Precor ENERGY SERIES User manual

© 2014 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law 1Page 1 of 54
Service Manual
Energy Series 200-14 Treadmills
TRM211 Base
Precor Customer Support

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Contents
About This Document..................................................................................................................................5
GeneralInformation ................................................................................................................................5
Lubricants............................................................................................................................................5
Power Requirements...........................................................................................................................5
Service Call Information.......................................................................................................................6
Console.......................................................................................................................................................7
Console Layout and Controls ...................................................................................................................7
Accessing the Odometer and Hour Meter................................................................................................7
Setting Units (U.S. Standard/Metric)........................................................................................................7
Console Removal/Installation..................................................................................................................8
Service Mode - Service Program Access.......................................................................................................9
Available Service Mode Programs............................................................................................................9
Accessing the Service Programs...............................................................................................................9
Calibration...........................................................................................................................................9
Key Test............................................................................................................................................. 10
Display Test .......................................................................................................................................10
Operation Verification Check..................................................................................................................... 11
Procedure .............................................................................................................................................11
Calibrating the Lift Motor ..........................................................................................................................12
Procedure.......................................................................................................................................... 12
Adjusting Drive Belt Tension......................................................................................................................14
. Procedure........................................................................................................................................14
Treadmill Belt Cleaning..............................................................................................................................15
. Procedure........................................................................................................................................15
Troubleshooting the keypad......................................................................................................................17
Procedure.......................................................................................................................................... 17
Troubleshooting the Lift System................................................................................................................18
Lift System Description: .....................................................................................................................18
Procedure.......................................................................................................................................... 18
Troubleshooting the Speed Sensor ............................................................................................................21
Procedure.......................................................................................................................................... 21

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Troubleshooting Display Does Not Illuminate............................................................................................22
Procedure.......................................................................................................................................... 22
Troubleshooting the Safe ty Key Circuit .....................................................................................................24
Procedure.......................................................................................................................................... 24
Troubleshooting the Drive Motor System.................................................................................................. 25
Troubleshooting the External AC Power Source......................................................................................... 26
Possible External AC Power Problems................................................................................................26
Troubleshooting Checklist..................................................................................................................26
Troubleshooting the Running Belt & Deck System .....................................................................................28
Troubleshooting Running Belt Slip.............................................................................................................31
Replacing the Lift Motor............................................................................................................................33
Procedure.......................................................................................................................................... 33
Replacing the Incline Platform...................................................................................................................34
Procedure.......................................................................................................................................... 34
Replacing the Lower PCA...........................................................................................................................35
Procedure.......................................................................................................................................... 35
Replacing the Speed Sensor.......................................................................................................................36
Procedure.......................................................................................................................................... 36
Replacing the Drive Motor......................................................................................................................... 37
Procedure.......................................................................................................................................... 37
Replacing the Circuit Breaker ....................................................................................................................38
Procedure.......................................................................................................................................... 38
Replacing the ON/OFF Switch....................................................................................................................39
Procedure.......................................................................................................................................... 39
Replacing the Drive Motor Brushes ...........................................................................................................40
Procedure.......................................................................................................................................... 40
Replacing the Safety Key Switch ................................................................................................................ 41
Procedure.......................................................................................................................................... 41
Replacing the Display Face with Keypad......................................................................................................42
Procedure.......................................................................................................................................... 42
Replacing the Upper PCA ........................................................................................................................... 43
Procedure.......................................................................................................................................... 43

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Replacing the Data Cable ...........................................................................................................................44
Procedure.......................................................................................................................................... 44
Replacing the Drive Roller ......................................................................................................................... 45
Procedure.......................................................................................................................................... 45
Replacing the Take-Up Roller..................................................................................................................... 48
Procedure.......................................................................................................................................... 48
Replacing the Running Belt and Deck.........................................................................................................50
Procedure.......................................................................................................................................... 50
Wire Diagram............................................................................................................................................53
System Functional Diagram ....................................................................................................................... 54

