Precor Experience 700 line Series User manual

Service Manual
Experience™ Series 700 line
TRM700-16/18 Treadmills

Contents
Introduction 1
Service Safety Guidelines 3
Safety guideline you need to know and follow: 3
General Information 5
Model and Serial Numbers 5
Model Numbers 5
Serial Numbers 6
Orientation 7
Covers and Panels 7
Tools and Supplies 8
Specification Summary 9
Fastener Torque Specification 9
BeltTension Specification 10
Bolt Grade Identification 10
Bolt Grade Markings Chart 11
Parts 11
Lubricants 12
Cleaning Procedure 12
Approved Cleaning Products: 12
Cleaning Procedure 13
Power Requirements 13
Equipment Operating Power Specification 13
Facility Input Power Requirements 13
Console and PVS Display Power Requirements 15
Cable TV and Ethernet Input Signal Requirements 16
Cable TV "CATV" RF input signal power requirements 16
Ethernet (LAN) input signal requirements 17
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Page ii

Treadmill Placement and Spacing Requirement 17
Operation Verification 19
Operation Verification Tests 19
Standard Service Menus 22
About 22
Service Access Codes 22
LED Consoles: P10, P30, P30i and P31 22
Touchscreen Consoles: P62, P80, and P82 23
How to Access the Service Menus 24
P10, P30, P30i and P31 LED consoles 24
P80 touchscreen console 24
P62 and P82 touchscreen consoles 25
Diagnostics menu access 26
Touchscreen Calibration shortcut 26
Debug Information Report shortcut 26
Navigating the Service Menus 28
P10, P30, P30i and P31 LED consoles 28
P10 and P30 consoles 28
P30i consoles 28
P80 and P82 touchscreen consoles 29
P62 touchscreen consoles 29
LED Console Standard Service Menus 30
Hardware Validation Diagnostics Tests Menu (51765761) 30
Club Settings Menu (5651565) 32
Information Display (65) 34
Touchscreen Console Standard Service Menus 37
Service Menus ((51765761) 37
About menu 38
40
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Page iii

Equipment Usage menu 40
Maintenance menu 40
System Settings menu 42
System Tests menu 47
Club Settings (5651565) 48
Information Display (65) 48
Adjustment Procedures 50
Available Adjustment Procedures 50
Drive Belt Tension and Alignment Adjustment 51
About 51
Procedure 51
Running Belt Tension and Tracking Adjustment 55
About 55
Tools 55
Specification 55
Procedure 56
Lift Motor Calibration 61
About 61
Specifications 61
Procedure 61
Lift Platform Assembly Access 64
Replacement Procedures 69
Available Replacement Procedures 69
Covers and Panels Replacement 70
About 70
Hood Cover Replacement 72
Hood Transition Cover Replacement 73
Trim Landing Covers Replacement 75
Trim End Cap Covers Replacement 78
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Page iv

Trim Side Cover Replacement 80
Dash Back Cover Replacement 82
Dash Front Cover Replacement 83
Dash Top and Bottom Cover Replacement 84
Side Arm Upper/Lower Covers Replacement 88
Power Cord Replacement 89
About 89
Procedure 89
ON/OFF SW Circuit Breaker Replacement 91
About 91
91
Wire Diagram 92
Procedure 92
ASL PCA Replacement 95
About 95
Wire Diagram 95
Procedure 96
E-Stop "Emergency Switch" Replacement 100
About 100
Procedure 100
Motor Controller (MC) Replacement 101
About 101
MC Wire Diagram 102
MC Connector Definition 103
MC Status Light 108
Replacement Procedure 109
Motor Controller Fan Replacement 112
About 112
MC Fan Connector Definition 112
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Page v

Drive Belt Replacement 117
About 117
Procedure 117
Drive Motor Replacement 124
About 124
Drive Motor Cable Schematic 125
Procedure 125
Drive Roller Replacement 131
About 131
Procedure 131
Take-up Roller Replacement 136
About 136
Procedure 136
Running Belt and Deck Replacement Procedure 140
About 140
Procedure 140
Lift Motor Replacement 147
About 147
Specification 147
Lift Motor Fuse 147
Lift motor cable schematic 148
Procedure 148
Lift Platform Replacement 158
About 158
Procedure 158
Troubleshooting 164
About 164
Introduction To Troubleshooting 164
Basic Steps 164
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Validate the customer reported issue: 164
Verify the Input Power (Powered units only) 165
Verify that the console is operating correctly 165
Review the Error Log or CPA Event Log for any active error codes 166
Verify (reproduce) the issue. 166
Perform hardware validation diagnostic tests 166
Verify Club Settings 167
Verify that there are no new error codes 167
Verify service bulletins 167
Standard Error Codes 168
About 168
Viewing Error Codes (Error Log & Event Log) 169
Error Code and Troubleshooting Guide 169
Troubleshooting with Error Codes 169
Error Log & CPA Event Log 171
About 171
LED Console (P10, P30, P30i and P31) Error Log 172
Touchscreen Console (P62, P80, and P82) CPA Event Log 172
Active Status Light (ASL) 175
About 175
ASL Light Equipment Location 175
ASL Overview 175
ASL States 176
ASL Settings and Functions 177
System Troubleshooting Procedures 181
Available System Troubleshooting Procedures 181
Tripped Circuit Breaker 182
Input Power Troubleshooting 186
Console Power Troubleshooting 188
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Page vii

