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C956i, C966i (Gen 06) Treadmill

Page 35

Procedure 6.4 - 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.

1.

Remove the hood.

2.

Disconnect the drive motor connector from the

OUTPUT

connector on the power control

module.

3.

Remove the four bolts that fasten the drive motor to the frame. Remove the drive belt from

the drive motor.

4.

Set the replacement drive motor in its mounting position. Place the drive belt on the drive

roller pulley and on the drive motor pulley.

5.

Adjust the drive belt tension and complete the motor installation per Procedure 4.2.

6.

Thoroughly check the treadmill per Section 3.

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Summary of Contents for C956i

Page 1: ...in this product This document contains general product information software diagnostic procedures when available preventative maintenance procedures inspection and adjustment procedures troubleshooting procedures replacement procedures and electrical block and wiring diagrams To move directly to a procedure click the appropriate procedure in the bookmark section to the left of this page You may dr...

Page 2: ...readmill operation Check treadmill operation at the end of a maintenance procedure and when it is necessary to ensure that the treadmill is operating properly Section Four Inspection and Adjustment Procedures Perform inspection procedures when a trouble symptom points to a particular problem and after removing and replacing major components Many maintenance problems can be fixed by adjusting vario...

Page 3: ...her 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 othe...

Page 4: ...956i C966i Gen 06 Treadmill Page 1 4 Page 4 General Information For the latest exploded view diagram part number and part pricing information visit the Precor dealer website at www precor com connection ...

Page 5: ...est Machine Test Belt Speed Incline Procedure 1 Plug the power cord into the wall outlet then turn on the treadmill with the circuit breaker 2 Using the RESET key and the numeric keypad press keys RESET 5 1 7 6 5 7 6 1 sequentially 3 Hardware Validation will scroll across the display followed by DISPLAY TEST Diagram 2 1 C956i C966i Treadmill Display Numeric Keypad Reset Key OK Key Back Key ...

Page 6: ...the wireless heart rate function after a couple of seconds the heart rate will be displayed in the heart rate and smart rate displays 11 Press the BACK key then the key MACHINE TEST will scroll across the display 12 You may now proceed to either the belt speed test or the incline test Press the key once to access the belt speed test or twice to access the incline test 13 BELT SPEED test Press the ...

Page 7: ...s See Procedure 2 3 The odometer is also used to provide the distance stamp for the error code log Note The odometer data is stored in non volatile memory on the upper PCA If the upper PCA is replaced the odometer data will be lost 7 Press the BACK key to exit the odometer display 8 HOUR METER display Press the OK key 9 The operating time of the unit will be displayed as 12345 HOURS The operating ...

Page 8: ...programs A message will scroll describing the program the number of times and the number of minutes the program was used 25 Press the BACK key to exit the usage log display 26 ERROR LOG display Press the OK key the quantity of errors in the log will be displayed 27 Press the OK key the most recent error will be displayed first 28 Use the keys to move through the list of errors The error messages w...

Page 9: ... sequentially 3 Use the keys to move to the desired display shown in the list above 4 DIAGS SET CLUB PARAMETERS will scroll across the display 5 SAFETY CODE display The safety code when enabled makes the user enter a password in order to start the treadmill Press the OK key 6 Use the keys to toggle between ENABLED and DISABLED 7 Press the BACK key to exit the safety code display 8 SELECT LANGUAGE ...

Page 10: ...BACK key to exit the set speed limit time display 26 SET INCLINE LIMIT display Press the OK key 27 Use the keys to select the maximum allowable incline setting 28 Press the BACK key to exit the set incline limit time display 29 HIDDEN PROGRAMS display Press the OK key 30 Use the keys to toggle between HIDE PROGRAMS and SHOW PROGRAMS 31 Press the BACK key to exit the hidden programs display 32 REMO...

Page 11: ... 36 SET CUSTOM PROGRAM 2 display Allows programing of the custom program 2 Follow the instructions scrolling on the display to program the custom course Use the ENTER key to save changes and exit or the BACK to exit without saving changes ...

Page 12: ...he following information Model and serial number Software version number Program number running when the problem occurred A description of a What happened or failed to happen b The action taken by the user just before the problem occurred c Problem related information such as how far into the program the problem occurred the work level being used when the problem occurred error code displayed etc ...

