Precor ENERGY SERIES User manual

© 2014 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law Page 1 of 56
Service Manual
Energy Series Treadmill
TRM 223 TRM243

Page 2 of 56
©2014 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law
Table of Contents
About This Document......................................................................................................................................5
GeneralInformation ........................................................................................................................................7
Service Calls.............................................................................................................................................7
Contact Information ................................................................................................................................7
Lubricants................................................................................................................................................7
Power Requirements ...............................................................................................................................7
Operation Verification Test..............................................................................................................................9
Procedure................................................................................................................................................9
Standard Service and Diagnostics Software ...................................................................................................11
Service Access Codes.................................................................................................................................11
How to Access the Service and Diagnostic Menus ......................................................................................11
R40 Console: How to access the service and diagnostic menus ..............................................................11
R20 Console: How to access the service and diagnostic menus ..............................................................12
Hardware Validation Diagnostic Tests (51765761) .....................................................................................13
R40 Console Hardware Validation Diagnostic Tests:...............................................................................13
R20 Console Hardware Validation Diagnostic Tests:...............................................................................13
Information Display (Access Code 65)........................................................................................................14
R40 console: Information Display...........................................................................................................14
R20 console: Information Display (65)....................................................................................................15
Adjustment Procedures.................................................................................................................................17
Calibrating the Lift Motor ..........................................................................................................................17
Drive Belt Tension Adjustment...................................................................................................................18
Running Belt Tension Adjustment ..............................................................................................................19
Replacement Procedures...............................................................................................................................21
Replacing the Lift Motor ............................................................................................................................21
Procedure..............................................................................................................................................21
Replacing the Incline Platform ...................................................................................................................23
Procedure..............................................................................................................................................23
Replacing the Lower PCA...........................................................................................................................23
Procedure..............................................................................................................................................23
Replacing the Speed Sensor.......................................................................................................................26

© 2014 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law Page 3 of 56
Procedure..............................................................................................................................................26
Replacing the Drive Motor.........................................................................................................................26
Procedure..............................................................................................................................................26
Replacing the Drive Motor Brushes ............................................................................................................27
Drive Roller Replacement...........................................................................................................................28
Take Up Roller Replacement.......................................................................................................................30
Running Belt and/or Deck Replacement .....................................................................................................31
Replacing the Data Cable............................................................................................................................32
Procedure..............................................................................................................................................32
Troubleshooting............................................................................................................................................33
Error Log....................................................................................................................................................33
R40 error Log Information .........................................................................................................................33
Accessing the Error Log..........................................................................................................................33
Clearing the Error Log ............................................................................................................................33
R20 Error Log Information .........................................................................................................................34
Accessing the Error Log..........................................................................................................................34
Clearing the Error Log ............................................................................................................................35
Understanding Error Codes........................................................................................................................35
Non-Fatal Error Codes............................................................................................................................35
Fatal Error Codes ...................................................................................................................................35
Troubleshooting the LiftSystem.................................................................................................................36
Troubleshooting the Speed Sensor .............................................................................................................39
Troubleshooting the External A.C. Power Source........................................................................................40
Troubleshooting Heart Rate .......................................................................................................................41
Troubleshooting Running Belt & Deck.........................................................................................................43
Preventative Maintenance ............................................................................................................................46
Inspection..................................................................................................................................................46
Cleaning the Equipment.........................................................................................................................46
Treadmill Deck and Running Belt Cleaning .................................................................................................47
Exploded View Diagram.................................................................................................................................49
Parts List........................................................................................................................................................53
System Functional Diagram ...........................................................................................................................56

