Service Manual, 9.55 Treadmill.fm
Contents
1. SPA SL uaap za 5 0 1002 bisaq 346171 umog uaap 9a 98 peu dawn 10109 sepoig 46m 02 9960 960 2960 99 6 48 Page 1 48 9 55 Treadmill Block Diagram 7 7 9 55 240 Vac version 2 gt 2 Aiddng 419M0g OPA 092 oz 9a OPA 69 poy dn 10105 61590 sepoig 3467 072 9960 7960 2560 99 6 492. 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 The most common problems found are 1 the circuit is fed by a circuit breaker of less than 20 amp capacity 2 the circuit breaker correctly feeds a single A C outlet but the neutral is common between several A C outlets and 3 both the hot and neutral leads feed several A C outlets The appropriate correction action or actions see below must be followed if any of the above conditions exist Corrective actions should only be undertaken by a licensed electrician 1 circuit breaker feeding the treadmill is not a 20 amp circuit breaker If the circuit 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 circuit breaker and the wiring from the A C distribution must be capable of safely handing 20 amps If the A C wiring is under sized it must be replaced with wire capable of safely handling 20 amps Please refer to local electrical codes when determining the appropriate wire size for a 20 amp circuit Page 23 9 55 Treadmill 2 The circuit breaker correctly feeds a single A C outlet but the neutral is common between several A
3. from the AC outlet Remove the lift motor connector from the J5 connector on the lower logic PCA Visually inspect the lift motor connector for broken or improperly crimped connections Using an ohmmeter read the resistance between terminals 1 amp 4 and between terminals 3 amp 4 Both readings should be approximately 15 Q If either reading is open or very high resistance replace the lift motor per Procedure 6 1 Set the treadmill s circuit breaker the off position and remove the AC line cord from the AC outlet Remove the lift motor connector from the J1 connector on the lower logic PCA Visually inspect the lift motor connector for broken or improperly crimped connections Using an ohmmeter measure between terminals 1 amp 3 1 amp 2 and 2 amp 3 of the lift motor connector Terminals 1 and 3 should read approximately 1 KQ The sum of the two readings between terminals 2 amp 3 and 1 amp 2 should total approximately 1 If either reading is open or very high resistance replace the lift motor per Procedure 6 1 If you have performed all of the procedures above and have been unable to correct the problem call Precor customer service Set the treadmills circuit breaker in the off position and remove the AC line cord from the AC outlet Remove the lift motor connector from the J5 connector on the lower logic PCA Visually inspect the lift motor connector for broken frayed or improperly crimped conne
4. Version 1 Lower Logic PCA s are no longer available If either the lower logic PCA or the lower Power PCA requires replacement it must be replaced with the version 2 lower PCA assembly Version 1 units can be identified in two ways the lower PCA assembly has two separate PCA s mounted on it and the serial number will indicate the unit was manufactured prior to July 2 2001 To replace the lower version 1 9 55 treadmills order 1 59036 101 9 55 lower PCA retrofit kit The kit comes complete with all necessary parts and installation instructions Page 27 9 55 Treadmill Procedure 6 4 Replacing the Lower Power PCA Version 1 Lower Power PCA s are no longer available If either the lower logic PCA or the lower Power PCA requires replacement it must be replaced with the version 2 lower PCA assembly Version 1 units can be identified in two ways the lower PCA assembly has two separate PCA s mounted on it and the serial number will indicate the unit was manufactured prior to July 2 2001 To replace the lower PCA version 1 9 55 treadmills order 1 59036 101 9 55 lower PCA retrofit kit The kit comes complete with all necessary parts and installation instructions Page 1 28 Page 28 9 55 Treadmill Procedure 6 5 Replacing the Lower PCA version 2 1 Set the treadmill circuit breaker in the off position Remove the AC line cord from the outlet 2 Note the routing and tie down points of all
5. Procedure 6 9 Replacing the Line Filter 6 Set the treadmill circuit breaker in the off position and unplug the treadmill s line cord from the AC outlet Remove the four screws that fasten the circuit breaker mounting plate to the treadmill See Diagram 6 8 Disconnect all of the wiring from the line filter Remove the screws that fasten the line filter to the circuit breaker mounting panel Set the replacement line filter in it s mounting position Fasten the line filter to the circuit breaker mounting panel with the screws removed in step 4 Connect the wiring to the line filter per Diagram 6 10 Diagram 6 10 Line Filter Wiring Not Used ower BL To Line Cord Power or Line Filter To Line Filter Set the circuit breaker mounting panel in it s mounting position Fasten the circuit breaker mounting panel to the treadmill using the screws removed in step 2 Check treadmill operation per Section 3 Page 37 9 55 Treadmill Procedure 6 10 Replacing the Line Cord 10 Set the treadmill circuit breaker in the off position and unplug the treadmill s line cord from the AC outlet Remove the four screws that fasten the circuit breaker mounting plate to the treadmill See Diagram 6 8 Remove the nut that fastens the line cord s ground wire green wire to the circuit breaker mounting plate Disconnect the line cord s brown wire from the circuit breaker Disconnec
6. The USER1 name will be displayed first The ENTER key will select USER2 then USER3 then USER4 With the user name to be edited displayed use the INCLINE INCLINE to select the character position to be edited Use the SPEED a SPEED v keys to select the letter to be placed in the selected character position The user name can be a maximum of five characters Press the ENTER key to select the next user name or to exit the program Page 9 9 55 Treadmill Procedure 2 4 Documenting Software Problems When a problem is found with the software in the upper or lower PCA record the information listed below When a problem occurs record the following 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 action taken by the user just before the problem occurred Problem related information such as how far into the program the problem occurred the work level being used when the problem occurred etc The frequency of occurrence Page 1 10 Page 10 9 55 Treadmill Section Three Checking Treadmill Operation This section provides you with a quick method of checking treadmill operation Check treadmill operation at the end of a maintenance procedure and when it is necessary to ensure that the treadmill is operating properly Procedure 4 5 Plug the power cord into the wall outlet
