Precor GEN06 Series User manual

Service Manual
TRM101/GEN06 Treadmill
1TRM800 version 1 treadmills mfg. dates 2010 thru 2014.

Contents
Introduction 1
Safety Guidelines 3
Safety guideline you need to know and follow: 3
General Information 5
Orientation 5
Tools 5
Parts 6
Lubrication 6
Cleaning Solutions 7
Electrical Requirements 7
Dedicated Branch Circuit 7
Input Power 8
Frame Ground 8
Operation Verification 9
Operation Verification Tests 9
Standard Service Menus 12
About 12
Service Access Codes 12
LED Consoles: P10, P30, P30i and P31 12
Touchscreen Consoles: P62, P80, and P82 13
How to Access the Service Menus 14
P10, P30, P30i and P31 LED consoles 14
P80 touchscreen console 14
P62 and P82 touchscreen consoles 15
Diagnostics menu access 16
Touchscreen Calibration shortcut 16
Debug Information Report shortcut 16
Contact Precor Customer Support at [e-mail] or 800.786.8404 with
any questions.
Page ii

Navigating the Service Menus 18
P10, P30, P30i and P31 LED consoles 18
P10 and P30 consoles 18
P30i consoles 18
P80 and P82 touchscreen consoles 19
P62 touchscreen consoles 19
LED Console Standard Service Menus 20
Hardware Validation Diagnostics Tests Menu (51765761) 20
Club Settings Menu (5651565) 22
Information Display (65) 24
Touchscreen Console Standard Service Menus 26
Service Menus ( (51765761) 26
About menu 27
29
Equipment Usage menu 29
Maintenance menu 29
System Settings menu 31
System Tests menu 36
Club Settings (5651565) 37
Information Display (65) 37
Adjustment Procedures 39
Available Adjustment Procedures 39
Drive Belt Tension & Alignment Adjustment 40
About 40
Procedure 40
Lift Motor Calibration 43
About 43
Procedure 43
Running Belt Tension and Tracking Adjustment 45
Contact Precor Customer Support at [e-mail] or 800.786.8404 with
any questions.
Page iii

About 45
Procedure 45
Replacement Procedures 48
Available Replacement Procedures 48
Auto Stop Magnet Replacement 49
About 49
Procedure 49
Auto Stop Sensor Replacement 51
About 51
Procedure 51
Circuit Breaker Replacement 53
About 53
Procedure 53
Drive Belt Replacement 55
About 55
Procedure 55
Drive Motor Replacement 59
About 59
Procedure 59
Drive Roller Replacement 62
About 62
Procedure 62
End Cap & Belt Guard Cover Replacement 66
About 66
Procedure 66
Incline Lift Motor Replacement 68
About 68
Procedure 68
Incline Lift Platform Replacement 71
Contact Precor Customer Support at [e-mail] or 800.786.8404 with
any questions.
Page iv

About 71
Procedure 71
Input Module Replacement 73
About 73
Procedure 73
Line Filter Replacement 75
About 75
Procedure 75
Power Control Module Replacement 77
About 77
Procedure 77
Power Cord Replacement 79
About 79
Procedure 79
Running Belt and Deck Replacement 81
About 81
Procedure 81
Take-Up roller Replacement 86
About 86
Procedure 86
Troubleshooting 88
About 88
Introduction To Troubleshooting 88
Basic Steps 88
Validate the customer reported issue: 88
Verify the Input Power (Powered units only) 89
Verify that the console is operating correctly 89
Review the Error Log or CPA Event Log for any active error codes 90
Verify (reproduce) the issue. 90
Contact Precor Customer Support at [e-mail] or 800.786.8404 with
any questions.
Page v

