

Error Code Table ................................................................................................................... 39

Validating the Reported Failure ........................................................................................ 40

Troubleshooting Input Power & Control Error Codes ................... 41

Error 05 - Key Depressed at Power Up .............................................................................. 41

Description ............................................................................................................................. 41

Possible Causes ..................................................................................................................... 41

Possible Remedies ................................................................................................................ 41

Error 09 - Lower PCA Memory Test Errors .......................................................................... 42

Description ............................................................................................................................. 42

Possible Cause ...................................................................................................................... 42

Possible Remedy................................................................................................................... 42

Error 12 - Watchdog (Lower PCA) ..................................................................................... 43

Description ............................................................................................................................. 43

Possible Causes ..................................................................................................................... 43

Possible Remedies ................................................................................................................ 43

Error 15 - A.C. Input Voltage Too High .............................................................................. 44

Description ............................................................................................................................. 44

Possible Causes ..................................................................................................................... 44

Possible Remedies ................................................................................................................ 44

Error 16 - A.C. Input Voltage Too Low .............................................................................. 46

Description ............................................................................................................................. 46

Possible Causes ..................................................................................................................... 46

Possible Remedies ................................................................................................................ 46

Error 80, 81, 82, & 83 – P30 Machine Controls Not Working .......................................... 47

Description ............................................................................................................................. 47

Possible Causes ..................................................................................................................... 47

Possible Remedies ................................................................................................................ 47

Troubleshooting the 3 Phase AC Drive Motor System ................... 48

Procedure: ............................................................................................................................. 48

Error 20 - Too many Maximum Power Requests in 1 Second ....................................... 51

Description ............................................................................................................................. 51

Possible Causes ..................................................................................................................... 51

Possible Remedies ................................................................................................................ 51

Error 27 - Too Much Drive Motor Current ......................................................................... 52

Description ............................................................................................................................. 52

Possible Causes ..................................................................................................................... 52

Possible Remedies ................................................................................................................ 52

Error 28 - Temperature Too High ........................................................................................ 53

Description ............................................................................................................................. 53

Possible Causes ..................................................................................................................... 53

Possible Remedies ................................................................................................................ 53

Error 29 - Excessive AC Input Current ................................................................................ 54

Description ............................................................................................................................. 54

Possible Causes ..................................................................................................................... 54

Possible Remedies ................................................................................................................ 54

Troubleshooting the Incline System .................................. 55

Operation of lift motor for testing: .................................................................................... 55

Error 40 - No Lift Motion Detected ..................................................................................... 56

Description ............................................................................................................................. 56

Possible Causes ..................................................................................................................... 56

Possible Remedies ................................................................................................................ 56

Error 42 - Lift Position Value Out of Range ....................................................................... 61

Troubleshooting Procedure ................................................................................................ 61

Description ............................................................................................................................. 61

Possible Cause ...................................................................................................................... 61

Possible Remedies ................................................................................................................ 61

Error 44 - Un-commanded Lift Motion .............................................................................. 64

Description ............................................................................................................................. 64

Possible Causes ..................................................................................................................... 64

Possible Remedies ................................................................................................................ 64

Error 45 - Lift Moving in Wrong Direction .......................................................................... 65

Description ............................................................................................................................. 65

Possible Causes ..................................................................................................................... 65

Possible Remedies ................................................................................................................ 65

Troubleshooting Communications Errors ............................... 66

Error 30, 31, 32 and 33 - Communications Error .............................................................. 66

Description ............................................................................................................................. 66

Possible Causes ..................................................................................................................... 66

Possible Remedies ................................................................................................................ 66

Error 37 - E-Stop Not Communicating............................................................................... 67

Description: ............................................................................................................................ 67

Possible Cause: ..................................................................................................................... 67

Possible Remedies: ............................................................................................................... 67

Running Belt & Deck Troubleshooting ................................. 68

Procedure .............................................................................................................................. 68

Troubleshooting the Auto Stop Feature ............................... 70

Error 60 or “Temporarily Out of Order” – Auto Stop Not Working ................................ 73

Description ............................................................................................................................. 73

Possible Causes ..................................................................................................................... 73

Possible Remedies ................................................................................................................ 73

Error 61 or “Temporarily Out of Order” – Auto Stop Not Present ................................. 75

Description ............................................................................................................................. 75

Possible Causes ..................................................................................................................... 75

Possible Remedies ................................................................................................................ 75

Troubleshooting Heart Rate Issues .................................................................................... 77

Hand Held Heart Rate Does Not Work ............................................................................. 77

Wireless Heart Rate Does Not Work .................................................................................. 78

Possible sources of interference signals include, BUT NOT LIMITED TO: ...................... 78

Section 8 - Replacement Procedures ..................................................................................... 79

Replacing the Line Cord ............................................. 79

Replacing the Circuit Breaker ....................................... 81

Replacing the Line Filter ........................................... 83

Replacing the Input Module .......................................... 85

Replacing the Auto Stop Sensor ...................................... 87

Replacing the Auto Stop Magnet ...................................... 89

Replacing Drive Motor ............................................... 92

Replacing the Incline Motor ......................................... 93

Replacing the Incline Platform ...................................... 96

Replacing the Power Control Module .................................. 98

Replacing the End Cap or Belt Guard ................................ 100

Drive Belt Replacement ............................................. 102

Replacing the Drive Roller ......................................... 105

Take Up Roller Replacement ......................................... 109

Running Belt and/or Deck Replacement ............................... 111

Section 9 - Adjustment Procedures ..................................................................................... 119

Adjusting Drive Belt Tension ....................................... 119

Tensioning the Running Belt ........................................ 122

Running Belt Tracking Adjustment ................................... 124

Running Belt Tracking Adjustment .................................................................................. 124

Calibrating the Lift Motor ......................................... 125

Section 10 - Preventive Maintenance .................................................................................. 127

Regular Preventative Maintenance - performed by owner .............. 127

Daily ...................................................................................................................................... 127

Weekly: (Plus Daily Preventive Maintenance) .............................................................. 127

Monthly: (Plus Daily and Weekly Preventive Maintenance) ...................................... 129

On-Site Preventative Maintenance - performed by Service Technician . 130

Preventative Maintenance Checklist (Facility personnel) ............ 133

To Be Done Daily: ............................................................................................................... 133

To Be Done Weekly: All of the above plus .................................................................... 133

To Be Done Monthly: All of the above plus ................................................................... 133

Preventative Maintenance Checklist (Service Technician) ............ 134

Section 11 - Block Diagram ................................................................................................. 135

Block Diagram - 120 Volt ........................................... 135

Section 12 - Exploded View & Parts Identification ........................................................... 136

Exploded View ...................................................... 136

Parts Identification List .......................................... 142

Warning:

This service manual is for use by Precor trained service providers only. If you are not a Precor Trained Servicer, you should not attempt to service any Precor products. Call your dealer for service.

This document contains information required to perform the majority of

Section 1 - About This Document

troubleshooting and replacement procedures required to repair and maintain this product.

This document contains general product information, software diagnostic procedures (when available), preventative maintenance procedures, inspection and adjustment procedures, troubleshooting procedures, replacement procedures and electrical block and wiring diagrams.

In This Section

GEN-06/ TRM10 Treadmill Base ...................... 6

Lubricants ........................................ 6

Electrical Requirements ........................... 6

Section 2 - General Information

GEN-06/ TRM10 Treadmill Base

This manual covers service information for the GEN-06 / TRM10 Treadmill Base.

 The GEN-06 treadmill base is defined as any treadmill produced between

April of 2006 and April of 2011. GEN-06 Treadmills include the following models; C952, C954, C956, and C966.

 The TRM10 treadmill base is defined as any treadmill produced after

April 2011 and is mated to a Pxx console. All of the base and console combinations are part of the "Experience" line of products.

Lubricants

 Do not apply any lubricants 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.

 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.

Electrical Requirements

It is extremely important that any Precor 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.

Nominal AC operating voltage on 120VAC circuits is 90VAC to 132VAC. Nominal AC operating voltage on 240VAC circuits is 180VAC to 264VAC. For operator safety considerations 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.

Important

If the AC circuit feeding a treadmill is found to be a non-dedicated branch circuit or a circuit equipped with a circuit breaker with a capacity of less than 20 amps, the AC circuit must be corrected before any reliable troubleshooting can be performed on the treadmill. More importantly, a non-dedicated branch circuit may constitute a safety hazard to the treadmill operator.

120 Vac Systems

120 VAC distribution systems utilize a single pole circuit breaker (hot lead) and a neutral lead connected to a common neutral (ground) bar. The A.C. 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.

Safety guidelines you should know and follow include:

Section 3 - Safety Guidelines

 Read the owner’s manual and follow all operating instructions.  Operate the equipment on a solid, level surface.  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.

 When operating the treadmill:

 Do not wear loose clothing. Do not wear shoes with heels or leather

soles.

 Check the soles of your shoes and remove any embedded stones.

 Tie long hair back.  Do not rock the unit.  Do not stand or climb on the handlebars, display enclosure or cover.  Do not set anything on the handlebars, display enclosure, or cover.

Never place liquids on any part of the treadmill while performing

service.

 To prevent electrical shock, keep all electrical components away from

water and other liquids.

 Do not use accessory attachments that are not recommended by the

manufacturer-such attachments might cause injuries.

 Removing the hood exposes high voltage components and potentially

dangerous machinery. Exercise extreme caution when you perform

maintenance procedures with the hood removed.

This section provides a method of checking the treadmill operation. Check

In This Section

Operation Verification ............................ 9

Operation Verification Checklist .................. 11

Section 4 - Operation Verification

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

1 Plug the power cord into the wall outlet and then switch the circuit

breaker to the "ON" position.

2 Press and hold the reset key for at least 6 seconds, if errors are

present the error log will be displayed. Make note of all the errors

in the error log and odometer reading for which the error occurred.

The odometer in the error log can help you determine age and relevance

of the error.

3 Clear the error log. 4 Enter the Hardware Validation test by entering Diagnostic mode as

follows:

5 Press either the STOP, PAUSE or RESET buttons and then enter

5,1,7,6,5,7,6,1

6 Select and run the Display Test, the Keypad Test, and the Heart Rate

Test. Verify the following results.