Page 4 of 56
©2014 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law

© 2014 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law Page 5 of 56
About This Document
Manual Part Number 20081-118 rev 04
Warning:
This service manual is for use by Precor trained service providers only. If you are
not a Precor certified servicer, you should not attempt to service any Precor
products. Call your dealer for service.
This document contains information required to perform the majority of troubleshooting, and
replacement procedures required to repair and maintain the following TRM 200-14 series
treadmill configurations:
Model
Base
Console
TRM 243
TRM 200-
14
R40
TRM 223
TRM 200-
14
R20
This document does not provide service information for the R20 and R40 consoles. For
console service information, refer to the respective R20 or R40 service manuals.
Note:
For console service information, refer to the respective R20 or R40 console
service manual.
Consoles

Page 6 of 56
©2014 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law

© 2014 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law Page 7 of 56
General Information
Service Calls
Before calling the Precor service center for troubleshooting assistance, gather and record the
following information.
•Model and serial number. Provide the model number as accessed in Procedure 2.2.
•Upper and Lower program version running when the problem occurred
•A description of event circumstances:
oWhat happened or failed to happen.
oThe action taken by the user just before the problem occurred.
oProblem-related information (such as how far into the program the problem
occurred, the work level being used when the problem occurred, etc.).
•The frequency of occurrence.
Contact Information
Precor Incorporated
20031 142nd Ave. NE
P.O.Box 7202
Woodinville, WA. 98072-4002
1-800-347-4404
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 warranty.
•Mobil 1, NLGI 2 Teflon Synthetic Grease
•Super Lube Gel with Teflon by Permatex
CAUTION: Do not apply any lubricants to the deck and belt. Do not use Wax Blast, silicon
sprays, or other applied lubricants. The use of these lubricants will quickly degrade the low-
friction surface of the deck.
CAUTION: Do not use petroleum based lubricants on mechanical components such as the lift,
as this may result in degradation of nylon gearing mechanisms. Use only synthetic lubricants
such as "Super Lube with Teflon" or "Mobile One Synthetic" grease (RED).
Power Requirements
Input Power Requirements
U.S. 120 V Units: 120v, 60 Hz, 15A Dedicated branch circuit
.Facility Input Power Requirements
Each treadmill must be connected to a dedicated, grounded circuit. A 15 amp dedicated circuit is
required, but a 20 amp dedicated circuit is recommended. The power outlet must have the same
configuration as the plug. No adapter should be used with this product.

Page 8 of 56
©2014 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law
Grounding Instructions
The unit is equipped with a power cord having an equipment-grounding conductor and a
grounding plug. The plug must be inserted into an outlet that is properly installed and
grounded in accordance with all local codes and ordinances. Failure to properly ground the
treadmill could void the Precor Limited Warranty.

© 2014 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law Page 9 of 56
Operation Verification Test
The Operation Verify Test procedure is used to verify normal operation of the machine.
Perform these operation verification tests at the end of a maintenance procedure or any time it
is necessary to ensure that the treadmill is operating properly.
Note:
This procedure cannot be performed when there is an active fatal error code. Repair
and reset any fatal error code condition before performing this procedure.
Procedure
1. Plug in the power cord and set the treadmill ON/OFF breaker switch to ON.
2. Verify successful power up.
A successful power up will open to the default Welcome screen.
Note:
If the console powers up showing an error code, cycle power to reset the
Error Code. If the error code cannot be cleared, you will need to resolve the
error before continuing with this operation verification tests
Note: If this is the initial power up, the console will open to the console setup screen. Follow
prompts to set up and configure the console (refer to the Owner’s manual).
3. Verify that there are no active Error Codes.
a. First fix any error codes that are shown at power up.
b. Then open the Error Log (refer to the Error Log section) and make sure that
there are no active error codes. Resolve any active error codes and clear the
Error Log before continuing.
4. Access the Diagnostics service menu (51765761) and perform the following
Hardware Validation system tests the R20 or R40 console (refer to the Standard
Service and Diagnostics Software “Performing System Tests”section):
5. R40 Console: Perform the following R40 diagnostic tests:
•Use the UP/DOWN arrow softkeys to scroll and browse tests.
•Press the Test softkey to start a test and then follow prompts to run the test.
•Press the Home softkey to exit the Diagnostics menu.
Test
Description
Display GUI/Metric
Test
Backlight brightness is varied and cycles thru
numbers.
Key Test
Tests the function keys.
Heart Rate Test
Test the heart rate and SmartRate functions, the
heart rate is acquired and shown.
Belt Speed Test
Select the SPEED control to vary the running belt
speed from 0.5 mph to 12.0 mph in 0.1 increments.
Incline Test
Select the INCLINE control to raise and lower the
deck. The incline A/D value is shown and verified at
the following incline settings:
•37 ±5 @ 0% incline

