Precor 9.23 Service Manual
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Precor 9.23 Service Manual

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9.23, 9.27 Treadmill
9.23, 9.27 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.
© 2007 Precor Incorporated
Unauthorized Reproduction and Distribution Prohibited By Law
20081-118
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  • Page 1 9.23, 9.27 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.

  • Page 2: Section One - Things You Should Know

    About This Appendix Section One, Things You Should Know. This section includes technical specifications. Read this section, as well as the 9.23, 9.27 Treadmill Owner’s Manual, before you perform the maintenance procedures in this manual. Section Two, Software Features. Precor treadmills are programmed with several diagnostic and setup features.
  • Page 3 9.23, 9.27 Treadmill Technical Specifications Length: 76.5 inches (194.3 cm.) Width: 30.5 inches (77.5 cm.) Height: 55 inches (140 cm.) Running surface: 20 inches by 59 inches (51 cm. by 149.9 cm.) Motor: 2.75 hp. continuous duty DC Speed: 0.5 to 12 mph or 0.8 to 20 kph)

  • Page 4: Procedure 2.1 - Error Codes And Lower Pca Indicators

    9.23, 9.27 Treadmill Procedure 2.1 - Error Codes and Lower PCA Indicators Error Codes: 03 - EEPROM Error: EEPROM checksum test error, when this error is consistently displayed, the upper PCA is usually the cause. If displayed intermittently, the cause is typically external, A.C.
  • Page 5 9.23, 9.27 Treadmill Procedure 2.2 - Accessing the Odometer and Hour Meter Set the on/off switch in the “on” position and remove the safety key from the console. Allow the internal power supply to discharge, approximately 10 seconds, and then replace the safety key on the console.
  • Page 6 9.23, 9.27 Treadmill Procedure 2.3 - Accessing the Service Mode Program Calibration - Incline calibration and treadmill calibration Console Sel - Sets the console for 9.23 or 9.27 operation Display Test - Tests the display Key Test - Tests the keypad Set the on/off switch in the “on”...
  • Page 7 STOP key to halt the display test. Console Sel 11. The display will indicate whether the console is set as a 9.23 or 9.27 treadmill/ The will toggle the setting. Press the ENTER key to save the setting that agrees with the treadmill’s model number.

  • Page 8: Procedure 2.4 - U.s. Standard/Metric Selection

    9.23, 9.27 Treadmill Procedure 2.4 - U.S. Standard/Metric Selection Set the on/off switch in the “on” position and remove the safety key from the console. Allow the internal power supply to discharge, approximately 10 seconds, and then replace the safety key on the console. Within 2 seconds of replacing the safety key, press the STOP,...

  • Page 9: Procedure 2.5 - Documenting Software Problems

    9.23, 9.27 Treadmill Procedure 2.5 - 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. Provide the model number as accessed in Procedure 2.2.
  • Page 10 9.23, 9.27 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.

  • Page 11: Procedure 4.1 - Calibrating The Lift Motor

    9.23, 9.27 Treadmill Procedure 4.1 - Calibrating the Lift Motor Note: This calibration procedure must be performed whenever the lift motor has been replaced or the lift calibration has been disturbed. Set the on/off switch in the “off” position and unplug the AC power cord from the AC outlet.
  • Page 12 9.23, 9.27 Treadmill The lift tube must turn freely during step 5, if you turn the lift drive screw while turning the lift tube, you must return to step 4 and repeat steps 4 and 5. Set the on/off switch in the “off”...

  • Page 13: Procedure 4.2 - Adjusting Drive Belt Tension

    9.23, 9.27 Treadmill Procedure 4.2 - Adjusting Drive Belt Tension Set the treadmill on/off switch in the “off” position and unplug the AC power cord from the AC outlet. Remove the hood. Place the drive belt tension gauge on the drive belt as shown in Diagram 4.2.
  • Page 14 9.23, 9.27 Treadmill Diagram 4.3 - Drive Motor Mounting Belt Tension Adjustment Bolt Plug the AC power cord into the AC outlet and set the treadmill circuit breaker in the “on” position. Check treadmill operation per Section 3. Page 14...

