Precor Experience 600 Series User manual

Service Manual
Experience™ Series 600 line
TRM600-18 Treadmills

Contents
Introduction 1
Service manual contents 2
Additional Service Documentation and Videos 2
Service Safety Guidelines 3
Safety guideline you need to know and follow: 3
General Information 5
Features 5
Model and Serial Numbers 7
Model Numbers 7
Serial Numbers 8
About 8
Serial Number Label Location 9
Orientation 9
Tools and Supplies 10
Specification Summary 11
Fastener Torque Specification 11
Calibration Specification 11
Bolt Grade Identification 12
Bolt Grade Markings Chart 12
Parts 13
Lubricants 13
Cleaning Procedure 14
Approved Cleaning Products 14
Cleaning Procedure 14
Power Requirements 15
Equipment Power Requirements 15
Plugs and Outlets 16
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Page ii

Console & PVS Display Power Requirements 18
LED consoles (P10, P30, P30i and P31) 18
Touchscreen consoles (P62, P80, and P82) 19
PVS Display 19
Cable TV RF Power Requirements 20
Touchscreen consoles (P62, P80, and P82) 20
MYE - PVS displays 20
RF cable TV wall outlet power requirements 20
Ethernet (LAN) Input Signal Requirements 21
Equipment Spacing Requirement 21
Operation Verification 23
Operation Verification Tests 23
Standard Service Menus 27
About 27
Service Menu Access Codes 27
LED Consoles: P10, P30, P30i and P31 27
Touchscreen Consoles: P62, P80, and P82 28
How to Access the Standard Service Menus 29
P10, P30, P30i and P31 LED consoles 29
P80 touchscreen console 30
P62 and P82 touchscreen consoles 30
Diagnostics menu access 30
Touchscreen Display Calibration shortcut 31
Debug Information Report shortcut 32
Navigating the Service Menus 34
P10, P30, P30i and P31 LED consoles 34
P10, P30 and P31 consoles 34
P30i consoles 34
P80 and P82 touchscreen consoles 35
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Page iii

P62 touchscreen consoles 35
LED Console Standard Service Menus 36
Hardware Validation Diagnostics Tests Menu (51765761) 36
Club Settings Menu (5651565) 38
Information Display (65) 40
Touchscreen Console Standard Service Menus 43
Service Settings Menu ( (51765761) 43
About menu 44
46
Equipment Usage menu 46
Maintenance menu(1) 46
System Settings menu 48
System Tests menu 53
Club Settings (5651565) 54
Information Display (65) 54
Adjustment Procedures 56
Available Adjustment Procedures 56
Drive Belt Tension and Alignment Adjustment 57
About 57
Specifications 57
Procedure 57
Running Belt Tension and Tracking Adjustment 62
About 62
Videos 62
Tools 62
Specification 62
Procedure 63
Lift Motor Calibration 69
About 69
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Page iv

Specifications 69
Procedure 69
How to Access the Lift Extension Tube & Jackscrew 74
Replacement Procedures 79
Available Replacement Procedures 79
Covers and Panels Replacement 80
About 80
Hood Cover Replacement 82
Hood Transition Cover Replacement 83
Trim Landing Covers Replacement 85
Trim End Cap Covers Replacement 88
Trim Side Cover Replacement 90
Dash Back Cover Replacement 93
Dash Front Cover Replacement 94
Dash Top and Bottom Cover Replacement 95
Side Arm Upper/Lower Covers Replacement 99
Power Cord Replacement 100
About 100
Procedure 100
ON/OFF Circuit Breaker Switch Replacement 102
About 102
102
Wire Diagram 103
Procedure 103
E-Stop "Emergency Switch" Replacement 106
About 106
Procedure 106
Motor Controller (MC) Replacement 107
About 107
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Page v

