Precor TRM10/GEN06 User manual

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TRM10/ GEN06 TREADMILL BASE
20039-165 REV A04
PRECOR CUSTOMER SUPPORT
Service Manual

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Contents
Section 1 - About This Document ........................................................................................... 5
Section 2 - General Information ............................................................................................. 6
GEN-06/ TRM10 Treadmill Base ......................................... 6
Lubricants ........................................................... 6
Electrical Requirements .............................................. 6
Section 3 - Safety Guidelines ................................................................................................... 8
Section 4 - Operation Verification.......................................................................................... 9
Operation Verification ............................................... 9
Procedure ................................................................................................................................ 9
Operation Verification Checklist .................................... 11
Section 5 - Standardized Service Access Codes................................................................... 12
Service Access Codes ................................................ 12
Accessing the Service Software ...................................... 12
P80 Console........................................................................................................................... 13
Access Code Table ................................................... 14
P20 Console Service Software Access ................................. 15
Hardware Validation - Diagnostic Tests (51765761) ................... 16
Club Parameter - Settings (5651565) ................................. 17
Information Display (65) ............................................ 18
Section 6 - Theory Of Operation........................................................................................... 19
Consoles ............................................................ 19
Basic operation of a console............................................................................................. 19
Consoles that could appear on the GEN-06 / TRM10 Treadmill Base........................ 20
Console To Base Communication ....................................... 22
Treadmill Base Operation ............................................ 23
Power Entry............................................................................................................................ 23
Lower Electronics Module .................................................................................................. 24
AC Drive Motor Controller .................................................................................................. 25
Auto-Stop............................................................................................................................... 27
AC Lift System –Motion Control ........................................................................................ 28
AC Lift System –Position Monitoring ................................................................................. 30
Section 7 - TRM Base Troubleshooting Procedures ........................................................... 31
Introduction to Treadmill Troubleshooting ........................... 31
Troubleshooting Tripped Breakers .................................... 31
If the unit trips the wall breaker: ........................................................................................ 32
If the Treadmill breaker (power switch) is tripped:......................................................... 33
Troubleshooting No Power to the Console ............................. 35
Standardized Error Codes ............................................ 36
Error Codes ............................................................................................................................ 38
Error Code Table................................................................................................................... 39
Validating the Reported Failure ........................................................................................ 40

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Troubleshooting Input Power & Control Error Codes ................... 41
Error 05 - Key Depressed at Power Up.............................................................................. 41
Description............................................................................................................................. 41
Possible Causes..................................................................................................................... 41
Possible Remedies ................................................................................................................ 41
Error 09 - Lower PCA Memory Test Errors .......................................................................... 42
Description............................................................................................................................. 42
Possible Cause ...................................................................................................................... 42
Possible Remedy................................................................................................................... 42
Error 12 - Watchdog (Lower PCA)..................................................................................... 43
Description............................................................................................................................. 43
Possible Causes..................................................................................................................... 43
Possible Remedies ................................................................................................................ 43
Error 15 - A.C. Input Voltage Too High.............................................................................. 44
Description............................................................................................................................. 44
Possible Causes..................................................................................................................... 44
Possible Remedies ................................................................................................................ 44
Error 16 - A.C. Input Voltage Too Low .............................................................................. 46
Description............................................................................................................................. 46
Possible Causes..................................................................................................................... 46
Possible Remedies ................................................................................................................ 46
Error 80, 81, 82, & 83 –P30 Machine Controls Not Working.......................................... 47
Description............................................................................................................................. 47
Possible Causes..................................................................................................................... 47
Possible Remedies ................................................................................................................ 47
Troubleshooting the 3 Phase AC Drive Motor System ................... 48
Procedure:............................................................................................................................. 48
Error 20 - Too many Maximum Power Requests in 1 Second ....................................... 51
Description............................................................................................................................. 51
Possible Causes..................................................................................................................... 51
Possible Remedies ................................................................................................................ 51
Error 27 - Too Much Drive Motor Current ......................................................................... 52
Description............................................................................................................................. 52
Possible Causes..................................................................................................................... 52
Possible Remedies ................................................................................................................ 52
Error 28 - Temperature Too High ........................................................................................ 53
Description............................................................................................................................. 53
Possible Causes..................................................................................................................... 53
Possible Remedies ................................................................................................................ 53
Error 29 - Excessive AC Input Current................................................................................ 54
Description............................................................................................................................. 54
Possible Causes..................................................................................................................... 54
Possible Remedies ................................................................................................................ 54
Troubleshooting the Incline System .................................. 55
Operation of lift motor for testing: .................................................................................... 55
Error 40 - No Lift Motion Detected..................................................................................... 56
Description............................................................................................................................. 56
Possible Causes..................................................................................................................... 56
Possible Remedies ................................................................................................................ 56