Page 10 of 56
©2014 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law
•120 ±5 @ 5.5 % incline
•242 ±5 @15% incline
6. R20 Console: R20 Console: Perform the following R40 diagnostic tests:
•Use the left/right arrow hardkeys to scroll and browse the test menu.
•Press GO to start a test.
•Use the WORKOUTS key as a BACK key to exit a test.
Test
Description
Heart Rate Test
Test the heart rate and SmartRate functions, the heart rate is
acquired and shown.
Beeper Test
Test the beeper sound.
Keypad Test
A map of the User keypad and Machine controls are shown on the
upper text window. Press a key and the corresponding LCD key light
will turn off.
To exit, press and hold the WORKOUTS key.
LCD Test
Cycles thru all the different functional areas of the LCD upper text
window and control indicators.
Machine Tests:
Performs tests to verify the Speed and Incline operation.
•Belt Test
The Belt test uses the SPEED controls and running belt operation.
•Incline Test
The Incline test uses the INCLINE controls to verify ramp operation
at 0.5 % increments.
Stop Key Test
Tests the press STOP key and the pull lanyard to remove STOP key
functions:
Both stop key operations will immediately slow and stop the running
belt.
Follow prompts to complete test.
7. From the Home screen, press the “QuickStart” softkey and verify SPEED and INCLINE
operation:
a. Adjust the SPEED from minimum to maximum range. Verify the belt operation is
normal (smooth, no unusual noises, etc.) and that the tracking remains centered.
Make sure the SPEED indicator is correctly displaying the belt speed. Reset the speed
to 0 mph (kph).
b. Adjust the INCLINE from minimum to maximum range. Verify the ramp incline
operation s normal (smooth, no glitches) and that the console INCLINE indicator is
displaying the correct incline level. Reset the incline level to 0 %.
8. Press QuickStart to start the belt, then press the STOP button. Verify that the running belt
immediately slows and stops.
9. Press QuickStart to start the belt, then use the Lanyard to pull the STOP button off the STOP
switch assembly. Verify that the running belt immediately slows and stops.
10. Go to the ERROR LOG and verify that no new error code events have occurred during these
tests (refer to the Error Log section). Resolve any new error codes and repeat the Operation
Verification procedure.

© 2014 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law Page 11 of 56
Standard Service and Diagnostics Software
Service Access Codes
Service Menu
Description
Access
Code
Hardware
Validation
Diagnostics
Set of system diagnostic tests that verify proper
operation of console and base functionality. Useful
for troubleshooting and resolving problems.
51765761
(536**)
Information
Display
Provides 1) Information page; provides product
software/hardware version and equipment usage
information and 2) Display Error Log; provides
history of event error codes and diagnostics used
for maintenance and troubleshooting.
65
My Settings*
Specify treadmill security, configuration, and
maximum machine parameter limits.
5671***
Demo mode***
Demo mode program used to demonstrate the
machine features...
Note: Demo mode cycles through the Workout
screens, shows the media control icons, and
disables the softkey menus. To stop demo mode,
press and hold the bottom right softkey for 5-8
seconds to open the Demo Settings screen.
Select “Turn demo OFF” softkey and then select
Save to disable Demo mode.
5555**
Note: * R20 Console only
** R40 Console only.
How to Access the Service and Diagnostic Menus
R40 Console: How to access the service and diagnostic menus
1. Go to the console default Home page.
2. Select the Settings softkey.
3. Simultaneously touch/release the My Settings (top right) and Edit (bottom right) softkeys.