7. then turn on the treadmill with the circuit breaker Place the treadmill in Manual Mode Adjust the speed of the running belt to 2 3 m p h Operate the treadmill for at least 5 minutes a Concentrate on the feel of the running belt and the sound of the drive motor and rollers Be on the alert for unusual noises smells or vibrations b Log the power bits under loaded and unloaded conditions c 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 If during step 1c squeaking noises associated with the running deck were heard check the lubrication of the running deck studs If necessary apply silicon grease to all of the running deck studs Press the STOP key When the treadmill comes to a stop view the electronic console as the treadmill scans time speed distance and percent of lift Press the INCLINE key while viewing the electronic console Confirm that the running bed inclines and the incline display increments to 12 as the INCLINE key is pressed Press the INCLINE W key while viewing the electronic console Confirm that the running bed returns to a level position and the incline display decrements to 0 as the INCLINE key is pressed Turn off the treadmill with the circuit breaker then unplug the treadmill from the wall outlet Page 11 9 55 Treadmill Procedure 4 1 Calibrating the Lift Motor
8. z gt 5 OSE OVA Ove A g ja 2 g 2 1050 oer etr A p dg S YAMS i Ya 092 HIT sh OVA orz m asuag Ag 19195 1520 14677 6 590 210105 sepoig Buri 34617 21601 072 9562 7462 2560 Note Fan sense function removed on units manufactured sfter 9 29 2000 Page 45 9 55 Treadmill Wiring Diagram 7 4 9 55 120 Vac version 2 CSAFE Heart Rate Stop Key BL Motor Line Filter 00 Drive Motor Circuit Breaker 0 Speed Line Cord Sense Ff 00 1 46 46 9 55 Treadmill Wiring Diagram 7 5 9 55 240 Vac version 2 CSAFE Heart Rate Keypad Stop Key BL Lift Motor Line Filter BL K Drive Motor Circuit Breaker K Speed Line Cord Sense 00 0 47 9 55 Treadmill Block Diagram 7 6 9 55 120 Vac version 2 Aiddng 056 1914 oul JOSUaS SOYoIMS
9. 1 Set the treadmill circuit breaker in the off position and unplug the line cord from the wall outlet 2 Remove the hood 3 Place the treadmill on it s right side Remove hitch and clevis pins that secure the lift tube to the lift platform See Diagram 4 1 Diagram 4 1 Lift Motor Mounting Clevis Pin Hitch Pin Drive Screw Lift Tube Clevis Pin Hitch Pin Page 1 12 Page 12 9 55 Treadmill 4 Plug the power cord into the wall outlet set the treadmill circuit breaker in the on position 5 Press keys RESET 5 1 7 6 5 7 6 1 sequentially to enter the diagnostics routine Refer to Procedure 2 1 and advance to the lift test When the lift calibration number is displayed on the console use the INCLINE or INCLINE key to set the lift calibration number to 20 CAUTION While running the lift motor in the diagnostics mode it is possible to operate the lift motor beyond it s normal range of motion When you perform the next step care must be taken not to jam the lift tube against the motor frame 6 Press the RESET key to exit the diagnostics mode 7 Setthe treadmill circuit breaker the position unplug the line cord from the wall outlet 8 Rotate the lift tube clockwise by hand as far as possible Then rotate the lift tube counter clockwise until the distance from the top of the lift tube to the lift motor is 5 8 inch See Diagram 4 1 While rotating the lift tube b
10. C outlets The common neutral lead must be removed from treadmill s A C outlet and a new neutral lead from the treadmill s A C outlet to the A C neutral distribution bar must be added 3 Both the hot and neutral leads feed several A C outlets Both the common neutral and hot leads must be removed from treadmill s A C outlet and a new neutral lead and hot lead from the treadmill s A C outlet to the A C neutral distribution bar and circuit breaker must be added 240 Vac Systems 240 Vac distribution systems utilize a double pole circuit breaker two hot leads The A C safety ground green wire is connected to a ground bar in the distribution system The most common problems found are 1 the circuit is fed by a circuit breaker of less than 20 amp capacity and 2 both the hot leads feed several A C outlets The appropriate correction action or actions see below must be followed if any of the above conditions exist Corrective actions should only be undertaken by a licensed electrician 1 The circuit breaker feeding the treadmill is not a 20 amp circuit breaker If the circuit 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 circuit breaker and the wiring from the A C distribution must be capable of safely handing 20 amps If the A C wiring is under sized it must be replaced with
11. Treadmill Procedure 6 6 Replacing the Speed Sensor Set the treadmill circuit breaker in the off position Remove the AC line cord from the outlet Disconnect the plug from the J2 connector on the lower logic PCA Rotate the flywheel so that the speed sensor is between flywheel lobes Remove the screws that fastens the speed sensor mounting bracket to the treadmill drive motor See Diagram 6 7 Diagram 6 7 Speed Sensor Mounting 8 9 Bracket Mounting Screws Remove the mounting bracket from the drive motor Remove the two screws that fasten the speed sensor to the bracket Mount the replacement speed sensor on the mounting bracket with the screws removed in step 6 Mount the bracket on the drive motor with the screws removed in step 4 Insert the speed sensor plug into the J2 connector on the lower logic PCA 10 Slowly rotate the flywheel to ensure that the flywheel lobes do not contact the speed sensor Page 31 9 55 Treadmill 11 Set the treadmill circuit breaker in the on position and check treadmill operation per Procedure 3 Page 1 32 Page 32 9 55 Treadmill Procedure 6 7 Replacing Drive Motor Set the treadmill circuit breaker in the off position and unplug the treadmill s line cord from the AC outlet Remove the hood The drive motor and flywheel are balanced as a matched pair Since the flywheel is balanced to a specific motor flywheels should not be removed fr
