Precor Experience 700 line Series Service Manual Download Page 65

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Replacement Procedures

Replacement procedures provide you with the step-by-step instructions to remove and install
system components.

Available Replacement Procedures

"Covers and Panels Replacement" on the next page

"Power Cord Replacement" on page 77

"ON/OFF SW Circuit Breaker Replacement" on page 79

"ASL PCA Replacement" on page 83

"E-Stop "Emergency Switch" Replacement" on page 88

"Motor Controller (MC) Replacement" on page 89

"Motor Controller Fan Replacement" on page 100

"Drive Belt Replacement" on page 105

"Drive Motor Replacement" on page 112

"Drive Roller Replacement" on page 119

"Take-up Roller Replacement" on page 124

"Running Belt and Deck Replacement Procedure" on page 128

"Lift Motor Replacement" on page 135

"Lift Platform Replacement" on page 146

Page 57

5 Replacement Procedures

Available Replacement Procedures

Summary of Contents for Experience 700 line Series

Page 1: ...Service Manual Experience Series 700 line TRM700 16 Base Treadmill 120 VAC and 240 VAC...

Page 2: ...ATV RF Cable and Ethernet Requirements 11 Treadmill Placement and Spacing Requirement 13 Safety Guidelines 14 Safety guideline you need to know and follow 14 2 Operation Verification 16 Operation Veri...

Page 3: ...P62 P80 and P82 consoles 25 Club Settings Service Menu 5651565 26 P10 P30 consoles 27 P62 P80 and P82 Console 28 About menu 28 Equipment Usage menu 30 System Settings menu 30 Maintenance menu 34 Info...

Page 4: ...ment 60 Hood Transition Cover Replacement 61 Trim Landing Covers Replacement 63 Trim End Cap Covers Replacement 66 Trim Side Cover Replacement 68 Dash Back Cover Replacement 70 Dash Front Cover Replac...

Page 5: ...96 Replacement Procedure 97 Motor Controller Fan Replacement 100 About 100 MC Fan Connector Definition 100 Drive Belt Replacement 105 About 105 Procedure 105 Drive Motor Replacement 112 About 112 Driv...

Page 6: ...152 Verify the Input Power Condition Powered units only 153 Verify that the console is operating correctly 153 Review the Error Log or CPA Event Log for any active error codes 153 Verify reproduce the...

Page 7: ...Circuit Breaker 167 Input Power Troubleshooting 171 Console Power Troubleshooting 173 Communications Error Troubleshooting 175 Machine Controls Troubleshooting 177 Auto Stop Troubleshooting 179 E Sto...

Page 8: ...6 System Wire Diagram Overview 206 System Wire Diagram Connector Pins 207 COMM Cable Wire Diagram 208 Console Wire Diagram 209 Power Entry Assemble Wire Diagram 210 10 Parts Exploded View Diagram Part...

Page 9: ...oot and maintain the treadmill Model TRM700 16 Base Configuration TRM731 TRM700 base 0 5 12 mph 0 15 incline with P30 console TRM761 TRM700 base 0 5 12 mph 0 15 incline with P62 console TRM781 TRM700...

Page 10: ...6 Standard Service and Diagnostics Software on page 18 Adjustment Procedures on page 38 Replacement Procedures on page 57 Troubleshooting on page 152 Preventive Maintenance on page 195 Theory of Opera...

Page 11: ...Page 3 1 Introduction...

Page 12: ...Type Product Line Console Feature Level TRM treadmill EFX elliptical 8 Experience Premium 8 P80 P82 7 EFX Fixed Ramp Moving Arms AMT AMT UBK Upright RBK Recumbent 7 Experience 6 P62 5 TRM High Speed...

Page 13: ...ber The hood serial number label may be wrong if the hood was incorrectly replaced with a different tread mill hood the serial number for that unit will be wrong Orientation The equipment orientation...

Page 14: ...Covers and Panels Covers and Panels Equipment cover and access panel locations For cover removal and installation see Covers and Panels Replacement on page 58 Page 6 1 Introduction General Information...

Page 15: ...ecor PN PPP000000020007101 Polar HRM simulator transmitter Precor PN PPP000000020045101 12 wonder bar ESD safe vacuum cleaner ESD wrist strap Supplies Super Lube Gel with Teflon by Permatex Cleaning r...

Page 16: ...t Motor Calibration gap 1 1 8 in 1 3 16 in 2 8 cm 3 0 cm Notes Referenced to 3 0 0 0 Understanding bolt grades For US SAE bolts the grade of the bolt is determined by the number of the lines on the he...

Page 17: ...agram Parts List on page 211 Lubricants Use only synthetic lubricants such as Mobil 1 synthetic or SuperLube with Teflon grease Use of unapproved lubricants cleaners or solvents may void the TRM warra...

Page 18: ...can be shared only with one PVS Personal Viewing System display If you need additional help with the power connections contact your Precor authorized dealer Individual branch circuit An individual bra...

Page 19: ...en a separate power connection is required Using a 20 amp branch circuit up to 10 displays can be connected No other devices except PVS may be connected to this circuit P62 P80 and P82 For self powere...

Page 20: ...hernet feed to each equipment location Communication Requirements l 512Kb s up l 5 10Mb s down l Switch Ports 80 123 443 The P80 console uses a security token for communication to Precor servers The s...

Page 21: ...eadmill Placement and Spacing Requirement The minimum side to side spacing between treadmills is 20 in 0 5 m and the minimum front to back spacing is 78 in 2 m Page 13 1 Introduction General Informati...

Page 22: ...f powered unit it will either be necessary to either equip the unit with the optional external power supply or have an assistant pedal on the unit while voltage measurements are being taken Because of...