Perform hardware validation diagnostic tests 90
Verify Club Settings 91
Verify that there are no new error codes 91
Verify service bulletins 91
Standard Error Codes 92
About 92
Viewing Error Codes (Error Log & Event Log) 93
Error Code and Troubleshooting Guide 93
Troubleshooting with Error Codes 93
Error Log & CPA Event Log 95
About 95
LED Console (P10, P30, P30i and P31) Error Log 96
Touchscreen Console (P62, P80, and P82) CPA Event Log 96
System Troubleshooting Procedures 99
Available Troubleshooting Procedures 99
Auto Stop Troubleshooting 100
Tripped Circuit Breaker 103
Communications Error Troubleshooting 106
No Power to the Console Troubleshooting 107
Drive Motor System Troubleshooting 108
E-Stop Not Communicating 111
Heart Rate Monitor Troubleshooting 112
Incline System Troubleshooting 115
Input Power and Machine Controls Troubleshooting 116
Running Belt and Deck Troubleshooting 117
Tripped Circuit Breaker 119
Preventive Maintenance 122
About 122
Maintenance Schedule 122
Contact Precor Customer Support at [e-mail] or 800.786.8404 with
any questions.
Page vi

Precor Preventative Maintenance Plan 122
Running Belt and Deck Cleaning Procedure 123
Theory of Operation 126
About 126
Console Operation 126
Controls 126
Features 126
Treadmill Base Operation 128
System Diagrams 134
System Block Diagram - 120 VAC 134
Parts 135
Exploded View Diagram 136
Parts Identification List 141
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
Contact Precor Customer Support at [e-mail] or 800.786.8404 with
any questions.
Page vii

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 following treadmill models:
lGEN06 series treadmill (120 VAC1and 240 VAC models): The GEN-06 treadmill base
is defined as any treadmill produced between April 2006 and April 2011. GEN-06 Tread-
mills include the following models; C952, C954, C956, and C966.
lTRM102series treadmill (120 VAC and 240 VAC models): The TRM10 treadmill base
is defined as any treadmill produced after April 2011 and is configured with a Pxx series
console. All of the base and console combinations are part of the "Experience" line of
products.
This document contains information required to perform troubleshooting and replacement pro-
cedures required to repair and maintain this equipment including: general product information,
software diagnostic procedures, preventative maintenance procedures, inspection and adjust-
ment procedures, troubleshooting procedures, replacement procedures and system block and
wiring diagrams.
Separate Base and Console Service Manuals
This document provides information to service the equipment base independent of the
installed console. For console service documentation, refer to the particular console service
manual.
Additional Documentation
1voltage in an alternating current circuit
2TRM800 version 1 treadmills mfg. dates 2010 thru 2014.
Contact Precor Customer Support at [e-mail] or 800.786.8404 with
any questions.
Page 1
1 Introduction

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" on the facing page
"Operation Verification" on page 9
"Standard Service Menus" on page 12
"Adjustment Procedures" on page 39
"Replacement Procedures" on page 48
"Troubleshooting" on page 88
"Preventive Maintenance" on page 122
"Theory of Operation" on page 126
"Parts" on page 135
"Theory of Operation" on page 126
Contact Precor Customer Support at [e-mail] or 800.786.8404 with
any questions.
Page 2
1 Introduction

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.
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.
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:
1Adaptive Motion Trainer
2Personal Viewing System display.
Contact Precor Customer Support at [e-mail] or 800.786.8404 with
any questions.
Page 3
1 Introduction
Safety Guidelines

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
Contact Precor Customer Support at [e-mail] or 800.786.8404 with
any questions.
Page 4
1 Introduction
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.
Orientation
The equipment orientation (front, right, left, back) used in manual is referenced to a user stand-
ing on the equipment facing the console.
Tools
General set of service and repair tools.
lUS and Metric Hex Key set lStandard and Philips screw driver set
lUS SAE and Metric Wrench set lDVM Multimeter
lTorque1wrench lCrank Puller (recommended Park Tool CCP-22)
lUS SAE and Metric socket set lBelt Tension Gauge (recommended Kent-Moore BT-33-73-
F)
lRunning belt tension gauge
(pn PPP00000002000710
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 newtons of force applied one meter from the center of
the bolt, 6 ft-lb is equivalent to 6 lb of force applied 1 foot away from the center of the bolt.
Contact Precor Customer Support at [e-mail] or 800.786.8404 with
any questions.
Page 5
2 General Information
Orientation