12. Upper PCA Keypad Connector Keypad Page 1 16 Page 16 10 11 15 9 55 Treadmill Set the circuit breaker in the on position If a key depressed message is immediately displayed when the treadmill is powered up replace the upper PCA If a key depressed message is not displayed when the treadmill is powered up replace the display housing front panel The display housing front panel is equipped with the keypad If you have performed all of the procedures above and have been unable to correct the problem call Precor customer service Access the diagnostics program per procedure 2 1 If the key s necessary to access the diagnostic program is not functioning skip to step 14 Test the keypad per Procedure 2 1 step 6 If all of the keys test good the problem may be user error or a key function that is normally disabled during a particular user program If one or more keys do not function correctly either the keypad display housing or upper PCA could be defective Replace the display and repeat step 12 If the display housing did not correct the problem re install the original display housing and replace the upper PCA If you have performed all of the procedures above and have been unable to correct the problem call Precor customer service Page 17 9 55 Treadmill Procedure 5 2 Troubleshooting the Lift System Lift System Description The lift system on these units consists of an
13. circuit breaker the position Press the QUICK START to start the running belt Use the INCLINE w key to lower the incline to 0 3 Setthe treadmill circuit breaker in the off position and remove the AC line cord from the AC outlet 4 Disconnect the lift motor plugs from J2 and J5 connectors of the lower logic PCA See Diagram 5 2 5 Lay the replacement lift motor on the floor in front of the treadmill and connect it s two plugs to the J2 amp J5 connectors of the lower logic PCA 6 Calibrate the lift motor per Procedure 4 1 steps 4 7 7 Remove the lower PCA per Procedure 6 4 steps 1 7 8 Remove the defective lift 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 the lift motor Remove the lift motor from the treadmill 9 Set the calibrated lift motor in its mounting position Replace the upper clevis and hitch pins 10 Replace the lower clevis and hitch pins It may be necessary to slightly rotate the lift tube to align it so that the clevis pin may be inserted To align the hole in the lift tube rotate it in the direction that will cause the least amount of rotation to make alignment possible 11 Connect the frame ground wire to the treadmill frame with the screw removed in step 6 Route both lift motor cables as noted in the lift motor removal procedure 12 Replace the low
14. following values are displayed time that the running belt has operated during this test current in amps through the drive motor belt speed in MPH and power bits PWM value This test is valuable in diagnosing treadmill load conditions such as running bed and or running belt condition As load is increased the speed is kept at a constant value as set via the SPEED keys and the current and power bits will vary proportionately to the load Page 5 22 23 24 25 26 27 28 29 30 31 32 9 55 Treadmill It is suggested that you perform this test on a treadmill known to be in excellent operating condition Note the values displayed at a fixed speed such as 3 MPH and your body weight Those values may then be used to benchmark the operation of treadmills you are diagnosing Press press the ENTER key to proceed to the belt power test The display will momentarily read BELT POWER TEST The belt power test is similar to the belt speed test except that the SPEED keys control the power bits PWM value instead of the belt speed The same see step 16 values will be displayed as in the belt speed test This test is valuable in diagnosing treadmill response to load conditions As load is increased the power bits are kept at a constant value as set via the SPEED keys and the current and belt speed will vary proportionately to the load It is suggested that you perform this test on a treadmill know
15. of the wiring coming into the lower PCA This information will be required after the replacement lower PCA has been installed It is important to have the cabling correctly routed and tied down Diagram 6 6 Lower PCA Mounting version 2 Left front mounting screw Right side mounting screws Lower PCA Left rear mounting nut 3 Disconnect all of the lower PCA wiring noted in step 2 the lower PCA 4 Remove the left rear mounting screw left front mounting screw and two right side mounting screws 5 Remove the lower PCA from the treadmill Fasten the lower PCA with the three screws and nut removed in step 4 6 Replace all of the lower PCA wiring removed in step 3 per the notes taken in step 2 If necessary refer to Wiring Diagram 7 4 Page 29 9 55 Treadmill 7 Ifthe treadmill being serviced operates on 120Vac the 120Vac jumper must be removed from the defective lower power PCA and re installed on the replacement lower power PCA between the M1 connector and the M6 connector Caution If the treadmill being serviced operates on 240 Vac the jumper in step 12 must not be installed If the jumper is installed and the treadmill is operated on 240 the lower power PCA will be operated on double the intended voltage Damage to the lower power PCA will result 8 Set the treadmill circuit breaker in the position and check treadmill operation per Procedure 3 Page 1 30 Page 30 9 55