 LEDs light

 Keys all function

 Heart rate is acquired and displayed

7 Enter the Machine Tests (submenu) and run the Belt Speed test and the

Incline test, verify following results:

 Running belt spins and is controlled from 0.1mph to 16.0mph.

 Lift goes up and down and the A/D value is approximately 6000+/-500

at 0% incline)

8 Press the reset key to exit diagnostics. 9 Operate the treadmill in the Manual program. Adjust the speed of the

running belt to 2–3mph. Operate the treadmill for at least 5 minutes

while walking on the unit.

 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.

 Observe the LED’s on the electronic console. Make sure that each LED

lights as the information corresponding to that LED is displayed on the electronic console.

10 Press the INCLINE  key while viewing the electronic console. Confirm

that the running deck inclines and the incline display increments to

15% as the INCLINE  key is continually pressed. 11 Press the INCLINE  key while viewing the electronic console. Confirm

that the running deck returns to a level position and the incline

display decrements to 0% as the INCLINE  key is pressed. (Depending

on the software configuration of the console, the lowest level of

incline might be -3%)

12 While the unit is running and the running belt is in motion, press the

STOP button and verify the running belt stops.

13 Restart the running belt and while the running belt is in motion, pull

the ESTOP cord and verify the running belt stops.

14 Press and hold the reset key for at least 6 seconds and look at the

error log again. This time look for any NEW errors displayed resulting

from the verification test indicating that the unit needs attention.

Operation Verification Checklist

 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 Validation 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  or  keys are pressed and is free of excessive noise or vibrations.

 The STOP button stops the running belt from moving.  Pulling the ESTOP cord stops the running belt from moving.  Check for new errors that may have been recorded in the error log during operation

verification of the treadmill.

In This Section

Service Access Codes .............................. 12

Accessing the Service Software .................... 12

Access Code Table ................................. 14

P20 Console Service Software Access ............... 15

Hardware Validation - Diagnostic Tests (51765761) . 16

Club Parameter - Settings (5651565) ............... 17

Information Display (65) .......................... 18

Section 5 - Standardized Service Access Codes

Service Access Codes

The standardized service access codes are utilized on the following consoles:

 Standard Console

 P10 Console

 P20 Console

 P30 Console

The service codes will allow access to three functional modes, Hardware Validation, Club Parameters, and a Information Display.

 Hardware Validation is a set of functional diagnostic tests that are

useful in troubleshooting problems as well as verifying proper operation.

 Club Parameters are sometimes referred to as Club Settings and are

used to manage usage of the machine.

 Information Display is used to access information such as the

odometer, software versions and error logs.

Accessing the Service Software

Accessing these three areas is accomplished the same on all consoles (Standard, P10, P20, P30) except the P80. To enter Service Software, press either the STOP, PAUSE, or RESET key (whichever is available on your specific console) followed by a numeric code for the area of service software you wish to access.

The standard access codes use sequential key presses, not simultaneously holding down multiple keys. The allowable delay between key presses is short. If too much time is taken between key presses or the wrong key is pressed, the access procedure will be aborted. If the access is aborted, it will be necessary to start over from the beginning.

P80 Console

1 Use the System Settings to test your equipment and set parameters that

benefit your users and your facility.

2 The Welcome screen will be the first screen you see when you approach

the P80 console. Press the Pause key and continue holding it down

while you double press (prior to 1.1 version software release) or

single press (1.1 version or after software release) in sequential

order an X configuration on the Volume and Channel key pad (Channel

Up, Volume Down, Volume Up, Channel Down). Release the Pause key

when done pressing the arrows.

Note: The keypad X configuration sequence should be not faster than 1 second between each key stroke. Any speed faster than 1 second may result in an unsuccessful access to the sign-in screen.

Figure 1: P80 Sign In Access

3 The sign-in screen will be displayed. Type in the technician access

,5,1,7,6,5,7,6,1, and then touch OK. The Settings menu will be

displayed.

Access Code

Heading Name

Function

5,1,7,6,5,7,6,1

Hardware Validation

Running Diagnostic Tests

5,6,5,1,5,6,5

Club Parameters (Commercial)

Changing Machine and /or Workout Parameters

6,5

Information Display

Acquiring Information

Access Code Table

P20 Console Service Software Access

The P20 console starts with STOP, PAUSE, or RESET, however the numeric values of the service software code is assigned to the function keys in the absence of the 10-key pad.

Figure 2: P20 Console Access Keys

Hardware Validation - Diagnostic Tests (51765761)

Figure 3: Hardware Validation Graphic

Safety Code

Either enabled or disabled, this setting requires a password (1234) to be entered in order to start the unit. Factory default is disabled.

Select Language

Sets the default language for ALL w orkouts on this m achine. Language for single use w orkouts can still be set by the user from the w orkout options.

Select Units

Sets units of m easure (US standard or M etric). Factory default is US standard.

Set M ax W orkout Tim e

Sets the m axim um allowable workout tim e for each user. Factory default is 60 m inutes.

Set M ax Pause Tim e

Sets the m axim um tim e that the workout can be paused for. Factory default is 120 seconds.

Set M ax Cool Dow n Tim e

Sets the am ount of tim e that a cool down period will occur at the end of every w orkout. Factory default is 5 m inutes.

Set M etrics D efault

Sets a m etric that m ay be of specific im portance to the specific facility or fitness trainer. The selected m etric will scroll across the screen at regular intervals during the

w orkout. Factory default is “N O NE”

Set Speed Lim it

Sets the m axim um speed that the user can set the unit to. Factory default is 16m ph.

Set Incline Lim it

Sets a m axim um value that the user can set the incline to. Factory default is 15% .

Show H idden Program s

Either enabled or disabled, this setting allow s the unit to access specialized fitness tests designed for police, fire fighters, and the m ilitary. Factory default is disabled.

Club Parameter - Settings (5651565)

O dom eter

D isplays the total num ber of accum ulated m iles on the unit. This value is stored in the upper PCA in the console, so if the PCA is replaced the

accum ulated m iles w ould start again from “0”.

H ours of Use

D isplays the total num ber of hours that the unit took to accum ulate those m iles unit. 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”

Upper Boot Softw are

D isplays the current version of softw are that handles flash upgrades of upper PCA (console) softw are.

Upper Base Software

D isplays the current version of softw are loaded in the upper PCA (console). This is the unit specific console software.

Lower Softw are

D isplays the current version of softw are loaded in the low er control m odule (IFT drive).

M etrics Board Softw are

D isplays the current version of softw are loaded in the m etrics board.

Serial Num ber

The base serial num ber can be set here using theW inCSAFE com puter softw are. Factory default is N O N E.

Usage Log

D isplays the type of workout program s the users are accessing m ost frequently.

Error Log

D isplays a running log of the last 10 errors encountered on the unit.

Information Display (65)

In This Section

Consoles .......................................... 19

Console To Base Communication ..................... 22

Treadmill Base Operation .......................... 23

Section 6 - Theory Of Operation

Consoles

Basic operation of a console

The purpose of this section is to describe the operation and maintenance of the treadmill base, however it would be difficult to explain the base operation without referring to the console controls. This section will explain basic functions that apply to all models of consoles. For specific details about a particular model of console (Standard, P10, P20, P30, P80), refer to the applicable console manual.

The Controls

All consoles provide user input (keypad functions), user display (LED display / user feedback), automated control (heart rate program, interval program) and service software routines (tests, settings, and information).

The keypad functions can vary between different console models, however the basic functions that all consoles have are Quick Start, Incline (up or down) and Speed (up or down).

The Display

The display features can vary between different console models, however the information conveyed by those displays are very similar.

Service software routines are handled exactly the same for all console models. Entering into Hardware Validation tests, Club Parameter settings, or Information Display is also the same and are called Standardized Service Access Codes.

The service software and standard access codes are described in detail

in, Standardized Service Access Codes (see "Section 5 - Standardized Service Access

Codes" on page 12) section of this manual.

The service software also includes Standard Error Codes, in all console models. For a full listing of Standard Error Codes used for this model

see, Section 7 - TRM Base Troubleshooting Procedures (on page 31).

Consoles that could appear on the GEN-06 / TRM10 Treadmill Base

Figure 4: Commercial Treadmill Consoles

Console To Base Communication

The processor in the console provides user input, user display and automated control to the system. The processor in the lower electronics module performs the actual machine function.

The two processors communicate via a serial data stream. When the user makes a requests a machine function to take place via the keypad, the console processor communicates the request to the processor in the lower electronics module.

Once the lower processor receives the request the lower control module performs the machine task associated with the request. The console processor continues to monitor keypad entry and provide display feedback.

The lower processor also provides status back to the console processor (via the serial data stream) to report if everything occurred properly, or if an error code needs to be written to the error log.

Figure 5: AC Drive Treadmill System

Treadmill Base Operation

Power Entry

The GEN-06 / TRM10 base is equipped with a removable line cord plugged into a power entry socket. This is designed to accommodate either 120V or 240V NEMA compatible line cords, as well as line cords for other countries. The diagram below shows a NEMA 20A plug for both 120V and 240V configurations in the United States.

Figure 6: NEMA Compatible Plugs

120v power, when measured from hot to neutral, should read between 90 and 132v. 240v power, when measured from hot to neutral should read between 180 and 264v. This input voltage is applied through the power entry plug and wired to the breaker switch. The 120v breaker switch only interrupts the hot line and the 240v breaker switch interrupts both the hot and neutral lines. The power is then fed through a line filter which removes high frequency noise from the line voltage. After the power is cleaned by the line filter it can be applied to the lower electronics module (IFT drive).

Lower Electronics Module

The lower control module consists of an AC drive motor controller, an AC lift motor controller and a +8.5V DC power supply to power the console.

The electronic circuits in the console operate on +5V DC, however the lower control module sends +8.5V DC due to the optional external equipment such as Fitlinxx, that may be connected to the CSAFE (Communication Standard for All Fitness Equipment) port. Sending a higher voltage (+8.5V) and regulating the voltage down to +5V DC, ensures that we can supply enough power to both the console and the optional external equipment.

It is important to note that the lower control module is a different part number for a 120V unit than for a 240V unit.

