Precor C932i, Service Manual

Page 1: ...ain this product This document contains general product information software diagnostic procedures when available preventative maintenance procedures inspection and adjustment procedures troubleshooti...

Page 2: ...eck treadmill operation at the end of a maintenance procedure and when it is necessary to ensure that the treadmill is operating properly Section Four Inspection and Adjustment Procedures Perform insp...

Page 3: ...ther 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 o...

Page 4: ...C932i C946i Treadmill Page 4 General Information For the latest exploded view diagram part number and part pricing information visit the Precor dealer website at www precor com connection...

Page 5: ...t Rate Test Belt Speed Incline Procedure 1 Plug the power cord into the wall outlet then turn on the treadmill with the circuit breaker 2 Using the RESET key and the numeric keypad press keys RESET 5...

Page 6: ...s are illuminated 6 Press the Clear key C932i or BA C K key C946i then the key KEYBOARD TEST will scroll across the display 7 Press the OK key a representation of all of the keys on the console will b...

Page 7: ...will indicate the power bits the elapsed time and the actual speed in either miles per hour or kilometers per hour depending on the club parameters setting see Procedure 2 3 13 Press the key the conso...

Page 8: ...Procedure 2 3 The odometer is also used to provide the distance stamp for the error code log Note The odometer data is stored in non volatile memory on the upper PCA If the upper PCA is replaced the...

Page 9: ...PCA has been replaced Please note the serial number function may not be equipped if not equipped no serial number will be displayed The serial number can be entered via the Windows CSAFE program see...

Page 10: ...keys to move to the desired display shown in the list above 5 SAFETY CODE display The safety code when enabled makes the user enter a password in order to start the treadmill Press the OK key 6 Use th...

Page 11: ...ey 24 Use the keys to select the maximum allowable treadmill speed 25 Press the Clear or OK key then the key SET INCLINE LIMIT will be displayed 26 SET INCLINE LIMIT display Press the OK key 27 Use th...

Page 12: ...ng information Model and serial number Software version number Program number running when the problem occurred A description of a What happened or failed to happen b The action taken by the user just...

Page 13: ...brations b 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 c Enter the diagnostics progr...

Page 14: ...rn the incline drive screw until the A D number is in the range of 3055 to 3065 C932i or 3010 to 3020 C946i If the A D number is greater than 3055 to 3065 C932i or 3010 to 3020 C946i operate the incli...

Page 15: ...C932i C946i Treadmill 20077 112 Page 15 8 Plug the line cord into the wall outlet set the treadmill circuit breaker in the on position...

Page 16: ...e 16 9 Check the calibration of the incline system by performing the following steps a Press the INCLINE key until maximum incline is obtained 15 b Press the INCLINE key to minimum incline is obtained...

Page 17: ...nds 5 If the drive belt tension is less than 70 or greater than 90 pounds slightly loosen the four drive motor mounting bolts The drive motor mounts on slotted holes allowing the drive motor to be mov...

Page 18: ...readmill Page 18 Diagram 4 3 Drive Belt Adjustment 6 Re install the hood 7 Plug the line cord into the wall outlet and set the treadmill circuit breaker in the on position 8 Check treadmill operation...

Page 19: ...approximately 36 inches or 1 meter in length is required 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 dec...

Page 20: ...nds on the towel and push it up and down the length of the running deck several times to clean the deck 6 Remove the towel It is recommended that this procedure be performed frequently to extend the l...

Page 21: ...eadmill is turned on skip to step 23 3 If a key does not function skip to step 18 4 If the display does not illuminate continue with step 5 Diagram 5 1 Display Face Rear View C946i 5 If the upper PCA...

Page 22: ...the upper PCA 15 If 8 Vdc is not present on J4 temporarily replace the upper PCA to power control module with a known good cable 16 If the upper PCA illuminates normally replace the upper PCA to powe...

Page 23: ...ort for assistance 23 Remove the keypad cable from the upper PCA See Diagram 5 1 24 Set the treadmill s on off switch in the on position 25 If the STUCK KEY message is no longer displayed replace the...

Page 24: ...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 measurement...

Page 25: ...ll in the manual program and press the INCLINE key The A C voltmeter should read A C line voltage either 120 Vac or 240 Vac Note that the A C line voltage reading will only be present before an error...

Page 26: ...l Precor customer service 14 Set the treadmill s on off switch in the off position Remove the incline motor s connector from the INCLINE connector on the power control module Visually inspect the incl...

Page 27: ...g no hand held reading chest strap normal no hand held or chest strap reading or constant or intermittent readings when neither hand held or chest strap are in use Diagram 6 3 Hand held chest strap he...