Page 13: ...rations b Observe the LED s on the electronic console Make sure that each LED lights as the in formation corresponding to that LED is displayed on the electronic console c Enter the diagnostics program see Procedure 2 1 and log the power bits under loaded and unloaded conditions 3 Press the STOP key When the treadmill comes to a stop view the electronic console as the treadmill scans time speed di...

Page 14: ...otor will immediately start to operate The lift motor will continue to operate until the system is at 0 incline 5 With the system at 0 incline rotate the incline tube until the distance from the top of the incline tube to the incline motor is 1 1 4 inch See Diagram 4 1 While rotating the incline tube be sure the incline motor drive screw does not rotate If the drive screw is rotated return to step...

Page 15: ...alibration of the incline system by performing the following steps a Press the INCLINE key until maximum incline is obtained 15 b Press the INCLINE key to minimum incline is obtained 0 on C956i treadmills or 3 on C966i treadmills 12 Re install the hood ...

Page 16: ...h pounds 5 If the drive belt tension is less than 70 or greater than 90 inch pounds slightly loosen the four drive motor mounting bolts The drive motor mounts on slotted holes allowing the drive motor to be move forward or rearward Move the drive motor forward or rearwards as required until the belt gauge reads approximately 80 inch pounds and tighten the four drive motor mounting bolts See Diagra...

Page 17: ...06 Treadmill Page 17 Diagram 4 3 Drive Belt Adjustment 6 Re install the hood 7 Plug the line cord into the wall outlet and set the treadmill circuit breaker in the on position 8 Check treadmill operation per Section 3 ...

Page 18: ...ssage STUCK KEY is displayed when the treadmill is turned on skip to step 23 3 If a key does not function skip to step 18 4 If the display does not illuminate continue with step 5 Diagram 5 1 Display Face Rear View 5 If the upper PCA is not illuminating skip to step 12 6 If the metrics PCA is not illuminating continue with step 7 7 Un clip the metrics PCA from the display face and rotate it so tha...

Page 19: ...place the upper PCA 15 If 8 Vdc is not present on J4 temporarily replace the upper PCA to power control module with a known good cable 16 If the upper PCA illuminates normally replace the upper PCA to power control module cable permanently If the upper PCA still does not illuminate replace the power control module 17 If you have performed steps 12 16 and the upper PCA still does not illuminate con...

Page 20: ... support for assistance 23 Remove the keypad cable from the upper PCA See Diagram 5 1 24 Set the treadmill s on off switch in the on position 25 If the STUCK KEY message is no longer displayed replace the display face 26 If the STUCK KEY is still being displayed with the keyboard cable disconnected replace the upper PCA 27 If you have performed steps 23 26 and the STUCK KEY message is still being ...

Page 21: ...4 1 subsequent motor movement is tracked via the potentiometer resistance reading Note All resistance measurements must be performed with power removed from the treadmill Performing resistance measurements with voltage applied may damage your ohmmeter Procedure 1 If the incline motor operates but creates a incline error error 40 or 42 go to step 14 If the incline motor will not move continue with ...

Page 22: ...treadmill in the manual program and press the INCLINE key The AC voltmeter should read AC line voltage either 120 Vac or 240 Vac Note that the AC line voltage reading will only be present before an error condition is displayed 8 If the incline moves normally skip to step 11 9 If the display indicates that the incline should be moving and the incline motor does not move and AC line voltage is prese...

Page 23: ... call Precor customer service 14 Set the treadmill s on off switch in the off position Remove the incline motor s connector from the INCLINE connector on the power control module Visually inspect the incline motor s wiring and connector for any broken or improperly crimped connections With an ohmmeter read between terminals 3 4 4 8 and 3 8 of the INCLINE connector Terminals 3 4 should read approxi...

Page 24: ... Set the on off switch in the on position and access the diagnostic program Procedure 2 1 Advance to the heart rate display portion of the diagnostic program Verify that a chest strap signal is not being accepted with either a Polar heart rate test transmitter or a known good chest strap transmitter If this reading is good skip to step 3 2 Using a Polar heart rate test receiver verify the operatio...