AC Drive Motor Controller

The Experience Line treadmills use an AC drive system to control a three phase AC drive motor. In an AC motor, speed is controlled by frequency independent of voltage or current and torque is controlled by the voltage/current applied to the 3 windings. The windings (stator) and rotor core of the motor are designed to spin at a specific speed at the design frequency. This is by design of the motor itself. By changing the frequency of the drive current, we can change the speed. The lower control module generates the correct frequency to drive the motor at the desired speed. Since the speed of an AC motor is controlled by frequency, there is no need for a speed sensor.

Figure 7: AC Drive Motor Controller

The frequency is then sent to the motor over 3 lines, with each of those lines being phase shifted 120 degrees from each other. This type of AC motor is referred to as a 3 phase AC motor and is used to allow enough torque to be applied over a continuous duty run time. The amplitude (voltage/current) of all three sine waves is the same at any given time and allows the torque to be applied smoothly throughout the rotation of the motor. Increasing the amplitude increases the torque and decreasing the amplitude decreases the torque.

The lower electronics module (IFT drive) is responsible for sending the proper frequency to control speed and the proper amplitude (same on all 3 lines) to control torque. The motor must then be balanced both mechanically and electrically in order to translate the frequency and amplitude into fluid motion. Mechanical balance is achieved by balancing the weight of the flywheel, and electrical balance is achieved by all 3 windings being equal (same number of ohms).

Other features of this AC drive motor controller include "Dynamic Braking" and "Power Factor Correction". Dynamic Braking addresses an issue where an over-speed condition could occur. If a heavy user runs at a high incline, the weight of the user has the potential to push the running belt to go faster than the motor control was trying to maintain. The dynamic brake circuit senses the load variations and applies a braking force within the motor. The system utilizes an external power resistor to determine the point at which the braking force is applied. Power Factor Correction is a feature that attempts to reduce power consumption. The system monitors that this power factor is held within certain parameters. If it falls outside those parameters (IE, the system is suing more current than expected), the system will flag an ERROR 29. Error codes are addressed in detail in the troubleshooting section of this manual.

Figure 8: AC Motor Phase Chart

Auto-Stop

The Auto Stop feature monitors up and down movement of the deck. The deck motion indicates a user is present. The lack of motion indicates that a user is not present. If the running belt is moving and the Auto Stop does not detect motion from the running deck, the Auto Stop feature will stop the motion of the running belt.

Treadmills built between April of 2006 and April of 2011 (referred to as the Gen-06 Treadmill) did not have this auto-stop feature. Treadmills built From April of 2011 to present (referred to as the "TRM10 Treadmill") support the auto-stop feature.

The auto-stop feature consists of a magnet mounted on the edge of the deck, the sensor mounted on the roller mounting bracket and a cable connecting Auto-stop to the console. When a user is running on the deck, it causes the magnet to be in motion relative to the sensor. When a program is entered, Quick Start is pressed or the treadmill has been resumed after being paused, the treadmill starts at 1 mph. The user will then have 60 seconds to enter any remaining workout settings before motion detection begins. Once motion detection has commenced and if no or very little motion is detected, the Auto Stop feature interprets that the treadmill is no longer in use. The Auto Stop feature will continue to monitor the treadmill for motion for 30 seconds; if motion is still not detected a 10 second count down will be displayed on the console. After the 10 second count down has elapsed and motion has not been detected, the Auto Stop feature will stop the motion of the running belt and go into pause mode. If motion is detected within the 10 second count down cycles the shut down feature will be aborted.

The Auto Stop feature can be enabled or disabled within the service software menus. See "Setting Club Parameters" in the corresponding P10 console, P20 console, P30 console or the P80 console service manual.

Note: If enabled, adjustment and tracking procedures should be preformed while in the Hardware Validation – Belt Speed Test. This is because the Auto-Stop feature is not active during the Belt Speed Test.

AC Lift System – Motion Control

The motor used in the lift system is a "Permanent Split Capacitance" type, single phase AC motor. What this means is that the motor incorporates the use of a capacitor to provide the torque required to lift the weight of the user as well as the weight of the unit. Power to the lift motor is provided directly from the AC coming into the unit.

In order to turn the motor in 2 directions, the AC motor has 2 separate windings, one for up and one for down. AC1 has a continuous connection to the center / common connection of the motor.

The system has a 2A fuse to protect the components from over-current failure.

When a control signal is applied to the "UP" input, TRIAC 1control line is active and turns on the up triac. This directs the AC2 connection to the up winding of the motor, causing the motor to spin in the up direction.

When a control signal is applied to the "DOWN" input, TRIAC 2 control line is active, turns on the down triac. This directs the AC2 connection to the down winding of the motor, causing the motor to spin in the down direction.

Since the lift motor runs directly on the AC line voltage coming into the unit, it is important to note that the lift motor is a different part number for a 120v unit than for a 240v unit.

Figure 9: AC Lift System - Motion Control

AC Lift System – Position Monitoring

The unit also requires an absolute measurement of lift position. This is achieved through the use of a potentiometer. The potentiometer is turned by connected gears in the lift motor, which changes the wiper resistance.

With +3.3V DC applied across the potentiometer, the center wiper connection will be a variable voltage (between 0 and +3.3V DC), dependant on the position of the lift. This variable voltage is applied to the input of a 16-bit A/D converter which converts the analog voltage into a 16-bit binary numeric representation that the processor can understand.

As the voltage returned by the potentiometer changes between 0 and 3.3V DC, the corresponding A/D values change between 0 and 65507. In this way, the processor can keep track of where the lift is positioned.

It is important to note that since the potentiometer is mechanically connected to the gearing of the motor, it would be highly unlikely for a lift motor to go out of calibration without having some damage that

needs to be repaired. See the section, Troubleshooting the Incline System (on

page 55) if this occurs.

This section contains troubleshooting procedures and presents a

In This Section

Introduction to Treadmill Troubleshooting ......... 31

Troubleshooting Tripped Breakers .................. 31

Troubleshooting No Power to the Console ........... 35

Standardized Error Codes .......................... 36

Troubleshooting Input Power & Control Error Codes . 41 Troubleshooting the 3 Phase AC Drive Motor System . 48

Troubleshooting the Incline System ................ 55

Troubleshooting Communications Errors ............. 66

Running Belt & Deck Troubleshooting ............... 68

Troubleshooting the Auto Stop Feature ............. 70

Section 7 - TRM Base Troubleshooting Procedures

methodology for identifying and isolating system issues. Not all system issues will create an error code condition so the approach is to identify and verify the stated problem and then use the systems own self tests to help isolate the problem. In many cases, that will include the use of error codes, but not always.

Introduction to Treadmill Troubleshooting

 The failure that is reported by the user may differ from your

observations as a trained technician. That is why it is important to validate the reported failure. The first step in this investigative troubleshooting methodology is to first identify the current overall operating condition of the treadmill. Is it operational or not. If the system powers up and can be at lease partially operated:

o Follow the procedure, Validating the Reported Failure (on page 40).

 If the treadmill does not turn on, trips the breaker or the console

will not illuminate:

o Follow the appropriate procedure for Troubleshooting Tripped Breakers

(on page 31) or Troubleshooting No Power to the Console (on page 35).

Troubleshooting Tripped Breakers

It is extremely important to note whether the unit’s breaker trips or the

wall outlet breaker trips. It is also extremely important to note when the trip occurs:

 Immediately on power up

 After the belt starts but before the user walks on the belt

 After the user walks on the belt.

If the unit trips the wall breaker:

1 Check the voltage coming from the wall. If it is approximately to 0V,

the wall breaker has likely tripped.

2 Inspect the line cord, If damaged, replace the line cord. If the line

cord is not damaged continue with the following steps.

3 Verify if two or more treadmills on the same wall breaker. This will

be especially evident if two or more treadmills shut down at the same

time. To verify if multiple treadmills are sharing the same wall

breaker, manually turned off the wall breaker. If more than one

treadmill loses power, the treadmills are on the same breaker.

 If YES, advise the customer to have their facility wiring upgraded

per Precor specifications.

 If NO, continue with the following steps. 4 Verify the wall outlets do not share neutral wiring and that each wall

outlet is on a individual branch circuit. A individual branch circuit

will have its own load line, neutral line and ground line. To verify

that the treadmill is not on a 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.

 If YES, advise customer to have their facility wiring upgraded per

Precor specifications, and then continue to step 5.

 If NO, Continue to step 6 5 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 about 6 volts RMS, and ideally

less.

 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.

 If NO, Continue to step 6. 6 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 user 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. Follow the steps

for these errors as per procedure, Troubleshooting the Drive Motor System

(see "Troubleshooting the 3 Phase AC Drive Motor System" on page 48) .

If the Treadmill breaker (power switch) is tripped:

1 Verify the wall outlets do not share neutral wiring and that each wall

outlet is on a individual branch circuit. A individual branch circuit

will have its own load line, neutral line and ground line. To verify

that the treadmill is not on a 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.

 If YES, advise customer to have their facility wiring upgraded per

Precor specifications, and then continue with step 2.

 If NO, continue with the following steps. 2 Verify that there long branch run with inadequate gauge wire.

 If YES, advise customer to have their facility wiring upgraded per

Precor specifications.

 If NO, continue with the following steps. 3 Verify line voltage. Low line voltage for the U.S. is anything below

108VAC, measured while the treadmill circuit breaker is turned "ON",

but the running belt is idle. For international, low line voltage is

anything below 200VAC while the treadmill circuit breaker is turned

"ON" and the running belt is idle. Measure the line voltage with the

treadmill circuit breaker is turned "ON", but the running belt is

idle. Make note of 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.

 If any measurement is below 108VAC (US) or 200VAC (International),

advise the customer to have their facility wiring inspected by an electrician.

 If the measurements are at or above 108VAC (US) or 200VAC

(International), continue with following steps.

4 Does the treadmill trip its breaker immediately on power up?

 If YES, it is likely that there is a shorted component (line filter,

lower control module) or faulty/shorted wiring.

 If NO, continue with the following steps. 5 Does the treadmill power up, but trips the breaker after the motor is

started?

 If YES, it is likely that there is a bad roller or bad drive motor.

 If NO, continue with the following steps.

6 Does the drive motor start up fine, but trips the breaker after a user

walks/runs on the running belt?