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.
Exploded View Diagram and Parts List
There is a copy of the parts Exploded View Diagram and Parts Identification List included in
the "Parts" on page 135 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
Exploded View Diagram and Parts list, see "Parts" on page 135.
.
Lubrication
Use only NLGI class 2 PTFE (Teflon) synthetic type grease (recommend Mobil 1®synthetic
grease or Super Lube®with Teflon grease, or equivalent). Use of unapproved lubricants,
cleaners, or solvents may void the product warranty.
CAUTION: Do not apply any lubricants or wax 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 syn-
thetic lubricants such as "Super Lube with Teflon" or "Mobile One Synthetic" grease
(RED).
Use of unapproved lubricants, cleaners, or solvents may void the treadmill warranty.
Contact Precor Customer Support at [e-mail] or 800.786.8404 with
any questions.
Page 6
2 General Information
Parts

Cleaning Solutions
Wipe down equipment with recommended cleaning solution. Use dry cloth to remove residue
solution.
lGeneral: 1 oz. mild soap (Simple Green) to 30 oz. water.
lConsole and PVS1: a diluted solution of one part 91% Isopropyl alcohol to one part
water.
CAUTION: Do not use acidic cleaners and do not spray directly onto the equipment
surfaces.
Electrical Requirements
Dedicated Branch Circuit
It is required that the treadmill be connected to and operated on a dedicated 20 amp AC2
branch circuit. A Dedicated Branch Circuit is defined as a circuit fed by a single circuit breaker
feeding a single load, with a single non-shared neutral providing a return line. A treadmill oper-
ating from a non-dedicated branch circuit or a circuit breaker of less than 20 amps capacity will
not have the necessary power to operate normally under higher load conditions.
120 Vac Systems
120 VAC3distribution systems utilize a single pole circuit breaker (power lead) and a neutral
lead connected to a common neutral (ground) bar. The AC. safety ground (green wire) is con-
nected to a separate ground bar in the distribution system.
If it is determined that any of the above electrical conditions are in question, please consult with
a qualified electrician to make appropriate circuit changes.
CAUTION: The treadmill requires a 20-amp individual branch circuit grounded per
NEC (National Electric Code) guidelines or local region electric code.
IMPORTANT: If the AC circuit feeding a treadmill is found to be a non-dedicated
branch circuit or a circuit equipped with a capacity of less than 20 amps, the AC circuit
must be corrected before any reliable Troubleshooting can be performed. More
importantly, a non-dedicated branch circuit may constitute a safety hazard to the tread-
mill operator.
1Personal Viewing System display.
2Alternating Current: electric current which periodically reverses direction between positive
and negative polarity.
3voltage in an alternating current circuit
Contact Precor Customer Support at [e-mail] or 800.786.8404 with
any questions.
Page 7
2 General Information
Cleaning Solutions

Input Power
Nominal 120 VAC models
lOperating voltage: 90 VAC to 132 VAC.
lFrequency: 47 65 Hz1
Nominal 240 AC Models
lRated Operating voltage: 180 VAC - 264 VAC.
NOTE: An Internal operating voltage range of 180 – 275 VAC with reduced per-
formance is allowed.
lFrequency: 47-65 Hz
Frame Ground
For operator safety and to minimize electrostatic discharge conditions the AC frame ground
continuity must also be verified to be a low resistance connection to the AC distribution ground
bar.
1The hertz (symbol: Hz) is the derived unit of frequency in the International System of Units
(SI) and is defined as one cycle per second.
Contact Precor Customer Support at [e-mail] or 800.786.8404 with
any questions.
Page 8
2 General Information
Electrical Requirements