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About This Document
This document contains information required to perform the majority of troubleshooting, and
replacement procedures required to repair and maintain this product.
Warning:
This service manual is for use by Precor trained service providers only. If you are not a
Precor Trained Servicer, you should not attempt to service any Precor products. Call your
dealer for service.
This document contains 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.
Manual Part Number20081-121 rev 01
Contact
Precor Incorporated
20031 142nd Ave. NE
P.O.Box 7202
Woodinville, WA. 98072-4002
1-800-347-4404
General Information
Lubricants
•Do not apply any lubricants to the deck and belt. Do not use Wax Blast, silicon sprays, or other applied
lubricants. The use of these lubricants will quickly degrade the low-friction surface of the deck.
•Do not use petroleum based lubricants on mechanical components such as the lift, as this may result in
degradation of nylon gearing mechanisms. Use only synthetic lubricants such as "Super Lube with
Teflon" or "Mobile One Synthetic" grease (RED).
NOTE
Use of unapproved lubricants, cleaners, or solvents may void the treadmill warranty
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.
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.

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Service Call Information.
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.
•Program number 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.

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Console
Console Layout and Controls
1
SMART DISPLAY
2
PROGRAMS
3
QUICKSTART
4
ENTER
5
INCLINE CONTROL
6
SPEED CONTROL
7
STOP
8
CENTER WINDOW
9
WORKOUT STATISTICS
10
LOWER WINDOW
Accessing the Odometer and Hour Meter
Use the following steps to access the Odometer and Hour Meter values.
1. Set the ON/OFF switch in the “ON” position and remove the safety key from the console.
Allow the internal power supply to discharge, approximately 10 seconds, and then replace
the safety key on the console. Within 2 seconds of replacing the safety key, press the
STOP, INCLINE UP, SPEED DWN keys, sequentially.
2. The Odometer in miles or kilometers will be displayed in the DISTANCE window of the
display.
3. The hour meter will be displayed in the TIME window.
4. The upper PCA software version will be displayed in the main window.
5. Press the STOP key to exit this program.
Setting Units (U.S. Standard/Metric)
Use this procedure to set the parameter units to U.S. Standard or Metric.
1. Set the ON/OFF switch in the “ON” position and remove the safety key from the console.
Allow the internal power supply to discharge, approximately 10 seconds, and then replace
the safety key on the console. Within 2 seconds of replacing the safety key, press the
STOP, INCLINE DWN, SPEED UP keys, sequentially.
2. Press the INCLINE UP key to toggle the selection between U.S. Standard and METRIC.
6. Press the ENTER key to save the selection. Press the STOP key to exit.
3.

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Console Removal/Installation
4. Set the ON/FF switch to “OFF”.
5. Remove the four screws that fastens the backplate to the rear of the console and remove
console from the backplate.
6.
7. Disconnect the heart rate cable and data cable from the rear of the console.
8. To install the console, connect the Data and Heart Rate cables.
9. Position the console onto the backplate and install the four screws that fastens the
backplate to the rear of the console.
10. Switch the power to ON
11. Run the Display and Key Service tests.
12. Verify treadmill operation.

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Service Mode - Service Program Access
Available Service Mode Programs
List of available service programs:
•Calibration - Incline calibration and treadmill calibration
•Console Sel - Sets the treadmill base model
•Display Test - Tests the display
•Key Test - Tests the keypad
Accessing the Service Programs
Use these steps to access the Service Programs.
1. Set the ON/OFF switch to “ON” and remove the safety key from the console. Allow the
internal power supply to discharge, approximately 10 seconds.
2. While pressing the QUICK START and SPEED UP keys, simultaneously, replace the
safety key on the console. Continue to press the QUICK START and SPEED UP keys until
the display scrolls “SERVICE MODE”. The main screen will display the upper software
version number.
3. Press the ENTER key, the display will read CALIBRATION. Use the UP/DWN arrows to
scroll between the test modes. Press the ENTER key to select the desired test. You can
press and hold the STOP key at any time to exit the SERVICE MODE program.
Calibration
4. Inc Limit will be displayed at the bottom of the display and the incline A/D number will be
displayed in the HEART RATE window. As the incline is raised or lowered the A/D number
should track the incline’s movement.
5. The A/D number will be used to calibrate the incline.
Important
Do not change the A/D number at this point, if the incline requires calibration.
6. Press the ENTER key to enter the treadmill calibration mode.
Warning
During this program the running belt will be accelerated to the treadmill
maximum (12.0 mph) speed. Do not stand on the treadmill running belt during
this procedure.
7. This program must be performed after the upper PCA, the upper PCA software or the
lower PCA has been replaced and before the treadmill is placed into normal operation.
8. When the running belt stops the display will show the test results Pass or FAIL and return
to the normal user mode and the calibration process is complete.