Page 23: ...elry especially from ears and neck o Tie up long hair o Remove neck ties and o Do not wear loose clothing See Also Safety Instruction on page ii Safety Notices on page iii Page 15 1 Introduction Safet...

Page 24: ...idation Diagnostic Tests 1 Access the Diagnostics Hardware Validation menu access code 5 1 7 6 5 7 6 1 and run the following tests On P10 P20 and P30 LED consoles l KEYPAD TEST Select KEYPAD TEST and...

Page 25: ...al noises l Also verify that the console parameter indicators and user interface displays are showing correct information 3 While walking on the treadmill press the STOP button and verify that the run...

Page 26: ...cs menus are accessed by entering the standardized service access code The user interface and service menu capabilities will vary based on the console model and type of exercise equipment Consoles tha...

Page 27: ...section listed below for your particular console to learn how to access the service menus P10 P20 and P30 consoles Steps 1 Press either the STOP PAUSE or RESET hardkey an immediately type in the acce...

Page 28: ...e 2 Press and hold the Pause key while pressing CH up VOL down VOL up CH down 3 Use the touch keypad to type in the service access code P62 and P82 consoles Page 20 3 Standard Service and Diagnostics...

Page 29: ...the service menus P10 P30 consoles The service menus are organized in a sequential top menu to sub menu to control item flow architecture Menus and submenus are accessed using a combination of Up Down...

Page 30: ...ger to touch the on screen softkey controls OK START STOP BACK etc or to select a menu item Scroll Up Dwn Use your finger to select while swiping your finger Up Dwn to scroll through menu items Some m...

Page 31: ...K hardkey to exit the service software PAUSE hardkey Stop a running diagnostic test Hardware Validation Service Menu 51765761 Access Code 5 1 7 6 5 7 6 1 see Service Access Codes on page 18 The Hardwa...

Page 32: ...w pulsing yellow AS LIGHT BRIGHTNESS 1 Sets the ASL light brightness level and ON OFF state HIGH MED LOW and ON OFF MC2 LIGHT Shows current state of MC LED Hold Quick Start to reset BELT SPEED TEST Me...

Page 33: ...Press the Stop button to reset and exit test Notes 1 Only used on machines that support the Active Status Light feature P62 P80 and P82 consoles Menu path Hardware Validation Tests 5 1 7 6 5 7 6 1 Sy...

Page 34: ...ration Backlight Test Tests the display backlight performance RGB Test Tests the display color performance Numeric Back light Test Tests the LED numeric display backlight brightness level Numeric Disp...

Page 35: ...English SET UNITS Sets units of measure to US standard or Metric Range U S Metric Default U S SET MAX WORKOUT TIME Sets the maximum allowable user workout time per session Range 1 to 240 min NO LIMIT...

Page 36: ...ut submenu the Equipment Usage submenu the System Settings sub menu and the Maintenance submenu l About menu below General information about the machine serial number name type location software versi...

Page 37: ...maintenance error event codes Console Serial Num ber menu About Serial Number User assigned machine name Lower Serial Number menu About Serial Number User assigned machine name Friendly Name menu Abou...

Page 38: ...nt Usage Last Workout End Timestamp The most recent workout end time System Settings menu menu Club Settings 5 6 5 1 5 6 5 System Settings System Settings submenus l Connectivity menu on the facing pa...

Page 39: ...stem Settings Connectivity Network Con figuration Specifies Precor Preva server URL na preva com Display menu menu Club Settings 5 6 5 1 5 6 5 System Settings Dis play Console default display configur...

Page 40: ...uner TV input signal source Region menu System Settings TV Settings Region Specifies the TV input signal modulation format for a particular geographical region Default Channel menu System Settings TV...

Page 41: ...mmary Time Out Sets the time to view the Workout Summary data Range 1 to 120 sec Default 60 sec Maximum Speed menu System Settings Workout Limits Maximum Speed Default 12 mph Sets the user maximum spe...

Page 42: ...of 0 or 1 will cause a blue pulsing ASL light indicating that there is a problem with the running belt deck and is in need of servicing or replacement Next Maintenance Due menu Maintenance Recommended...

Page 43: ...see Service Access Codes on page 18 The Information Display is only supported on P10 P20 and P30 consoles On P62 P80 and P82 consoles refer to Club Settings for similar information The Information Dis...

Page 44: ...s TREADMILL MAINTENANCE 1 Used to monitor and reset the 1000 mile belt cleaning main tenance reminder Mileage counter starts at 1000 miles and decreases to 0 miles which triggers a blue pulsing ASL li...

Page 45: ...service menu 6 5 On P62 P80 and P82 consoles the Information Display 6 5 type data is located in Club Settings 5 6 5 1 5 6 5 service menu see the P62 P80 and P82 console Club Settings Ser vice Menu 5...

Page 46: ...ment procedures whenever a trouble symptom points to a particular component and after a major component is removed re placed Available Adjustment Procedures Drive Belt Tension and Alignment Adjustment...

Page 47: ...to the first installation of a new belt Procedure Review entire procedure before starting Drive belt alignment adjustment CAUTION Improper Drive Belt alignment can cause unusual operating noises and...

Page 48: ...belt tension reinstalling the belt and then verifying the adjusted belt tension The process is repeated until the belt tension meets specification Belt tension verification 1 Switch the input power OF...

Page 49: ...lbs 45 54 kgs Used 80 90 lbs 36 41 kgs Belt tension calibration adjustment 4 Walk the belt off the Drive Motor pulley You can use your free hand to move the motor flywheel to rotate the motor pulley...