  • Page 15: Procedure 4.3 - Treadmill Belt Cleaning

    9.23, 9.27 Treadmill Procedure 4.3 - Treadmill Belt Cleaning Procedure: First, check for proper operation of the safety stop key. Stand to one side of the treadmill. Insure that the stop key tether is hanging straight down from the stop key and is not wrapped around the handle bars.
  • Page 16 9.23, 9.27 Treadmill Turn the power off. Place your hands on the towel and push it up and down the length of the running deck several times to clean the deck. Remove the towel. Safety Stop Key Tether It is recommended that this procedure be performed frequently to extend the life of the running belt and running deck.

  • Page 17: Procedure 5.1 - Troubleshooting The Keypad

    Set the on/off switch in the “on” position. If the stuck key is still displayed, replace the display face. If the stuck is no longer displayed, replace the upper PCA. If you have performed all of the procedures above and have been unable to correct the problem, call Precor customer support. 20081-118 Page 17...

  • Page 18: Procedure 5.2 - Troubleshooting The Lift System

    9.23, 9.27 Treadmill Procedure 5.2 - Troubleshooting the Lift System Lift System Description: The lift system on these units consists of an AC line voltage driven lift motor (120 Vac), and an internal 10 KΩ potentiometer for lift position identification. The lift motor contains two motor windings, one to operate the motor in an “upward”...
  • Page 19 Procedure 6.1. 12. If you have performed all of the procedures above and have been unable to correct the problem, call Precor customer support. 13. Remove Jk3 connector from the lower PCA, refer to Diagram 5.2. With an ohmmeter, measure between pins 1 and 3 of JK3 (red and black wires).
  • Page 20 17. If the measurements in step 16 are still significantly incorrect, replace the incline motor per Procedure 6.1. 18. If you have performed all of the procedures above and have been unable to correct the problem, call Precor customer support. Page 20...

  • Page 21: Procedure 5.3 - Troubleshooting The Speed Sensor

    If the measurements in step 5 are now correct, replace the drive roller. If the measurements are still incorrect, replace the speed sensor per Procedure 6.4. If you have performed all of the procedures above and have been unable to correct the problem, call Precor customer support. 20081-118 Page 21...

  • Page 22: Procedure 5.4 - The Display Does Not Illuminate

    9.23, 9.27 Treadmill Procedure 5.4 - The Display does not Illuminate Set the on/off switch in the “off” position and insert the AC power cord into a 120 Vac outlet. The on/off switch should illuminate. If the on/off switch illuminates skip to step 5. If the on/off switch does not illuminate continue with step 2.
  • Page 23 9.23, 9.27 Treadmill Diagram 5.5 - Circuit Breaker and On/Off Switch On/Off Switch Power Circuit Cord Breaker 10. If the readings in step 8 are not correct, press the circuit breaker’s reset button and repeat the measurements in step 8. If the readings are still not correct, replace the circuit breaker per Procedure 6.6.
  • Page 24 PCA JK1 connector. If the reading is still 0 Vdc or significantly low, replace the data cable. If the reading is now correct, replace the upper PCA. 17. If you have performed all of the procedures above and have been unable to correct the problem, call Precor customer support. Page 24...

  • Page 25: Procedure 5.5 - Troubleshooting The Safety Key Circuit

    9.23, 9.27 Treadmill Procedure 5.5 - Troubleshooting the Safety Key Circuit Set the on/off switch in the “off” position and remove the console from the backplate from the console. Refer to Diagram 5.2. Remove the JK7 connector from the upper PCA.

  • Page 26: Procedure 5.6 - Troubleshooting The Drive Motor System

    9.23, 9.27 Treadmill Procedure 5.6 - Troubleshooting the Drive Motor System Note: The drive motor controller is a PWM (pulse width modulated) system. The system incorporates current limit (set at 28 amps of drive motor current). The lower PCA has several LED indicators to depict lower PCA status.
  • Page 27 9.23, 9.27 Treadmill lower PCA per Procedure 6.3. 20081-118 Page 27...
  • Page 28 14. If the drive motor does not function normally with the bypass cable installed, replace the lower PCA per Procedure 6.5. 15. If you have performed all of the procedures above and have been unable to correct the problem, call Precor customer support. Page 28...

  • Page 29: Procedure 5.7 - Troubleshooting The External A.c. Power Source

    Procedure 5.7 - Troubleshooting the External A.C. Power Source It is extremely important that any Precor treadmill be connected to and operated on a dedicated 15 amp A.C. circuit. A 15 amp dedicated circuit is defined as: a circuit fed by a 15 amp circuit breaker that feeds a single load.
  • Page 30 9.23, 9.27 Treadmill The circuit breaker correctly feeds a single A.C. outlet but the neutral is common between several A.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.
  • Page 31 9.23, 9.27 Treadmill Procedure 5.8 - Running Belt & Deck Troubleshooting This procedure is to be used to determine the condition of the running belt and running deck combination. A clamp-on ammeter will be used to measure the treadmill’s A.C. input current under load.
  • Page 32 9.23, 9.27 Treadmill 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 deck combination’s general condition.