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Key Test
9. One at a time press all of the keys on the console, the key name should be displayed at
the bottom of the display. Pressing the STOP key a second time will exit the key test.
Display Test
10. The display test will light every segment in the display. You must watch the display
throughout the test to ensure that every display segment is functioning. This test will run
continuously until you press the STOP key to halt the display test.

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Operation Verification Check
This section provides an operational check of the treadmill basic functionality. Use this procedure
to verify the treadmill operation at the completion of a maintenance procedure or any time it is
necessary to ensure that the treadmill is operating properly. For a complete guide to all operating
functions, refer to the Operators Manual.
Procedure
1. Plug the power cord into the AC outlet. Set the safety switch to the operating position on the
console. Set the ON/OFF switch in the “ON” position, the ON/OFF switch should illuminate. All
of the LED’s on the display should illuminate for a couple of seconds and the scroll the
message PRESS QUICKSTART OR PROGRAM. The POWER LED will illuminate on the
lower PCA.
2. Place the treadmill in Manual Mode. Adjust the speed of the running belt to 2–3 mph
11. Remove the safety switch from the console. The display should go blank and the treadmill belt
stop. Replace the safety switch on the console, all of the LED’s on the display should
illuminate for a couple of seconds and the scroll the message PRESS QUICKSTART OR
3. Place the treadmill in Manual Mode. Adjust the speed of the running belt to 2–3 mph
12. 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. Log the AC input current under loaded and unloaded conditions.
c. 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.
4. Press the STOP key. When the treadmill comes to a stop, view the electronic console as the
treadmill the message PAUSED - PRESS QUICK START TO CONTINUE scrolls on the
display. Adjust the speed of the running belt to 2–3 mph
5. Press the INCLINE up key while viewing the electronic console. Confirm that the running
bed inclines and the incline display increments to 15% as the INCLINE up key is pressed.
6. Press the INCLINE down key while viewing the electronic console. Confirm that the running
bed re turns to a level position and the incline display decrements to 0% as the INCLINE
down key is pressed.
7. Set the ON/OFF switch in the “OFF” position, then unplug the treadmill from the AC outlet.

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Calibrating the Lift Motor
Video: EFX 200 Lift Calibration
1.
Procedure
Note
This calibration procedure must be performed whenever the lift motor has been replaced or the
lift calibration has been disturbed
1. Set the ON/OFF switch in the “OFF” position and unplug the AC power cord from the AC
outlet.
2. Place the treadmill on the left side. Remove the bolt that fastens the lift tube to the lift
platform and swing the lift platform away from the lift motor’s lift tube.
3. Plug the treadmill AC power cord into a 120 VAC outlet. Set the ON/OFF switch in the “ON”
position. When the treadmill is initially placed in a program and the running belt starts in
motion, the incline will always return to the 0% incline position (unless it is already in the 0%
inclineposition).
4. Press the QUICKSTART key when the running belt starts the incline will move to its 0%
incline position (unless it is already in the 0% incline position). When the incline motor stops
remove the safety key. Enter the incline calibration mode. Set the incline A/D number
between 50.
Incline Level
A/D
0%
50 +/- 2
15%
200 +/-2
5. Press the ENTER key to save the A/D number. The treadmill will then go into the calibration
mode.
Warning:
During this procedure the running belt will be accelerated to the treadmill maximum (12.0 mph)
speed.
6. Rotate the lift tube until the distance from the end of the lift tube to the lift tube sleeve is
1-9/16 inch.