Page 50: ...specification 9 Connect the power cord and switch the input power ON 10 Run the treadmill speed at 3 mph 5 kph for 1 minute 11 Switch the input power OFF and unplug the power cord 12 Remeasure the be...

Page 51: ...oning of the belt requires the use of two tensioning gauges Pre cor part number PPP000000020007101 Specification System Component Specification Ammeraal Beltech brand running belt tension gauge percen...

Page 52: ...anels Replacement on page 58 4 Make sure that the left and right Roller Keeper s are installed Note TRM800 16 Treadmills Some early production TRM800 16 treadmills may only have one or no Roller keepe...

Page 53: ...bolt CAUTION Only use hand tools to adjust tension Power tools can easily over and or under tension causing damage to the belt and or tension hardware mechanism 6 Verify that the running belt is cente...

Page 54: ...dial divisions so that the belt is evenly tensioned to the manufacturer spe cification a Incrementally and alternately tighten the left and right adjustment bolts entail each gauge dial reaches a val...

Page 55: ...the belt does not remain centered follow the following instruction to make adjustments a If the belt starts to drift toward the right slowly turn the right side tension adjust ment bolt clockwise in...

Page 56: ...ts as needed 5 Make sure that the treadmill is setting level and stable adjust the two rear leveling feet as necessary Note An unlevel unstable treadmill can cause tracking issues with use 6 Replace t...

Page 57: ...1 1 8 in 1 3 16 in 2 8 cm 3 0 cm Note Calibration distance is specified at incline level 0 Procedure Review entire procedure before starting 1 Remove the Hood cover see Hood Cover Replacement on page...

Page 58: ...easure the lift motor calibration distance between the top of the extension tube nut and the bottom of the lift motor actuator jackscrew housing Verify that the distance is within the specified limits...

Page 59: ...ch pin and clevis pin Retain fastener hardware for installation 5 Firmly hold the jackscrew and rotate the extension tube to adjust the calibration dis tance The calibration distance is measured betwe...

Page 60: ...access on the facing page or the Front lift platform assembly access on page 55 8 Reinstall the hood 9 Connect the power cord and switch the power ON 10 Verify incline operation from the minimum to ma...

Page 61: ...e position Incline level 0 is also the lift motor calibration reference incline level IMPORTANT It is important to set the incline level to 0 calibration ref level before switching the power OFF 2 Swi...

Page 62: ...Returning the treadmill to the upright position 1 Switch the power OFF and unplug the power cord Move the power cord so it will not be damaged as the treadmill is set to the upright position 2 Clear t...

Page 63: ...frame weldment 4 Slowly lower the incline level in 0 5 increments setting the frame onto the supports Verify the supports are stable carrying the weight of the treadmill and continue lowering the inc...

Page 64: ...e position 1 Access the service menu 51765761 and select the INCLINE TEST Increase the incline level enough to lift the treadmill frame off the supports 2 Remove the support stands and clear any other...

Page 65: ...CA Replacement on page 83 E Stop Emergency Switch Replacement on page 88 Motor Controller MC Replacement on page 89 Motor Controller Fan Replacement on page 100 Drive Belt Replacement on page 105 Driv...

Page 66: ...Covers Trim End Cap Covers Replacement on page 66 Trim Side Covers Trim Side Cover Replacement on page 68 Dash Back Cover Dash Back Cover Replacement on page 70 Dash Front Cover Dash Front Cover Repl...

Page 67: ...Cover Remove lnstall Procedure page 76 Page 59 5 Replacement Procedures Covers and Panels Replacement...

Page 68: ...slide the hood towards the back of the treadmill through the targa uprights to remove Installation Instructions 1 Position the hood cover over the front motor compartment by sliding the hood front th...

Page 69: ...the two 3 Phillips hood transition cover fasteners Pull down and away from the frame rail to release tab clips and remove the cover 3 Repeat procedure for both left and right covers Installation Instr...

Page 70: ...2 Repeat procedure for both left and right covers 3 Replace the hood cover see Hood Cover Replacement on page 60 Page 62 5 Replacement Procedures Covers and Panels Replacement...

Page 71: ...oval Instructions The same procedure applies to both the left and right trim landing covers 1 Remove the hood cover see Hood Cover Replacement on page 60 2 Remove the left and right trim landing cover...

Page 72: ...ed to reinstall the keeper block 2 Grab the outer edge and the inside edge at the rear of the trim landing cover see figure lift point and lift up to release the rear tab clip Continue to slide the co...

Page 73: ...int to lock the rear cover tab clip in place 3 Secure the rear tab clip by fully tightening the 2 Phillips keeper block fastener 4 Secure the front of the trim landing cover using the 3 Phillips screw...

Page 74: ...n page 60 2 Remove the left and right trim landing covers see Covers and Panels Replacement on page 58 3 Remove the three 3 Phillips left and right trim end cap cover fastener screws One fastener on t...

Page 75: ...tabs in place Secure using the three 3 Phillips screw fasteners One fastener on the top one fastener on the end and one fastener on the bottom 2 Repeat procedure for both the left and right end cap c...

Page 76: ...move the trim landing cover see Covers and Panels Replacement on page 58 3 Remove the hood transition cover see Covers and Panels Replacement on page 58 4 Starting from the front moving reward use a s...

Page 77: ...y attached at all five anchor mounts 2 Next use the palm of your hand to strike the top of the cover at each of the five anchor mounts to engage and lock the cover in place Make sure that the trim sid...

Page 78: ...rst and then the remaining four top screws Carefully hold the cover from falling while removing the fasteners Retain fastener hardware for installation Installation Instructions 1 Reinstall and hold t...