Page 12 of 56
©2014 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law
Note:
The My Settings softkey may be blank, however it remains an active
softkey. Simultaneously select the TOP and Bottom right side softkeys
to access the System Settings page.
4. Use the numbered softkeys to type in the Service Software Access Code:
5. Select Next.to access the Service software.
R20 Console: How to access the service and diagnostic menus
1. Press/Release PAUSE and quickly type in the access code using the User Keypad.
•Use the Left and Right arrow keys to browse and scroll menus
•Select the GO key (ENTER) to select or start a menu item.

© 2014 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law Page 13 of 56
•Select WORKOUTS (BACK) to return to the previous menu item.
•Select PAUSE to exit Service Software.
Hardware Validation Diagnostic Tests (51765761)
Hardware Validation service software provides a set of system tests used to verify proper
operation of the console and base hardware. System tests can also be used to troubleshoot
and resolve problem issues.
R40 Console Hardware Validation Diagnostic Tests:
System Test
Console
Description
Display GUI/Metric
Test
R40
Backlight brightness is varied and cycles thru numbers.
Key Test
R40
Tests the function keys.
Heart Rate Test
R40
Test the heart rate and SmartRate functions, the heart rate is
acquired and shown.
Belt Speed Test
R40
Select the SPEED control to vary the running belt speed from 0.5
mph to 12.0 mph in 0.1 increments.
Incline Test
R40
Select the INCLINE control to raise and lower the deck. The incline
A/D value is shown and verified at the following incline settings:
•37 ± 5 @ 0% incline
•120 ± 5 @ 5.5 % incline
•242 ± 5 @15% incline
R20 Console Hardware Validation Diagnostic Tests:
System Test
Console
Description
Heart Rate Test
R20
Test the heart rate and SmartRate functions, the heart rate is
acquired and shown.
Beeper Test
R20
Test the beeper sound.
Keypad Test
R20
A map of the User keypad and Machine controls are shown on the
upper text window. Press a key and the corresponding LCD key light
will turn off.
To exit, press and hold the WORKOUTS key.
LCD Test
R20
Cycles thru all the different functional areas of the LCD upper text
window and control indicators.
Machine Tests:
R20
Performs tests to verify the Speed and Incline operation.
•Belt Test
The Belt test uses the SPEED controls and running belt operation.
•Incline Test
The Incline test uses the INCLINE controls to verify ramp operation
at 0.5 % increments.

Page 14 of 56
©2014 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law
Stop Key Test
R20
Tests the press STOP key and the pull lanyard to remove STOP key
functions:
Both stop key operations will immediately slow and stop the running
belt.
Follow prompts to complete test.
Information Display (Access Code 65)
R40 console: Information Display
The R40 Information Display provides the software versions, machine usage information, and
the Error Log:
•SW Release PN
•Hardware Version
•Usage (hours :: minutes)
•Odometer (Miles)
•Console S/N
•LPCA Version
•uPA Boot Version
•CPA Boot Version
•CPA Current Version
•CPA Restore Version
•GUI Current Version
•GUI Restore Version
•Error Log
How to access the Information Display:
The Information and Error Log can be accessed by one of two methods: 1) the Information
menu or 2) the Information service software (Access Code “65”)
Accessing the Information Display and Error Log:
1. From the Home page select the Settings softkey.

© 2014 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law Page 15 of 56
2. Select the Information softkey to open the Information page.
3. Select Error Log to open the Display Error Log page
Error Log
R20 console: Information Display (65)
The R20 Information Display provides the software versions, machine usage information, and
the Error Log:
•ODOMETER (total number of miles)
•HOUR METER (total machine use hours)
•UPPER SOFTWARE (upper software version)
•LOWER SOFTWARE (lower software version)
•USAGE LOG
oMANUAL USED (number of manual workouts)
oTIMES (number of times the machine was powered ON)
oTOTAL MINUTES (total minutes the machine was used)

Page 16 of 56
©2014 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law
•ERROR LOG (list of all logged error codes, see Error Log)
How to access the R20 Information Display (65):
1. Press/Release PAUSE and quickly type in the access code “65” using the User
Keypad.
•Use the Left and Right arrow keys to browse and scroll menus
•Select the GO key (ENTER) to select or start a menu item.
•Select WORKOUTS (BACK) to return to the previous menu item.
•Select PAUSE to exit Service Software.