Operation Verification
This section provides a method to verify that the machine is operating correctly and can be
returned to service. Do these operation verification tests at the end of a maintenance pro-
cedure or whenever it is necessary to ensure that the machine is operating properly.
Operation Verification Tests
Error Code Verification Test
Verify that there are no current active logged error codes:
1. Access either the Error Log (or CPA1Event Log) and record any current active
logged error codes:
lOn P10, P30, P30i and P31 LED consoles, Press & hold down the
PAUSE/RESET key for 6 seconds minimum to access the Error Log.
lOn P62, P80, and P82 touchscreen consoles, access Service menu
(51765761), select About >CPA Even Log.
2. Resolve any current active logged error code issues.
3. Delete resolved error codes:
lOn P10, P30, P30i and P31 LED consoles, clear the Error Log, see "Error
Log & CPA Event Log" on page 95.
Press and hold the PAUSE/RESET key for 6 seconds minimum to access
the Error Log. If there are no logged error codes, the "Stuck Key" message
will show. To remove an error code, press/hold down the QUICK START
key until the "NO ERRORS" message shows.
l. On P62, P80, and P82 touchscreen consoles, error codes cannot be
deleted from the CPA Event Log)
Console Verification Tests
Verify the LED console or touchscreen console operation.
LED consoles (P10, P30, P30i and P31) only
1. Access the Diagnostic/Test menu (51765761) and run the following tests:
lKEYPAD TEST: Select KEYPAD TEST and follow prompts to run test.
lDISPLAY TEST: Select DISPLAY TEST and follow prompts to run test.
2. Exit the Diagnostic Test menu (press the PAUSE/RESET key).
Touchscreen consoles (P62, P80, and P82) only
1. Access the Service menu (51765761) and perform the following console System
Tests (Settings >System Settings >System Tests):
1Touchscreen console Control Processing Assembly.
Contact Precor Customer Support at [e-mail] or 800.786.8404 with
any questions.
Page 9
3 Operation Verification
Operation Verification Tests

lTouchscreen Calibration: Follow screen prompts to complete test. When
the test is completed the console will automatically exit and return to the
System Tests menu.
lTouchscreen Test: Verify that there is a trace created that follows your fin-
ger movement across the touchscreen surface. Select Finish to exit. move
your finger and verify that a trace follows
lBacklight Test: Tests the display backlight brightness. Follow prompts to
complete test.
lRGB Test: Touch the screen to cycle through the test colors: Red, Green,
Blue, White, & Black. Returns to the System Tests menu when completed.
lNumeric Backlight Test: Tests the controls numeric display brightness.
Returns to the System Tests menu when completed.
lNumeric Display Test: Tests the controls numeric display. Returns to the
System Tests menu.
2. Exit the Diagnostic Test menu. (press Back to exit & return to the banner screen)
Motion Controls Test
Verify the machine operation.
1. Select QUICKSTART to begin a manual workout and operate the treadmill at
least 5 minutes. While walking on the unit perform the following tests:
2. Operate the SPEED motion control from minimum to maximum range while veri-
fying the machine operation.
lMake sure that the console SPEED paddle control operation is smooth
and working correctly.
lVerify that the running belt can reach the maximum speed and then returns
to the minimum speed level.
lMake sure that the running belt speed change is smooth and that there are
no unusual noises.
lVerify that the console SPEED indicators and workout displays are show-
ing correct information.
3. Operate the INCLINE motion controls from minimum to maximum range while
verifying the machine operation.
lMake sure that the console INCLINE paddle controls operation is smooth
and working correctly.
lVerify that the running deck can reach the maximum incline and then return
to the minimum incline level.
lVerify that the lift motor operation is smooth while changing the INCLINE
from minimum to maximum levels.
lVerify that the console INCLINE level indicators and user workout displays
are showing correct information.
Running Belt Test
Verify the running belt alignment and tracking.
Contact Precor Customer Support at [e-mail] or 800.786.8404 with
any questions.
Page 10
3 Operation Verification
Operation Verification Tests