MC Wire Diagram 109
MC Connector Definition 110
MC Status Light 115
Replacement Procedure 115
Motor Controller Fan Replacement 120
About 120
MC Fan Connector Definition 120
Drive Belt Replacement 125
About 125
Procedure 125
Drive Motor Replacement 130
About 130
Drive Motor Cable Schematic 131
Procedure 131
Drive Roller Replacement 139
About 139
Procedure 139
Take-up Roller Replacement 144
About 144
Procedure 144
Removal 145
Installation 147
Running Belt and Deck Replacement Procedure 149
About 149
Procedure 149
Lift Motor Replacement 156
About 156
Videos 156
Specification 156
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Page vi

Lift Motor Fuse 156
Lift motor cable schematic 157
Procedure 157
Lift Platform Replacement 167
About 167
Procedure 167
Troubleshooting 174
About 174
Introduction to Troubleshooting 174
Basic Troubleshooting Steps 174
Validate the customer reported issue 175
Verify Input Power 175
Verify (reproduce) the customer issue 176
Verify the Club Settings 176
Verify service bulletin and software update incorporation 176
Verify console operation 177
Verify that there are no current active error codes 178
Verify hardware validation diagnostic tests 178
Verify that there are no new error codes 178
Standard Error Codes 180
About 180
Viewing Error Codes (Error Log & CPA Event Log) 181
Error Code and Troubleshooting Guide 181
Troubleshooting with Error Codes 182
Error Log & CPA Event Log 183
About 183
Error Log 184
CPA Event Log 186
System Troubleshooting Procedures 189
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Available System Troubleshooting Procedures 189
Tripped Circuit Breaker 190
Input Power Troubleshooting 194
Console Power Troubleshooting 197
Communications Error Troubleshooting 200
Machine Controls Troubleshooting 202
Auto Stop Troubleshooting 204
E-Stop not Communicating Troubleshooting 206
Heart Rate Monitor Troubleshooting 207
Drive Motor System Troubleshooting 210
Incline Lift System Troubleshooting 215
Error Code 40 "NO Lift Motion Detected" 216
Possible Fault Causes: 217
Running Belt Troubleshooting 221
Preventive Maintenance (PM) 225
About 225
PM Guides and Videos 225
Product PM Guides 225
PM Service Videos 227
Running Belt and Deck Cleaning Procedure 229
Videos 229
Procedure 229
Theory of Operation 232
What's New 232
TRM600, TRM700, TRM800 feature/components comparison 232
Console Upper PCA and Base Lower PCA Operation 235
Console - Upper PCA board (UPCA) 235
Base - Lower PCA board (LPCA) 235
TRM600/700/800 Common Frame Overview 235
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Page viii

About 235
Ordering Parts 236
Common Frame Drive Roller 236
Common Frame Take-up Roller 238
Common Frame Running Deck 240
Landing Trim End Cap Covers 241
Drive Belt Tension Adjustment 241
Dust Guard 242
System Wiring Diagram 244
System Wire Diagram 244
COMM Cable Wire Diagram 245
Console Wire Diagram 246
Power Entry Assemble Wire Diagram 247
Product Literature & Videos 248
Service & Maintenance Documentation 248
Precor Websites 248
Service Videos 249
Parts 251
About 251
Precor Connect Partner's website 251
Exploded View Diagrams and Parts List 254
Exploded View Diagram 255
Parts List - TRM600-18, 120 V 262
Parts List - TRM600-18, 240 V 265
Appendix A : Edition Information i
Edition i
Additional Documentation i
Copyright i
Appendix B : Notices and Safety ii
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Page ix

Trademarks ii
Intellectual Property ii
Warranty ii
Safety Notices iii
Service Safety Guidelines iii
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Page x