Page 79: ...and remove the front cover Retain fastener hardware for installation Installation Instructions 1 Reinstall front cover and secure using the four 3 Phillips screw fasteners 2 Reinstall the console ref...

Page 80: ...from the dash assy bottom cover Retain fastener hardware for installation 2 Carefully flip the dash top cover over and remove the four 2 Philips emergency stop switch E Stop fasteners Carefully lay t...

Page 81: ...3 Remove the dash bottom cover from between the dash assembly weldment cross member and HHHR bar Page 73 5 Replacement Procedures Covers and Panels Replacement...

Page 82: ...Installation Instructions 1 Install the dash bottom cover into position between the dash assembly weldment cross member and HHHR bar Page 74 5 Replacement Procedures Covers and Panels Replacement...

Page 83: ...ched and secure 3 Position the dash top cover onto the dash bottom cover and secure using the two 3 Phillips fasteners Make sure the interface cable is routed correctly and not pinched Make sure that...

Page 84: ...fastener hardware for installation 2 Remove the one 3 Phillips screw from the upper side arm cover Pull the cover up and forward to remove Retain fastener hardware for installation Installation Instru...

Page 85: ...al Instructions 1 Switch the power OFF and unplug1 the power cord TIP For easier access raise the incline to maximum before removing input power Access the service Hardware Validation 51765761 and use...

Page 86: ...tely removed Retain fastener hardware for installation Installation Instructions 1 Connect the replacement power cord into the power cord AC input assembly 2 Position power cord cable clamp over the p...

Page 87: ...ss member contains the Power Cord Inlet Assembly the ON OFF SW Circuit Breaker and the ASL1 PCA board The Power Entry Assembly Bracket must be removed to access these components ID Description Power E...

Page 88: ...Wire Diagram Power Entry Assembly wire diagram Procedure Review entire procedure before starting Page 80 5 Replacement Procedures ON OFF SW Circuit Breaker Replacement...

Page 89: ...the power cord TIP For easier access raise the incline to maximum before removing power Access the service Hardware Validation 51765761 and use the CROSSRAMP INCLINE Test to raise the incline and then...

Page 90: ...tion Installation Instructions 1 Reinstall the ON OFF SW Circuit Breaker and secure using the two 2 Phillips fasteners 2 Reconnect the two brown input power wires or two brown and two blue for the 240...

Page 91: ...Cord Inlet Assembly the ON OFF SW Circuit Breaker and the ASL PCA board The Power Entry Assembly Bracket must be removed to access these components ID Description Power Entry Assembly Bracket Power Co...

Page 92: ...Procedure Review entire procedure before starting Page 84 5 Replacement Procedures ASL PCA Replacement...

Page 93: ...unplug1 the power cord TIP For easier access raise the incline to maximum before removing power Access the service Hardware Validation 51765761 and use the CROSSRAMP INCLINE Test to raise the incline...

Page 94: ...for installation 4 Disconnect the ASL interface cable RJ11 connector see Wire Diagram on page 83 5 Remove the ASL PCA Bracket by pressing the inner and outer tab clips on the bot tom underside of the...

Page 95: ...our 3 Phillips fasteners Make sure that the wire cables are not pinched or damaged during install ation 5 Reinstall the hood cover see Hood Cover Replacement on page 60 6 Connect the power cord and sw...

Page 96: ...g Removal and Installation procedures 1 The removal and installation procedures are included in the Dash Top and Bottom Cover Removal Installation procedure see Dash Top and Bottom Replacement on page...

Page 97: ...MC1 The Motor Controller MC is located in the Drive Motor compartment at the front of the tread mill under the hood cover ID Description Motor Controller MC Lift Motor Drive Motor Line Filter Power En...

Page 98: ...MC Wire Diagram Page 90 5 Replacement Procedures Motor Controller MC Replacement...

Page 99: ...Connector Definition MC I O connectors The MC interface input output connectors are located on the front and back sides of the MC housing Page 91 5 Replacement Procedures Motor Controller MC Replaceme...

Page 100: ...Page 92 5 Replacement Procedures Motor Controller MC Replacement...

Page 101: ...BLE 1 DIGITAL GROUND 2 8 VDC 3 TCD DATA OUTPUT 4 DIGITAL GROUND 5 8 VDC 6 RXD DATA INPUT 7 DIGITAL GROUND 8 E STOP DBR1 1 DYNAMIC BRAKE RESISTOR SENSE 1 THERMAL RESISTOR SENSE 2 THERMAL RESISTOR SENSE...

Page 102: ...2 RED POTENTIOMETER 3 NC 4 WHITE MOTOR COMMON 5 WHITE POTENTIOMETER WIPER 6 NC 7 RED MOTOR EXTEND 8 BLK MOTOR RETRACT GFX1 not used not used Notes 1 TRM800 14 treadmills only 1Ground Effects Impact Co...

Page 103: ...is located under the MC top cover Note For MC Fan replacement see Motor Controller Fan Replacement on page 100 Component PIN Description Fan motor 1 Black 24V GND 2 Yellow Fault signal 3 Red 24 Vdc Pa...

Page 104: ...r log for more information The MC may continue to operate after a fault reset or there may be an internal MC fault that needs to be corrected before the MC will operate The MC status light will not au...

Page 105: ...acing the front of the treadmill remove the two right side 5 16 hex fasteners and then loosen the two left side 5 16 hex fasteners approximately 4 full turns Slide the MC base to the right to remove R...

Page 106: ...ctors LIFT motor cable Drive MOTOR cable COMM cable MON ASL cable Thermal switch MTH cable power INPUT cable It will be easier to attach the connectors before installing the MC into the mounting faste...