16. will be displayed When the QUICK START key is held for 2 seconds the message HOLD TO CLEAR ERRORS will be displayed If the QUICK START key is held for an additional 2 seconds the message CLEARED will be displayed When the QUICK START key is released the message NO MORE ERRORS will be displayed and all error are erased from the log Press the RESET the ENTER key to exit the information display Page 1 8 Page 8 9 55 Treadmill Procedure 2 3 Accessing the User Parameter Program This procedure allows you to change the following settings Set Measurement Units Enable Disable Password Set User Name Procedure 10 11 12 13 14 Plug the power cord into the wall outlet then turn on the treadmill with the circuit breaker Press keys RESET 5 6 7 1 sequentially The display will momentarily read DIAGS SET USER PARAMETERS The display will momentarily read SELECT UNITS The currently selected measurement unit will then be displayed Use the keys to scroll through the available measurement units Press the ENTER key to select the currently displayed measurement unit The display will momentarily read PASSWORD Use A V keys to select either PASSWORD ENABLED or PASSWORD DISABLED Press the ENTER key to continue The display will momentarily read USER NAME Up to four user names may be entered If user names have not been previously entered the default user names will be USER1 USER2 USER3 and USER4
17. wire capable of safely handling 20 amps Please refer to local electrical codes when determining the appropriate wire size for a 20 amp circuit 2 Both the hot leads feed several A C outlets Both hot leads must be removed from treadmill s A C outlet and two new hot leads from the treadmill s A C outlet to the circuit breaker must be added A licensed electrician may use the followings hints to determine if an A C service is dedicated 1 If ona 120 Vac system the A C distribution panel contains more circuit breakers than neutral leads the system has shared neutral leads and is not dedicated 2 Ifan A C outlet 120 240 Vac has multiple hot and or neutral leads it is not a dedicated If either of the above conditions exist the system is not dedicated However absence of the above conditions does not necessarily mean that the system is dedicated If any doubt exists about A C systems dedication point to point tracing of the A C wiring may be the only way to prove system dedication Page 1 24 Page 24 9 55 Treadmill Procedure 6 1 Replacing the Lift Motor Note The replacement lift motor must be calibrated prior to installation The lower PCA bracket assembly must be removed to gain access to the lift motor The defective lift motor is then removed and the calibrated replacement lift motor is installed The lower PCA bracket is then replaced 1 If the incline is at 0 skip to step 2 Set the treadmill
18. 1 is 0 Vdc or significantly low when a flywheel lobe is between the speed sensor legs continue with step 3 3 Measure the voltage between terminal 1 of J2 red wire and terminal 4 of J2 black wire on the lower PCA The voltage should read approximately 5 Vdc Page 21 9 55 Treadmill 4 Ifthe voltage is missing or significantly low disconnect the speed sensor plug from the lower PCA Measure the voltage between pins 1 amp 4 of the J2 plug on the lower PCA If the voltage is approximately 5 Vdc replace the speed sensor If the voltage is missing or significantly low replace the lower logic PCA 5 At this point the speed sensor output is good but a speed error occurs There two potential causes for this condition They are upper PCA or lower logic PCA There are no good means of troubleshooting these components other than substituting known good components Replace only one component at a time If the component that you replaced does not correct the problem replace the original component Try substituting the lower logic PCA first then the upper PCA if necessary 6 Ifyou have performed all of the above procedures have been unable to correct the problem call Precor Customer Support Page 1 22 Page 22 9 55 Treadmill Procedure 5 4 Troubleshooting the External A C Power Source It is extremely important that any Precor treadmill be connected to and operated on a dedicated 20 amp A C circuit A 20 amp d
19. 2 1 Lift System Fuse Fuse Page 1 18 Page 18 9 55 Treadmill Insert the treadmill s line in the AC outlet and set the circuit breaker in the position Set the treadmill in the manual program and press the LIFT A key If the lift motor operates normally test treadmill operation per Section 3 If the lift motor still does not operate retest the lift fuse per steps 2 amp 3 If the fuse is open again continue with step 13 If the fuse is good continue with step 5 Connect an AC voltmeter between terminals 1 amp 3 of the J5 connector See Diagram 5 2 Set the treadmill in the manual program and press the LIFT A key The AC voltmeter should read AC line voltage either 120 Vac or 240 Vac and the UP LED should illuminate Note that the AC line voltage reading will only be present before an error condition is displayed If the F2 fuse is good and the UP LED illuminates and the AC voltmeter does not read the presence of AC line voltage replace the lower logic PCA per Procedure 6 3 If the UP LED does not illuminate and the display indicates that the lift should be moving upward replace the upper PCA per Procedure 6 8 If the AC voltmeter reads the presence of AC line voltage and an error 40 is displayed go to step 10 If the AC voltmeter reads the presence of AC line voltage and an error 42 is displayed continue with step 11 Set the treadmill s circuit breaker in the off position and remove the AC line
20. 4 it L E CSAFE 1 STOP SWITCH tue SERIAL INTERCONNECT CABLE 1 LIFT MOTOR LIFT POSITION black LIFT POWER LOWER LOGIC PCA NEUTRAL J3 violet violet TO BRIDGE TERM BLOCK brown tp une PEYTTE blue je SPER blue neutral brown NEUTRAL SIDE SIDE 8 TERM BLOCK FOR 120V USE ONLY SEE DETAIL OF BREAKERS grn yel Page 43 9 55 Treadmill gt gt 092 2 gt oz OVA 4 021 Sur 2 Josuss sor Ser rer bof 5 asuas uey OPA SE usa 59 0 51590 1467 1 poy 5 pou za 5 20105 61590 sepoig 1467 yod7 21607 1 02 9562 V969 2560 Block Diagram 7 2 9 55 120 Vac version 1 Note Fan sense function removed on units manufactured sfter 9 29 2000 Page 44 Page 1 44 9 55 Treadmill Block Diagram 7 3 9 55 240 Vac version1 ya Aiddns dwe oz 18 56 18