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Error 42 - Lift Position Value Out of Range ....................................................................... 61
Troubleshooting Procedure ................................................................................................ 61
Description............................................................................................................................. 61
Possible Cause ...................................................................................................................... 61
Possible Remedies ................................................................................................................ 61
Error 44 - Un-commanded Lift Motion .............................................................................. 64
Description............................................................................................................................. 64
Possible Causes..................................................................................................................... 64
Possible Remedies ................................................................................................................ 64
Error 45 - Lift Moving in Wrong Direction .......................................................................... 65
Description............................................................................................................................. 65
Possible Causes..................................................................................................................... 65
Possible Remedies ................................................................................................................ 65
Troubleshooting Communications Errors ............................... 66
Error 30, 31, 32 and 33 - Communications Error .............................................................. 66
Description............................................................................................................................. 66
Possible Causes..................................................................................................................... 66
Possible Remedies ................................................................................................................ 66
Error 37 - E-Stop Not Communicating............................................................................... 67
Description:............................................................................................................................ 67
Possible Cause: ..................................................................................................................... 67
Possible Remedies:............................................................................................................... 67
Running Belt & Deck Troubleshooting ................................. 68
Procedure .............................................................................................................................. 68
Troubleshooting the Auto Stop Feature ............................... 70
Error 60 or “Temporarily Out of Order” – Auto Stop Not Working................................ 73
Description............................................................................................................................. 73
Possible Causes..................................................................................................................... 73
Possible Remedies ................................................................................................................ 73
Error 61 or “Temporarily Out of Order” – Auto Stop Not Present ................................. 75
Description............................................................................................................................. 75
Possible Causes..................................................................................................................... 75
Possible Remedies ................................................................................................................ 75
Troubleshooting Heart Rate Issues .................................................................................... 77
Hand Held Heart Rate Does Not Work............................................................................. 77
Wireless Heart Rate Does Not Work .................................................................................. 78
Possible sources of interference signals include, BUT NOT LIMITED TO:...................... 78

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Section 8 - Replacement Procedures..................................................................................... 79
Replacing the Line Cord ............................................. 79
Replacing the Circuit Breaker ....................................... 81
Replacing the Line Filter ........................................... 83
Replacing the Input Module .......................................... 85
Replacing the Auto Stop Sensor ...................................... 87
Replacing the Auto Stop Magnet ...................................... 89
Replacing Drive Motor ............................................... 92
Replacing the Incline Motor ......................................... 93
Replacing the Incline Platform ...................................... 96
Replacing the Power Control Module .................................. 98
Replacing the End Cap or Belt Guard ................................ 100
Drive Belt Replacement ............................................. 102
Replacing the Drive Roller ......................................... 105
Take Up Roller Replacement ......................................... 109
Running Belt and/or Deck Replacement ............................... 111
Section 9 - Adjustment Procedures..................................................................................... 119
Adjusting Drive Belt Tension ....................................... 119
Tensioning the Running Belt ........................................ 122
Running Belt Tracking Adjustment ................................... 124
Running Belt Tracking Adjustment ..................................................................................124
Calibrating the Lift Motor ......................................... 125
Section 10 - Preventive Maintenance.................................................................................. 127
Regular Preventative Maintenance - performed by owner .............. 127
Daily ......................................................................................................................................127
Weekly: (Plus Daily Preventive Maintenance) ..............................................................127
Monthly: (Plus Daily and Weekly Preventive Maintenance)......................................129
On-Site Preventative Maintenance - performed by Service Technician . 130
Preventative Maintenance Checklist (Facility personnel) ............ 133
To Be Done Daily: ...............................................................................................................133
To Be Done Weekly: All of the above plus ....................................................................133
To Be Done Monthly: All of the above plus ...................................................................133
Preventative Maintenance Checklist (Service Technician) ............ 134
Section 11 - Block Diagram................................................................................................. 135
Block Diagram - 120 Volt ........................................... 135
Section 12 - Exploded View & Parts Identification........................................................... 136
Exploded View ...................................................... 136
Parts Identification List .......................................... 142

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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 information required to perform the majority of
troubleshooting and replacement procedures required to repair and
maintain this product.
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.
Section 1 - About This Document

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In This Section
GEN-06/ TRM10 Treadmill Base ...................... 6
Lubricants ........................................ 6
Electrical Requirements ........................... 6
GEN-06/ TRM10 Treadmill Base
This manual covers service information for the GEN-06 / TRM10 Treadmill
Base.
The GEN-06 treadmill base is defined as any treadmill produced between
April of 2006 and April of 2011. GEN-06 Treadmills include the
following models; C952, C954, C956, and C966.
The TRM10 treadmill base is defined as any treadmill produced after
April 2011 and is mated to a Pxx console. All of the base and console
combinations are part of the "Experience" line of products.
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).
Use of unapproved lubricants, cleaners, or solvents may void the
treadmill warranty.
Electrical Requirements
It is extremely important that any Precor treadmill be connected to and
operated on a dedicated 20 amp AC 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 operating 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.
Section 2 - General Information

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Nominal AC operating voltage on 120VAC circuits is 90VAC to 132VAC.
Nominal AC operating voltage on 240VAC circuits is 180VAC to 264VAC. For
operator safety considerations 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.
Important
If the AC circuit feeding a treadmill is found to be a non-dedicated
branch circuit or a circuit equipped with a circuit breaker with a
capacity of less than 20 amps, the AC circuit must be corrected before
any reliable troubleshooting can be performed on the treadmill. More
importantly, a non-dedicated branch circuit may constitute a safety
hazard to the treadmill operator.
120 Vac Systems
120 VAC distribution systems utilize a single pole circuit breaker (hot
lead) and a neutral lead connected to a common neutral (ground) bar. The
A.C. safety ground (green wire) is connected 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.

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Safety guidelines you should know and follow include:
Read the owner’s manual and follow all operating instructions.
Operate the equipment on a solid, level surface.
Visually 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.
When operating the treadmill:
Do not wear loose clothing. Do not wear shoes with heels or leather
soles.
Check the soles of your shoes and remove any embedded stones.
Tie long hair back.
Do not rock the unit.
Do not stand or climb on the handlebars, display enclosure or cover.
Do not set anything on the handlebars, display enclosure, or cover.
Never place liquids on any part of the treadmill while performing
service.
To prevent electrical shock, keep all electrical components away from
water and other liquids.
Do not use accessory attachments that are not recommended by the
manufacturer-such attachments might cause injuries.
Removing the hood exposes high voltage components and potentially
dangerous machinery. Exercise extreme caution when you perform
maintenance procedures with the hood removed.
Section 3 - Safety Guidelines