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Service Manual, C956i, C966i (Gen 06) Treadmill.fm

1. Data Cable Connector Incline Connector AC Input Connector Motor Connector Dynamic Braking Connector 3 With the incline below 15 connect an AC voltmeter between terminals 1 amp 6 of the INCLINE connector See Diagrams 5 3 and 5 4 Set the treadmill in the manual program and press the INCLINE 4 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 Page 21 C956i C966i Gen 06 Treadmill Diagram 5 4 Power Control Module Connector Numbering 10 11 dani sal EE ET ED COMM INCLINE INPUT DB OUTPUT 28 If the display indicates that the incline should be moving and the incline motor does not move and AC line voltage is present skip to step 12 If the incline moves normally skip to step 7 If the display indicates that the incline should be moving and the incline motor does not move and AC line voltage is not present replace the power control module With the incline above 0 connect an AC voltmeter between terminals 1 amp 5 of the INCLINE connector See Diagrams 5 3 and 5 4 Set the treadmill in the manual program and press the INCLINE w 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 If the incline moves normally skip to step 1
2. d j HES Metrics Cable i Metrics PCA D Pad Assembly 5 Ifthe upper PCA is not illuminating skip to step 12 6 Ifthe metrics PCA is not illuminating continue with step 7 7 Un clip the metrics PCA from the display face and rotate it so that the front of the PCA is visible Set the treadmill s on off switch in the on position Page 1 18 Page 18 8 C956i C966i Gen 06 Treadmill With a DC voltmeter measure between TP1 8V and TP3 DGND for 8 Vdc and between TP4 5V and TP3 DGND for 5Vdc See Diagram 5 2 Diagram 5 2 Metrics ae View 10 11 12 13 14 15 16 17 18 19 20 TP1 8V Z TP3 DGND ae Ap TP4 5V If 5 Vdc is not present on TP4 and 8 Vdc is present on TP1 replace the metrics PCA If 8 Vdc is not present on TP1 and the upper PCA is illuminating normally replace the cable between the upper PCA and the metrics PCA If you have performed steps 7 10 and the metrics PCA still does not illuminate contact Precor customer support for assistance Set the treadmill s on off switch in the on position With a DC voltmeter measure between pins 2 and 6 of J1 ISP for 5 Vdc and between pins 4 and 5 of J4 entertainment for 8 Vdc If 5 Vdc is not present on J1 and 8 Vdc is present on J4 replace the upper PCA If 8 Vdc is not present on J4 temporarily replace the upper PCA to power control module with a known good cable If
3. and block diagrams for the C956i C966i Treadmills Page 1 2 Page 2 C956i C966i Gen 06 Treadmill Safety guidelines you should know and follow include Read the owner s manual and follow all operating instructions Operate the treadmill on a solid level surface Visually check the treadmill before beginning service or maintenance operations If it is not completely assembled or is damaged in any way exercise extreme caution while operating and checking the treadmill 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 Page 3 C956i C966i Gen 06 Treadmill General Information For the latest exploded view diagram part number and part pricing information visit the P
4. 29 30 31 32 Slide the drive roller into running belt and into the drive belt Hand start both drive roller mounting bolts Tighten the left hand drive roller bolt fully The left hand side of the drive roller should be as far forward as possible Tighten the right hand drive roller bolt until the mark placed on it in step 5 aligns with the front edge of the drive roller shaft Steps 12 and 13 should place the drive roller into its original position and should now be square to the treadmill frame Page 1 60 Page 60 33 34 35 36 37 38 39 40 41 42 43 44 45 46 C956i C966i Gen 06 Treadmill Slowly rotate the drive motor flywheel while pressing the drive belt onto of the drive roller pulley Continue until the drive belt walks completely onto of the drive roller pulley Be sure that the drive belt is fully onto and correctly aligned on the drive roller pulley Slide the take up roller into the running belt and set it in its mounting position Hand start both take up roller mounting bolts that were removed in step 2 Alternate tightening the two take up roller mounting bolts in order to tighten both ends evenly until both running belt gauges again read exactly 3 5 on consumer treadmills or 3 55 on commercial treadmills When both gauges again read 3 5 or 3 55 the belt is at its original tension It will now be necessary to touch up the running belt tracking how
5. POH VOd SOU 1eddn Aiowayy USE v9dn jj u pee SEA 047 19969 19969 Ire puofag AoW OU D i Block Diagram 7 4 C956i C966i 240 Vac Page 65
6. a separate ground bar in the distribution system The most common problems found are 1 the circuit is fed by a circuit breaker of less than 20 amp capacity 2 the circuit breaker correctly feeds a single A C outlet but the neutral is common between several A C outlets and 3 both the hot and neutral leads feed several A C outlets The appropriate correction action or actions see below must be followed if any of the above conditions exist Corrective actions should only be undertaken by a licensed electrician 1 The circuit breaker feeding the treadmill is not 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 capable of safely handling 20 amps Please refer to local electrical codes when determining the appropriate wire size for a 20 amp circuit Page 27 C956i C966i Gen 06 Treadmill 2 The circuit breaker correctly feeds a single A C outlet but the neutral is common between several A C outlets The common neutral lead must be removed from treadmill s A C outlet and a new neutral lead from the treadmill s A C outlet to the A C neutral distribution bar must be added 3 Both
7. accuracy when the replacement drive roller is installed Page 59 24 20 26 27 28 C956i C966i Gen 06 Treadmill Remove both drive roller mounting bolts Remove the drive roller from the treadmill Remove the running belt and deck from the treadmill If both sides of the deck have been used discard the deck If the bottom side of the deck has not been used flip the deck so that when it is replaced it will now be the top side Decks with inserts that are being flipped need to be reversed so that the bottom of the deck can be used the inserts can be removed by threading the deck screw into the insert from the top Using a hammer or mallet the insert can be tapped out the bottom of the deck Remove the insert from the deck screw Using one of the CATN025 150 bolts and a flat washer to cover the hole thread the bolt into the insert and pull the insert into the opposite side of the deck until the insert is flush with the deck surface Repeat this procedure with the remaining five inserts Using a clean dry cloth wipe the top surface of the deck clean of any dirt dust or debris Set the replacement or flipped deck inside of the replacement running belt Set the running belt and deck combination in its mounting position on the treadmill Place two running belt gauges on each side of the running belt being sure that the gauges are not across a belt seam Set the gauges to the 3 mark as shown in the Illustration below
8. eight screws that fasten the display back cover and remove the display back cover Disconnect the data cable 2 CSAFE cables and the heart rate cable from the upper PCA See Diagram 6 9 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 cap The display face snaps 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 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 Disconnect the Metrics cable D pad cable and the keypad cable from the upper PCA See Diagram 5 1 The upper PCA snaps into the display face Press the upper PCA tabs outward and remove the upper PCA from the display face Disconnect the Metrics cable from the Metrics PCA See Diagram 5 1 The Metrics PCA snaps into the display face Press the Metrics PCA tabs outward and remove the Metrics PCA from the display face Disconnect the D pad cable from the D pad assembly See Diagram 5 1 The D pad assembly snaps into the display face Release the D pad assembly s tabs and push the D pad assembly out of the front of the display face Snap the upper PCA into its mounting o