Page 107: ...Log resets the ASL and MC status lights Verify that the ASL status light is blue and the MC status light is green P62 P80 and P82 a Reset the ASL and MC status lights Access the service Settings menu...

Page 108: ...place the Motor Controller MC1 Fan MC Fan Connector Definition The fan motor interface cable connector is located under the MC top cover Component PIN Description Fan motor 1 Black 24V GND 1Motor Cont...

Page 109: ...Component PIN Description 2 Yellow Fault_signal 3 Red 24 VDC Page 101 5 Replacement Procedures Motor Controller Fan Replacement...

Page 110: ...lift the fan and remove from top cover Guide the power cable and con nector through the cable routing opening while removing Discard the fan Installation Instructions 1 Make sure that the replacement...

Page 111: ...ing the top cover into the housing tabs Secure top cover using the one screw fastener 5 Reinstall the Motor Controller see Motor Controller MC Replacement on page 89 6 Plug1 in the power cord and swit...

Page 112: ...ng Maintenance menu parameters l Recommended Action None l Operating Condition Normal l Active Status Light Solid Blue 9 Verify that the MC status light is now green and the ASL light is solid blue 10...

Page 113: ...ions 1 Switch the power OFF and unplug1 the power cord 2 Remove the hood cover see Covers and Panels Replacement on page 58 3 Remove the left and right trim landing covers see Trim Landing Covers Repl...

Page 114: ...roller tension mechanism CAUTION Only use hand tools to adjust tension Power tools can easily over and or under tension causing damage to the belt and or tension hardware mechanism 5 Walk the Drive Be...

Page 115: ...ive Roller Keepers one 3 Phillips screw per keeper Retain fastener hardware for installation 8 Lift the Drive Roller enough to remove the Drive Belt off the pulley Lift the left side of the Dust Guard...

Page 116: ...Page 108 5 Replacement Procedures Drive Belt Replacement...

Page 117: ...enough to install the Drive Belt over the Dust Guard 2 Lift the Drive Roller enough to place the Drive Belt onto the Drive Roller pulley Reinstall the Drive Roller into the left and right mounting br...

Page 118: ...ng belt to specification see Running Belt Tension and Tracking Adjustment on page 43 Do not verify tracking or apply power at this step in the process the running belt tracking will be verified after...

Page 119: ...Belt Tension and Alignment Adjustment on page 39 6 Connect the power cord and switch the power ON 7 Operate the treadmill and verify the running belt tracking see Running Belt Tension and Tracking Ad...

Page 120: ...e provides instruction to replace the Drive Motor The Drive Motor is located in the Drive Motor compartment at the front of the treadmill under the hood cover ID Description Drive Motor Page 112 5 Rep...

Page 121: ...ons a Remove the MC2 base from the mounting fasteners to allow connector access see Motor Controller MC Replacement on page 89 b Disconnect the MC MTH and MOTOR interface cable connectors see Motor Co...

Page 122: ...make a motor base position reference mark This reference mark will be used to help position the replacement motor installation position 6 Remove Drive Belt tension by loosening the four Drive Motor 1...

Page 123: ...top hat washers and bottom washers fastener hard ware a If you made a motor base install reference mark prior to removal adjust the Drive Motor base position to the motor base install reference mark...

Page 124: ...s securely connected to the frame When the ground wire is not con nected touching the motor housing could cause static charge electrical shock and personal injury 3 Reconnect the Motor Controller MTH...

Page 125: ...troller MC Replacement on page 89 5 Route cables and secure using the three frame cable clamps Recheck all cable MC con nections and make sure that the cables have freedom of movement and clear of any...

Page 126: ...o specification see Drive Belt Tension and Alignment Adjustment on page 39 9 Reinstall the hood cover see Hood Cover Replacement on page 60 10 Do the Operation Verification tests see Operation Verific...

Page 127: ...ee Covers and Panels Replacement on page 58 3 Relax the running belt tension by loosening the left and right 5 16 hex key tension adjustment bolts Alternately loosen the left and right adjustment bolt...

Page 128: ...screws and two 7 16 hex head fasteners and remove the Dust Guard Retain fastener hardware for installation 5 Remove the Drive Belt Walk the belt off the Drive Roller pulley and remove 6 Remove the one...

Page 129: ...adjustment bolts enough to allow the freedom of movement required to lift the Drive Roller from the mounting brackets Slide the Drive Roller through the running belt and remove Page 121 5 Replacement...

Page 130: ...u the Running Belt and then set the Roller back into position in the mounting brackets 2 Reinstall the left and right Roller Keepers and secure using the 3 screw fasteners one fastener per Keeper Page...

Page 131: ...ure using the two 3 Phillips and two 7 16 hex head fasteners Make sure to insert the left Dust Guard bracket through the Drive Belt pulley before securing the fasteners 6 Make sure the Drive Belt pull...

Page 132: ...ing belt tension by loosening the left and right 5 16 hex key Take up roller tension adjustment bolts Alternately loosen the left and right adjustment bolts in 1 4 turn increments so that the running...

Page 133: ...roller does not drag across the deck surface while removing causing damage to the deck surface Installation Instructions 1 Insert the Take up roller through the running belt so that the roller shaft...

Page 134: ...g belt between the Drive and Take up rollers Tension to specification and verify tracking see Running Belt Tension and Tracking Adjustment on page 43 5 Reinstall the left and right Landing Trim covers...

Page 135: ...6 Do the Operation Verification tests see Operation Verification on page 16 and return to service Page 127 5 Replacement Procedures Take up Roller Replacement...

Page 136: ...r use on Precor treadmills Ammerall Beltech and Fobo brand running belts Ammeraal Beltech and Forbo brand running belts l The Ammeraal Beltech running belt is a wax infused belt and must NOT be used w...