Communications Error Troubleshooting 191
Machine Controls Troubleshooting 193
Auto Stop Troubleshooting 195
E-Stop not Communicating Troubleshooting 197
Heart Rate Monitor Troubleshooting 198
Drive Motor System Troubleshooting 201
Incline Lift System Troubleshooting 205
Error Code 40 "NO Lift Motion Detected" 206
Possible Fault Causes: 207
Running Belt Troubleshooting 210
Preventive Maintenance 212
About 212
Maintenance Schedule 212
Precor Preventative Maintenance Plan 212
Running Belt and Deck Cleaning Procedure 213
Theory of Operation 216
What's New 216
Console Upper PCA and Base Lower PCA Operation 216
Console - Upper PCA board (UPCA) 216
Base - Lower PCA board (LPCA) 217
COMM Communication Interface Cable 217
Active Status Light (ASL) 218
218
System Wiring Diagram 219
System Wire Diagram Overview 219
System Wire Diagram - Connector Pins 220
COMM Cable Wire Diagram 221
Console Wire Diagram 222
Power Entry Assemble Wire Diagram 223
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Page viii

Parts Exploded View Diagram & Parts List 224
About 224
Exploded View Diagram 225
Parts List 232
Appendix A : Edition Information i
Edition i
Additional Documentation i
Copyright i
Appendix B : Notices and Safety ii
Trademarks ii
Intellectual Property ii
Warranty ii
Safety Notices ii
Service Safety Guidelines iii
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Page ix

Introduction
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 providers
only. Personal injury can result from electrical shock and/or mechanical moving parts.
This service manual applies to the TRM700-16/18 Experience™ Series 700 Line treadmills
including the 120 VAC1and 240 VAC models. This document contains information required to
service, repair, troubleshoot, and maintain the machine base.
Model TRM700-16 Base Configuration
TRM731 TRM700 base (0.5-12 mph, 0-15% incline) with P30 console
TRM761 TRM700 base (0.5-12 mph, 0-15% incline) with P62 console
TRM781 TRM700 base (0.5-12 mph, 0-15% incline) with P82 console
Separate Base/Console Service Manuals
There are separate service manuals for the machine base and consoles. Use this service
manual to service, repair, and maintain the machine base. Refer to the particular console ser-
vice manual for console service, repair, and maintenance information.
1voltage in an alternating current circuit
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Page 1
1 Introduction

Additional Documentation
There is also an online web version if you have internet access at: Online Service Manuall
See Also
"General Information" on page5
Safety Guidelines
"Operation Verification" on page19
"Standard Service Menus" on page22
"Adjustment Procedures" on page50
"Replacement Procedures" on page69
"Troubleshooting" on page164
"Theory of Operation" on page216
"System Wiring Diagram" on page219
"Parts Exploded View Diagram & Parts List" on page224
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Page 2
1 Introduction

Service Safety Guidelines
WARNING: Only Precor certified servicers and technicians are permitted to service
Precor products. Personal injury can result from electrical shock and/or mechanical
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 equip-
ment.
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 ATM units when the stairarms are in motion; the generator will operate and produce
potentially hazardous voltages even when the battery is disconnected.
lOn AMT1units 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 ATM 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 dan-
gerous 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 bear-
ing components:
oRemove jewelry (especially from ears and neck),
oTie up long hair,
oRemove neck ties, and
oDo not wear loose clothing
See Also
"Notices and Safety" on pageii
"Safety Notices" on pageii
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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.
Model and Serial Numbers
Model and Serial Numbers
Model Numbers
The product model number is a six digit alphanumeric code "AAAXXX" containing the fol-
lowing components. Use the Product Model Number table to interpret the product number
code.:
Product model number format: "AAAXXX"
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: TRM833
lTRM1– Treadmill
l8 – Experience Line
l3 – P30 console
l3 – Fixed ramp
Product Model Number Table
PRODUCT TYPE PRODUCT LINE CONSOLE FEATURE LEVEL
TRM: treadmill
EFX2: elliptical
AMT3: AMT
UBK4: Upright
8-Experience,
Premium
7-Experience,
6-Assurance, Stand-
8-P80, P82
6-P62
3-P30,P31
2-P20
7EFX: Fixed Ramp/Moving
Arms
1Treadmill
2Elliptical Fitness Crosstrainer
3Adaptive Motion Trainer
4Upright Bike
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2 General Information
Model and Serial Numbers