9. in step 2 Page 43 C956i C966i Gen 06 Treadmill Diagram 6 8 Belt Guard Mounting Notch Belt Guard Page 1 44 Page 44 C956i C966i Gen 06 Treadmill Procedure 6 10 Replacing the Upper PCA 1 Set the treadmill circuit breaker in the off position and unplug the treadmill s line cord from the AC outlet 2 The PCA s in the display are static sensitive They can be damaged if proper static prevention equipment is not used Attach an anti static wrist strap to your arm then connect the ground lead of the wrist strap to the treadmill s frame ground 3 Remove the eight screws that fasten the display back 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 Display Cap CSAFE Cable Upper PCA Tab Upper PCA Tab HR Cable Data Cable Handlebar Cable HR PCA 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 cap 6 The display face snaps 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 Page 45 10 11 12 13 14 15 16 17 C956i C966i Gen 06 Treadmil
10. 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 the hardware removed in step 3 7 Set the input panel in its mounting position and fasten it with the hardware removed in step 3 8 Check treadmill operation per Section 3 Page 41 C956i C966i Gen 06 Treadmill Procedure 6 8 Replacing the Input Module 10 Set the treadmill circuit breaker in the off position and unplug the treadmill s line cord from the AC outlet Remove the treadmill s hood Remove the two screws that fastens the AC input panel to the frame See Diagram 6 4 Lift the AC input panel from the frame and rotate it to expose the AC line cord clamp screws and input module screws See Diagram 6 5 Remove the hardware that retains the AC line cord clamp and remove the clamp Disconnect the AC line cord from the input module Disconnect the wiring from the input module 1 blue wire 1 brown wire and 1 green yellow wire Remove the hardware that retains the input module and remove the input module Set the input module in its mounting position with the side with two terminals facing the circuit breaker 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 the input module See Diagram 6 6 Diagram 6 6 Input Module Wiring 11 12 13 Insert the AC line cord firm
11. 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 annunciated terminal mounted directly on the line filter case ke from the circuit breaker to the L1 terminal on wire from the circuit breaker to the L2 terminal e green yellow wire to the annunciated On 240 Vac treadmills connec the LINE side of thq AC line fil on the CHN i SAC tH terminal mounted directly on th Green Yellow Set the input ES in its mount nd fasten it with the hardware removed in step rown 3 Thoroughly check the treadmill Page 1 40 Page 40 C956i C966i Gen 06 Treadmill Procedure 6 7 Replacing the Line Cord 1 Gei 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 1 Remove the two screws that fastens the AC input panel to the frame See Diagram 6 4 2 Liftthe AC input panel from the frame and rotate it to expose the 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
12. the hot and neutral leads feed several A C outlets Both the common neutral and hot leads must be removed from treadmill s A C outlet and a new neutral lead and hot lead from the treadmill s A C outlet to the A C neutral distribution bar and circuit breaker must be added 240 Vac Systems 240 Vac distribution systems utilize a double pole circuit breaker two hot leads The A C safety ground green wire is connected to a ground bar in the distribution system The most common problems found are 1 the circuit is fed by a circuit breaker of less than 20 amp capacity and 2 both the hot leads feed several A C outlets The appropriate correction action or actions see below must be followed if any of the above conditions exist Corrective actions should only be undertaken by a licensed electrician 1 The circuit breaker feeding the treadmill is not 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 capable of safely handling 20 amps Please refer to local electrical codes when determining the appropriate wire size for a 20 amp circuit 2 Both the hot leads feed several A C outlets Bot
13. 1 If the display indicates that the incline should be moving and the incline motor does not move and AC line voltage is present skip to step 12 If the display indicates that the incline should be moving and the incline motor does not move and AC line voltage is not present replace the power control module The incline is moving normally in both directions there is either is not an incline problem or the problem is intermittent Intermittent problems are often caused by poor connections or wiring problems Page 1 22 Page 22 12 13 14 15 C956i C966i Gen 06 Treadmill Set the treadmill s on off switch in the off position Visually inspect the incline motor s wiring and connector for any broken or improperly crimped connections With an ohmmeter measure between terminals 1 amp 5 and 1 amp 6 of the INCLINE connector Both readings should be approximately 120 If either reading is significantly high or open replace the incline motor If you have performed all of the procedures above and have been unable to correct the problem call Precor customer service 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 amp 4 4 amp 8 and 3 amp 8 of the INCLINE conne
14. IIPRELOR 20077 111 Move Beyond C956i C966i Gen 06 Treadmill C956i C966i Treadmill Warning This service manual is for use by Precor trained service providers only If you are nota Precor Trained Servicer you must not attempt to service any Precor Product Call your dealer for service This document contains information required to perform the majority of troubleshooting and replacement procedures required to repair and maintain this product This document contains general product information software diagnostic procedures when available preventative maintenance procedures inspection and adjustment procedures troubleshooting procedures replacement procedures and electrical block and wiring diagrams To move directly to a procedure click the appropriate procedure in the bookmark section to the left of this page You may drag the separator bar between this page and the bookmark section to change the size of the page being viewed 2006 Precor Incorporated Unauthorized Reproduction and Distribution Prohibited By Law Page 1 C956i C966i Gen 06 Treadmill Section One Things you Should Know About This Appendix The C956i C966i Gen 06 incorporate new drive motor system and display systems The drive motor is a three phase AC motor The drive motor controller converts a single phase AC input into three phase motor control Section One Things You Should Know This section includes technical specification
15. a new running belt and deck are between 3 and 6 amperes 3 Ifthe peak current reading approach 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 X for running belt and running deck replacement Page 31 C956i C966i Gen 06 Treadmill 4 Ifthe peak A C 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 Page 1 32 Page 32 C956i C966i Gen 06 Treadmill Procedure 6 1 Replacing the Incline Motor Note The replacement incline motor must be calibrated prior to installation See Procedure 4 1 1 Gei 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 Diagrams 5 3 and 5 4 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 3 Calibrate the incline motor per Procedure 4 1 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
16. act pin on the J1 connector and the lower right hand held heart rate contact on the handlebar The reading should be 1 2 or less Measure between the upper right contact pin on the J1 connector and the upper right hand held heart rate contact on the handlebar The reading should be 1 Q or less Measure between the upper left contact pin on the J1 connector and the upper left hand held heart rate contact on the handlebar The reading should be 1 or less Measure between the lower left contact pin on the J1 connector and the lower left hand held heart rate contact on the handlebar The reading should be 1 or less If any of the above readings are greater than 1 replace the heart rate PCA to handlebar wire harness Page 25 C956i C966i Gen 06 Treadmill No hand held reading No chest strap reading 11 12 13 14 Access the diagnostic program Procedure 3 2 Advance to the heart rate display portion of the diagnostic program Verify that neither a chest strap signal or a hand held signal is being accepted with either a heart rate test transmitter or a chest strap transmitter Check the plug connector connections on both the heart rate PCA J4 and upper PCA J1 If neither a chest strap signal or a hand held signal is being accepted measure between the ground and 5 Vdc pins on J4 for 5 Vdc If 5 Vdc is present replace the heart rate PCA If 5 Vdc is not present remove the connector f