Page 137: ...move the four 5 32 hex key bolt and washer rear deck fasteners These fasteners attach to the left and right rear deck pivot assemblies The 1 2 fastener nuts are press fit into the bottom of the deck p...

Page 138: ...steners These fasteners are attached to the left and right front GFX1 Cushion tinnerman clips Retain fastener hardware for installation 1Ground Effects Impact Control System Patented treadmill design...

Page 139: ...deck surface must used with each new running belt replacement CAUTION Make sure the correct running belt brand and deck combination are installed together l The Ammeraal Beltech running belt is a wax...

Page 140: ...que to specification 27 33 in lbs 3 1 3 7 Nm Its important to correctly torque these fasteners or they may loosen with use Retain fastener hardware for installation IMPORTANT Its important to correctl...

Page 141: ...deck pivot assemblies The 1 2 fastener nuts are press fit into the bottom of the deck pivot housing Be aware that the nuts can fall from the housing as the bolts are being installed and fall to the fl...

Page 142: ...lt tracking see Running Belt Tension and Tracking Adjustment on page 43 8 Reinstall the hood cover see Covers and Panels Replacement on page 58 and left right Landing Trim covers see Covers and Panels...

Page 143: ...in 2 8 cm 3 0 cm Note Calibration distance is specified at incline level 0 Lift Motor Fuse he lift motor fuse 2 Amp is located on the LPCA1 board in the MC2 module Remove the MC bottom cover to acces...

Page 144: ...1 Remove the hood cover see Hood Cover Replacement on page 60 2 You can access the lift motor jackscrew in one of two methods 1 by raising the tread mill providing access from the front of the treadm...

Page 145: ...weldment 5 Slowly lower the incline level in 0 5 increments until the complete weight of the frame is setting on the supports Verify the supports are stable and secure carrying the weight of the trea...

Page 146: ...ground wire GRN or GRN YEL from the frame chassis ground screw fastener 9 Remove the extension tube hitch pin and clevis pin fastener hardware from the lift plat form mounting bracket Hold the lift p...

Page 147: ...tor housing mount hitch pin and clevis pin fastener from the frame pan mounting bracket Hold the lift motor while removing fasteners and carefully remove from the treadmill Page 139 5 Replacement Proc...

Page 148: ...ctions Lift motor calibration 1 Lay replacement lift motor on the floor in front of treadmill Connect the the lift motor interface cable to the MC LIFT connector Page 140 5 Replacement Procedures Lift...

Page 149: ...sing Adjust the calibration distance to specification between 1 1 8 in 1 3 16 in 2 8 cm 3 0 cm IMPORTANT Make sure the extension tube does not rotate after setting the cal ibration distance Use tape t...

Page 150: ...ssary to slightly rotate the extension tube to align the clevis pin mounting holes Choose an adjustment direction that will minimize the change to the extension tube calibration distance Firmly hold t...

Page 151: ...I O cable MC LIFT connector Route cable and secure in the frame routing cable clamp Connect the ground wire GRN or GRN YEL to the chassis ground screw and fully tighten Page 143 5 Replacement Procedur...

Page 152: ...incline platform to move and return to the level 0 position WARNING Keep hands and appendages clear of the incline platform assembly before switching power ON Switching power ON will cause the incline...

Page 153: ...admill incline operation from minimum to maximum levels Make sure that there are no active Incline function related error codes 16 Do the Operation Verification tests see Operation Verification on pag...

Page 154: ...Landing Covers Replacement on page 63 3 Remove the left and right trim side covers see Covers and Panels Replacement on page 58 4 You can access and remove the lift platform from the front of the tre...

Page 155: ...y resting on the supports Keep the wheels as close to floor as possible without touching the floor making sure all the weight of the treadmill is carried by the supports Verify the supports are stable...

Page 156: ...ins at the same position for installation Use tape to mark the extension tube position on the jackscrew Allowing the extension tube to rotate will change the cal ibration distance nullifying the calib...

Page 157: ...at form to be removed Retain fastener hardware for installation Installation Instructions 1 Install the lift platform left and right pivot brackets into position and insert the right and left clevis p...

Page 158: ...to slightly rotate the extension tube to align the clevis pin mounting holes If the extension tube has been rotated during or after it was removed recalibrate the lift motor prior to installation see...

Page 159: ...treadmill frame off the supports 3 Remove the supports and clear any other items that might either block the treadmill from lowering or may be damaged as it lowers 4 Lower the incline to level 0 Opera...

Page 160: ...on page 160 l Review the System Troubleshooting Procedures topic for any possible related issue fixes or repairs see System Troubleshooting Procedures on page 166 Introduction To Troubleshooting Troub...

Page 161: ...The error logs will contain any triggered error code events and related information You can then refer to Error Code Troubleshooting Guide to help resolve the issue Also when calling Precor cus tomer...

Page 162: ...g and verify that there are no remaining active error codes This will verify that the original error codes are not reoccurring and that there are no new error code issues If the error code is reoccurr...

Page 163: ...g or CPA1 Event Log along with the event mileage hours and motor current Error code numbers range from 01 to 99 There are also a small number of alpha and alpha numeric codes Most but not all error co...

Page 164: ...of error codes including the code description related issues symptoms troubleshooting and repair information is provided in the Error Code Troubleshooting Guide see Error Code Troubleshooting Guide Th...

Page 165: ...ored in the number one position pushing any current error codes down one position When the memory is full the oldest error code is pushed off the stack and removed from memory When an error event is d...

Page 166: ...ving Error Event Codes To remove an error code select the error code to be removed and press hold the QUICK START key for a minimum of 6 secs until the NO ERRORS message shows TIP Error Log Delete Sho...