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7. The lift tube must turn freely during step 5, if you turn the lift drive screw while turning the lift
tube, you must return to step 4 and repeat steps 4 and 5. Set the ON/OFF switch in the
“OFF” position.
8. Swing the lift platform into its mounting position with the lift tube and fasten it with the bolt
removed in step 2.
9. Set the treadmill in its normal upright position. Set the ON/OFF switch in the “ON” position.
Place the treadmill in the manual program and operate the incline several times between its
minimum and maximum incline positions to ensure that the incline is operating normally
throughout its entire range.

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Adjusting Drive Belt Tension
. Procedure
1. Set the treadmill ON/OFF switch in the “OFF” position and unplug the AC power cord from the
AC outlet.
2. Remove the hood.
3. Place the drive belt tension gauge on the drive belt.
4.
5. The gauge should read approximately 80 pounds. The drive belt tension is acceptable if it is
in the range of 70 to 90 pounds.
6. If the drive belt tension is less than 70 or greater than 90 pounds, slightly loosen the four drive
motor mounting nuts. The drive motor mounts on slotted holes allowing the drive motor to be
move forward or rearward. Using the drive belt tension adjustment bolt, move the drive motor
forward or rearwards, as required, until the belt gauge reads approximately 80 pounds and
tighten the four drive motor mounting nuts. 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 nuts to 180 inch pounds.
7. Plug the AC power cord into the AC outlet and set the treadmill circuit breaker in the “ON”
position.
8. Verify treadmill operation.

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Treadmill Belt Cleaning
. Procedure
1. First, check for proper operation of the safety stop key. Stand to one side of the treadmill.
2. Insure that the stop key is hanging straight down from the stop key and is not wrapped
around the handle bars. Push the “Quick Start” button and wait for the display to count down
and for the running belt to begin moving. Once the running belt is moving pull the safety stop
key.
CAUTION :
If the running belt does not stop, turn off the power using the ON/ OFF
switch at the front of the treadmill and unplug the power cord. The
treadmill must remain out of service until the stop switch is repaired.
If the running belt stops, continue with the cleaning procedure
3. .A clean, dry towel approximately 36 inches (1 meter) in length is required.
4. Fold the towel in half lengthwise, lift the running belt up and insert the towel beneath the belt
so that an end of towel extends on to each deck trim.
5. Stand to one side of the treadmill, push the “Quick Start” button, and grasp the towel as
shown in the illustration above. Note: You will have 3 seconds to firmly grasp your hands on
the towel before the treadmill running belt begins to move. Allow the treadmill to run for about
one minute while holding the towel firmly in place.
CAUTION
:
If the towel becomes loose it may be pulled into the treadmill rollers. Pull the
safety key to stop the treadmill and retrieve the towel, no damage should
occur. Start the procedure over again.
6. Keep one hand firmly grasped on the towel, use your other hand to pull on the safety stop key
to stop the treadmill running belt.
7. Turn the power off. Place your hands on the towel and push it up and down the length of the
running deck several times to clean the deck.

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13. Remove the towel.
8. It is recommended that this procedure be performed frequently to extend the life of the
running belt and running deck.

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Troubleshooting the keypad
Procedure
1. If the malfunctioning key is stuck in the operated condition, the key name will be constantly
displayed. If the key is not functioning, the key’s name will not be displayed when the key is
pressed.
2. If the malfunctioning key is not required for access to the service mode program, run the KEY
TEST service program test to troubleshoot the problem.
3. Set the ON/FF switch to “OFF”.
4. Remove the four screws that fastens the backplate to the rear of the console and remove
console from the backplate.
5. Disconnect the heart rate cable and data cable from the rear of the console.
6. Remove the six screws from the rear of the console, remove the display face from the console
rear cover. The keypad connector (JK6) on the upper PCA is now accessible.
7. If the key is stuck in the operated condition, disconnect the keypad cable from the JK6
connector on the PCA. Replace the console rear cover, reconnect the data cable to the
console. Set the ON/OFF switch in the “ON” position. If the stuck key is remains displayed,
replace the display face. If the stuck is no longer displayed, replace the upper PCA.
8. If you have performed all of the procedures above and have been unable to correct the
problem, call Precor customer support.