17. age 6 C956i C966i Gen 06 Treadmill Procedure 2 2 Displaying Information The information display will access the following data Odometer Hour Meter U Boot Software U Base Software Lower Software Serial Number Usage log Error Log Procedure Plug the power cord into the wall outlet then turn on the treadmill with the circuit breaker With the PRECOR banner scrolling press the keys RESET 6 5 seguentially DIAGS INFORMATION DISPLAY will scroll across the display Use the 4 Y keys to move to the desired display shown in the list above ODOMETER display Press the OK key The odometer will be displayed as 1234567 MILES or 1234567 KM depending on club parameter settings 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 10 11 12 is replaced the odometer data will be lost Press the BACK key to exit the odometer display HOUR METER display Press the OK key The operating time of the unit will be displayed as 12345 HOURS The operating time is defined as total amount of time that the unit has operated in program modes with the drive motor running The hour meter is also used to provide the time stamp for the error code log Press the BACK key to exit the hour meter display U BOOT SW display This display the installed version of upper boot software The b
18. amp 5 4 amp 6 and 5 amp 6 of the drive motor connector Each reading should be approximately 2 5Q If any of the readings are significantly high or open replacement the drive motor 9 If you have performed all of the procedures above and have been unable to correct the problem call Precor customer service Page 29 10 11 12 13 C956i C966i Gen 06 Treadmill Connect an AC voltmeter between terminals 4 amp 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 Repeat the procedure in step 4 between terminals 4 amp 6 of the OUTPUT connector on the power control module Repeat the procedure in step 4 between terminals 5 amp 6 of the OUTPUT connector on the power control module If one or more of voltage readings in steps 4 through 6 are not present replace the power control module If the voltage readings in steps 10 through 12 are present skip to step 8 Page 1 30 Page 30 C956i C966i Gen 06 Treadmill Procedure 5 6 Running Belt amp 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 A C input current under load The A C input current is a direct indication o
19. ay Press the OK key Use the A Y keys to select the maximum allowable incline setting Press the BACK key to exit the set incline limit time display HIDDEN PROGRAMS display Press the OK key Use the 4 Y keys to toggle between HIDE PROGRAMS and SHOW PROGRAMS Press the BACK key to exit the hidden programs display REMOTE SPEED CONTROL display Remote speed control allows the treadmill speed to be controlled by an external source such as InSite Press the OK key Use the 4 Y keys to toggle between ENABLED and DISABLED Press the BACK key to exit the remote speed control display SET CUSTOM PROGRAM 1 display Allows programing of the custom program 1 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 1 10 Page 10 C956i C966i Gen 06 Treadmill 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 11 C956i C966i Gen 06 Treadmill Procedure 2 4 Documenting Software Problems When a problem is found with the software in the upper or lower PCA record the information listed below When a problem occurs record the following information Model and serial number Software version number Program number runnin
20. ay face into place on the display Reconnect the data cable two CSAFE cables and the HR cable to the upper PCA as shown in Diagram 6 9 Snap the HR PCA into its mounting See Diagram 6 9 Snap the display cap into place on the display Page 47 C956i C966i Gen 06 Treadmill 16 Replace the display back cover with the hardware removed in step 3 17 Check treadmill operation per Section 3 Page 1 48 Page 48 C956i C966i Gen 06 Treadmill Procedure 6 12 Replacing the D Pad Assembly 10 11 12 13 14 15 Set the treadmill circuit breaker in the off position and unplug the treadmill s line cord from the AC oullet The PCA s in the display are static sensitive They can be damaged if proper static prevention equipment is not used Attach an anti static wrist strap to your arm then connect the ground lead of the wrist strap to the treadmill s frame ground Remove the eight screws that fasten the display back cover and remove the display back cover Disconnect the data cable 2 CSAFE cables and the heart rate cable from the upper PCA See Diagram 6 9 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 cap The display face snaps onto the display with six tabs One of the tabs is behind the HR PCA The HR PCA snaps into its mounting Press its ta
21. bs downward and remove the HR PCA from its mounting 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 Disconnect the D pad cable from the D pad assembly See Diagram 5 1 The D pad assembly snaps into the display face Release the D pad assembly s tabs and push the D pad assembly out of the front of the display face With the replacement D pad assembly oriented so that the incline and speed switches are correctly aligned slide the D pad assembly into the display face until it snaps into place 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 Connect the stop switch cable to upper PCA and snap the display face into place on the display Reconnect the data cable two CSAFE cables and the HR cable to the upper PCA as shown in Diagram 6 9 Snap the HR PCA into its mounting See Diagram 6 9 Snap the display cap into place on the display Page 49 C956i C966i Gen 06 Treadmill 16 Replace the display back cover with the hardware removed in step 3 17 Check treadmill operation per Section 3 Page 1 50 Page 50 C956i C966i Gen 06 Treadmill Procedure 6 13 Replacing the HR PCA 1 Set the treadmill circuit breaker in the off position and unplug the treadmill
22. ctor Terminals 3 amp 4 should read approximately 1KQ The sum of the readings between terminals 4 amp 8 and 3 amp 8 should total approximately 1KQ If either reading is significantly high or open replace the incline motor If you have performed all of the procedures above and have been unable to correct the problem call Precor customer service Page 23 C956i C966i Gen 06 Treadmill Procedure 5 3 Troubleshooting Hand Held Heart Rate Circuit Description The hand held heart rate system is actually a dual system that is it can accept a heart rate signal from either the hand held heart rate contacts on the unit s handlebar or from a Polar heart rate chest strap transmitter The PCA is configured for hand held priority That is if both a chest strap and hand heart rate signal are being received the system will accept the hand held signal and ignore the chest strap signal If a hand held signal is not being received the system will accept the chest strap signal Note There are four typical failure modes for the hand held chest strap heart rate system They are hand held is normal no chest strap reading no hand held reading chest strap normal no hand held or chest strap reading or constant or intermittent readings when neither hand held or chest strap are in use Diagram 6 3 Hand held chest strap heart rate PCA J3 HR Output 5 Vdc 43579 108 or higher Heart Rate PCA Gnd J1 Lower Right Upper Ri
23. e treadmill scans time speed distance and percent of incline Press the INCLINE A key while viewing the electronic console Confirm that the running bed inclines and the incline display increments to 15 as the INCLINE A key is pressed Press the INCLINE Y key while viewing the electronic console Confirm that the running bed returns to a level position and the incline display decrements to 0 as the INCLINE W key is pressed Turn off the treadmill with the circuit breaker then unplug the treadmill from the wall outlet Page 13 C956i C966i Gen 06 Treadmill Procedure 4 1 Calibrating the Incline Motor 1 Setthe treadmill circuit breaker in the off position and unplug the line cord from the wall outlet 2 Remove the hood 3 Place the treadmill on its right side Remove hitch and clevis pins that secure the incline tube to the incline platform See Diagram 4 1 Diagram 4 1 incline 4 Plug the power cord into the wall outlet set the treadmill circuit breaker in the on position If the lift was not set at 0 incline the lift motor 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 ro