Page 167: ...Number o Error Code Description o Odometer o Hours o Motor Current o Input Line Current o Input line voltage o Buss Voltage o OEM Factory only data Note machine dependent parameter Removing Error Code...

Page 168: ...etected ASL Overview l An externally visible indicator of the current machine operational status There are four supported states 1 solid blue indicates normal operation 2 pulsing blue indicates preven...

Page 169: ...operator to do a manual reset from the service menu l Maintenance counter operation The counter starts at 1000 miles and counts down the miles of active use to 0 miles When the counter reaches zero th...

Page 170: ...setting switches the ASL light brightness OFF for all ASL state conditions Setting the ASL Light Brightness OFF only switches the ASL light brightness OFF and not the ASL active status functionality l...

Page 171: ...solid yellow or pulsing yellow can be viewed using the service menu ACTIVE STATUS LIGHT parameter P10 P20 and P30 consoles Access Hardware Validation 5 1 7 6 5 7 6 1 ACTIVE STATUS LIGHT current ASL st...

Page 172: ...he pulsing yellow ASL state An ASL pulsing yellow state is triggered when an error code event occurs and is logged To clear a pulsing yellow state the error condition causing the ASL pulsing yellow mu...

Page 173: ...Note Clearing the CPA Event Log does NOT clear the error codes from the Event Log Page 165 6 Troubleshooting Active Status Light ASL...

Page 174: ...bleshooting on page 175 l Machine Controls Troubleshooting on page 177 l Auto Stop Troubleshooting on page 179 l E Stop not Communicating Troubleshooting on page 180 l Heart Rate Monitor Troubleshooti...

Page 175: ...e same time To verify if multiple treadmills are sharing the same wall breaker manually switched OFF the facility outlet circuit breaker If more than one treadmill loses power the treadmills are on th...

Page 176: ...t to the power distribution panel o If NO continue Troubleshooting l Overloading is the most frequent cause of a tripped treadmill ciruit breaker Overloading is most often caused by worn belt deck exc...

Page 177: ...function on your volt meter while someone is running on the treadmill at 7 0 MPH or higher o If any measurement is below 108 Vac US 120 Vac or 200 VAC International 240Vac advise the customer to have...

Page 178: ...See Also System Troubleshooting Procedures on page 166 Page 170 6 Troubleshooting System Troubleshooting Procedures...

Page 179: ...e machine operating issues The following error codes are related to poor input power issues Related Error Codes RELATED ERROR CODE DESCRIPTION 10 Line Frequency Out Of Acceptable Range 11 Low Voltage...

Page 180: ...er Verification Verify that the facility outlet wiring is an individual branch circuit voltage the voltage level is within limits and that the frequency is within limits see on page 10 Tripped machine...

Page 181: ...t power b If YES continue procedure 2 Remove the treadmill hood switch power ON and measure the AC voltage at the input side of the line filter Verify that line voltage is within operating limits see...

Page 182: ...e 2 Obtain a known good console and communication cable First reconnect the com munications cable from the motor controller MC to the console and then the power sup ply cable Does the test console pow...

Page 183: ...des Communications error codes 30 through 33 RELATED ERROR CODE DESCRIPTION 30 Error 30 is defined as upper PCA is active the lower PCA is not com municating 31 Error 31 is defined as faulty data rece...

Page 184: ...Page 176 6 Troubleshooting System Troubleshooting Procedures...

Page 185: ...start is not needed to clear the error self recovery possible when the control is returned to the center position 81 Error 81 Incline or crossramp will stop at current incline Error 81 is dis played w...

Page 186: ...See Also System Troubleshooting Procedures on page 166 Page 178 6 Troubleshooting System Troubleshooting Procedures...

Page 187: ...with a normal cadence The feature is selectable ON or OFF in the facility settings menus It is default from the factory set to ON and it is recommended to be set ON Related Error Codes RELATED ERROR C...

Page 188: ...ill reset the E STOP turning the treadmill back on and then starting a course Also possible is a break in the E STOP line or a loose cable connection Related Error Codes RELATED ERROR CODE DESCRIPTION...

Page 189: ...tion correctly continue procedure 4 Verify the chassis ground cable is connected to the HHHR PCA board Also verify the ground cable is connected to the console weldment and provides a zero resistance...

Page 190: ...The voltage should measure between 4 5 and 5 Vdc see HHHR PCA schematic below a If no voltage make sure the Power Pulse Signal cable 3 pin plug is correctly con nected to the UPCA1 board connector Rem...

Page 191: ...Cell Phones l Electronic Dog Fences l Garage Door Remotes l Florescent light ballasts 4 Power OFF any possible sources of signal interference while using the wireless HHHR chest transmitter and note i...

Page 192: ...29 refer to the Error Code Troubleshooting Guide RELATED ERROR CODE DESCRIPTION 20 Motor Will Not Start No Motor Movement Detected 21 too Many Maximum Consecutive Power Requests 22 Error 22 indicates...

Page 193: ...onnector If the MC is supplying output power you will momentarily approx 2 sec read an AC voltage value Make a note of the voltage and switch the treadmill ON OFF to OFF Note If the drive motor does n...

Page 194: ...MOTOR connector white wire pin 5 the black wire pin 6 The measured voltage should read approximately the same value as the previously measured voltage between the red pin 4 black pin 6 wires Set the...

Page 195: ...d damaged Take care and use light probe contact pressure when making multimeter measurements DO NOT insert large diameter probes into the plug terminals which will spring and dam age the pin terminals...

Page 196: ...ting Procedure Error code events are generated when the lift system has been commanded to move and no and or incorrect lift motion has been detected Review the machine Error Log or CPA2 Event Log and...