© 2014 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law Page 17 of 56
Adjustment Procedures
Calibrating the Lift Motor
Note: This calibration procedure must be performed whenever the lift motor has been replaced
or the lift calibration has been disturbed.
Video: TRM 200 Lift Motor Calibration
1. Switch the power “OFF”.
2. Carefully rotate the treadmill onto the left side.
3. Use two 17 mm wrenches and remove the bolt that fastens the lift tube to the lift platform.
Then swing the lift platform away from the lift motor - lift tube. Retain bolt and nut for
installation.
4. Keep hands away from the lift motor mechanism and switch the power “ON”. If the lift motor
incline is not positioned at the default 0% incline position, the liftmotor will start and return to the
default 0% incline position.
5. Access the service mode (51765761) MACHINE TEST “INCLINE TEST”. Adjust the incline to
0% and 15% and verify the A/D number per the following table. Return the INCLINE to 0%
Incline Level
A/D
0%
50 +/- 2
15%
200 +/-2
6. Make sure the INCLINE is set to 0%. Then verify the lift tube calibration distance (distance
from the end of the lift tube to the lift tube sleeve) is 1-9/16 inches. Rotate the lift tube as
needed to adjust the lift tube to the specified calibration distance.
7. Reattach the lift tube to the lift platform and secure using the removed 17 mm bolt and 17 mm
nut.
8. Switch the power OFF and return the treadmill to the upright position.

Page 18 of 56
©2014 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law
9. Switch the power ON. Then start a manual program and operate the incline several times from
the minimum to maximum incline levels. Verify that the incline is operating normally.
10. Verify operation and return to service, see “Operation Verification Test” procedure.
Drive Belt Tension Adjustment
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.
4. The gauge should read approximately 80
pounds. The drive belt tension is acceptable if it is
in the range of 70 to 90 pounds.
5. If the drive belt tension is less than 70 or greater
than 90 pounds, slightly loosen the four drive
motor mounting bolts. The drive motor mounts on
slotted holes allowing the drive motor to be
move forward or rearward. Move the drive motor
forward or rearwards, as required, until the belt
gauge reads approximately 80 inch/pounds and
tighten the four drive motor mounting bolts. See
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.
Torque the four drive motor mounting bolts to 180 inch pounds.
6. Re-install the hood.

© 2014 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law Page 19 of 56
7. Plug the line cord into the wall outlet and set the treadmill circuit breaker in the “ON” position.
8. Check treadmill operation.
Running Belt Tension Adjustment
This procedure needs to be accomplished any time the Drive roller or Take up roller are
removed or replaced.
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. 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.
3. 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
4. Remove both belt gauges from the running belt.
5. Start the treadmill and operate it at 2 mph. Observe the running belt. If the belt drifts away from
its centered position re-track it by adjusting the take up roller mounting bolts.
6. 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 right hand mounting bolt counter-clockwise until
the drifting stops. Only a very small adjustment should be required, 1/8 to 1/4 turn.
7. Increase the treadmill speed to 4 mph. if the belt drifts away from center, touch up the tracking
as described above.
8. Increase the treadmill speed to 8 mph., if the belt drifts away from center, track it as described
above

Page 20 of 56
©2014 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law
9. Increase the treadmill speed to maximum, if the belt drifts away from center, track it as
described above
10. 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 above.
11. If applicable, replace the finger guard removed in step 2.
12. Replace the end caps and motor cover removed in step 1.