24. e necessary power available to operate normally under higher load conditions The lack of available power can cause any number of symptoms ranging from numerous intermittent seemingly inexplicable error conditions poor speed control or tripping the house circuit breaker If any of the above symptoms exist the external A C circuit must be checked and confirmed to be a 20 amp dedicated circuit before troubleshooting the treadmill In addition the A C voltage must be checked Nominal A C operating voltage on 120 Vac circuits is 105 Vac to 120 Vac Nominal A C operating voltage on 240 Vac circuits is 208 Vac to 240 Vac For operator safety considerations and to minimize electrostatic discharge conditions the A C frame ground continuity must also be verified to be a low resistance connection to the A C distribution ground bar Important If the A C circuit feeding a treadmill is found to be a non dedicated circuit or a circuit equipped with a 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 connected to a common neutral ground bar The A C safety ground green wire is connected to
25. ent should be reguired 1 8 to 1 4 turn Increase the treadmill speed to 8 m p h if the belt drifts away from center track it as described in step 16 Increase the treadmill speed to maximum if the belt drifts away from center track it as described in step 18 Set the treadmill at a comfortable running speed and run on the treadmill for a couple of minutes and note the running belt tracking If required track it as described in step 16 Replace the end caps and motor cover removed in step 3 Page 1 56 Page 56 C956i C966i Gen 06 Treadmill Procedure 6 16 Take Up Roller Replacement This procedure is to be used to replace a take up roller while maintaining the running belt s original tension and tracking settings Two running belt gauges Precor part number 20007 101 are reguired Itis important that this procedure be followed to maintain correct running belt tension When tension is removed from the running belt the belt reguires 24 hours for it to relax If tension is removed from the belt and then re tensioned without following this procedure or allowing a 24 hour relaxation period the running belt may be over tensioned Over tensioning the belt will lead to premature running belt wear premature driver roller bearing failure and premature take up roller bearing failure 1 Place two running belt gauges on each side of the running belt being sure that the gauges are not across a belt seam Set the gauges to the 3 mark a
26. ention equipment is not used Attach an anti static wrist strap to your arm then connect the ground lead of the wrist strap to the treadmill s frame ground Remove the eight screws that fasten the display back cover and remove the display back cover Disconnect the data cable 2 CSAFE cables and the heart rate cable from the upper PCA See Diagram 6 9 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 cap The display face snaps 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 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 Disconnect the Metrics cable from the Metrics PCA See Diagram 5 1 The Metrics PCA snaps into the display face Press the Metrics PCA tabs outward and remove the Metrics PCA from the display face Snap the replacement Metrics PCA into its mounting on the display face The red wire in the Metrics cable indicates pin 1 Align the red wire in the Metrics cable with the pin 1 markings on the Metrics PCA Connect the Metrics cable to the Metrics PCA Connect the stop switch cable to upper PCA and snap the displ
27. errors The error messages will list the error name the odometer reading when the error occurred the hour meter when the error occurred and the drive motor current reading when the error occurred If you wish to clear the error log press and hold the QUICK START key The message HOLD TO CLEAR ERRORS will be displayed The error log will be cleared when the message NO ERRORS is displayed Press the RESET key to exit the information display Please note that the ERROR LOG may also be accessed at any time by pressing and holding the RESET key for four seconds If the error log does not contain any errors the message STUCK KEY will be displayed Page 1 8 Page 8 C956i C966i Gen 06 Treadmill Procedure 2 3 Setting Club Parameters This procedure allows you to change the following club settings Safety Code Select Language Select Units Set Max Workout Time Set Max Pause Time Set Cool Down Time Set Speed Limit Set Incline Limit Hidden Programs Remote Speed Control Set Custom Program 1 Set Custom Program 2 Procedure 10 11 12 13 Plug the power cord into the wall outlet then turn on the treadmill with the circuit breaker With the banner scrolling press keys RESET 5 6 5 1 5 6 5 sequentially Use the A Y keys to move to the desired display shown in the list above DIAGS SET CLUB PARAMETERS will scroll across the display SAFETY CODE display The safety code when enab
28. ever if this procedure was carefully followed the belt tracking should be very close Remove both belt gauges from the running belt Start the treadmill and operate it at 2 m p h Observe the running belt If the belt drifts away from its centered position re track it by adjusting the take up roller mounting bolts as described in step 21 If the belt drifts to the right slowly turn the right hand mounting bolt clockwise until the drifting stops If the belt drifts to the left slowly turn the left hand mounting bolt clockwise until the drifting stops Only a very small adjustment should be required 1 8 to 1 4 turn Increase the treadmill speed to 4 m p h if the belt drifts away from center touch up the tracking as described in step 23 If the belt drifts to the right slowly turn the left hand mounting bolt counter clockwise until the drifting stops If the belt drifts to the left slowly turn the right hand mounting bolt counter clockwise until the drifting stops Only a very small adjustment should be required 1 8 to 1 4 turn Increase the treadmill speed to 8 m p h if the belt drifts away from center track it as described in step 21 Increase the treadmill speed to maximum if the belt drifts away from center track it as described in step 23 Set the treadmill at a comfortable running speed and run on the treadmill for a couple of minutes and note the running belt tracking If required track it as described in step 21 If ap
29. f the load being placed on the treadmill Treadmill loading consists of several factors the user s weight treadmill speed treadmill incline setting and the condition of the running belt and running deck condition By making all of the other factors consistent we will be able to determine the relative condition of the running belt and deck combination The A C input current measurements will be performed at 3 m p h 4 8 k p h and 0 incline Because the loading varies with the user s weight you should perform the A C 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 A C 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 A C current pulses The refresh rate on digital ammeters may make it difficult to see the current peaks 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 Circuit Breaker A C Input Module Clamp on Ammeter 2 Setthe treadmill s speed at 3 m p h 4 8 k p h and the incline at 0 Walk on the treadmill and observe the peak A C current reading Typical peak A C current readings on
30. g 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 Thefrequency of occurrence Page 1 12 Page 12 C956i C966i Gen 06 Treadmill Section Three Checking Treadmill Operation This section provides you with a guick method of checking treadmill operation Check treadmill operation at the end of a maintenance procedure and when itis necessary to ensure that the treadmill is operating properly Procedure 1 2 Plug the power cord into the wall outlet then turn on the treadmill with the circuit breaker Operate the treadmill in the Manual program Adjust the speed of the running belt to 2 3 m p h Operate the treadmill for at least 5 minutes a Concentrate on the feel of the running belt and the sound of the drive motor and rollers Be on the alert for unusual noises smells or vibrations b 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 Press the STOP key When the treadmill comes to a stop view the electronic console as th
31. ght Upper Left Lower Left Normal hand held reading No chest strap reading 1 Access the diagnostic program Procedure 3 2 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 known good Polar heart rate chest strap verify that the heart rate operates with the known good chest strap Ifthe known good Polar chest strap does corrects the problem replace the original chest strap transmitter 3 If the above procedures did not correct the problem replace the heart rate PCA Page 1 24 Page 24 C956i C966i Gen 06 Treadmill No hand held reading Normal chest strap reading 4 10 Access the diagnostic program Procedure 3 2 Advance to the heart rate display portion of the diagnostic program Verify that a hand held signal is not being accepted by firmly grasping both the right and left hand held contacts on the handlebars Cover as much ofthe contact surface area with your hands as possible without moving your hands you should receive a heart rate reading within ten seconds If the hand held signal is now being accepted something in the near vicinity is radiating RF radio freguency energy that is being received by the chest strap portion of the heart rate PCA If a hand held signal still not being accepted sk