Introduction
Only Precor certified technicians are authorized to service Precor equipment. If you are not
a Precor certified servicer, you must not attempt to service any Precor product. Call your
dealer for service information
WARNING: This service documentation is for use by Precor certified servicer pro-
viders only. Personal injury can result from electrical shock and/or mechanical moving
parts.
This service manual applies to the Experience™ Series 600 Line treadmills including the
120 VAC1and 240 VAC models.
Model Configuration
TRM631 TRM600-18 base with P30 or P31 console: speed: 0.5 - 12 mph (0.8-19.2
kph), incline: 0-15% (0.5% increments)
TRM661 TRM600-18 base with P62 console: speed: 0.5 - 12 mph (0.8-19.2 kph),
incline: 0-15% (0.5% increments)
TRM681 TRM600-18 base with P82 console: speed: 0.5 - 12 mph (0.8-19.2 kph),
incline: 0-15% (0.5% increments)
1voltage in an alternating current circuit
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Page 1
1 Introduction

Service manual contents
The service manual contains information to service, repair, troubleshoot, and maintain the
machine base.
This manual does not include console service and repair information, for console service
and repair information, refer to the console service manual.
However, the service manual does include information about how to use the console stand-
ard service menus, diagnostic tests, and error code log to help troubleshoot and repair
machine issues.
Additional Service Documentation and Videos
There are additional literature and video resources available that can help you to use, ser-
vice, troubleshoot, and repair the machine. Refer to Product Literature & Videos topic:
l"Product Literature & Videos" on page 248
See Also
"General Information" on page 5
"Operation Verification" on page 23
"Standard Service Menus" on page 27
"Adjustment Procedures" on page 56
"Replacement Procedures" on page 79
"Troubleshooting" on page 174
"Preventive Maintenance (PM)" on page 225
"Theory of Operation" on page 232
"System Wiring Diagram" on page 244
"Parts " on page 251
"Service Safety Guidelines" on the facing page
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Page 2
1 Introduction
Service manual contents

Service Safety Guidelines
WARNING: Only Precor certified servicers and technicians are permitted to ser-
vice Precor products. Personal injury can result from electrical shock and/or mech-
anical moving parts.
Review the following safety information prior to servicing the equipment. This safety inform-
ation will help to prevent personal injury or damage to the equipment while servicing the
equipment.
Safety guideline you need to know and follow:
lRead and follow all Warning notices to protect yourself from personal injury.
lRead and follow all Caution notices to prevent damage to the equipment.
lRead the owner’s manual and follow all operating instructions.
lOperate the equipment on a solid, level surface.
lVisually check the equipment before beginning service or maintenance operations. If
it is not completely assembled or is damaged in anyway, do not attempt to operate the
equipment.
lNever place liquids on any part of the equipment while performing service.
lTo prevent electrical shock, keep all electrical components away from water and
other liquids.
lDo not use accessory attachments that are not recommended by the manufacturer.
Non-OEM accessories can cause injuries.
lDo not stand or climb on the handlebars, display enclosure or cover.
lOn a self-powered unit, it will either be necessary to either equip the unit with the
optional external power supply or have an assistant pedal on the unit while voltage
measurements are being taken. Because of the danger of working on the unit while it
is in motion using the optional external power supply is strongly recommended.
lOn AMT1units when the stairarms are in motion; the generator will operate and pro-
duce potentially hazardous voltages even when the battery is disconnected.
lOn AMT units with Cardio Theater PVS2units will have external power supply and
coaxial cable routed through the bottom of the unit to the top of the display console.
Cord management must be maintained
lOn AMT units, a pinching hazard exists when the unit is operated. It is possible to ser-
iously pinch a finger. The AMT can be mechanically locked by inserting a screwdriver
through the primary sheave and frame.
1Adaptive Motion Trainer
2Personal Viewing System display.
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Page 3
1 Introduction
Service Safety Guidelines

lOn treadmills, removing the hood exposes high voltage components and potentially
dangerous machinery. Exercise extreme caution when you perform maintenance pro-
cedures with the hood removed.
When servicing the equipment:
lDuring service operations you will be very close to moving machinery and voltage
bearing components:
oRemove jewelry (especially from ears and neck).
oTie up long hair.
oRemove neck ties.
oDo not wear loose clothing.
See Also
"Notices and Safety" on page ii
"Safety Notices" on page iii
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Page 4
1 Introduction
Service Safety Guidelines