21. 9 55 Treadmill 9 55 Treadmill Warning This service manual is for use by Precor trained service providers only If you are not a Precor Trained Servicer you must not attempt to service any Precor Product 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 To move directly to a procedure click the appropriate procedure in the bookmark section to the left of this page You may drag the separator bar between this page and the bookmark section to change the size of the page being viewed 2003 Precor Incorporated Unauthorized Reproduction and Distribution Prohibited By Law Page 1 9 55 Treadmill Section One Things you Should Know About This Appendix The 9 55 has been manufactured in two versions When servicing a 9 55 it is critical that you are aware of which version of version you are servicing The differences in the versions may greatly impact service requirements and procedures For convenience the versions detailed below will be referred to as version 1 or version 2 in the reminder of this service manual Any proced
22. AC line voltage driven lift motor 120 Vac or 240 Vac and an internal 1 KQ potentiometer for lift position identification The lift motor contains two motor windings one to operate the motor in an upward direction and the other to operate the motor a downward direction As the lift motor is operated the motor also rotates the potentiometer via an internal gear system Therefore the position of the lift system can be determined by monitoring the value of the internal potentiometer The lift motor is initially set at a known starting position calibration See Procedure 4 1 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 measurements with voltage applied may damage your ohmmeter Procedure 1 Ifthe lift motor operates but creates a lift error error 40 or 42 go to step 16 the lift motor will not move continue with step 2 2 Set the treadmill s circuit breaker in the off position and remove the AC line cord from the AC outlet 3 Remove the F2 Lift AC fuse from the lower logic PCA Using an ohmmeter check the resistance of the F2 fuse See Diagram 5 2 The fuse should measure approximately 0 1 Q or less If the fuse is open or high resistance replace the fuse Up LED S PR 29 A Down LED gt
23. P for Polar filtering The Polar filtered heart rate will also appear in the normal heart rate display since Polar filtering is the filtering used during normal operation The right most red LED in the smart rate display will flash each time a heart beat is detected Note If there is not a heart rate receiver installed or there is a bad or intermittent connection 20 21 between the heart rate receiver and the upper PCA the messages in step 9 will be replaced by the message NO HEART RATE RECEIVER Press the ENTER key to proceed to the lift test The display will momentarily read LIFT TEST Two numbers will be displayed the percent of lift and A D number related to the current lift position The A D analog to digital number represents the lift potentiometer reading The A D number will be in the range of 0 to 255 The lift may be operated using the INCLINE keys The incline percentage and A D numbers will change accordingly Care must be taken while operating the lift in this mode because the normal upper and lower range limits are not in effect It is possible to operate the lift to it s physical limits and may cause the lift motor to jam A D reading will be used later in this service manual to calibrate the lift Press the ENTER key to proceed to the belt speed test The display will momentarily read BELT SPEED TEST The speed of the running belt is controlled by the SPEED keys during this test The
24. STOP is key number 4 and is located directly below the QUICK START key The QUICK START key is not part of the numbering sequence Plug the power cord into the wall outlet then turn on the treadmill with the circuit breaker Press keys RESET 5 1 7 6 5 7 6 1 sequentially The display will momentarily read DIAGS HARDWARE VALIDATION The display will momentarily read DISPLAY TEST and then illuminate every LED on the display Check all LED positions to ensure that all of the LED s are functioning Press the ENTER key to continue Diagram 2 1 9 55 Treadmill Display Reset Key 1 O Tma 9 SRAMENT TIME 7 raoa 474 7 1 4 4 9 55 Treadmill The display will momentarily read KEYBOARD TEST The keyboard test will place two dots on the display for each key on the display including the numeric keypad Pressing a key will cause the upper of the two dots associated with the key to go out Test all of the keys in this manner Tug on the safety key lanyard to ensure that the STOP key is activated Press and hold the ENTER key to proceed to the heart rate test The display will momentarily read HEART RATE TEST The heart rate test will display the heart rate being received during this test from either a chest strap transmitter or test transmitter Three heart rate values will be displayed They will be prefixed U for unfiltered F for filtered and
25. ave been unable to correct the problem call Precor customer service Page 1 20 Page 20 9 55 Treadmill Procedure 5 3 Troubleshooting the Speed Sensor Note The speed sensor is a hall effect sensor that emits a pulse when a flywheel lobe passes between it s transmitter and receiver The speed control circuit processes the pulse train emitted by the speed sensor The speed sensor signal is a real time representation of the operating speed of the treadmill The speed control circuit compares the real time speed speed sensor output with the speed that it expects the treadmill to be operating at and acts accordingly to control treadmill speed or initiate an error code sequence if necessary Typically if a problem exists with the speed sensor the drive motor will operate perhaps only briefly before a speed related error occurs errors 20 26 1 Set the treadmill circuit breaker the on position Using a DC voltmeter measure the voltage between terminal 3 of J2 green wire and terminal 4 of J2 black wire on the lower logic PCA Slowly rotate the drive motor flywheel The voltage should read approximately 5 Vdc when a flywheel lobe is between the speed sensor legs and approximately 0 25 Vdc when a flywheel is not between the speed sensor legs Diagram 5 3 Speed Sensor Mounting Flywheel Speed _ 2 Ifthe voltages step 1 are correct go to step 5 the voltage step