32. gram 5 3 and 5 4 Remove the four screws that mount the power control module See Diagram 6 3 Diagram 6 3 Power Control Module Mounting Control m Power Module Mounting Screw Set the replacement power control module in its mounting position Fasten the power control module with the four screws removed in step 4 Reconnect the COMM INCLINE INPUT DB and OUTPUT connectors removed in step 3 The mating connectors on the power control module are polarized therefore they can not be reconnected incorrectly Replace the treadmill s hood Thoroughly check the treadmill per Section 3 Page 1 36 Page 36 C956i C966i Gen 06 Treadmill 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 Page 37 C956i C966i Gen 06 Treadmill Procedure 6 5 Replacing the Circuit Breaker 1 Set the treadmill ci
33. 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 Insert the incline motor connector in the INCLINE connector on the power control module 10 Check treadmill operation per Procedure 3 Page 33 C956i C966i Gen 06 Treadmill Procedure 6 2 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 4 1 4 Remove t
34. h hot leads must be removed from treadmill s A C outlet and two new hot leads from the treadmill s A C outlet to the circuit breaker must be added A licensed electrician may use the followings hints to determine if an A C service is dedicated 1 If ona 120 Vac system the A C distribution panel contains more circuit breakers than neutral leads the system has shared neutral leads and is not dedicated 2 Ifan A C outlet 120 or 240 Vac has multiple hot and or neutral leads it is not a dedicated If either of the above conditions exist the system is not dedicated However absence of the above conditions does not necessarily mean that the system is dedicated If any doubt exists about A C systems dedication point to point tracing of the A C wiring may be the only way to prove system dedication Page 1 28 Page 28 C956i C966i Gen 06 Treadmill Procedure 5 5 Troubleshooting the 3 Phase AC Drive Motor System Circuit Description The power control module converts single phase 120Vac or 240Vac into three phase variable freguency current for the AC drive motor The motor speed is controlled by controlling the freguency ofthe drive motor current 1 When taking voltage readings of the AC drive motor current the readings will not be accurate because of the freguencies being used however they are indicative of the presence of drive motor voltage and relative freguency changes 2 Ifthe symptoms are the drive motor starts
35. he two large 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 Mounting Pin Hitch Pin Incline Platform M Sey UR BROT YW W AL EE 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 the incline mounting pin with the keyway in the frame and slide the incline mounting pins into place See Diagram 6 2 Fasten the incline mounting pins with the hitch pins removed in step 4 7 Ifthe incline tube or the incline motor s drive screw have been moved re calibrate the incline motor per Procedure 4 1 at this time Page 1 34 Page 34 C956i C966i Gen 06 Treadmill 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 Page 35 C956i C966i Gen 06 Treadmill Procedure 6 3 Replacing the Power Control Module 4 Set the treadmill s on off switch in the off position and remove the AC line cord from the AC outlet Remove the treadmill s hood Disconnect the COMM INCLINE INPUT DB and OUTPUT connectors from the power control module See Dia
36. ile maintaining the drive belt s original tensioning and setting the running belt s tension and tracking Two running belt gauges Precor part number 20007 101 are reguired It is important that this procedure be followed to maintain correct drive belt and running belt tension Over tensioning the belt will lead to premature running belt wear premature driver roller bearing failure and premature take up roller bearing failure This procedure addresses decks that can be flipped however it is important to note that only double sided decks can be flipped Single sided decks must be replaced 19 Remove the end caps from the rear of treadmill to expose the take up roller mounting bolts Remove the treadmill s motor cover 20 If applicable remove the finger guard from in front of the take up roller 21 Remove both take up roller mounting bolts Remove the take up roller from the treadmill Take Up Roller Mounting Bolt 22 Slowly rotate the drive motor flywheel while pressing the drive belt off of the drive roller pulley Continue until the drive belt walks completely off of the drive roller pulley Drive Belt Mark Bolt Here Drive Roller Pulley 23 Using a fine tip marker or scribe place a mark on the right hand drive roller mounting bolt directly in front of the drive roller shaft The bolt is being marked so that the drive roller can be returned to the exact same position The use of a fine marking line allows for more
37. ip to step 8 Replace the heart rate PCA with a 43579 108 or higher heart rate PCA 43579 108 and higher versions of heart rate PCA are less susceptible to radiated RF energy Access the diagnostic program Procedure 3 2 Advance to the heart rate display portion of the diagnostic program Verify that a hand held signal is not being accepted by firmly grasping both the right and left hand held contacts with the opposite hands right hand on the left handlebar contacts and left hand on the right handlebar contacts Cover as much ofthe contact surface area with your hands as possible you should receive a heart rate reading within ten seconds If a hand held signal is still not being accepted skip to step 10 If a hand held signal was accepted in step 11 the hand held contact wiring is reversed The end ofthe wire harness that connects to the hand held contacts in the handlebar is segregated into two groups One group has blue shrink wrap around it and the other group has black shrink wrap around it The blue group must go to the right hand contacts and the black group must go 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 4 If the wiring is correct refer to Diagram 6 3 for the following measurements With an ohmmeter measure between the lower right cont
38. l 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 Disconnect the Metrics cable D pad cable and the keypad cable from the upper PCA See Diagram 5 1 The upper PCA snaps into the display face Press the upper PCA tabs outward and remove the upper PCA from the display face Snap the replacement upper PCA into its mounting on the display face 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 Connect the stop switch cable to upper PCA and snap the display face into place on the display Reconnect the data cable two CSAFE cables and the HR cable to the upper PCA as shown in Diagram 6 9 Snap the HR PCA into its mounting See Diagram 6 9 Snap the display cap into place on the display Replace the display back cover with the hardware removed in step 3 Check treadmill operation per Section 3 Page 1 46 Page 46 C956i C966i Gen 06 Treadmill Procedure 6 11 Replacing the Metrics PCA 10 11 12 13 14 15 Set the treadmill circuit breaker in the off position and unplug the treadmill s line cord from the AC oullet The PCA s in the display are static sensitive They can be damaged if proper static prev
39. led makes the user enter a password in order to start the treadmill Press the OK key Use the A Y keys to toggle between ENABLED and DISABLED Press the BACK key to exit the safety code display SELECT LANGUAGE display Press the OK key Use the A Y keys to toggle between the available languages Press the BACK key to exit the select language display SELECT UNITS display Press the OK key Use the A Y keys to toggle between U S miles per hour and METRIC kilometers per hour Press the BACK key to exit the set units display Page 9 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 C956i C966i Gen 06 Treadmill SET MAX WORKOUT TIME display Press the OK key Use the A Y keys to select the maximum time a user can remain in a program Press the BACK key to exit the set max workout time display SET MAX PAUSE TIME display Press the OK key Use the A Y keys to select the maximum time a program will remain in the pause mode Press the BACK key to exit the set max pause time display SET COOL DOWN TIME display Press the OK key Use the A Y keys to select the cool down time Press the BACK key to exit the set cool down time display SET SPEED LIMIT display Press the OK key Use the A Y keys to select the maximum allowable treadmill speed Press the BACK key to exit the set speed limit time display SET INCLINE LIMIT displ