General Information
The following information provides general equipment and service information that will help
you to use this manual to properly repair and maintain the treadmill.
Features
The equipment operating specifications.
Feature Specification
Consoles LED consoles: P30, P30i and P31
Touchscreen consoles: P62 and P82
Incline
Elevation system generates up to 1000 lb / 453.6 kg of thrust and
operated in compression for reliable operation.
Range: 0% - 15% in 0.5% increments.
Speed Range: 0.0 - 12 mph in 0.5 increments (0.0 - 19.3 kph) in 0.1 kph
increments)
Auto Stop
Auto stop is a safety feature that shuts off a treadmill that has been
abandoned while the belt is running. Exclusive of the first sixty
seconds after a workout has begun or resumed, any 30 second
window with no user detected will prompt a 10 second countdown
and then a full stop. The detection is accomplished through soft-
ware and is rated to detect persons weighing 50 lbs (22.7kg) or
greater walking with a normal cadence.
The feature is selectable ON or OFF in the facility settings menus.
It is default from the factory set to ON, and it is recommended to be
set ON.
Belt/Deck
Belt:
Uses the Forbo brand belt with pre-waxed reversible deck.
Running surface: 60" x 22" (153 x 56 cm)
Deck:
The deck is a one-inch Slik-Dek bed with a thin layer of wax to
assist in the break-in of the new belt / deck system. The deck is
composed of 52 lb / 23.6 kg high-density fiberboard core with phen-
olic laminate bonded on both sides. Can be flipped to double life.
Drive/Take-up Rollers
Steel tapered rollers keep the belt centered to reduce main-
tenance.
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Page 5
2 General Information
Features

Feature Specification
lDiameter: approx. 2.5 in / 6.35 cm (smaller than the
TRM700/800)
lDrive roller installation: Bracket plate shaft mount on the
right side and shaft pin frame hole mount on the right side.
lTake-up roller installation: Uses the single bolt fastener/belt
tension adjustment mechanism.
Drive Motor
230V, 1.12 kW, 3-phase AC1induction motor.
The motor controller (MC2) implements Integrated Foot Plant
Technology™ and sensorless variable frequency drive technology
for high reliability and accurate speed control.
Emergency Stop
(ESTOP3)
Exerciser safety clip and lanyard connected to the stop switch to
immediately switch off power bringing the treadmill to a stop.
Heart Rate
Two Heart Rate sensor types:
lTouch Handheld Handlebar Heart Rate sensors (HHHR4).
lTelemetry equipped for wireless chest strap heart rate mon-
itoring.
Ground Effects®
Impact Control Sys-
tem (GFX5®)
Progressive shock absorption system that absorbs high impact
movements and supports a solid and controlled push off.
Frame Multi-model common frame (TRM600, TRM700, TRM800).
Step-up Height 8.4" (21.3 cm)
Max User Weight Maximum exerciser weight: 350 lbs (159 kgs)
Dimension/Weight
Weight: 392 lbs (149 Kg)
Dimensions:
Length 83 in / 211 cm
1Alternating Current: electric current which periodically reverses direction between positive
and negative polarity.
2Motor controller, motor controller unit, or motor controller module: used on treadmills, con-
tains the LPCA and motor controller functionality.
3Emergency Stop: Safety clip and lanyard attached to the stop switch to immediately turn
off power bringing the treadmill to a stop.
4Handheld Handlebar Heart Rate
5Ground Effects Impact Control System: Patented treadmill design that out performs a nat-
ural running surface, absorbs high-impact movement, reduces joint stress and minimizes
fatigue and supports a solid and controlled push off.
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2 General Information
Features