Page 25: ...o to the left hand contacts In both groups the black wire must go to the lower contact and the red wire must go to the upper contact If necessary rewire the hand held contacts as described above and test as described in step 7 9 Set the on off switch in the off position Refer to Diagram 5 5 for the following measurements With an ohmmeter measure between the lower right contact pin on the J1 connec...

Page 26: ...er the hand held or chest strap is in use 14 Constant or intermittent heart rate readings when neither heart rate system is in use is caused by something in the near vicinity radiating RF energy that is being received by the chest strap portion of the heart rate PCA 15 If the hand held signal is now being accepted something in the near vicinity is radiating RF energy that is being received by the ...

Page 27: ...circuit breaker with a capacity of less than 20 amps the A C circuit must be corrected to be a 20 amp dedicated circuit before any reliable troubleshooting can be performed on the treadmill More importantly a non dedicated 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 c...

Page 28: ...t a 20 amp circuit breaker If the circuit breaker is greater than 20 amps the circuit breaker should be replaced with a 20 amp circuit breaker If the circuit breaker is less than 20 amps the circuit breaker must be replaced with a 20 amp circuit breaker and the wiring from the A C distribution must be capable of safely handing 20 amps If the A C wiring is under sized it must be replaced with wire ...

Page 29: ... running belt 4 Connect an AC voltmeter between terminals 4 5 of the OUTPUT connector on the power control module See Diagrams 5 3 and 5 4 Set the treadmill s on off switch in the on position Press the QUICK START key If the power control module is supplying output you will momentarily read approximately 55 Vac Set the treadmill s on off switch in the off position 5 Repeat the procedure in step 4 ...

Page 30: ...l module is supplying output you will momentarily read approximately 55 Vac 11 Repeat the procedure in step 4 between terminals 4 6 of the OUTPUT connector on the power control module 12 Repeat the procedure in step 4 between terminals 5 6 of the OUTPUT connector on the power control module 13 If one or more of voltage readings in steps 4 through 6 are not present replace the power control module ...

Page 31: ...ve 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...

Page 32: ...ge hitch pins one each side from the incline platform to frame mounting See Diagram 6 1 Remove the incline platform mounting pins and remove the incline platform from the treadmill Diagram 6 1 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 t...

Page 33: ... Page 33 Diagram 6 2 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 Section 3 Key ...

Page 34: ...he four screws that mount the power control module See Diagram 6 3 Diagram 6 3 Power Control Module Mounting 5 Set the replacement power control module in its mounting position 6 Fasten the power control module with the four screws removed in step 4 7 Reconnect the COMM INCLINE INPUT DB and OUTPUT connectors removed in step 3 The mating connectors on the power control module are polarized therefor...

Page 35: ...ector from the OUTPUT connector on the power control module 3 Remove the four bolts that fasten the drive motor to the frame Remove the drive belt from the drive motor 4 Set the replacement drive motor in its mounting position Place the drive belt on the drive roller pulley and on the drive motor pulley 5 Adjust the drive belt tension and complete the motor installation per Procedure 4 2 6 Thoroug...

Page 36: ...panel to the frame See Diagram 6 4 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 Diagram 6 4 AC Input Panel 5 Lift the AC input panel from the frame and rotate it to expose the circuit breaker mounting screws See Diagram 6 5 Diagram 6 5 AC Input Panel AC Input Panel Input Module Circuit Breaker AC Line Filter C...

Page 37: ... 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 9 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 ...

Page 38: ...re 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 9 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 ...

Page 39: ...e AC line cord clamp screws See Diagram 6 5 3 Remove the hardware that retains the AC line cord clamp and remove the clamp 4 Disconnect the AC line cord from the input module 5 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 6 Set the AC line cord clamp in its mounting position and fasten it with...

Page 40: ...t 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 10 Connect the blue wire removed in step 5 to terminal N the brown wire to terminal L and the green yellow wire to terminal E of...

Page 41: ... cap off of the treadmill 4 If you are not replacing the belt guard skip to step 8 5 The tabs on the belt guard 1 each side snap into the take up roller mounts See Diagram 6 8 6 Press inwards on the belt guard to remove the belt guard s tabs from the take up roller mounts Slide the belt guard off of the treadmill 7 Slide the replacement belt guard into place so that the tabs on the belt guard enga...