Page 197: ...Then use the Error Code Troubleshooting Guide see Error Code Troubleshooting Guide to isol ate and resolve the fault condition a Along with the Error Code and Troubleshooting Guide review the followi...

Page 198: ...he motor housing rotate the lift nut or lift tube away from the motor housing a If the lift motor was jammed make sure the lift fuse is good Do the Check for a blown lift motor fuse step b If the lift...

Page 199: ...e lift motor connector Select the manual running program and press the INCLINE UP control The AC voltmeter should momentarily read between 1 5 to 2 0 times the AC line voltage If this read ing is sign...

Page 200: ...tage either 120VAC or 240VAC Note that the AC line voltage reading will only be present before an error condition is displayed A correct read ing verifies that the DOWN switch is working properly It t...

Page 201: ...elt deck friction increases as the belt rating number approaches 0 As the friction increases so does the amount of motor current required to move the belt Typ ically cleaning the belt and deck will re...

Page 202: ...ber and that the ASL has returned to Solid Blue 5 If the ASL light has returned to the Pulsing Blue state replace the belt and deck surface either flip the deck or replace deck if both surfaces are us...

Page 203: ...OUT OF SERVICE sign on the equipment and make it clear to all patrons and other users that they must not use it Daily Maintenance Perform the following maintenance tasks daily Daily Task Description...

Page 204: ...inspect the running belt operation and condition Inspect the running belt for the following possible issues l Belt slipping l Frayed or worn condition l Belt alignment and tracking is centered on the...

Page 205: ...ollowing monthly maintenance tasks WARNING DANGER USE EXTREME CAUTION when the rear cover of any TRM is removed Serious injury could result if fingers are pinched between the fly wheel spokes cranks m...

Page 206: ...ion Verify the Drive Motor belt tension and adjust as neces sary see Drive Motor Belt Tension Adjustment pro cedure Vacuum the front compartment and Motor Controller fan Remove hood and vacuum the com...

Page 207: ...ths Semiannual Task Instruction Clean and lubricate the Lift Motor jackscrew Raise the Incline to maximum Switch the input power OFF and unplug the power cord Clean the jackscrew and apply approved gr...

Page 208: ...admill must remain out of service until the stop switch is repaired 2 Get a clean dry cotton towel that is at least 36 inches 1 meter in length and fold it in half lengthwise a Lift the running belt a...

Page 209: ...rollers 4 The treadmill will begin to run at 1 mph Allow the treadmill to run for one minute while keeping the towel firmly in place WARNING Do not adjust the treadmill s speed or run it higher than...

Page 210: ...the length of the belt several times to clean the top of the deck 8 Remove the towel from beneath the belt 9 Turn the power switch to ON 10 Verify operation and return to service Page 202 7 Preventati...

Page 211: ...data from the base which is used to maintain the Error Log ser vice menu The console also controls and sends the ASL7 status state based on the received error codes to the base The LPCA makes use of t...

Page 212: ...r COMM Communication Interface Cable Active Status Light ASL Active Status Light similar to Treadmill ASL except that operation has been changed for self powered machines A separate microprocessor and...

Page 213: ...Page 205 8 Theory of Operation...

Page 214: ...9 System Wiring Diagram System Wire Diagram Overview Page 206 9 System Wiring Diagram...

Page 215: ...System Wire Diagram Connector Pins Page 207 9 System Wiring Diagram...

Page 216: ...COMM Cable Wire Diagram COMM Cable Wire Diagram Page 208 9 System Wiring Diagram COMM Cable Wire Diagram...

Page 217: ...Console Wire Diagram Console Wire Diagram Page 209 9 System Wiring Diagram Console Wire Diagram...

Page 218: ...Power Entry Assemble Wire Diagram Power Entry Assembly Wire Diagram Page 210 9 System Wiring Diagram Power Entry Assemble Wire Diagram...

Page 219: ...artners Precor Connect website to view the most current Exploded View Diagram and Parts Identification List information l Precor Connect Partner website IMPORTANT Always purchase OEM replacement parts...

Page 220: ...Exploded View Diagram Page 212 10 Parts Exploded View Diagram Parts List Exploded View Diagram...

Page 221: ...Page 213 10 Parts Exploded View Diagram Parts List Exploded View Diagram...

Page 222: ...Page 214 10 Parts Exploded View Diagram Parts List Exploded View Diagram...

Page 223: ...Page 215 10 Parts Exploded View Diagram Parts List Exploded View Diagram...

Page 224: ...Page 216 10 Parts Exploded View Diagram Parts List Exploded View Diagram...

Page 225: ...Page 217 10 Parts Exploded View Diagram Parts List Exploded View Diagram...

Page 226: ...Page 218 10 Parts Exploded View Diagram Parts List Exploded View Diagram...

Page 227: ...Parts List Continue to view the hard copy version Page 219 10 Parts Exploded View Diagram Parts List Parts List...

Page 228: ...Page 220 10 Parts Exploded View Diagram Parts List Parts List...

Page 229: ...Page 221 10 Parts Exploded View Diagram Parts List Parts List...

Page 230: ...018 Precor Incorporated No part of this manual may be reproduced in any form or by any means including electronic storage and retrieval or translation into a foreign language without prior agreement a...

Page 231: ...ghts to be a very serious matter Precor will vigorously pursue all unauthorized appro priation of its proprietary rights Warranty The material contained in this document is provided as is and is subje...

Page 232: ...ot correctly performed or adhered to could result in per sonal injury or death Do not proceed beyond a WARNING notice until the indicated conditions are fully understood Caution A CAUTION notice denot...

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