Feature Specification
Width 35 in / 89 cm
Height 62 in / 157.5 cm
Model and Serial Numbers
Model and Serial Numbers
Model Numbers
The product model number is a six digit alphanumeric code "AAAXXX" containing the
product type, product line, console type, and feature level designator:
l"AAA" - three alpha character PRODUCT TYPE designator
l"X" – 1 digit numeric PRODUCT LINE designator
l"X" – one digit numeric CONSOLE type designator
l"X" – one digit numeric FEATURE LEVEL designator
Example
Product model number: TRM1833
lTRM – Treadmill
l8 – Experience Line
l3 – P30 console
l3 – Fixed ramp
Product Model Number Designator Definitions
PRODUCT TYPE PRODUCT LINE CONSOLE FEATURE LEVEL
TRM: treadmill
EFX2: elliptical
AMT3: AMT
UBK4: Upright
RBK5: Recumbent
8-Experience
Premium
7-Experience Stand-
ard
6-Experience Good
8-P80, P82
6-P62
4-R40
3-P30, P31
2-P20/R20
7EFX: Mov Ramp/Cnvrt
Arms
1Treadmill
2Elliptical Fitness Crosstrainer
3Adaptive Motion Trainer
4Upright Bike
5Recumbent Bike
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2 General Information
Model and Serial Numbers

PRODUCT TYPE PRODUCT LINE CONSOLE FEATURE LEVEL
SCL StairClimber
6-Assurance Stand-
ard
4-Precision, Con-
sumer
2-Energy, Consumer
1-P10 5TRM: High Speed/De-
cline
AMT: Moving Step Height
EFX: Mov Ramp/Mov
Arms
RBK: Standard features
UBK: Standard features
SBK1Standard features
3TRM: Fixed Ramp
AMT: Fixed Step Height
EFX: Moving Ramp/Fixed
Arms
2EFX: Man Ramp/Mov
Arms
1EFX: Fixed Ramp/Moving
Arms
Serial Numbers
About
The serial number uniquely identifies each machine. The serial number is an alphanumeric
code comprised of a four character model designator, a 1 letter build month code, a 2 digit
day built, a 2 digit year built and a four digit consecutive daily build number.
1Spinner Indoor Cycle
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Page 8
2 General Information
Serial Numbers

Serial Number Label Location
The serial number label is located on the left side of the hood and on the left side of the front
frame weldment underneath the hood.
Note: Always use the frame serial number label to verify the machine serial num-
ber. Do not use a label attached to a plastic cover, the cover may have been
replaced from a different machine.
Orientation
The equipment orientation (front, right, left, & back) is referenced to an exerciser standing
on the machine facing the console.
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Page 9
2 General Information
Orientation

Tools and Supplies
Tools and supplies required to complete the machine service and repair.
Tools
• US and Metric Hex Key set • Standard straight slot tip screw drive set
• US and Metric socket set • Philips tip screwdriver set
• Us and Metric wrench set • US & metric Allen wrench set
• Cutters • 7/16” Allen key, socket mounted
• Rubber mallet • Pliers
• Tape measure /Straight edge ruler • Inner and outer snap ring pliers
• DVM meter • Torque1Wrenches: 9 in lbs to 100 in - lbs
(83 ft-lbs)
• AC Clamp-on averting current meter • DVM Multimeter
• ESD wrist strap and pad • Compatible HR2chest strap or Polar HRM
simulator xmitter (Precor PN:
PPP000000020045101)
• 12 " wonder bar • Vacuum cleaner (recommend ESD safe
model)
• 2 - Running Belt tension gauge – OTC
Tools Model #: 6673 (Precor PN:
PPP000000020007101)
• Drive Belt tension Gauge (Kent-Moore BT-
33-73-F
Supplies
• Super Lube Gel with Teflon by Permatex
(1)
• Cleaning rags
• Loctite 243 Blue Medium Strength Thread-
locker
• Cleaner Degreaser (see "" on page 14)
• Cable tie assortment (1 3/4", 3", 4"
1Torque is a measure of the force that can cause an object to rotate about an axis. Bolt/nut
example: 5 NM torque is equivalent to 5 newton's of force applied one meter from the center
of the bolt, 6 ft-lb is equivalent to 6 lbs of force applied 1 foot away from the center of the
bolt.
2Heart Rate
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Page 10
2 General Information
Tools and Supplies