  • Page 33: Procedure 6.1 - Replacing The Incline Motor

    9.23, 9.27 Treadmill Procedure 6.1 - Replacing the Incline Motor Set the on/off switch in the “off” position and remove the AC power cord from the AC outlet. Remove the treadmill’s hood. Disconnect the JK3 and JK4 cables from the lower PCA. Disconnect the incline motor’s frame ground (green wire) from the frame.

  • Page 34: Procedure 6.2 - Replacing The Incline Platform

    9.23, 9.27 Treadmill Procedure 6.2 - Replacing the Incline Platform Set the treadmill’s on/off switch in the “off” position. Remove the AC power cord from the AC outlet. Carefully, lay the treadmill on either it’s left or right side. Remove the bolt that fastens the incline motor to the lift platform. Care must be taken throughout this procedure to not allow the incline motor’s lift tube to rotate.
  • Page 35 9.23, 9.27 Treadmill Thread the rubber bumpers, removed in step 6, into the replacement lift platform. Install both wheels on the replacement lift platform with the hardware removed in step 5. Set the replacement lift platform in its mounting position and fasten it with the hardware removed in step 4.

  • Page 36: Procedure 6.3 - Replacing The Lower Pca

    9.23, 9.27 Treadmill Procedure 6.3 - Replacing the Lower PCA Note: If the lower PCA is replaced, the treadmill calibration procedure (Procedure 2.3) must be performed to ensure proper operation. Set the treadmill’s on/off switch in the “off” position and remove the AC power cord from the AC outlet.

  • Page 37: Procedure 6.4 - Replacing The Speed Sensor

    9.23, 9.27 Treadmill Procedure 6.4 - Replacing the Speed Sensor Set the treadmill’s on/off switch in the “off” position. Remove the AC power cord from the AC outlet. Remove the treadmill’s hood. Disconnect the JK2 connector from the lower PCA, refer to Diagram 5.2.

  • Page 38: Procedure 6.5 - Replacing Drive Motor

    9.23, 9.27 Treadmill Procedure 6.5 - Replacing Drive Motor Set the treadmill’s on/off switch in the “off” position and remove the treadmill’s power cord from the AC outlet. Remove the treadmill’s 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 from one motor and installed on a different motor.
  • Page 39 9.23, 9.27 Treadmill Connect the black wire removed in step 4 to the T4 (M-) terminal of the lower PCA, the red wire removed in step 4 to the T3 (M+) terminal of the lower PCA and the green -yellow lead to its frame ground termination.

  • Page 40: Procedure 6.6 - Replacing The Circuit Breaker

    9.23, 9.27 Treadmill Procedure 6.6 - Replacing the Circuit Breaker Set the treadmill’s on/off switch in the “off” position and remove the treadmill’s power cord from the AC outlet. Remove the treadmill’s hood. Make note of the location of the wiring and disconnect both red leads from the circuit breaker.

  • Page 41: Procedure 6.7 - Replacing The On/Off Switch

    9.23, 9.27 Treadmill Procedure 6.7 - Replacing the On/Off Switch Set the treadmill’s on/off switch in the “off” position and remove the treadmill’s power cord from the AC outlet. Remove the treadmill’s hood. Make note of the location of the switch’s wring and remove the white and black wires from the on/off switch.
  • Page 42 9.23, 9.27 Treadmill Connect the white wire from the AC power cord to the lower left hand terminal of the on/off switch, the black wire from the AC power cord to the lower right hand terminal of the on/off switch, the red wire from the circuit breaker to the upper left hand terminal of the on./off switch and the red-black wire from the lower PCA to the upper right hand terminal of on/off switch.