40. ly into the input module Set the AC line cord clamp in its mounting position and fasten it with the hardware removed in step 5 Set the input panel in its mounting position and fasten it with the hardware removed in step 3 Check treadmill operation per Section 3 Page 1 42 Page 42 C956i C966i Gen 06 Treadmill Procedure 6 9 Replacing the End Cap or Belt Guard 1 Set the treadmill circuit breaker in the off position and unplug the treadmill s line cord from the AC outlet 2 Remove the four screws 2 lower screws each side that retain the end cap Do Not loosen or move the take up roller mounting adjustment bolts Doing so will change the running belt s tension and alignment See Diagram 6 7 Diagram 6 7 End Cap Mounting Take up Roller Mtg Adj Bolt End Cap Bolts 3 Slide the end cap off of the treadmill 4 Ifyou 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 engage in both take up roller mounts 8 Slide the end cap into place so that the tabs on the end cap engage in the notches in the running belt trim strips See Diagram 6 8 9 Fasten the end cap with the hardware removed
41. n the replacement display face Page 1 52 Page 52 15 16 17 18 19 20 21 22 23 24 25 C956i C966i Gen 06 Treadmill 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 Snap the Metrics PCA into its mounting on the replacement display face The red wire in the Metrics cable indicates pin 1 Align the red wire in the Metrics cable with the pin 1 markings on the Metrics PCA Connect the Metrics cable to the Metrics PCA With the D pad assembly oriented 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 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 Connect the stop switch cable to upper PCA and snap the display face into place on the display Reconnect the data cable two CSAFE cables and the HR cable to the upper PCA as shown in Diagram 6 9 Snap the HR PCA into its mounting See Diagram 6 9 Snap the display cap into place on the display Replace the display back cover with the hardware removed in step 3 Check treadmill operation per Section 3 Page 53 C956i C966i Gen 06 Treadmill Procedure 6 15 Drive R
42. oller Replacement This procedure is to be used to replace a drive roller while maintaining the drive belt s original tensioning and the running belt s original tension and tracking settings Two running belt gauges Precor part number 20007 101 are required It is important that this procedure be followed to maintain correct drive belt and running belt tension When tension is removed from the running belt the belt reguires 24 hours for it to relax If tension is removed from the belt and then re tensioned without following this procedure or allowing a 24 hour relaxation period the running belt may be over tensioned Over tensioning the belt will lead to premature running belt wear premature driver roller bearing failure and premature take up roller bearing failure 1 Place two running belt gauges on each side of the running belt being sure that the gauges are not across a belt seam Set the gauges to the 3 mark as shown in the Illustration below 2 Once set the belt gauges can not be disturbed or moved doing so will invalidate the tension settings and necessitate a 24 hour relaxation period before the running belt can be re tensioned 3 Remove the end caps from the rear of treadmill to expose the take up roller mounting bolts Remove the treadmill s motor cover 4 Loosen but do not remove the take up roller mounting bolts The bolts are being loosened to remove tension from the running belt Take Up Roller Mounting Bol
43. oot software is used to upload new software into the upper display PCA Press the OK key The software part number will be displayed as XXXXX XXX Page 7 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 C956i C966i Gen 06 Treadmill Press the BACK key to exit the U Boot SW display U BASE SW display This display the installed version of upper PCA software Press the OK key The software part number will be displayed as XXXXX XXX Press the BACK key to exit the U Base SW display LOWER SW display This display the installed version of lower PCA software Press the OK key The software part number will be displayed as XXXXX XXX Press the BACK key to exit the lower SW display SER NUMBER display Press the OK key The treadmill s serial number will be displayed The serial number may be incorrect or not displayed if the upper PCA has been replaced Press the BACK key to exit the serial number display USAGE LOG display Press the OK key Use the A Y keys to move through the list of programs A message will scroll describing the program the number of times and the number of minutes the program was used Press the BACK key to exit the usage log display ERROR LOG display Press the OK key the quantity of errors in the log will be displayed Press the OK key the most recent error will be displayed first Use the A Y keys to move through the list of
44. per PCA If you have performed steps 23 26 and the STUCK KEY message is still being displayed contact Precor customer support for assistance Page 1 20 Page 20 C956i C966i Gen 06 Treadmill Procedure 5 2 Troubleshooting the Incline System Incline System Description The incline system on these units consists of an AC line voltage driven incline motor 120 Vac or 240 Vac and an internal 1 KQ potentiometer for incline position identification The incline motor contains two motor windings one to operate the motor in an upward direction and the other to operate the motor in a downward direction As the incline motor is operated the motor also rotates the potentiometer via an internal gear system Therefore the position of the incline system can be determined by monitoring the value of the internal potentiometer The incline motor is initially set at a Known starting position calibration See Procedure 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 step 2 2 Set the treadmill s on off switch in the on position Diagram 5 3 Power Control Module
45. plicable replace the finger guard removed in step 2 Replace the end caps and motor cover removed in step 1 Page 61 C956i C966i Gen 06 Treadmill Wiring Diagram 7 1 C956i C966i 120 Vac G Y O Input O IModule BR METRICS PCA J1 Circuit Q D PAD a E PCA BR J1 J4 Breaker Module Incline G Y Motor Page 1 62 Page 62 C956i C966i Gen 06 Treadmill Block Diagram 7 2 C956i C966i 120 Vac ug 100W OV li gt H y VOd Soe Lipea4 ILA OCL 19969 25 6 19569 4369 1f dNI 5 ug a du e 02 OVA 1231 0zl eur LNdLNO aINPOIN 013409 19MOd SNITONI al s EL 11 131 z gt k g 3 a Q a e 3 2 g Jaddn Aua USE VIdN rir Eur EH Lu VOd r ag UESL puo ag aaoy OT D n Page 63 C956i C966i Gen 06 Treadmill Wiring Diagram 7 3 C956i C966i 240 Vac Gly Input Module METRICS B t hs e PGA R BL J 1 A Circuit Breaker D PAD J1 CA O P in Gly a O Line Filter 8 e J15 J13 J17 J14 Gr ml a EJ me on 1000 50W BK j Incline BR T84 motor kal DR _ R Drive w we 6 Page 1 64 Page 64 C956i C966i Gen 06 Treadmill yg Ma sk LAdNI Ta a GI OVA a NP 02 Oz aur CES LNdLAO M _ _ Ionuoo y JeMOd WER ul 9ul ML H 3NI1ONI z e 2 et EL J EI tel del TE ST TEL TEI TE sl FL TL J VOd Ped d GINO Ad rir tw EH LH VOd yams dois H op
46. rcuit 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 fastens the AC input 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 AC Input Panel AC Line Filter Input Module Circuit Breaker 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 Circuit Breaker Hardware Clamp Hardware Input Module Hardware Page 1 38 Page 38 10 11 C956i C966i Gen 06 Treadmill Remove the two screws retaining the circuit breaker and remove the circuit breaker 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 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