 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 user 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. Perform an amp draw test by following

troubleshooting procedure, Running Belt & Deck Troubleshooting (on page

68) .

Troubleshooting No Power to the Console

This troubleshooting is for Standard, P10, P20, or P30 consoles only. P80 use their own power source separate from the lower control module.

1 Using an AC voltmeter, verify that the outlet voltage is appropriate.

See procedure, Troubleshooting Tripped Breakers (on page 31)

 If NO, advise customer to have their facility wiring upgraded per

Precor specifications and then continue with troubleshooting.

 If Yes, continue with the following steps. 2 Remove the treadmill hood and measure the AC voltage at the input side

of the line filter with a voltmeter. Verify that line voltage is

present when the breaker switch is turned on.

 If NO, Replace the breaker switch.

 If Yes, continue with the following steps.

3 Measure the AC voltage at the output side of the line filter with a

voltmeter. Verify that line voltage is present when the breaker switch

is turned on.

 If NO, Replace the line filter.

 If Yes, continue with the following steps.

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?

 If NO, Replace the lower control module (IFT drive).

 If Yes, continue with the following steps.

5 If the test console did power up in step 4, re-connect the test

communications cable from the test console to the original console.

Does the original console power up?

 If Yes, Replace the Communications Cable.

 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.This could potentially produce two bad units instead of one.

Standardized Error Codes

The system generates error codes and stores those codes in a block of memory known as the ERROR LOG. The error is entered into the error log when it detects conditions that are defined in the error reporting software.

The error log displays the 10 most resent errors, with error location one being the most recent. Not all system issues will generate an error code, only the errors that can be generated in the treadmill will be described in this section. The error codes are useful in isolating certain system issues.

To view errors in the error log, press and hold the reset key for at least 6 seconds. If there are errors logged, this action will take you into the error log. The error log can also be accessed through the Information Display by pressing either STOP, PAUSE, or RESET, then the numbers 6, 5.

Figure 10: Standard Error Codes_Flow Chart

Error Codes

The subsequent pages list the details of each of the error codes that exist within the Precor software hierarchy. Each page will include a description of the error code being displayed and the systems associated with the error code.

Potential causes for the error codes will be listed with the most likely cause first and the least likely cause listed last. It must be understood that this document can not anticipate every possible cause for a particular error code. However, it should list the causes encountered in the majority of cases.

The document will then list the suggested remedies associated with each of the possible causes. The possible remedy listing will numerically coincide with the possible cause listing.

System s Errors Error Description

Error 05

Key depressed at pow er up

Error 09

M em ory error (Low er PCA)

Error 12

W atchdog (Low er PCA)

Error 15

AC input voltage too high

Error16

AC input voltage too low

Error 20

D rive M otor Does Not Start

Error 27

D rive m otor current too high

Error 28

D rive m otor tem perature too high

Error 29

Excessive AC Input Current

Error 30

Upper PCA not receiving data from low er PCA

Error 31

Faulty data received from lower PCA

Error 32

Low er PCA not receiving data from upper PCA

Error 33

Faulty data received from upper PCA

Error 37

ESTO P Not W orking

Error 40

N o lift m otion detected

Error 42

Lift position value out of range

Error 44

Un-com m anded lift m ovem ent

Error 45

Lift m oving in incorrect direction

Error 60

“Tem porarily O ut O f O rder” – Auto Stop Not W orking

Error 61

“Tem porarily O ut O f O rder” – Auto Stop Not Present

Error 80

P30 Lift Up Not W orking

Error 81

P30 Lift D own Not W orking

Error 82

P30 Speed Up Not W orking

Error 83

P30 Speed Dow n Not W orking

P30 M achine

Control Errors

Input Power & Control Errors

D rive System

Errors

Com m unicatio

n Errors

Lift System

Errors

A uto Stop

Errors

Error Code Table

The following is a list of the error codes currently assigned to the Gen06 / TRM10:

Table 1: Error Code Table by Systems

Validating the Reported Failure

1 Look to see if there is an error in the error log. This is often the

source of vital information to point your troubleshooting in the right

direction. Write down the errors and the odometer readings that are

reported in the log and then clear the error log by pressing and

holding the "Quick Start" key.

2 Run the unit in normal user mode and verify that the reported failure

occurs. Make note of any other observations of things that occur at

the time of the failure.

3 Run the unit in the service access software per the procedure in

section 5 (5-1-7-6-5-7-6-1, Hardware Validation Tests), and verify

that the console (display, keypad, and heart rate) functions are

working normally.

NOTE: Keep in mind that if a key on the keypad does not function, the lower control module will not be aware of any request for action that the user has initiated. In this case the cause for the failure would not be in the lower portion of the unit, and no errors will be logged.

4 Run the unit in the service access software per the procedure in

section 5 (5-1-7-6-5-7-6-1, Hardware Validation Tests), and verify

that the machine (belt speed and incline) functions are working

normally.

NOTE: If a failure is observed in user mode but works perfectly in the hardware validation tests, this could be an indication that a setting in the club parameters has been incorrectly set. It is also important to keep in mind that some problems are weight (load) related and you may need to recreate that condition.

5 Look at the error log again to see what errors have returned. This

will validate that they are real and current errors. Do not disregard

the previous errors that were cleared, but understand that the

odometer reading when compared to the total unit odometer reading will

determine how recent the error message occurred.

NOTE: If no error codes are present but the system is not operating normally, such as irregular or rough drive motor movement, follow the troubleshooting steps for the most directly related troubleshooting topic.

6 Look up the current service bulletins for this unit. If no service

bulletin 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).

Troubleshooting Input Power & Control Error Codes

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.

Error 05 - Key Depressed at Power Up Description

The power up test sequence has detected a key in the operated condition. The power up test sequence is performed every time the unit is turned on (powered up). This test is performed because a permanently stuck key will inhibit the correct operation of the unit.

Possible Causes

1 A key on the display housing is permanently stuck in the operated

condition.

2 One of the upper PCA’s keypad interface chips has failed. 3 Liquid (perhaps perspiration) is present on the surface of the display

overlay.

Possible Remedies

1 Remove the keypad connector cable from the upper PCA. Restart the

power up sequence, if the ERROR 5 is no longer present, the keypad is

the cause. The keypad is typically part of the display housing.

Replace the display housing to correct the problem.

2 Remove the keypad connector cable from the upper PCA. Restart the

power up sequence, if the ERROR 5 is still present, the upper PCA is

the cause. Replace the upper PCA to correct this problem.

3 Wipe the surface of the display overlay clean of all liquid. Restart

the power up sequence, if the ERROR 5 is no longer present, the liquid

was the cause.

Error 09 - Lower PCA Memory Test Errors Description

Error 09 checks lower PCA memory locations during the power up test sequence. If a fault is found during the power up test sequence, error 09 will be displayed. This error code is only used on products utilizing the dual microprocessor system.

Possible Cause

This error message almost always indicates a lower PCA problem when it is consistently displayed. Failures causing this error message to be displayed are rare.

Possible Remedy

If the error message is consistently displayed when the unit is powered up, the lower PCA should be replaced. It is possible to see this error message displayed intermittently due to external causes. If the unit's A.C. input significantly dips during the power up test sequence the test could fail resulting in this message being displayed. Treadmills operating on non-dedicated A.C. circuits may see this message displayed on an intermittent basis.

Error 12 - Watchdog (Lower PCA) Description

The error 12 watchdog monitors the lower PCA low voltage power. If the low voltage power drops below a preset level, the error 12 will be displayed.

Possible Causes

1 A failure in the lower PCA overloads the low voltage power supply and

causes it to drop below the preset limit.

2 A fault is in the interconnect cable (lower PCA to upper PCA) causing

the lower PCA low voltage power supply be too low.

3 A failure in the upper PCA that overloads the lower PCA low voltage

power supply causing it to be too low.

Possible Remedies

1 If the error message is consistently displayed when the unit is

powered up, the lower PCA should be replaced. It is possible to see

this message displayed intermittently due to external causes. If the

unit's A.C. input significantly dips during the power up test sequence

the test could fail resulting in this message being displayed.

Treadmills operating on non-dedicated A.C. circuits may see this

message displayed on an intermittent basis.

2 Substitute a known good interconnect cable in place of the existing

cable to determine if the interconnect cable is the cause. For the

purpose of the test, the substitute cable should be connected directly

between the upper and lower PCA’s.

3 Substitute a known good upper PCA for the existing PCA to determine if

the upper PCA is the cause.

Error 15 - A.C. Input Voltage Too High Description

This error monitors the AC input voltage. If the AC input momentarily reaches the upper limit, an error 15 will be logged. The upper acceptable input voltage limit is 132V AC on 120V AC systems or 264V AC on 240V AC systems.

When the treadmill is used by a vigorous exerciser walking or running at steep incline, the AC motor can become a generator, forcing power

backwards into the IFT module. This excess power would cause the IFT’s

internal reservoir, called the Bus Voltage, to rise to the point of damaging the drive were it not for the DB (dynamic brake) resistor, which automatically switches on to absorb it.

Error 15 is an indication that the Bus Voltage somehow rose too high,

either because the DB system wasn’t functional or because the Bus Voltage

power was more than the DB system could absorb at once. The power reservoir is also fed by the input (line) voltage, so it is also possible that a temporary line voltage surge could result in an Error 15 condition.

Possible Causes

1 AC input voltage transients. Transients can be caused by lightning

strikes or by other pieces of equipment sharing the treadmill’s AC

power.

2 Lower control module failure, or dynamic braking resistor failure. 3 Sticky substances on the underside of the running belt causing high

current.

Possible Remedies

1 Verify that the AC grounding is good at the treadmill’s AC outlet.

Verify that the treadmill is operating on a dedicated 20 amp branch

circuit. This condition would require a licensed electrician to

correct the problem.

2 This could be either the lower control module or the dynamic braking

resistor.

 Check error logs to determine Error 15 frequency.

 Has this continued to happen for this treadmill, or was it a one-

time event?

 Could it have happened when a user intentionally pushed against the

handrail, back-driving the motor for a sustained time?

o If YES, and the problem has only happened once or twice for this

treadmill, dismiss it and clear the error logs.

o If NO, proceed with the tests below.