26. ctions Using an ohmmeter read the resistance between terminals 1 amp 4 3 amp 4 and 1 amp 3 The readings should be approximately 15 15 and 30 Q respectively If the reading is significantly low replace the lift motor per Procedure 6 1 Page 19 14 15 16 17 18 9 55 Treadmill If the resistance readings in step 13 are normal replace the lower logic PCA per Procedure 6 3 If you have performed all of the procedures above and have been unable to correct the problem call Precor customer service Set the treadmill s circuit breaker in the off position and remove the AC line cord from the AC outlet Remove the lift motor connector from the J1 connector on the lower logic PCA Visually inspect the lift motor connector for broken or improperly crimped connections Using an ohmmeter measure between terminals 1 amp 3 1 amp 2 and 2 amp 3 of the lift motor connector Terminals 1 and 3 should read approximately 1 The sum of the two readings between terminals 2 amp 1 amp 2 should total approximately 1 If either reading is open or very high resistance replace the lift motor per Procedure 6 1 If the resistance measurements in step 16 are normal the problem may be either the lower logic PCA or the upper PCA Replace the lower logic PCA If the problem persists reinstall the original lower logic PCA and replace the upper PCA If you have performed all of the procedures above and h
27. e sure the lift motor drive screw does not rotate If the drive screw is rotated return to step 4 and repeat steps 4 through 7 9 Replace the clevis and hitch pins removed in step 3 Return the treadmill to an upright position 10 Plug the line cord into the wall outlet set the treadmill circuit breaker in the on position 11 check the calibration of the lift system by performing the following steps a Press the INCLINE key until the console displays 12 incline b Press the INCLINE v key to return to 0 incline 12 Re install the hood Page 13 9 55 Treadmill Procedure 4 2 Adjusting Drive Belt Tension 1 Set the treadmill circuit breaker in the off position and unplug the line cord from the wall outlet 2 Remove the hood 3 Place the drive belt tension gauge on the drive belt as shown in Diagram 4 2 Diagram 4 2 Drive Belt Tension Gauge 4 The gauge should read approximately 80 inch pounds The drive belt tension is acceptable if it is in the range of 70 to 90 inch pounds 5 If the drive belt tension is less than 70 or greater than 90 inch pounds adjust the drive belt adjustment bolt until the belt gauge reads approximately 80 inch pounds See Diagram 4 3 Momentarily remove the drive belt tension gauge from the drive belt Replace the drive belt tension gauge on the drive belt and the drive belt tension if necessary 6 Re install the hood Page 1 14 Page 14 9 55 Treadmil
28. edicated circuit is defined as a circuit fed by a 20 amp circuit breaker that feeds a single load A treadmill operating from a non dedicated circuit or a circuit breaker of less than 20 amps capacity will not have the necessary power available to operate normally under higher load conditions The lack of available power can cause any number of symptoms ranging from numerous intermittent seemingly inexplicable error conditions poor speed control or tripping the house circuit breaker If any of the above symptoms exist the external A C circuit must be checked and confirmed to be a 20 amp dedicated circuit before troubleshooting the treadmill In addition the A C voltage must be checked Nominal A C operating voltage on 120 Vac circuits is 105 Vac to 120 Vac Nominal A C operating voltage on 240 Vac circuits is 208 Vac to 240 Vac For operator safety considerations and to minimize electrostatic discharge conditions the A C frame ground continuity must also be verified to be a low resistance connection to the A C distribution ground bar Important If the A C circuit feeding a treadmill is found to be a non dedicated 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 circuit before any reliable troubleshooting can be performed on the treadmill More importantly a non dedicated circuit may constitute a safety hazard to the treadmill operator
29. eplace the drive motor per Procedure 6 7 steps 11 15 7 Check treadmill operation per Procedure Page 39 9 55 Treadmill Procedure 6 12 Replacing the Drive Motor Brushes 5 Diagram 6 12 Drive Motor Brush Set the treadmill circuit breaker in the off position and unplug the treadmill s line cord from the AC outlet Remove the hood Remove the drive motor per Procedure 6 7 steps 2 6 Remove the screws that retain the drive motor brush cover Carefully remove the heavy paper cover from the brush access opening Disconnect the brush wire from the tab on the brush housing Remove the brush spring by depressing the tab on the brush spring Remove the brush from it s brush holder See Diagram 6 12 Brush Brush Spring Slide the replacement brush into the brush holder Be sure that the angled edge of the brush is oriented so that the brush face makes full contact with the motor commutator Reinstall the brush spring and connect the brush wire to the tab on the brush holder Replace the heavy paper cover in the brush access opening Replace the brush cover and fasten it with the screws removed in step 3 Page 1 40 Page 40 Repeat 3 8 with remaining drive motor brush Replace the drive motor per Procedure 6 7 steps 11 14 Re install the hood Check treadmill operation per Procedure 3 9 55 Treadmill Page 41 9 55 Treadmill Procedure 6 13 Replacing the PROM Anti static kits part nu
30. er PCA per Procedure 6 steps 8 12 13 Route the lift motor cables to the lower logic PCA as noted during the previous removal procedure Plug the lift motor plugs into the J2 amp J5 connectors on the lower logic PCA 14 Check treadmill operation per Procedure 3 Page 25 9 55 Treadmill Procedure 6 2 Replacing the Lift Platform 1 Set the treadmill circuit breaker in the off position Remove the AC line cord from the outlet 2 Remove the treadmill hood Carefully lay the treadmill on it s right side 3 Remove the hitch pin and clevis pin that fastens the lift motor tube to the lift platform While the lift tube is not fastened to the lift platform care must be taken to not allow the lift tube to rotate If the lift tube rotates the lift motor must be re calibrated per Procedure 4 1 4 Remove the four bolts 2 each side that fasten the lift platform to the treadmill frame See Diagram 6 1 Remove the lift platform from the treadmill Diagram 6 1 Lift Platform Mounting Mounting Bolt 5 Set the replacement lift platform in it s mounting position Start all four lift platform bolts Securely tighten all four lift platform bolts 6 Fasten the lift platform to the lift motor tube with the clevis and hitch pins removed in step 3 Do not allow the lift tube to rotate 7 Check treadmill operation per Procedure Page 1 26 Page 26 9 55 Treadmill Procedure 6 3 Replacing the Lower Logic PCA