Page 28: ...ld signal was accepted in step 6 the hand held contact wiring is reversed The end of the wire harness that connects to the hand held contacts in the handlebar is segregated into two groups One group h...

Page 29: ...ground and 5 Vdc pins of the connector just removed from the heart rate PCA for 5 Vdc If 5 Vdc is present replace the heart rate PCA If the 5 Vdc is not present measure between the corresponding pins...

Page 30: ...d branch circuit or a circuit equipped with a circuit breaker with a capacity of less than 20 amps the A C circuit must be corrected to be a 20 amp dedicated branch circuit before any reliable trouble...

Page 31: ...breaker is greater than 20 amps the circuit breaker should be replaced with a 20 amp circuit breaker If the circuit breaker is less than 20 amps the circuit breaker must be replaced with a 20 amp cir...

Page 32: ...running belt 4 Connect an A C voltmeter between terminals 4 5 of the OUTPUT connector on the power control module See Diagrams 5 3 and 5 4 Set the treadmill s on off switch in the on position Press th...

Page 33: ...dule is supplying output you will momentarily read approximately 55 Vac 11 Repeat the procedure in step 4 between terminals 4 6 of the OUTPUT connector on the power control module 12 Repeat the proced...

Page 34: ...ovide you with a benchmark reading to account for your individual weight Because the A C input current reading will pulse between a high value during foot plant and a low reading between foot plants w...

Page 35: ...age 35 4 If the peak A C current readings are greater than on a new running belt and deck combination but not approaching 20 amperes the reading will give you an indication of the running belt and dec...

Page 36: ...he defective incline motor as follows remove the screw that fastens the frame ground wire green with yellow stripe to the treadmill frame Remove the hitch and clevis pins from the top and bottom of th...

Page 37: ...ch pins one each side from the incline platform to frame mounting See Diagram 6 1 Remove the incline platform mounting pins and remove the incline platform from the treadmill Diagram 6 1 Incline Platf...

Page 38: ...ine Mounting Pin 8 Fasten the incline tube to the incline platform with the clevis pin and hitch pin removed in step 3 9 Set the treadmill in its upright position set the on off switch in the on posit...

Page 39: ...mount the power control module See Diagram 6 3 Diagram 6 3 Power Control Module Mounting 5 Set the replacement power control module in its mounting position 6 Fasten the power control module with the...

Page 40: ...he power control module 3 Remove the four bolts that fasten the drive motor to the frame Remove the drive belt from the drive motor 4 Set the replacement drive motor in its mounting position Place the...

Page 41: ...to the frame See Diagram 6 4 4 Disconnect the wiring from the circuit breaker 2 blue wires on 120 Vac treadmills or 2 blue and 2 brown wires on 240 Vac treadmills Diagram 6 4 A C Input Panel 5 Lift th...

Page 42: ...le to the LINE terminal on the circuit breaker and the blue wire from the A C line filter to the LOAD terminal on the circuit breaker 9 On 240 Vac treadmills connect the blue wire from the input modul...

Page 43: ...wire from the power control module to the L1 terminal on the LOAD side of the A C line filter and the brown wire from the power control module to the L2 terminal on the LOAD side of the A C line filt...

Page 44: ...line cord clamp screws See Diagram 6 5 3 Remove the hardware that retains the A C line cord clamp and remove the clamp 4 Disconnect the A C line cord from the input module 5 Feed the end of the repla...

Page 45: ...rd from the input module 7 Disconnect the wiring from the input module 1 blue wire 1 brown wire and 1 green yellow wire 8 Remove the hardware that retains the input module and remove the input module...

Page 46: ...off of the treadmill 4 If you are not replacing the belt guard skip to step 8 5 The tabs on the belt guard 1 each side snap into the take up roller mounts See Diagram 6 8 6 Press inwards on the belt...

Page 47: ...C932i C946i Treadmill 20077 112 Page 47 Diagram 6 8 Belt Guard Mounting Belt Guard Tab Notch...

Page 48: ...remove the display back cover as follows Grasp the display back cover by the top two holes and pull downward to release the top of the cover Grasp the top and bottom of the cover and pull towards you...

Page 49: ...the replacement upper PCA into its mounting on the display face 11 The red wire in the Metrics and D pad cables indicate pin 1 Align the red wire in the Metrics and D pad cables with the pin 1 markin...

Page 50: ...ards to disengage the tabs and remove the display cap 6 The display face snaps onto the display with six tabs One of the tabs is behind the HR PCA The HR PCA snaps into its mounting Press its tabs dow...

Page 51: ...play cap into place on the display 16 Replace the display back cover by sliding the lower portion of the cover over the targas then press the cover into place Fasten the cover with the hardware remove...