1. Step off the running belt and operate the treadmill at 12 mph (19 kph) for one
minute.
2. Verify the running belt alignment is centered and tracking.
ESTOP Switch Test
Verify the ESTOP emergency switch operation.
1. While walking on the treadmill, press the STOP emergency button and verify that
the running belt immediately slows to a stop.
2. While walking on the treadmill, pull the ESTOP lanyard and make sure the run-
ning belt immediately slows to a stop.
3. Inspect the condition of the ESTOP lanyard clip, that the spring is in place and
that the clip will firmly hold when attached.
Heart Rate Test
Verify the Hand Held Heart Rate (HHHR1) monitor operation.
LED consoles (P10, P30, P30i and P31) only
1. Access the Diagnostic menu (51765761) and run the following test:
lHEART RATE TEST: Select HEART RATE TEST and follow prompts
run test.
Touchscreen consoles (P62, P80, and P82) only
1. Access the Service menu (51765761) and run the following test.
lHEART RATE TEST: Select HEART RATE TEST and follow prompts
run test (System Tests (select System Settings >System Tests).
Verify the wireless heart rate monitor operation.
1. Use a wireless heart rate monitor chest strap (pn PPP000000038819103 or
ANT+2wireless compatible HR3chest strap) and verify that the console heart
rate icon is flashing and the HR indicator is showing the heart rate beats per
minute (bpm).
Return to service
1. Switch the power OFF.
2. Make sure that the machine is setting level and stable.
3. Make sure that any external power cords or interface cables are properly routed,
connected, and safe from being damaged.
4. On successful completion of all verification tests, return to service.
1Hand Held Heart Rate
2ANT+ (pronounced ant plus) is a wireless protocol for monitoring sensor data such as a per-
son's heart rate or a bicycle's tire pressure
3Heart Rate
Contact Precor Customer Support at [e-mail] or 800.786.8404 with
any questions.
Page 11
3 Operation Verification
Operation Verification Tests

Standard Service Menus
About
The Standardized Service Menus are supported across Precor cardio product lines designed
to allow servicers and clubs to manage, configure/setup, and maintain/test the equipment: The
service menus are grouped into functional service categories depending on the console type
as follows:
LED Consoles
(P10, P30, P30i and P31)
Touchscreen Consoles
(P62, P80, and P82)
lHardware Validation
(51765761)
lClub Settings (5651565)
lInformation Display (65)
lService Menus
(51765761)
lClub Settings
(5651565)
On LED consoles, there are three service menus grouped by function; the
Hardware Validation menu provides a set of automated diagnostic tests used to troubleshoot,
calibrate, and verify machine operation, the Club Settings menu is used to configure the equip-
ment workout settings, and the Information Display menu provides information about the
equipment hardware, software, usage, and error log data.
On touchscreen consoles, there are two service menus; one intended for service technicians
(the Service menu) and one intended for club operators (Club Settings menu). The Service
Settings menu provides access to all available equipment service menus used by service tech-
nicians to service and maintain the equipment. The Club Settings menu is a subset of service
menus directed toward club operation used by club operators to manage, configure, and main-
tain the equipment.
Each service menu is assigned a unique service access code. To access a service menu, type
in the access code at the service menu login, see "Standard Service Menus" above.
Service Access Codes
Service Access Codes
LED Consoles: P10, P30, P30i and P31
SERVICE
ACCESS CODE SERVICE MENU FUNCTION
51765761 Hardware Validation Set of automated diagnostic tests
used to troubleshoot, calibrate, and
verify machine operation.
Contact Precor Customer Support at [e-mail] or 800.786.8404 with
any questions.
Page 12
4 Standard Service Menus
About

SERVICE
ACCESS CODE SERVICE MENU FUNCTION
5651565 Club Settings Used to configure the club specific
workout, console and maintenance
reminder settings.
65 Information Display Used to access the equipment
usage, hardware, software, error
code, and maintenance information.
Touchscreen Consoles: P62, P80, and P82
SERVICE
ACCESS CODE SERVICE MENU FUNCTION
51765761 Service Menus Service Menu access code provide
access to all available equipment ser-
vice menus used to service, con-
figure, test, and maintain the
equipment including the legacy
Information Display, Club Settings,
and Hardware Validation Diagnostic
Tests menus.
5651565 Club Settings Club Settings access code is a sub-
set of service menus directed
toward club operation, used by club
operators to manage, configure, and
maintain the equipment.
Note: Service access code 65 "Information Display" is not used on touchscreen consoles.
Contact Precor Customer Support at [e-mail] or 800.786.8404 with
any questions.
Page 13
4 Standard Service Menus
Service Access Codes