47. recor dealer website at www precor com connection Page 1 4 Page 4 C956i C966i Gen 06 Treadmill Procedure 2 1 Accessing the Diagnostic Software The treadmill s diagnostic software consists of the following modes Display Test Keyboard Test Heart Rate Test 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 Back Key OK Key Reset Key Page 5 10 11 12 13 14 15 16 17 18 C956i C966i Gen 06 Treadmill Press the OK key the upper most group of LED s will iluminate on the display Check the display to ensure that all LED segments are illuminated Press the OK key four more times to display the remaining LED groups Check each display group to ensure that all LED segments are illuminated Press the BACK key then the Y key KEYBOARD TEST will scroll across the display Press the OK key a representation of all of the keys on the console will be displayed Pressing a key on the console will cause the representation of that key to go off Press all of the keys on the console to ensure that all of the keys are functioning Press and hold
48. rom J4 ofthe heart rate PCA Measure between the ground and 5 Vdc pins of the connector just removed from the heart rate PCA for 5 Vdc If 5 Vdc is present replace the heart rate PCA If the 5 Vdc is not present measure between the corresponding pins of J1 on the upper PCA red and black wires If 5 Vdc is not present replace the upper PCA If 5 Vdc is present replace the upper PCA to heart rate PCA cable Constant or intermittent readings when neither the hand held or chest strap is in use 15 16 17 Page 1 26 Verify that a ferrite core is clamped around the heart rate PCA to upper PCA cable 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 Replace the heart rate PCA with a 43579 108 or higher heart rate PCA 43579 108 and higher versions of heart rate PCA are less susceptible to radiated RF energy Page 26 C956i C966i Gen 06 Treadmill Procedure 5 4 Troubleshooting the External A C Power Source It is extremely important that any Precor treadmill be connected to and operated on a dedicated 20 amp A C circuit A 20 amp dedicated circuit is defined as a circuit fed by a 20 amp circuit breaker that feeds a single load A treadmill operating from a non dedicated circuit or a circuit breaker of less than 20 amps capacity will not have th
49. s Read this section as well as the C956i C966i Treadmill Owners Manual before you perform the maintenance procedures in this manual Section Two Software Features Precor s C956i C966i Treadmills are programmed with several diagnostic and setup features This section contains the procedures you need to access the diagnostic features on this treadmill Section Three Checking Treadmill Operation This section provides you with a quick way of checking treadmill operation Check treadmill operation at the end of a maintenance procedure and when it is necessary to ensure that the treadmill is operating properly Section Four Inspection and Adjustment Procedures Perform inspection procedures when a trouble symptom points to a particular problem and after removing and replacing major components Many maintenance problems can be fixed by adjusting various treadmill components This section also provides you with the step by step procedures required to make these adjustments Section Five Troubleshooting Procedures The diagnostic and troubleshooting procedures contained in this section should be performed when it is necessary to isolate a problem to a particular component Section Six Replacement Procedures When a treadmill component must be replaced go to this section and follow the step by step procedures required to remove and replace the component Section Seven Technical Diagrams and Parts Lists This section includes wiring diagrams
50. s line cord from the AC outlet 2 The PCA s in the display are static sensitive They can be damaged if proper static prevention equipment is not used Attach an anti static wrist strap to your arm then connect the ground lead of the wrist strap to the treadmill s frame ground 3 Remove the 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 Connect the handlebar cable to the upper connector on the HR PCA and the HR cable to the lower connector on the HR PCA See Diagram 6 9 8 Replace the display back cover with the hardware removed in step 3 9 Check treadmill operation per Section 3 Page 51 C956i C966i Gen 06 Treadmill Procedure 6 14 Replacing the Display Face 10 11 12 13 14 Set the treadmill circuit breaker in the off position and unplug the treadmill s line cord from the AC oullet The PCA s in the display are static sensitive They can be damaged if proper static prevention equipment is not used Attach an anti static wrist strap to your arm then connect the ground lead of the wrist strap to the treadmill s frame ground Remove the
51. s shown in the Illustration below 2 Once set the belt gauges can not be disturbed or moved doing so will invalidate the tension settings and necessitate a 24 hour relaxation period before the running belt can be re tensioned 3 Remove the end caps from the rear of treadmill to expose the take up roller mounting bolts 4 If applicable remove the finger guard located in front of take up roller 5 Remove both take up roller mounting bolts The belt gauge readings will decrease as the take up roller mounting bolts are removed Remove the take up roller from the treadmill Take Up Roller Mounting Bolt Page 57 10 11 12 13 14 15 16 17 18 C956i C966i Gen 06 Treadmill Slide the replacement take up roller into the running belt and set it in its mounting position Hand start both take up roller mounting bolts that were removed in step 5 Alternate tightening the two take up roller mounting bolts in order to tighten both ends evenly until both running belt gauges again read exactly 3 When both gauges again read 3 the belt is at its original tension It will now be necessary to touch up the running belt tracking however if this procedure was carefully followed the belt tracking should be very close Remove both belt gauges from the running belt Start the treadmill and operate it at 2 m p h Observe the running belt If the belt drifts away from its centered position re track it by adjus
52. t Page 1 54 Page 54 C956i C966i Gen 06 Treadmill 5 Slowly rotate the drive motor flywheel while pressing the drive belt off of the drive roller pulley Continue until the drive belt walks completely off of the drive roller pulley 1 i Drive Belt Mark Bolt Here Drive Roller Pulley 6 Using a fine tip marker or scribe place a mark on the right hand drive roller mounting bolt directly in front of the drive roller shaft The bolt is being marked so that the drive roller can be returned to the exact same position The use of a fine marking line allows for more accuracy when the replacement drive roller is installed 7 Remove both drive roller mounting bolts Remove the drive roller from the treadmill 8 Slide the replacement drive roller into running belt and into the drive belt Hand start both drive roller mounting bolts 9 Tighten the left hand drive roller bolt fully The left hand side of the drive roller should be as far forward as possible 10 Tighten the right hand drive roller bolt until the mark placed on it in step 6 aligns with the front edge of the drive roller shaft Steps 8 and 9 should place the drive roller into its original position and should now be square to the treadmill frame 11 Slowly rotate the drive motor flywheel while pressing the drive belt onto of the drive roller pulley Continue until the drive belt walks completely onto the drive roller pulley Be sure that the drive bel
53. t is fully onto and correctly aligned on the drive roller pulley 12 Alternate tightening the two take up roller mounting bolts in order to tighten both ends evenly until both running belt gauges again read exactly 3 13 When both gauges again read 3 the belt is at its original tension It will now be necessary to touch up the running belt tracking however if this procedure was carefully followed the belt tracking should be very close 14 Remove both belt gauges from the running belt 15 Start the treadmill and operate it at 2 m p h Observe the running belt If the belt drifts away from its centered position re track it by adjusting the take up roller mounting bolts as described in step 16 Page 55 16 17 18 19 20 21 C956i C966i Gen 06 Treadmill If the belt drifts to the right slowly turn the right hand mounting bolt clockwise until the drifting stops If the belt drifts to the left slowly turn the left hand mounting bolt clockwise until the drifting stops Only a very small adjustment should be required 1 8 to 1 4 turn Increase the treadmill speed to 4 m p h if the belt drifts away from center touch up the tracking as described in step 18 If the belt drifts to the right slowly turn the left hand mounting bolt counter clockwise until the drifting stops If the belt drifts to the left slowly turn the right hand mounting bolt counter clockwise until the drifting stops Only a very small adjustm