 Raise elevation to 15%. Walk at a fast but comfortable pace on the

belt, and push off slightly against the treadmill handrail. Are you able to generate an Error 15 relatively easily?

o If YES, replace the IFT drive and DB resistor. o If NO, proceed with next step.

 Test the IFT drive. Have someone run on the treadmill at moderate

speed (7 or 8 MPH) with the incline at 0%.Is it possible to induce an Error 15 within 30 seconds?

o If YES, replace the IFT drive and DB resistor. o If NO, proceed with next step.

 Test the DB resistor. With power turned off, unplug DB cable from

IFT drive and then measure across the resistor with an ohmmeter. It should measure 90 to 110 ohms. Is there high resistance or an open circuit?

o If NO, and the problem has only happened once or twice for this

treadmill, dismiss it and clear the error logs.

o If NO (the resistor is good), but the problem has happened

chronically for this particular treadmill, check the line voltage.

o If YES (the resistor is bad), replace both DB resistor and IFT

drive.

3 Replace the running belt.

Error 16 - A.C. Input Voltage Too Low Description

This error monitors the A.C input voltage. If the A.C. input momentarily reaches the lower limit, an error 16 will be logged. The lower acceptable input voltage limit is 90 V.A.C. on 120 V.A.C systems or 180 V.A.C. on 240 V.A.C. systems

Possible Causes

1 A.C input voltage incorrect, treadmill is operating on undersized

A.C. wiring and/or is drawing high current.

2 Treadmill is operating on a non-dedicated circuit.

Possible Remedies

1 Voltage drop across the AC input wiring is a product of the length

of the wire run and the amount of current being demanded by the treadmill. The longer the run and the higher the current the larger the wire must be. The AC wiring must be sized to handle 20 amps of current over the loop length of the AC wiring. This condition would require a licensed electrician to correct the problem.

2 Verify that the treadmill is operating on a dedicated 20 amp branch

circuit. This condition would require a licensed electrician to correct the problem.

Error 80, 81, 82, & 83 – P30 Machine Controls Not Working Description

This error monitors the incline (up and down), and speed (up and down) controls of a P30 console. These switches are not traditional mechanical switches, they are optical switches.

 Error 80, P30 Lift Up Not Working  Error 81, P30 Lift Down Not Working  Error 82, P30 Speed Up Not Working  Error 83, P30 Speed Down Not Working

Possible Causes

1 Machine control interconnect cable has come unplugged from the upper

PCA.

2 Bad machine control cable. 3 Bad machine control assembly.

Possible Remedies

1 Open the P30 console to expose the circuit boards, and verify that

the machine control cable has not become unplugged from the upper PCA.

2 Substitute a known good machine control cable. 3 Substitute a known good machine control assembly.

Troubleshooting the 3 Phase AC Drive Motor System

Occasionally, there may be issues with the proper operation of the drive system that do not generate error codes. This troubleshooting procedure is intended for those times.

If there is an error code for the drive system (Error 20 through 29) in the error log, go to the appropriate error code troubleshooting page and follow the steps for that error.

If there are no errors in the log, yet the drive system appears to have an issue (such as jittery motion) follow the steps below.

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.

Procedure:

If the drive motor starts when you force the running belt to move and once running the drive motor runs rough, skip to step 8. If the drive motor will not start at all, continue with step 1.

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 advisable in this case)

1 Connect an AC voltmeter between terminals 4 (red) & 5 (white) of the

OUTPUT connector on the lower control module. See Figure Below. Set

the treadmill’s 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 value and set the treadmill’s on/off switch to the off position.

2 Set the treadmill’s on/off switch to the off position and repeat the

procedure in step 1 between terminals 4 (red) & 6 (black) of the OUTPUT connector on the power control module. Voltage should read the same value as in step 1. Set the treadmill’s on/off switch to the off position.

3 Set the treadmill’s on/off switch to the off position and repeat the

procedure in step 1 between terminals 5 (white) & 6 (black) of the OUTPUT connector on the lower control module. Voltage should read

the same value as in step 1. Set the treadmill’s on/off switch to

the off position.

4 If one or more of the voltage readings in steps 1 through 3 are not

present, replace the lower control module. If the voltage readings in steps 1 through 3 are present, continue with step 5.

NOTE: All resistance measurements must be performed with power removed from the treadmill. Performing the resistance measurements with voltage applied may damage your multi-meter.

5 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 W (Ohms). If any of the readings are significantly high or open, replace the drive motor.

6 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, the connector CAN BE repaired (using the appropriate crimper and connector ends) as a preferable solution to replacing a costly drive motor.

7 If you have performed all of the procedures above and have been

unable to correct the problem, call Precor customer support.

Note: All resistance measurements must be performed with power removed from the treadmill. Performing resistance measurements with voltage applied may damage your ohmmeter.

Figure 11: Lower Control Module

Figure 12: Lower Control Module Connector Numbering

Error 20 - Too many Maximum Power Requests in 1 Second Description

The lower control module monitors drive system loading effects to determine many parameters of the drive system, including if the motor starts. If the motor does not start, and error 20 is reported

Possible Causes

1 This error requires that the power must be cycled on the lower

control module.

2 The drive motor could be bad. 3 The lower control module could be bad.

Possible Remedies

1 Cycle the power on the lower control module by setting the units

breaker switch to OFF and then ON again.

2 Test the drive motor per procedure, Troubleshooting the Drive Motor System

(see "Troubleshooting the 3 Phase AC Drive Motor System" on page 48) , step

6. A known good drive motor can be substituted for the existing drive motor.

3 Test the lower control module per procedure,Troubleshooting the Drive

Motor System (see "Troubleshooting the 3 Phase AC Drive Motor System" on

page 48) , steps 1 thru 4). A known good lower control module can be substituted for the existing lower control module.

Error 27 - Too Much Drive Motor Current Description

Some treadmill motor controllers monitor the amount of current being delivered to the drive motor. The software sets a maximum amount of allowable drive motor current. This error indicates that maximum drive motor current has been reached.

Possible Causes

1 The running belt and/or running bed is badly worn.

Possible Remedies

1 A clamp-on AC ammeter must be used to determine the amount of AC

input current being drawn by the treadmill under no load and loaded

conditions. Follow the troubleshooting per procedure, Running Belt &

Deck Troubleshooting (on page 68).

Error 28 - Temperature Too High Description

Some treadmill motor controllers monitor the temperature of the motor controller output switching device. Typically, these motor controllers use a fan to force cool the output devices heat sink. This error indicates that the heat sink temperature has exceeded maximum.

Possible Causes

1 The lower PCA cooling fan is clogged. 2 The lower PCA cooling fan is inoperative. 3 The lower PCA is defective.

Possible Remedies

1 Check the cooling fan mounted on the lower control module to ensure

that the fan is not clogged with dust. Thoroughly clean the fan and ensure that it spins freely. Insure that machine motor cables are not routed to close and not touching the fan.

2 The lower PCA is clean and unobstructed but the fan does not spin.

Ensure that the fan wiring is securely and correctly connected to the lower control module. If the fan is unobstructed and the fan wiring is good, replace the lower control module.

3 Substitute a known good lower control module to determine if the

lower control module is defective.

NOTE: Some older lower control module software revisions used error 28 as a "catch all" and therefore reported a wider range of errors as an error 28. Verify lower control module software is current.

Error 29 - Excessive AC Input Current Description

This error code is used on three phase AC drive motor systems. If the AC input current reaches a value slightly over 20 amps R.M.S. or there is an instantaneous AC input current spike of 65 amps, the drive motor system will shut down and an error 29 will be logged.

Possible Causes

1 If the facility is powered by a generator, or frequently switches

between city and generator backup voltage, interruption of the treadmill operation may occur.

2 The neutral wires are shared on multiple outlets. 3 The running belt and/or running bed is badly worn. 4 A shorted lower control module (IFT module). 5 A shorted drive motor is causing the high power demand.

Possible Remedies

1 Call Precor support for lower board built specifically to handle

generator power.

2 The outlet is not on a dedicated 20 amp branch circuit. Using 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 they are sharing neutral lines. If YES, advise customer to have their facility wiring upgraded per Precor specifications. This condition would require a licensed electrician to correct the problem

3 A clamp-on AC ammeter must be used to determine the amount of AC

input current being drawn by the treadmill under no load and loaded

conditions. Follow the troubleshooting procedure, Running Belt & Deck

Troubleshooting (on page 68).

4 A known good drive motor power module must be substituted for the

existing drive motor power module.

5 A known good drive motor must be substituted for the existing drive

motor.

Troubleshooting the Incline System

Incline System Description:

The Lift 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.

This will 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.

Press and hold the reset key for at least 6 seconds, if there are errors logged in the error log this action will take you into the error log.

If there is an error code for a lift system error (Error 40 through 45) logged in the error log, go to the appropriate error code troubleshooting page and follow the steps for that error.

Note: All resistance measurements must be performed with power removed from the treadmill. Performing resistance measurements with voltage applied may damage your ohmmeter.

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 Machine Tests within the "Hardware Validation" mode (accessible through Pause-5-1-7-6-5-7-6-1) to check lift operation.

Error 40 - No Lift Motion Detected Description

Error indicates that the incline (lift) system on either a treadmill, EFX or AMT12 has been instructed to start moving and no lift motion has been detected by the lift position monitoring system.

Possible Causes

1 The lower control module lift fuse blown. 2 The lift motor is physically jammed and unable to move. 3 The lower control module is bad. 4 The lift capacitor is bad. 5 A lift motor winding is bad.

Possible Remedies

1 Remove power from the unit. Remove the screw from the back of the

lower control (IFT) module and press in the two locking tabs to remove the cover. Remove the 2amp fuse (it looks like a pencil eraser) and with an ohmmeter, check the resistance. The ohm value of the fuse should be less than 1 ohm.

 If the fuse is higher than one ohm, replace it.  If the fuse is one ohm or less, plug it back into its socket and

re-install the cover. If the fuse is good and the lift still will not move, continue to the next possible cause.

Figure 13: Lower Control Module - Fuse Location

 Disconnect the lift motor from the lift platform. If the lift

tube or lift nut is jammed against the motor housing, rotate the lift nut or lift tube away from the motor housing.

 If the lift was jammed, please refer to step 3 before you

continue. Calibrate the lift motor per the procedure, Calibrating the Incline Motor, and reattach the lift motor to the lift platform or ramp.