  • Page 43: Procedure 6.8 - Replacing The Drive Motor Brushes

    9.23, 9.27 Treadmill Procedure 6.8 - Replacing the Drive Motor Brushes Set the treadmill’s on/off switch in the “off” position and remove the treadmill’s power cord from the AC outlet. Remove the treadmill’s hood. Unsnap both brush covers (front and rear of the drive motor) from the drive motor. Refer to Diagram 6.8.
  • Page 44 9.23, 9.27 Treadmill Procedure 6.9 - Replacing the Safety Key Switch Set the treadmill’s on/off switch in the “off” position and remove the treadmill’s power cord from the AC outlet. A grounded anti-static wrist strap must be worn whenever the upper PCA is being handled.
  • Page 45 9.23, 9.27 Treadmill Procedure 6.10 - Replacing the Display Face with Keypad Note: The keypad is furnished as part of the display face, the display face must be replaced when a replacement keypad is required. Set the treadmill’s on/off switch in the “off” position and remove the treadmill’s power cord from the AC outlet.
  • Page 46 9.23, 9.27 Treadmill Set the safety switch in its mounting position on the replacement display face and fasten it with the screws removed in step 7. 10. Set the upper PCA in its mounting position in the replacement display face and fasten it with the hardware removed in step 8.

  • Page 47: Procedure 6.11 - Replacing The Upper Pca

    9.23, 9.27 Treadmill Procedure 6.11 - Replacing the Upper PCA Note: If the upper PCA is replaced, the treadmill calibration procedure (Procedure 2.3) must be performed to ensure proper operation. Set the treadmill’s on/off switch in the “off” position and remove the treadmill’s power cord from the AC outlet.
  • Page 48 9.23, 9.27 Treadmill Procedure 6.12 - Replacing the Data Cable Set the treadmill’s on/off switch in the “off” position and remove the treadmill’s power cord from the AC outlet. Remove the treadmill’s hood. Remove the four screws that fasten console to the backplate. Refer to Diagram 6.9.
  • Page 49 Two running belt gauges, Precor part number 20007-101, are required. It is important that this procedure be followed to maintain correct drive belt and running belt tension. When tension is removed from the running belt, the belt requires 24 hours for it to “relax”.
  • Page 50 9.23, 9.27 Treadmill Slowly rotate the drive motor flywheel while pressing the drive belt off of the drive roller pulley. Continue until the drive belt “walks” completely off of the drive roller pulley. Drive Belt Mark Bolt Here Drive Roller Pulley Using a fine tip marker or scribe, place a mark on the right hand drive roller mounting bolt directly in front of the drive roller shaft.
  • Page 51 9.23, 9.27 Treadmill 16. If the belt drifts to the right, slowly turn the right hand mounting bolt clockwise until the drifting stops. If the belt drifts to the left, slowly turn the left hand mounting bolt clockwise until the drifting stops. Only a very small adjustment should be required, 1/8 to 1/4 turn.
  • Page 52 This procedure is to be used to replace a take up roller while maintaining the running belt’s original tension and tracking settings. Two running belt gauges, Precor part number 20007-101, are required. It is important that this procedure be followed to maintain correct running belt tension.
  • Page 53 9.23, 9.27 Treadmill Slide the replacement take up roller into the running belt and set it in its mounting position. Hand start both take up roller mounting bolts that were removed in step 5. Alternate tightening the two take up roller mounting bolts, in order to tighten both ends evenly, until both running belt gauges again read exactly 3%.
  • Page 54 Two running belt gauges, Precor part number 20007-101, are required. It is important that this procedure be followed to maintain correct drive belt and running belt tension. Over tensioning the belt will lead to premature running belt wear, premature driver roller bearing failure and premature take up roller bearing failure.
  • Page 55 9.23, 9.27 Treadmill Remove both drive roller mounting bolts. Remove the drive roller from the treadmill. Remove the running belt and deck from the treadmill. If both sides of the deck have been used, discard the deck. If the bottom side of the deck has not been used, flip the deck so that when it is replaced it will now be the top side.
  • Page 56 9.23, 9.27 Treadmill 15. Slowly rotate the drive motor flywheel while pressing the drive belt onto of the drive roller pulley. Continue until the drive belt “walks” completely onto of the drive roller pulley. Be sure that the drive belt is fully onto and correctly aligned on the drive roller pulley.
  • Page 57 9.23, 9.27 Treadmill Diagram 7.1 - Wiring Diagram Safety Keypad Switch Upper HHHR User 1/2 JK10 Grips Keypad Circuit Speed T1 (AC1) Breaker Sensor BK-W T3 (M+) Drive T4 (M-) Motor On/Off T2 (AC2) Switch Lower Incline Motor A.C. Power...
  • Page 58 9.23, 9.27 Treadmill Diagram 7.2 Block Diagram Page 58...

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