PRODUCT TYPE PRODUCT LINE CONSOLE FEATURE LEVEL
RBK1: Recumbent ard
4-Precision, Con-
sumer
2-Energy, Consumer
1-P10 5TRM: High Speed/Decline
AMT: Moving Step Height
EFX: Moving Ramp/Mov-
ing Arms
3TRM: Fixed Ramp
AMT: Fixed Step Height
EFX: Moving Ramp/Fixed
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.
Serial Number Label Location
The serial number label is located on the hood and frame.
Note:Always use the frame serial number label to verify the machine serial number.
Do not use a label attached to a plastic cover, the cover may have been replaced from
a different machine.
1Recumbent Bike
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Page 6
2 General Information
Model and Serial Numbers

Orientation
The equipment orientation (front, right, left, & back) is referenced to an exerciser standing on
the machine facing the console.
Covers and Panels
Covers and Panels
Equipment cover and access panel locations.
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Page 7
2 General Information
Orientation

For cover removal and installation, see "Covers and Panels Replacement" on page70.
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 screw driver 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
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2 General Information
Tools and Supplies

• DVM meter • Torque1Wrenches: 9 in lbs to 100 in - lbs
(83 ft-lbs)
•AC2Clamp-on averting current meter • DVM Multimeter
• Belt tension gauge – OTC Tools Model #:
6673
• Drive Belt tension Gauge (Kent-Moore BT-
33-73-F
• 2 Running belt tension gauges (Precor
PN: PPP000000020007101)
• Compatible HR3chest strap or Polar HRM
simulator xmitter (Precor PN:
PPP000000020045101)
• 12 " wonder bar • Vacuum cleaner (recommend ESD safe
model)
• ESD wrist strap
Supplies
• Super Lube Gel with Teflon by Permatex • Cleaning rags
• Mobil 1, NLGI 2 Teflon Synthetic Grease • Cleaner Degreaser (see )
• Loctite 243 Blue Medium Strength Thread-
locker
• Cable ties (1- 3/4", 3", 4" lengths)
Specification Summary
Fastener Torque Specification
System component fastener torque specification:
System Component Specification
RF4coax connector 2.4 in-lbs (0.271 Nm)
Display mounting fasteners 180 in-lbs (20 Nm
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.
2Alternating Current: electric current which periodically reverses direction between positive
and negative polarity.
3Heart Rate
4Radio Frequency: Identifies electromagnetic signals with frequency spectrum between the 3
kHz (3,000 hertz) to 300 GHz (300 billion hertz) range.
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2 General Information
Specification Summary

System Component Specification
Set screws 300 in-lbs (34 Nm)
Plastite screw fasteners 20 in-lbs (2.3 Nm)
Flathead screws 25 in-lbs (2.8 Nm)
Deck front fasteners 27-33 in-lbs (3.1-3.7 Nm)
Deck rear fasteners 50-55 in-lbs (5.6-(6.2 Nm)
Lift Motor Calibration gap 1 1/8 in - 1 3/16 in (2.8 cm - 3.0 cm)
BeltTension Specification
.Belt tension specification:
System Component Specification
Drive Belt Tension New Belt(1) 100-120 lbs (45-54 kgs)
Drive Belt Tension Used Belt(1) 80-90 lbs (36-41 kgs)
Drive Motor fasteners 204 in-lbs (17 ft-lbs, 23 N-m)
Ammeraal brand running belt tension (gauge/-
percent)
3.75 (0.75%)(2)
Forbo brand running belt tension (gauge/percent) 3.55 (0.55%)(2)
(1)New belt tension applies to new belt first time installations. Used belt tension applies to
reinstalling an existing belt or re-tensioning an existing used belt.
(2)Referenced to 3.0 (0.0%).
Bolt Grade Identification
Bolt grade markings are used to categorize bolts according to the bolt material, manufacturing
process, and mechanical properties.The grade of the bolt is stamped on the head of the bolt.
US SAE bolts: The bolt grade markings are determined by the number of the lines stamped
on the head of the bolt. The number of lines is always two less than the grade of the bolt.
Count the lines, add two, and you can determine the grade of the bolt.
Metric bolts: On metric bolts, the bolt grade is identified by a bolt grade number stamped on
the head of the bolt.
CAUTION:Always replace bolts with the same grade bolt. If you don’t know the
grade of the replacement bolt – DO NOT USE THE BOLT.
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2 General Information
Bolt Grade Identification

Bolt Grade Markings Chart
Example bolt grades used on Precor equipment (may not represent all bolt grades). Always
match the replacement bolt grade marking to the removed bott grade marking.
Parts
IMPORTANT: Always purchase OEM replacement parts and hardware from Precor.
If you use parts not approved by Precor, you could void the Precor Limited Warranty.
Use of parts not approved by Precor may cause injury.
There is a copy of the parts Exploded View Diagram and Parts Identification List included in
the "Parts Exploded View Diagram & Parts List" on page224 chapter that you can use as a
quick reference. It is recommended that you go to the servicer partners Precor Connect (or
Precor Connection) website to view the most current parts information including the Exploded
View Diagram and Parts Identification List .
lPrecor Connect Partner website
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Page 11
2 General Information
Parts