31. l Drive Belt Adj Bolt 7 Plug the line cord into the wall outlet and set the treadmill circuit breaker in the position 8 Check treadmill operation per Section 3 Page 15 9 55 Treadmill Procedure 5 1 Troubleshooting the Keypad and Upper PCA If the function keys on the electronic console are unresponsive the problem may be either the upper PCA or keypad The keys on this unit are touch sensitive keys It is necessary to use the keypad diagnostics to troubleshoot the key functions Procedure 1 Set the circuit breaker in the off position WARNING Before continuing with this procedure review the Warning and Caution statements listed in Section One of the Commercial Treadmill Service Manual 2 Ifthe treadmill powers up and functions normally until a particular key s is pressed skip to step 11 3 Ifa key depressed message is immediately displayed when the treadmill is powered up continue with the next step 4 This condition may be caused by either the keypad or upper PCA Set the circuit breaker in the off position 5 Remove the four screws that fastens the display housing front panel to the display housing backing plate These screws are located on the rear of the display housing backing plate 6 Lift the display housing front panel off of the display housing backing plate Remove the keypad connector from the upper PCA See Diagram 5 1 Diagram 5 1 Upper PCA amp Keypad
32. lar component Section Six Replacement Procedures When a treadmill component must be replaced go to this section and follow the step by step procedures required to remove and replace the component Section Seven Technical Diagrams and Parts Lists This section includes wiring diagrams and block diagrams for the 9 55 Treadmill Page 1 2 Page 2 General Information 9 55 Treadmill For the latest exploded view diagram part number and part pricing information visit the Precor dealer website at www precor com Dealer Technical Specifications Physical Specifications Length Width Height Running surface Motor Speed Incline Power Weight Shipping Weight 84 inches 213 cm Handrails 36 75 inches 93 cm Base 33 75 inches 86 cm 55 inches 140 cm 26 inches by 60 inches 51 cm by 152 cm 2 hp continuous duty DC 0 5 to 12 mph 0 8 to 19 kph 10 mph is equivalent to a 6 minute mile 0 to 12 grade 120 Vac 50 60 Hz 20 amp 240 Vac 50 60 Hz 20 amp 350 Ibs 158 kg 460 Ibs 207 kg Page 3 9 55 Treadmill Procedure 2 1 Accessing the Hardware Validation Program The treadmill s diagnostic program consists of the following modes Display Test Keyboard Test Heart Rate Test Lift Test Belt Speed Test Belt Power Test Circuit Breaker Test Procedure 1 The keys on the display hypothetically numbered 1 to 7 from left to right See Diagram 2 1 The
33. latile memory on the upper PCA If the upper PCA 10 11 12 is replaced the odometer data will be lost Press the ENTER key to proceed to the hour meter display The display will momentarily read HOUR METER The operating time of the unit will be displayed as 12345 HOURS The operating time is defined as total amount of time that the unit has operated in program modes with the drive motor running The hour meter is also used to provide the time stamp for the error code log Press the ENTER key to proceed to the software version display The display will momentarily read SOFTWARE VERSION The software versions of the upper and lower PCA s will be displayed as UPPER 1 01 LOWER 1 01 Press the ENTER key to proceed to the error log Page 7 13 14 15 16 17 9 55 Treadmill The error log will store up to 10 error conditions The errors are logged with the most recent error in position one When a new error condition occurs each existing error is pushed down one position in log If there was an error in position 10 when a new error was logged the error that was in position 10 will be lost Each error in the log will show the odometer reading in miles and the time hour meter when the error occurred The errors are displayed as 1 ER20 1234567 MI 12345 HRS The arrows keys will allow you to scroll through the log When the first unused position is reached in the log the message NO MORE ERRORS
34. mber 20024 101 can be ordered from Precor 1 The PROM and associated printed circuit assembly PCA are static sensitive Anti static devices must be used and all anti static precautions must be followed during this procedure Remove the printed circuit assembly per its associated procedure Currently we are using two styles of IC software packages they are a 28 pin dual in line package DIP28 and a forty four pin square package PLCC44 Each of these packages should be removed with r IC removal tool see the illustrations below PLCC44 removal tool DIP28 removal tool The IC s may inserted into their socket by hand by carefully aligning the notch on the IC with the notch on the IC socket and carefully pressing the IC into its socket See the illustrations below for the alignment notches Care must be taken that the IC legs on a DIP28 are all aligned in the socket to prevent the legs from bending when inserted The PLCC44 IC must be carefully aligned squarely in its socket or it will not insert Do not force the IC into its socket If it does not insert easily remove the it and re align it in its socket 5 1 02 LWR 4 B 0 32 00 5 1 42 42 9 55 Treadmill Wiring Diagram 7 1 9 55 version 1 gt 120 240 45 DETAIL OF BREAKERS 240VOLT 120VOLT TO J3 PINS 3 amp 4 UPPER DISPLAY PCA TO J3 PINS 3 amp