2 The lower control module can fail in one of two modes. The lift

switch could fail in an operated (shorted) condition.

3 If this happens the lift will move (either up or down) as soon as

the unit is powered up. The typical result is that the lift will be physically jammed as described above, and it will also probably cause the lift fuse to blow. If the lift moves un-commanded as soon as the power is turned on to the machine and eventually jams, the lower control module (IFT drive) must be replaced. The lift switch may also fail in an open condition. If this happens the lift will not operate in one direction. Perform the following steps to determine if the switch is open.

 With the incline below 15% (to allow room for lift travel up),

connect an AC voltmeter between terminals 1 (white) & 6 (red) of the INCLINE connector. (See Figure above for connector location, and Figure below for the connector pin-out). Set the treadmill in the manual program and press the INCLINE  key. The AC voltmeter should read AC line voltage (either 120VAC or 240VAC). Note that the AC line voltage reading will only be present before an error condition is displayed. A correct reading here verifies that the UP triac switch is working properly.

Figure 14: Lower Control Module Connector Numbering

 With the incline above 0% (to allow room for lift travel down),

connect an AC voltmeter between terminals 1 (white) & 5 (black) of the INCLINE connector. Set the treadmill in the manual program and press the INCLINE  key. The AC voltmeter should read AC line voltage (either 120VAC or 240VAC). Note that the AC line voltage reading will only be present before an error condition is displayed. A correct reading here verifies that the DOWN triac switch is working properly.

o If either of these conditions fail, the lower control module

must be replaced.

4 The lift capacitor mounted inside the lift motor. If the lift

capacitor is shorted (0 W), the lift fuse will blow. The capacitor may be checked by disconnecting the lift motor connector from the lower control module and using an ohmmeter to measure between pins 5 & 6 of the lift motor connector.

 If the capacitor is open or leaky it cannot be determined with an

ohmmeter. A leaky capacitor functions normally for light users, while failing to move the lift for heavier users. An open capacitor will not function at all and cannot be determined by an ohmmeter, so the following test will determine if the capacitor is bad.

 With the incline below 15% (to allow room for lift travel),

connect an AC voltmeter between terminals 5 (black) & 6 (red) of the INCLINE connector. See Figure above and below. Set the treadmill in the manual program and press the INCLINE  key. The AC voltmeter should read between 1.5 to 2.0 times the AC line voltage. If this reading is significantly low, replace the lift motor. Note that the AC line voltage reading will only be present before an error condition is displayed.

o If the capacitor is bad the lift motor must be replaced.

5 If a lift motor winding is bad, the lift will not operate in one or

both directions depending on the exact fault in the motor.

Error 42 - Lift Position Value Out of Range Troubleshooting Procedure

Set the treadmill’s on/off switch in the off position. Visually inspect the lift motor’s wiring and connector for any broken or improperly

crimped connections. With an ohmmeter, measure between terminals 1 (white) & 5 (black) and 1 (white) & 6 (red) of the INCLINE connector.

Both readings should be approximately 12  (Ohms) for a 120VAC lift motor and approximately 24  (Ohms) for a 240 VAC lift motor. If

either reading is significantly high or open replace the lift motor.

Description

This error code monitors the physical lift position via a lift position potentiometer that mechanically tracks the lift's physical position and sends a DC voltage back to the control system. The voltage is converted to a 16 bit digital number. This number is then used to represent the lifts physical position. Software sets upper and lower numerical limits. If the lift position number is found to be outside of the set limits, error 42 will be displayed.

When troubleshooting an error 42 it is important to be aware of the actual physical position of the lift when the error occurs. If the lift is physically out of range or jammed you must first determine why the lift is physically out of range. When the lift is out of range the error 42 is a secondary symptom and the problem should be treated as an error 40 instead of an error 42.

The A/D value for the home position (0%) is approximately 6200, and its A/D value at its lowest incline (-3%) is approximately 3200

Possible Cause

1 Incorrect lower control module part number. 2 Bad or intermittent connection in the lift motor connector. 3 The lift motor requires re-calibration.

If the lift had been calibrated correctly at the time of installation and working for some period of time it would be highly unlikely (if not impossible) for lift calibration to go out of calibration on its own. It would be more likely that something has broken causing the A/D value to be wrong.

4 The lift motor potentiometer is bad.

Possible Remedies

1 The vertical market treadmill uses an IFT lower control module that

looks the same, but is programmed differently. One of the things that is programmed differently is the lowest A/D value for the lift range (approximately 3000 in the vertical market unit). Having the wrong lower control module installed could easily cause an out of range (error 42) condition.

2 Intermittent connections can be difficult to locate. If the error 42

condition is intermittent a connection is almost certainly the problem. This is especially true if the error 42 occurs while the lift is within its normal physical range.

 Carefully inspect the lift potentiometer connector, repair the

poor connection, if possible. If the intermittent connection cannot be found or repaired, replace the lift motor.

 A lift calibration number of 0 or 65535 indicates an open or

shorted potentiometer connection. This problem could be anywhere between the lift motor and the upper PCA. It can typically be found and traced with an ohmmeter.

Figure 15: Lower Control Module Connector Numbering

 Set the treadmill’s on/off switch in the off position. Remove the

lift motor’s connector from the INCLINE connector on the power control (IFT) module. Visually inspect the lift motor’s wiring

and connector for any broken or improperly crimped connections. With an ohmmeter, read between terminals 3 (red) & 4 (black), 4

(black) & 8 (white) and 3 (red) & 8 (white) of the INCLINE connector. Terminals 3 (red) & 4 (black) should read approximately 1K W (Ohms). The sum of the readings between terminals 4 (black) & 8 (white) and 3 (red) & 8 (white) should total approximately 1K W (Ohms). If either reading is significantly high or open, replace the lift motor.

NOTE: Readings While The Unit Is In The Home Position (Level)

 Potentiometer resistance black to red = approximately 1kW.  Potentiometer resistance black to white = 20% of black to red

(approximately 200W)

 Potentiometer voltage black to red = approximately 3.3 volts.  Potentiometer voltage black to white = 20% of black to red

(approximately 0.66 volts)

 A/D value = approximately 6200 3 Refer to the lift calibration procedure. If the lift position number

and physical lift position measurement does not correspond with the service manual, calibrate the lift motor.

Note: There must be a reason for the lift motor to be out of calibration, therefore simply re-calibrating the lift motor will often not fix the problem.

4 If the lift calibration number (A/D value) is not 0 or 65535 and

does not increment when the lift motor moves, replace the lift motor.

Error 44 - Un-commanded Lift Motion

If you have performed all of the procedures above and have been unable to correct the problem, search for solutions in the service bulletins or call Precor customer service.

Description

The lift control system has detected that the lift is in motion without a lift command having been issued. This can happen in one of two ways: either the lift drive circuit has failed in a turned on condition or the lift position sensor (lift position potentiometer or revolution sensor) is sending an erroneous signal to the lift control circuit.

Possible Causes

1 The sensitivity of the 16-bit A/D converter has generated a false

error.

2 Poor or intermittent connection in the lift position sensor

(potentiometer).

3 Bad lift position sensor 4 Bad lower control module.

Possible Remedies

1 Due to the high sensitivity of the 16-bit A/D converter, vibration

during foot plant can cause the A/D value to change enough to generate this error. This condition is most likely to occur while the lift is not commanded to move. While the system software detects this as an error code 44, it does not stop the lift system from functioning normally. If this is the case the error should be considered a nuisance error, and the error log should be cleared.

2 This is the most common cause of an error 44. Verify all wiring and

connections associated with the lift position potentiometer. Repair or replace wiring or connections as appropriate. Because of the nature of the revolution sensor an error 44 is rarely associated with it.

3 Operate the lift in the diagnostics while monitoring the lift

position number being displayed. If the reading is erratic and makes large changes in readings the lift position potentiometer is probably bad. Replace the lift motor.

4 If there is actual lift motion without a manual or program control

lift command having been issued, replace the lower control module.

Error 45 - Lift Moving in Wrong Direction Description

The lift control system has detected that the lift is moving in the opposite direction of the issued lift command.

Possible Causes

1 Lift Motor hysteresis. 2 Bad lower control module

Possible Remedies

1 This error would typically happen when the lift was already in

motion (typically downward) when a lift command in the opposite direction (lift up) was issued.

Some motors exhibited a very long turnaround time and the lift motor would still be moving in the original direction (downward) while the control system was attempting to move the lift in the opposite direction.

If the error 45 condition is persistent, replace the lift motor.

2 This is a very rare condition, if the lift moves in the opposite

direction of the issued lift command, replace the lower control module.

Troubleshooting Communications Errors

Error 30, 31, 32 and 33 - Communications Error Description

Errors 30 through 33 all indicate the loss of communications or erratic communications between the microprocessors in the upper PCA and the lower PCA. The trouble shooting procedures for all of the communication errors are essentially the same.

 Error 30 is defined as upper PCA not receiving from lower PCA.  Error 31 is defined as faulty data received from lower PCA.  Error 32 is defined as lower PCA not receiving from upper PCA.  Error 33 is defined as faulty data received from upper PCA

Possible Causes

1 An upper PCA to lower PCA interconnect cable is bad. 2 The interconnect cable at the upper PCA was mistakenly plugged into

the CSAFE connector.

3 +5V DC power supply is being overloaded by another component that is

plugged onto the lower PCA.

4 A defective lower control module. 5 A defective upper PCA.

Possible Remedies

1 Substitute a know good interconnect cable between the upper and

lower PCAs to determine if the interconnect cable is defective.

2 Remove the interconnect cable from the CSAFE connector and insert it

in the correct upper PCA connector.

3 Unplug all the components from the upper PCA and lower control

module except, data cable, and the AC power going to the lower control module. If the unit shows an error other than a communication error, plug in components one at a time, cycling power after each new component is plugged in. If a communication error is displayed, the last component plugged in is the cause of the error.

4 Substitute a known good lower control module to determine if the

lower control module is defective.

5 Substitute a known good upper PCA determine if the upper PCAs

defective.

Error 37 - E-Stop Not Communicating Description:

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.