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Troubleshooting the Lift System
Lift System Description:
The lift system on these units consists of an AC line voltage driven lift motor (120 VAC), and an
internal 10 K ohms potentiometer for lift position identification. The lift 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 lift motor is operated, the motor also rotates the potentiometer via an
internal gear system. Therefore, the position of the lift system can be determined by monitoring
the value of the internal potentiometer. The lift 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 lift motor operates briefly and creates a lift error (error 40) go to step 13. If the lift motor
will not move continue with the next step.
2. Set the treadmill on/off switch in the “off” position and remove the AC power cord from the AC
outlet.
3. Remove the hood from the treadmill.
4. Insert the AC power cord in the AC outlet and set the on/off switch in the “on” position. Set the
treadmill to operate in the manual program. Connect an AC voltmeter between terminal of 1
(red wire) and terminal 2 (white wire) of the JK4 connector on the lower PCA. Press the
INCLINE UP key. The UP LED should illuminate and the AC voltmeter should read AC line
voltage (105 to 120 VAC). If the incline operated normally in the upward direction go to step 8.
5. If the display indicated that the incline should be moving upwards and the UP LED did not
illuminate the problem is probably in the data cable between the upper and lower PCA.
Replace the data cable.
6. If the UP LED illuminated and the AC voltage reading in step 4 was absent or significantly low,

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the problem is probably in the lower PCA. Replace the lower PCA.
7. If the voltage reading in step 4 was correct and incline motor did not move, the problem is
probably the incline motor. To verify the lift motor’s condition, remove power from the treadmill
and measure between terminals 1 and 2 of JK4 with an ohmmeter. The motor winding should
measure approximately 27 ohms. If the measurement is significantly high, replace the incline
motor.
8. Connect an AC voltmeter between terminal 2 (white wire) and terminal 3 (black wire) of the
JK4 connector on the lower PCA. Press the INCLINE DWN key. The DOWN LED should
illuminate and the AC voltmeter should read AC line voltage (105 to 120 VAC)
9. If the display indicated that the incline should be moving downwards and the DOWN LED did
not illuminate the problem is probably in the data cable between the upper and lower PCA.
Replace the data cable.
10. If the DOWN LED illuminated and the AC voltage reading in step 8 was absent or significantly
low, the problem is probably in the lower PCA. Replace the lower PCA.
11. If the voltage reading in step 8 was correct and incline motor did not move, the problem is
probably the incline motor. To verify the lift motor’s condition, remove power from the treadmill
and measure between terminals 2 and 3 of JK4 with an ohmmeter. The motor winding should
measure approximately 27 ohms. If the measurement is significantly high, replace the incline
motor.
12. If you have performed all of the procedures above and have been unable to correct the
problem, call Precor customer support.
13. Remove Jk3 connector from the lower PCA. With an ohmmeter, measure between pins 1 and
3 of JK3 (red and black wires). You should measure approximately 10 K ohm (10000 ohms).
14. With an ohmmeter, measure between pins 1 and 2 of JK3 (red and white wires) and measure
between pins 2 and 3 of JK3 (white and black wires). These two measurements should total
10K ohms when added together. If these three measurements in steps 13 and 14 are correct
the incline should be functioning normally, replace JK3 and re test incline operation. If any of
the three measurements were significantly incorrect continue with step 15.
15. Remove the screw that fasten the cover on the top of the incline motor and carefully lift the
cover off of the incline motor. Check the wire connections on the incline potentiometer to
ensure they are securely connected to the incline potentiometer.
9. Repeat the three ohmmeter measurements in steps 13 and 14 directly on the three terminals

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of the incline potentiometer. If the three measurements are now correct the problem is in the
cable from the incline potentiometer to the lower PCA. The cable may be repairable. If the
cable cannot be repaired, replace the incline motor.
10. If the measurements in step 16 are remains significantly incorrect, replace the incline motor.
11. If you have performed all of the procedures above and have been unable to correct the
problem, call Precor customer support.