54. tated return to step 4 and repeat steps 4 and 5 6 Set the treadmill circuit breaker in the off position and remove the line cord from the wall outlet 7 Replace the clevis and hitch pins removed in step 3 Return the treadmill to an upright position 8 Plug the line cord into the wall outlet set the treadmill circuit breaker in the on position Page 1 14 Page 14 C956i C966i Gen 06 Treadmill 9 Check the calibration of the incline system by performing the following steps a Press the INCLINE A key until maximum incline is obtained 15 b Press the INCLINE Y key to minimum incline is obtained 0 on C956i treadmills or 3 on C966i treadmills 12 Re install the hood Page 15 C956i C966i Gen 06 Treadmill Procedure 4 2 Adjusting Drive Belt Tension 1 Set the treadmill circuit breaker in the off position and unplug the line cord from the wall outlet 2 Remove the hood 3 Place the drive belt tension gauge on the drive belt as shown in Diagram 4 2 Diagram 4 2 Drive Belt Tension Gauge P GE 4 The gauge should read approximately 80 inch pounds The drive belt tension is acceptable ifitis in the range of 70 to 90 inch pounds 5 Ifthe 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 rear
55. the BACK key then the Y key HEART RATE will be displayed Grasp both of the heart rate grips on the handlebar after a couple of seconds the heart rate will be displayed in the heart rate and smart rate displays Use chest strap transmitter or a test transmitter to test the wireless heart rate function after a couple of seconds the heart rate will be displayed in the heart rate and smart rate displays Press the BACK key then the Y key MACHINE TEST will scroll across the display You may now proceed to either the belt speed test or the incline test Press the Y key once to access the belt speed test or twice to access the incline test BELT SPEED test Press the OK key the console will display the power bits PWRB Press the SPEED A key to start the treadmill running belt the display will indicate the power bits the elapsed time and the actual speed in either miles per hour or kilometers per hour depending on the club parameters setting see Procedure 2 3 Press the Y key the console will display the motor current AMPS the elapsed time and the actual speed Press the BACK key to exit the belt speed test INCLINE test The console will display the analog to digital A D incline position number and the incline position in percent of incline Press the inline 4 Y keys to operate the incline through out its range Press the BACK key to exit the incline test Press the RESET key to exit the hardware validation test Page 1 6 P
56. 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 Set the input panel in its mounting position and fasten it with the hardware removed in step 3 Thoroughly check the treadmill per Section 3 Page 39 C956i C966i Gen 06 Treadmill Procedure 6 6 Replacing the Line Filter 10 11 12 Set the treadmill circuit breaker in the off position and unplug the treadmill s line cord from the AC oullet Remove the treadmill s hood Remove the two screws that fastens the AC input panel to the frame See Diagram 6 4 Disconnect the wiring from the AC line filter 2 blue wires 2 brown wires and a green yellow wire Lift the AC input panel from the frame and rotate it to expose the AC line filter mounting screws See Diagram 6 5 Remove the screws that retain the AC line filter Remove the AC line filter Set the replacement AC line filter in its mounting position with the side with three terminal facing the circuit breaker 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
57. 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 If you have performed steps 12 16 and the upper PCA still does not illuminate contact Precor customer support for assistance Set the treadmill s on off switch in the on position If none of the keys on the display are functioning check the stop switch cable connection to the upper PCA If the stop switch is not connected or the stop switch is not functioning none of the display keys will operate This feature insures that the treadmill has a functioning stop switch when it is in use If a particular key is not functioning perform the keyboard test in Procedure 2 1 If the test verifies that the key is not functioning replace the display face Page 19 21 22 23 24 25 26 21 C956i C966i Gen 06 Treadmill If the display face has been replaced and the same key is still not functioning replace the upper PCA If you have performed steps 18 22 and the same key is still not functioning contact Precor customer support for assistance Remove the keypad cable from the upper PCA See Diagram 5 1 Set the treadmill s on off switch in the on position If the STUCK KEY message is no longer displayed replace the display face If the STUCK KEY is still being displayed with the keyboard cable disconnected replace the up
58. ting the take up roller mounting bolts as described in step 11 If the belt drifts to the right slowly turn the right hand mounting bolt clockwise until the drifting stops If the belt drifts to the left slowly turn the left hand mounting bolt clockwise until the drifting stops Only a very small adjustment should be required 1 8 to 1 4 turn Increase the treadmill speed to 4 m p h if the belt drifts away from center touch up the tracking as described in step 13 If the belt drifts to the right slowly turn the left hand mounting bolt counter clockwise until the drifting stops If the belt drifts to the left slowly turn the right hand mounting bolt counter clockwise until the drifting stops Only a very small adjustment should be required 1 8 to 1 4 turn Increase the treadmill speed to 8 m p h if the belt drifts away from center track it as described in step 11 Increase the treadmill speed to maximum if the belt drifts away from center track it as described in step 13 Set the treadmill at a comfortable running speed and run on the treadmill for a couple of minutes and note the running belt tracking If required track it as described in step 11 If applicable replace the finger guard removed in step 4 Replace the end caps removed in step 3 Page 1 58 Page 58 C956i C966i Gen 06 Treadmill Procedure 6 17 Running Belt and or Deck Replacement This procedure is to be used to replace the running belt and or deck wh
59. wards as reguired until the belt gauge reads approximately 80 inch pounds and tighten the four drive motor mounting bolts See Diagram 4 3 Momentarily remove the drive belt tension gauge from the drive belt Replace the drive belt tension gauge on the drive belt and re adjust the drive belt tension if necessary Torgue the four drive motor mounting bolts to 204 inch pounds 17 foot pounds Page 1 16 Page 16 C956i C966i Gen 06 Treadmill 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 17 C956i C966i Gen 06 Treadmill Procedure 5 1 Troubleshooting the Keypad and Upper PCA Procedure Note The red wire on the cables shown in Diagram 5 1 denotes pin 1 When these cables are inserted into their connectors the red wire must align with the pin 1 designation on the PCA 1 Setthe treadmill s on off switch in the off position Remove the display back plate and display face per Procedure 6 10 2 Ifthe message STUCK KEY is displayed when the treadmill is turned on skip to step 23 3 Ifa key does not function skip to step 18 4 Ifthe display does not illuminate continue with step 5 Diagram 5 1 Display Face Rear View J4 Entertainment Connector J1 ISP Connector Upper PCA Keypad Cable D Pad Cable Stop Switch Connector
60. when you force the running belt to move and once running the drive motor runs rough skip to step 10 If the drive motor will not start continue with step 3 3 Ifthe drive motor does not start the power 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 4 Connect an AC voltmeter between terminals 4 amp 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 between terminals 4 amp 6 of the OUTPUT connector on the power control module 6 Repeat the procedure in step 4 between terminals 5 amp 6 of the OUTPUT connector on the power control module 7 If one or more of voltage readings in steps 4 through 6 are not present replace the power control module If the voltage readings in steps 4 through 6 are present continue with step 8 8 Set the treadmill s on off switch in the off position Disconnect the drive motor connector from the OUTPUT connector on the power control module With an ohmmeter measure between terminals 4

Service Manual, C956i, C966i (Gen 06) Treadmill.fm

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