Possible Cause:

1 Out of date software in a P30 Upper PCA. 2 Bad data cable or mating connector. 3 Bad lower control module.

Possible Remedies:

1 Ensure that the software in the upper PCA is at the current

revision..

2 Substitute a known good data cable. 3 Substitute a known good lower control module.

Running Belt & 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 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.

Figure 16: A.C. Clamp-On Ammeter

2 Set the treadmill’s speed at 7-8 m.p.h. and the incline at 0%. Walk

on the treadmill and observe the average A.C. current reading. Typical average A.C. current readings on a new running belt and deck are between 8 to 12 amperes. average readings (those read by a digital meter) could be 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 previously flipped. See

Procedure, Running Belt and/or Deck Replacement (on page 111) 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.

Troubleshooting the Auto Stop Feature

Auto stop is a feature incorporated into all next generation Experience series treadmills. This procedure will provide troubleshooting steps for the Auto Stop feature

Procedure:

1 If the Auto Stop feature does not function continue with step 3. 2 If the Console is displaying Temporarily Out of Order (P80) or

Please use another Treadmill (P30, P20, P10) go to step 7.

3 Check the treadmill to ensure the Auto Stop hardware is installed.

See Figure Below.

 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.

 If the Auto Stop hardware is installed, Continue.

4 Verify that the Auto Stop cable was 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.

 If the cables were reversed, swap the connectors and re-test.  If the cables were correctly connected, continue

5 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 Procedure (P80), (P30), (P20) or (P10) Setting Club Parameters.

6 If the Auto Stop feature is enabled and you have performed steps 3

and 4 contact Precor customer service.

7 Access the service access software (hardware validation tests), and

select the Auto Stop test (see section-5). 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 is displayed and the Auto Stop feature still does not function contact Precor Customer Support. If the Auto Stop did not pass the test continue with step

8.

Figure 17: Auto Stop Assembly

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. Should this occur, contact PRECOR customer service for possible options for repairing the magnet assembly or to obtain a replacement part.

8 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.

9 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 step 9. See Figure Below.

Figure 18: Auto Stop LED's and Wire Connector

10 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.

11 Place the meter’s 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 skip to step 12.

12 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.

13 With the Auto Stop connector plugged into the Auto Stop sensor place

the meter’s 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 and/or bounce on the deck The voltage between the black and green wires should fluctuate when the deck is moving up and down. If the voltage does not change with movement replace the Auto Stop Sensor.

14 If you have preformed all the described steps and the Auto Stop

feature will still not function contact Precor Customer Support.

Error 60 or “Temporarily Out of Order” – Auto Stop Not Working Description

The error indicates the Auto Stop feature has stopped functioning during a workout. If the error is detected while a workout is in progress, the treadmill will operate normally until the workout has ended. At the end of the workout, the error will lock out the next user, displaying "Temporarily Out of Order, Please Use another treadmill" on the P80 console and "PLEASE USE ANOTHER TREADMILL" on the P30 and P20 consoles.

When this error occurs "1376256 E_AUTOSTOP_SENSOR_FAILURE" will be recorded to the event log of the P80 console. Error 60 will be recorded in the error log of the P10, P20 or P30 console.

Possible Causes

1 Intermittent connections. 2 Bad upper PCA or Console. 3 Bad Auto Stop cable. 4 Damaged or faulty Auto Stop sensor. 5 Damaged or missing Auto Stop magnet. 6 The gap or alignment between the Auto Stop magnet and sensor is

incorrect.

Possible Remedies

1 Check that the Auto Stop cable connectors are secure at the sensor

and console.

2 Check for 5VDC at the upper PCA or console. Disconnect the Auto Stop

cable connector from the upper PCA or console and measure the voltage from the console. If 5VDC is not present replace the upper PCA or console. If 5VDC is present then continue troubleshooting the Auto Stop cable.

3 Check for 5VDC at the Auto Stop sensor. Disconnect the Auto Stop

cable connector from the Auto Stop sensor, turn the treadmill’s

"On/Off" switch to "On", and check for 5VDC between the red and black wire in the Auto Stop cable connector. If 5VDC is present at the at the Auto Stop connector of the console, but not at the end of the cable, then replace the Auto Stop cable.

4 Visually inspect the Auto Stop sensor for physical damage. Replace

if appropriate. Access the Service Access software (hardware validation tests), and select the Auto Stop test (see section-5).

 If the feature is enabled the P80 Auto Stop sensor test will

count the number of times the magnet crosses the sensor.

o The P10, P20 and 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 Auto Stop test in the P80 did not count steps or if the P10, P20 or P30 consoles displayed "NO USER DETECTED", disconnect the Auto Stop cable from the Auto Stop sensor and check for 5vDC between the red and black wire.

 If 5VDC is present replace the Auto Stop sensor.

5 Ensure the Auto Stop magnet and/or holder is mounted on the edge of

the running deck and visually inspect for damage. Replace if appropriate.

6 Check the gap and alignment between the Auto Stop magnet and sensor.

The gap should be approximately 3/16 of an inch and the center markings on the top of the magnet and sensor should be aligned. If the gap is larger than 3/16"and/or the magnet and sensor are not aligned, adjust the running deck to the correct alignment and gap.

Error 61 or “Temporarily Out of Order” – Auto Stop Not Present Description

This error is associated with the TRM Treadmill. The error indicates the Auto Stop sensor is not detected. If the error is detected the user will be locked out, displaying "Temporarily Out of Order, Please Use another treadmill" on the P80 console and "PLEASE USE ANOTHER TREADMILL" on the P30 and P20 consoles. When this error occurs "1376257-E_AUTOSTOP_SENSOR_NOT_INSTALLED" will be recorded to the event log of the P80 console. Error 61 will be recorded in the error log of the P10, P20 or 30 console.

Possible Causes

1 Intermittent connections. 2 Bad upper PCA or Console. 3 Bad Auto Stop cable. 4 Damaged or faulty Auto Stop sensor.

Possible Remedies

1 Visually verify the Auto Stop hardware components are installed onto

the treadmill frame. The Auto Stop feature was not on the TRM as a standard feature until 12/28/2010 but may have shipped with a P80 console prior to 12/28/2010. If the Auto Stop hardware is not present contact Precor Customer Support. Check that the Auto Stop cable connectors are secure at the sensor and console.

2 Check for 5vDC at the upper PCA or console. Disconnect the Auto Stop

cable connector from the upper PCA or console and measure the voltage from the console. If 5vDC is not present replace the upper PCA or console. If 5vDC is present then continue troubleshooting the Auto Stop cable.

3 Check for 5vDC at the Auto Stop sensor. Disconnect the Auto Stop

cable connector from the Auto Stop sensor, turn the treadmill’s "On/Off" switch to "On", and check for 5vDC between the red and black wire in the Auto Stop cable connector. If 5vDC is present at the at the Auto Stop connector of the console, but not at the end of the cable, then replace the Auto Stop cable.

4 Visually inspect the Auto Stop sensor for physical damage. Replace

if appropriate. Access the Service Access software (hardware validation tests), and select the Auto Stop test (see section-5). 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 and 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 Auto Stop test in the P80 did not count steps or if the P10, P20 or P30 consoles displayed "NO USER DETECTED", disconnect the Auto Stop cable from the Auto Stop sensor and check for 5vDC between the red and black wire. If 5vDC is present replace the Auto Stop sensor.

Troubleshooting Heart Rate Issues 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.

 If the unit displays a heart rate, no problem exists.  If the unit does not display a heart rate value within this time,

Continue to step 2.

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.

 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.

 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 5.5VDC.

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,

 If NO, Correct the wiring error.  If Yes, Continue.

5 Verify that the grip connections are free of corrosion.

 If NO, Replace the corroded HHHR grips.  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.

Figure 19: Hand Held - Chest Strap Heart Rate PCA

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 with step 2.

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 5.5VDC.

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 above procedures do not correct the problem, replace the

heart rate board.

Possible sources of interference signals include, BUT NOT LIMITED TO:

 Wi-Fi Network Routers  Cordless Telephones  Cell Phones  Electronic Dog Fences  Garage Door Remotes  Noisy AC feeds  Florescent light ballasts

In This Section

Replacing the Line Cord ........................... 79

Replacing the Circuit Breaker ..................... 81

Replacing the Line Filter ......................... 83

Replacing the Input Module ........................ 85

Replacing the Auto Stop Sensor .................... 87

Replacing the Auto Stop Magnet .................... 89

Replacing Drive Motor ............................. 92

Replacing the Incline Motor ....................... 93

Replacing the Incline Platform .................... 96

Replacing the Power Control Module ................ 98

Replacing the End Cap or Belt Guard ............... 100

Drive Belt Replacement ............................ 102

Replacing the Drive Roller ........................ 105

Take Up Roller Replacement ........................ 109

Running Belt and/or Deck Replacement .............. 111

Section 8 - Replacement Procedures

Replacing the Line Cord

1 Set the treadmill circuit breaker in the off position and unplug the

treadmill’s line 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.

Figure 20: AC Input Panel

4 Lift the AC input panel from the frame and rotate it to expose the AC

line cord clamp screws.

Figure 21: AC Input Panel Hardware

5 Remove the hardware that retains the AC line cord clamp and remove the

clamp.

6 Disconnect the AC line cord from the input module. 7 Feed the end of the replacement AC line 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 line cord clamp in its mounting position and fasten it with

the hardware removed in step 3.

9 Set the input panel in its mounting position and fasten it with the

hardware removed in step 5.

10 Check treadmill operation per, Checking Treadmill Operation (see "Section 4 -

Operation Verification" on page 9).

Replacing the Circuit Breaker

1 Set the treadmill circuit breaker in the off position and unplug the

treadmill’s line 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. 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.

Figure 22: AC Input Panel

5 Lift the AC input panel from the frame and rotate it to expose the

circuit breaker mounting screws.

Figure 23: AC Input Panel Hardware

6 Remove the two screws retaining the circuit breaker and remove the

circuit breaker.

7 Reference the label on the replacement circuit breaker and set the

circuit breaker in its mounting position with the LINE side of the

breaker facing the input module and the LOAD side of the circuit

breaker facing the AC line filter. Fasten the circuit breaker with the

hardware removed in step 6.

NOTE: 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.

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.

8 Set the input panel in its mounting position and fasten it with the

hardware removed in step 3.