Page 42: ...C956i C966i Gen 06 Treadmill Page 1 42 Page 42 Diagram 6 8 Belt Guard Mounting Belt Guard Tab Notch ...

Page 43: ... cover and remove the display back cover 4 Disconnect the data cable 2 CSAFE cables and the heart rate cable from the upper PCA See Diagram 6 9 Diagram 6 9 Upper PCA and Heart Rate PCA Mounting 5 The display cap snaps onto the display with two tabs Reach into the upper portion of the display and locate the two display cap tabs Press the tabs outwards to disengage the tabs and remove the display ca...

Page 44: ...t upper PCA into its mounting on the display face 11 The red wire in the Metrics and D pad cables indicate pin 1 Align the red wire in the Metrics and D pad cables with the pin 1 markings on the upper PCA Connect the Metrics D pad and keypad cables to the upper PCA 12 Connect the stop switch cable to upper PCA and snap the display face into place on the display 13 Reconnect the data cable two CSAF...

Page 45: ...ix tabs One of the tabs is behind the HR PCA The HR PCA snaps into its mounting Press its tabs downward and remove the HR PCA from its mounting 7 Press the four display face tabs outwards and disengage the display face from the display Disconnect the stop switch cable from the upper PCA and remove the display face from the display 8 Disconnect the Metrics cable from the Metrics PCA See Diagram 5 1...

Page 46: ...C956i C966i Gen 06 Treadmill Page 1 46 Page 46 16 Replace the display back cover with the hardware removed in step 3 17 Check treadmill operation per Section 3 ...

Page 47: ...naps into its mounting Press its tabs downward and remove the HR PCA from its mounting 7 Press the four display face tabs outwards and disengage the display face from the display Disconnect the stop switch cable from the upper PCA and remove the display face from the display 8 Disconnect the D pad cable from the D pad assembly See Diagram 5 1 9 The D pad assembly snaps into the display face Releas...

Page 48: ...C956i C966i Gen 06 Treadmill Page 1 48 Page 48 16 Replace the display back cover with the hardware removed in step 3 17 Check treadmill operation per Section 3 ...

Page 49: ...e eight screws that fasten the display back cover and remove the display back cover 4 Disconnect the HR cable and handlebar cable from the HR PCA See Diagram 6 9 5 The HR PCA snaps into its mounting Press its tabs downward and remove the HR PCA from its mounting 6 Orient the replacement HR PCA so that the side with three connectors is facing to the left and snap the HR PCA into its mounting 7 Conn...

Page 50: ...aps onto the display with six tabs One of the tabs is behind the HR PCA The HR PCA snaps into its mounting Press its tabs downward and remove the HR PCA from its mounting 7 Press the four display face tabs outwards and disengage the display face from the display Disconnect the stop switch cable from the upper PCA and remove the display face from the display 8 Disconnect the Metrics cable D pad cab...

Page 51: ...iented so that the incline and speed switches are correctly aligned slide the D pad assembly into the replacement display face until it snap into place 19 The red wire in the D pad cable indicates pin 1 Align the red wire in the D pad cable with the pin 1 markings on the D pad PCA Connect the D pad cable to the D pad PCA 20 Connect the stop switch cable to upper PCA and snap the display face into ...

Page 52: ... PCA HR J1 J4 PCA METRICS J1 D PAD PCA J1 J17 J13 J15 J14 Switch Stop PCA Upper J12 Incline Motor Motor Drive G Y BK W R BK W R BK W R 6 5 4 4 8 3 5 1 6 OUTPUT INCLINE COMM BR BR 50W 100Ω 2 1 DB Control Module Power 3 1 2 INPUT G Y BR BL Filter Line G Y BR Breaker Circuit BL Module Input BR G Y ...

Page 53: ...C956i C966i Gen 06 Treadmill Page 53 Block Diagram 7 2 C956i C966i 120 Vac ...

Page 54: ...C956i C966i Gen 06 Treadmill Page 1 54 Page 54 Wiring Diagram 7 3 C956i C966i 240 Vac BL BL Stop Switch J14 1 2 BR BR DB 50W 100Ω ...

Page 55: ...C956i C966i Gen 06 Treadmill Page 55 Block Diagram 7 4 C956i C966i 240 Vac VAC 240 ...

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