35. n to be in excellent operating condition Note the values displayed at a fixed power bit reading as set by the SPEED keys and your body weight Those values may then be used to benchmark the operation of treadmills you are diagnosing Press the ENTER key to proceed to the circuit breaker test The display will momentarily read CIRCUIT BREAKER TEST The message HOLD ARROW KEY TO TRIP will be displayed When the arrow key is held the message BREAKER WILL TRIP 3 2 1 0 will flash on the screen one word at a time Shortly after the 0 is displayed the circuit breaker will trip If the arrow key is released before the circuit breaker trips the test will be terminated The circuit breaker test is the last test in the diagnostics routine If you do not wish to cause the circuit breaker to trip press the RESET or the ENTER key to exit the diagnostics routine Page 1 6 Page 6 9 55 Treadmill Procedure 2 2 Accessing the Information Display Program The information display will access the following data Odometer Hour meter Software version Error log Procedure 4 5 Plug the power cord into the wall outlet then turn on the treadmill with the circuit breaker Press the keys RESET 6 5 sequentially The display will momentarily read DIAGS INFORMATION DISPLAY The display will momentarily read ODOMETER The treadmill s odometer will be displayed as 1234567 MPH or 1234567 KPH Note The odometer data is stored in non vo
36. om one and installed ona different motor If the drive motor is replaced the drive motor and flywheel should be replaced as a unit Disconnect the wires from the drive motor cooling fan Disconnect the speed sensor connector from the J2 connector on the lower logic PCA Disconnect the drive motor s in line connector located in the drive motor wires Remove the drive belt tension bolt see Diagram 4 2 Rotate the drive motor as far as possible toward the rear of the treadmill Remove the drive belt from the drive motor pulley Remove the four bolts that fasten the drive motor onto it s mounting plate Remove the drive motor from the treadmill Remove the screws that mount the speed sensor and bracket onto the drive motor see Diagram 6 7 Mount the speed sensor and bracket on the replacement drive motor using the screws removed in step 7 Remove the four screws that fasten the drive motor cooling fan onto the drive motor See Diagram 6 11 Mount the drive motor cooling fan onto the replacement drive motor with the screws removed in step 9 Set the drive motor in it s mounting position Fasten the drive motor to it s mounting plate using the bolts removed in step 6 Set the drive belt in place on the drive motor pulley Rotate the drive motor forward and replace the drive belt tension bolt removed in step 4 Tension the drive belt per procedure 4 2 Connect the brown and blue fan wires to the drive motor cooling fan The bl
37. t the line cord s blue wire from the line filter 120 Vac units or from the circuit breaker 240 Vac units Remove the line cord s strain relief mounting nut and remove the line cord Remove the mounting nut from the replacement line cord and feed the line cord through the circuit breaker mounting plate Fasten the line cord to the circuit breaker mounting plate with the nut removed in the previous step Connect the line cord s brown wire to the circuit breaker per Diagram 6 9 Connect the line cord s blue wire to the line filter per Diagram 6 10 120 Vac units or to the circuit breaker per Diagram 6 9 240 Vac units Connect the line cord s ground wire green wire to the circuit breaker mounting panel with the hardware removed in step 3 Check treadmill operation per Section 3 Page 1 38 Page 38 9 55 Treadmill Procedure 6 11 Replacing the Drive Motor Cooling Fan 1 Set the treadmill circuit breaker in the off position and unplug the treadmill s line cord from the AC outlet 2 Remove the hood 3 Remove the drive motor per Procedure 6 7 steps 2 8 4 Remove the four screws that mount the drive motor cooling fan to the drive motor See Diagram 6 11 Diagram 6 11 Drive Motor Cooling Fan Mounting My Mounting Screw _ 5 Setthe replacement drive motor cooling fan at it s mounting position on the drive motor and fasten it with the hardware removed in step 4 6 R
38. ue and brown wires can be connected to either terminal Reconnect the drive motor in line connector Reconnect the speed sensor to the J2 connector of the lower logic PCA Page 33 9 55 Treadmill 15 Re install the hood 16 Check treadmill operation per Procedure 3 Page 1 34 Page 34 9 55 Treadmill Procedure 6 8 Replacing the Circuit Breaker 1 Set the treadmill circuit breaker in the off position and unplug the treadmill s line cord from the AC outlet 2 Remove the four screws that fasten the circuit breaker mounting plate to the treadmill See Diagram 6 8 Diagram 6 8 Circuit Breaker Mounting Panel Mounting Screw 3 Disconnect all of the wiring from the circuit breaker 4 Remove the circuit breaker mounting screws Remove the circuit breaker from the treadmill 5 Set the replacement circuit breaker in its mounting position Fasten the circuit breaker to the circuit breaker mounting panel using the screws removed in step 4 6 Connect the wiring to the circuit breaker per Diagram 6 9 Page 35 Diagram 6 9 Circuit Breaker Wiring 240 Vac P2 9 55 Treadmill 120 Vac To Line Filter To Logic PCA J3 To Line Cord P1 P2 7 Set the circuit breaker mounting panel in its mounting position Fasten the circuit breaker mounting panel to the treadmill using the screws removed in step 2 8 Check treadmill operation per Section 3 Page 1 36 Page 36 9 55 Treadmill
39. ures that do not reference a specific version is applicable to all versions of the 9 55 Version 1 was manufactured between March 2000 and July 1 2001 Version 2 was manufactured between July 2 2001 and the present Section One Things You Should Know This section includes technical specifications Read this section as well as the 9 55 Treadmill Owner s Manual before you perform the maintenance procedures in this manual Section Two Software Features Precor s 9 55 Treadmill is programmed with several diagnostic and setup features This section contains the procedures you need to access the diagnostic features on this treadmill Section Three Checking Treadmill Operation This section provides you with a quick way of checking treadmill operation Check 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 inspection procedures when a trouble symptom points to a particular problem and after removing and replacing major components Many maintenance problems can be fixed by adjusting various treadmill components This section also provides you with the step by step procedures required to make these adjustments Section Five Troubleshooting Procedures The diagnostic and troubleshooting procedures contained in this section should be performed when it is necessary to isolate a problem to a particu
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