9 Thoroughly check the treadmill per, Checking Treadmill Operation (see

"Section 4 - Operation Verification" on page 9).

Replacing the Line Filter

1 Set the treadmill circuit breaker in the off position and unplug the

treadmill’s line 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, See

Figure below.

4 Disconnect the wiring from the AC line filter (2 blue wires, 2 brown

wires and a green/yellow wire).

5 Lift the AC input panel from the frame and rotate it to expose the AC

line filter mounting screws.

Figure 24: AC Input Panel Hardware

6 Remove the screws that retain the AC line filter. Remove the AC line

filter.

7 Set the replacement AC line filter in its mounting position with the

side with three terminals facing the circuit breaker and replace the

screws removed in step 6.

NOTE: 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.

On 120 Vac treadmills, connect the blue wire from the input module to the L1 terminal 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.

On 240 Vac treadmills, connect the blue wire from the circuit breaker to the L1 terminal 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.

8 Set the input panel in its mounting position and fasten it with the

hardware removed in step 3.

9 Thoroughly check the treadmill per, Checking Treadmill Operation (see

"Section 4 - Operation Verification" on page 9).

Replacing the Input Module

1 Set the treadmill circuit breaker in the off position and unplug the

treadmill’s line 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.

Figure 25: AC Input Panel

4 Lift the AC input panel from the frame and rotate it to expose the AC

line cord clamp screws and input module screws.

Figure 26: AC Input Panel Hardware

5 Remove the hardware that retains the AC line cord clamp and remove the

clamp.

6 Disconnect the AC line cord from the input module. 7 Disconnect the wiring from the input module (1 blue wire, 1 brown wire

and 1 green/yellow wire).

8 Remove the hardware that retains the input module and remove the input

module.

9 Set the input module in its mounting position with the side with two

terminals facing the circuit breaker. Replace the hardware that

fastens the module to the input panel.

10 Connect the blue wire removed in step 7 to terminal N, the brown wire

to terminal L and the green/yellow wire to terminal E of the input

module.

Figure 27: Input Module Wiring

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 hardware

removed in step 5.

12 Set the input panel in its mounting position and fasten it with the

hardware removed in step 3.

13 Check treadmill operation per, Checking Treadmill Operation (see "Section 4 -

Operation Verification" on page 9).

Replacing the Auto Stop Sensor

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. Should this occur, contact PRECOR customer service for possible options for repairing the magnet assembly or to obtain a replacement part.

1 Remove the motor hood. 2 Unplug the Auto Stop Cable from the Auto Stop assembly. 3 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.

Figure 28: Auto Stop Sensor Mounting

4 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 treadmills frame mounting holes securing the auto stop

assembly in place.

5 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 allen wrench 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 procedure,

Replacing the Auto Stop Magnet (on page 89)

6 Replace the Auto Stop Cable to the Auto Stop Sensor Assembly.

7 Replace the motor hood.

Replacing the Auto Stop Magnet

1 Remove the motor hood. 2 Remove the left and right trim strips from the treadmill deck. 3 Remove the four mounting bolts and two top plates that fasten the

running deck to the pivot bracket at the back end of the treadmill.

4 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. (Left

and Right side orientations are based as if you were standing on the

treadmill facing the console.)

Figure 29: Running Deck Removal

5 Pry out the two push fasteners from the deck using a flat head screw

driver and remove the Auto Stop magnet.

6 Align the replacement magnet on the running deck and then secure the

magnet to the running deck using the two push fasteners removed in

step 4.

7 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.

8 Replace the plates and the running deck mounting bolts removed in step

3. Only tighten the bolts by hand at this time.

Figure 30: Auto Stop Magnet Mounting

9 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 allen wrench 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.

Figure 31: Auto Stop Alignment

10 Securely tighten the running deck mounting bolts. Torque the bolts to

150 inch pounds.

11 Replace the left and right running deck trim strips. 12 Replace the motor hood.

Replacing Drive Motor

1 Set the treadmill's on/off switch in the off position and unplug the

treadmill’s line cord from the AC outlet.

2 Remove the hood. 3 Disconnect the drive motor connector from the OUTPUT connector on the

power control module.

4 Remove the drive belt from the drive motor. 5 Mark the outline of the current motors mounting plate for reference

when you install the new motor.

6 Remove the four bolts that fasten the drive motor to the frame. 7 Set the replacement drive motor in its mounting position and fasten

the drive motor with four mounting bolts removed in step 5 and fasten

the drive motor with four mounting bolts removed in step 6.

8 Place the drive belt on the drive roller pulley and on the drive motor

pulley.

9 Adjust the drive belt tension and complete the motor installation per

Procedure, Adjusting Drive Belt Tension.

10 Thoroughly check the treadmill per, Checking Treadmill Operation (see

"Section 4 - Operation Verification" on page 9).

Replacing the Incline Motor

Note: The replacement incline motor must be calibrated prior to installation.

1 Set the treadmill’s circuit breaker in the off position and remove the

AC line cord from the AC outlet.

2 Disconnect the incline motor connector from the INCLINE connector on

the power control module. See Figures Below (TRM Lift Motor and Lower

Control Module).

3 Lay the replacement incline motor on the floor in front of the

treadmill and insert its connector in the INCLINE connector on the

power control module.

Figure 32: TRM Lift Motor

Figure 33: Power Control Module

4 Either lay the treadmill on its side or securely block the front of

the treadmill so that the treadmill’s weight is off of the incline

platform.

5 Remove the defective incline motor as follows: remove the screw that

fastens the frame ground wire (green with yellow stripe) to the

treadmill frame. Remove the hitch and clevis pins from the top and

bottom of the incline motor. Remove the incline motor from the

treadmill.

6 Set the calibrated incline motor in its mounting position. Replace the

upper clevis and hitch pins.

7 Replace the lower clevis and hitch pins. It may be necessary to

slightly rotate the incline tube to align it so that the clevis pin

may be inserted. To align the hole in the incline tube, rotate it in

the direction that will cause the least amount of rotation to make

alignment possible.

8 Connect the frame ground wire to the treadmill frame with the screw

removed in step 5. Route both incline motor cables as noted in the

incline motor removal procedure.

9 Route both lift motor cables in the cable management clips to hold the

cables away from the jack screw.

10 Insert the incline motor connector in the INCLINE connector on the

power control module.

11 Check treadmill operation per Procedure, Checking Treadmill Operation (see

"Section 4 - Operation Verification" on page 9).

Replacing the Incline Platform

1 Set the treadmill circuit breaker in the off position. Remove the AC

line cord from the AC outlet.

2 Carefully, lay the treadmill on its side. 3 Remove the hitch pin and clevis pin that fastens the incline motor

tube to the incline platform. While the incline tube is not fastened

to the incline platform, care must be taken to not allow the incline

tube to rotate. If the incline tube rotates, the incline motor must be

re-calibrated per Procedure, Calibrating the Incline Motor.

4 Remove the two large hitch pins (one each side) from the incline

platform to frame mounting. See Figure Below. Remove the incline

platform mounting pins and remove the incline platform from the

treadmill.

Figure 34: Incline Platform Mounting

5 Remove the wheels from the old incline platform and remount them on

the replacement incline platform.

6 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. See Figure Below (Incline

Mounting Pin). Fasten the incline mounting pins with the hitch pins

removed in step 4.

7 If the incline tube or the incline motor’s drive screw has been moved,

re-calibrate the incline motor per Procedure, Calibrating the Incline

Motor, at this time.

Figure 35: Incline Mounting Pin

8 Fasten the incline tube to the incline platform with the clevis pin

and hitch pin removed in step 3.

9 Set the treadmill in its upright position and thoroughly check it per

Checking Treadmill Operation (see "Section 4 - Operation Verification" on page 9).

Replacing the Power Control Module

1 Set the treadmill’s on/off switch in the off position and remove the

AC line cord from the AC outlet.

2 Remove the treadmill’s hood. 3 Disconnect the COMM, INCLINE, INPUT, DB and OUTPUT connectors from the

power control module.

Figure 36: Power Control Module

4 Remove the four screws that mount the power control module. See Figure

Below (Lower Control Module Mounting.

Figure 37: Lower Control Module Mounting

5 Set the replacement power control module in its mounting position.

Precor TRM10/GEN06 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Section 1 - About This Document

Section 2 - General Information

GEN-06/ TRM10 Treadmill Base

Lubricants

Electrical Requirements

Important

120 Vac Systems

Safety guidelines you should know and follow include:

Section 3 - Safety Guidelines

Section 4 - Operation Verification

Operation Verification

Procedure

Operation Verification Checklist

Section 5 - Standardized Service Access Codes

Service Access Codes

Accessing the Service Software

P80 Console

Access Code Table

P20 Console Service Software Access

Hardware Validation - Diagnostic Tests (51765761)

Club Parameter - Settings (5651565)

Information Display (65)

Section 6 - Theory Of Operation

Consoles

Basic operation of a console

The Controls

The Display

Consoles that could appear on the GEN-06 / TRM10 Treadmill Base

Console To Base Communication

Treadmill Base Operation

Power Entry

Lower Electronics Module

AC Drive Motor Controller

Auto-Stop

AC Lift System – Motion Control

AC Lift System – Position Monitoring

Section 7 - TRM Base Troubleshooting Procedures

Introduction to Treadmill Troubleshooting

Troubleshooting Tripped Breakers

If the unit trips the wall breaker:

If the Treadmill breaker (power switch) is tripped:

Troubleshooting No Power to the Console

Standardized Error Codes

Error Codes

Error Code Table

Validating the Reported Failure

Troubleshooting Input Power & Control Error Codes

Possible Causes

Possible Remedies

Possible Cause

Possible Remedy

Possible Causes

Possible Remedies

Possible Causes

Possible Remedies

Possible Causes

Possible Remedies

Error 80, 81, 82, & 83 – P30 Machine Controls Not Working Description

Possible Causes

Possible Remedies

Troubleshooting the 3 Phase AC Drive Motor System

Procedure:

Possible Causes

Possible Remedies

Possible Causes

Possible Remedies

Possible Causes

Possible Remedies

Possible Causes

Possible Remedies

Troubleshooting the Incline System

Incline System Description:

Operation of lift motor for testing:

Possible Causes

Possible Remedies

Description