Page 52: ...e display face snaps onto the display with six tabs One of the tabs is behind the HR PCA The HR PCA snaps into its mounting Press its tabs downward and remove the HR PCA from its mounting 7 Press the...

Page 53: ...play cap into place on the display 16 Replace the display back cover by sliding the lower portion of the cover over the targas then press the cover into place Fasten the cover with the hardware remove...

Page 54: ...nward to release the top of the cover Grasp the top and bottom of the cover and pull towards you and then downward to remove cover 4 Disconnect the HR cable and handlebar cable from the HR PCA See Dia...

Page 55: ...tabs Press the tabs outwards to disengage the tabs and remove the display cap 6 The display face snaps onto the display with six tabs One of the tabs is behind the HR PCA The HR PCA snaps into its mou...

Page 56: ...ad assembly into the replacement display face until it snap into place 19 The red wire in the D pad cable indicates pin 1 Align the red wire in the D pad cable with the pin 1 markings on the D pad PCA...

Page 57: ...rive Roller Removal 1 Remove the end caps from the rear of treadmill to expose the take up roller mounting bolts Remove the treadmill s motor cover 2 Remove the deck trim from both sides 3 Loosen but...

Page 58: ...ting bolts Move back and forth between the left and right side mounting bolts so the bolts will tension evenly which will reduce the stress on the threads of the bolts The left side drive roller shaft...

Page 59: ...pounds The drive belt de tension after use A range of 80 90 pounds after the belt has been installed for a while is acceptable Tensioning the Running Belt 10 Move the running belt so that the seam is...

Page 60: ...ph Observe the running belt if the belt starts to drift toward the right slowly turn the right side take up roller mounting bolt clockwise until the drifting stops If the belt starts to drift toward t...

Page 61: ...e the tension evenly on both sides These bolts are being loosened to remove the tension on the running belt 5 If applicable remove the rear roller guards located in the front of the take up roller 6 R...

Page 62: ...er use A range of 80 90 pounds after the belt has been installed for a while is acceptable 11 Move the running belt so that the seam is underneath the treadmill Place a running belt tension gauge on e...

Page 63: ...drifting stops If the belt starts to drift toward the left slowly turn the right side take up roller mounting bolt counterclockwise until the drifting stops The adjustments should only be done in 1 4...

Page 64: ...ilure and premature take up roller bearing failure 1 Remove the end caps from the rear of treadmill to expose the take up roller mounting bolts Remove the treadmill s motor cover 2 If applicable remov...

Page 65: ...he treadmill 6 Remove both drive roller mounting bolts releasing the tension evenly on both sides Remove the drive roller from the treadmill using the drive belt as a handle 7 Remove the Auto Stop mag...

Page 66: ...om of the deck 8 The new running belt will have an arrow pointing in one direction on the underside The arrow indicates the correct direction of travel for the belt Premature belt failure will occur i...

Page 67: ...uring the bottom retaining plates are between the deck and the pivots Verify the spacing on all four corners that they are the same 12 Check the alignment of the magnet and the auto stop assembly The...

Page 68: ...nd right side mounting bolts so the bolts will tension evenly which will reduce the stress on the threads of the bolts The left side drive roller shaft will tighten flush to the front frame bracket Us...

Page 69: ...rotating the drive motor flywheel Be sure the belt is fully seated in the grooves of both pulleys and correctly aligned A drive belt tension gauge should read 100 120 pounds The drive belt de tension...

Page 70: ...the take up roller mounting bolts Tighten the take up roller mounting bolts alternately in order to evenly tighten the running belt Tighten bolts until the gauges read 55 which is five and 1 2 lines p...

Page 71: ...mph for a minute then 6 mph 9 mph and finally 12 mph making any small adjustments as needed 22 Set the treadmill speed to 3 mph and walk on the treadmill for a couple of minutes Verify that the belt...

Page 72: ...1 J4 PCA METRICS J1 D PAD PCA J1 J17 J13 J15 J14 Switch Stop PCA Upper J12 Incline Motor Motor Drive G Y BK W R BK W R BK W R 6 5 4 4 8 3 5 1 6 OUTPUT INCLINE COMM BR BR 50W 100 2 1 DB Control Module...

Page 73: ...C932i C946i Treadmill 20077 112 Page 73 Block Diagram 7 2 C932i C946i 120 Vac...

Page 74: ...C932i C946i Treadmill Page 74 Wiring Diagram 7 3 C932i C946i 240 Vac BL BL Stop Switch J14 1 2 BR BR DB 50W 100...

Page 75: ...C932i C946i Treadmill 20077 112 Page 75 Block Diagram 7 4 C932i C946i 240 Vac...