Precor C532i, Service Manual

Page 1: ...quired to repair and maintain this product This document contains general product information software diagnostic procedures when available preventative maintenance procedures inspection and adjustment procedures trou bleshooting 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 ...

Page 2: ...ponent during EFX operation Caution statements are intended to prevent damage to the EFX as a result of the current activity Caution statements included in this manual are listed below Notice the orientation notch on the lower PCA PROM These components must be positioned with the same notch orientation Safety guidelines you should know and follow include Read the owner s manual and follow all oper...

Page 3: ...ot use accessory attachments that are not recommended by the manufacturer such attachments might cause injuries General Information For the latest exploded view part number and part pricing information visit the Precor dealer website at www precor com connection ...

Page 4: ...e Precor s EFX TOOLS EQUIPMENT phillips and flat head screwdrivers digital multimeter standard and metric allen wrench sets open end wrench set Supplies blue loctite drive ratchet and ratchet set socket drive allen set cable ties chip puller Spares rubber mallet data cables snap ring pliers 100 ft lb torque wrench 300 in lb torque wrench automotive belt tension gauge ...

Page 5: ...tware cycles through the following tests Hardware Validation Display Test Keyboard Test Heart Rate Brake RPM Battery Procedure Note Use the RESET key and the ten key keypad to enter the access code 1 Access the diagnostic program by pressing keys RESET 5 1 7 6 5 7 6 1 sequentially Diagram 2 1 C532i Display Arrow Keys OK Key Cancel Key ...

Page 6: ...LED blocks one press of the OK key will cause all of the LED s to be off 5 Press the CANCEL key 532i or the BACK key C56i Navy to proceed to the keyboard test 6 The test name KEYBOARD will be displayed Press the OK key to enter the keyboard test or an key to proceed to a different test 7 A graphical representation of all the keys on the keyboard will be displayed When a key is pressed the represen...

Page 7: ...indow and the resistance level will be displayed in the lower middle window Pressing the resistance keys will change the number of power bits being applied to the eddy current system ranging from 60 to 170 powerbits Because this is a self powered EFX you must pedal fast enough to keep the EFX powered up and the resistance up otherwise the powerbits will bo below the selected setting 16 Press the C...

Page 8: ...to a different test 28 The auto level incline position will be displayed press an key to change the auto level 29 Press the CANCEL key 532i or the BACK key C56i Navy to proceed to the battery test 30 The test name BATTERY will be displayed Press the OK key to enter the battery test or an key to proceed to a different test 31 The battery voltage will be displayed as XX X VDC 32 Press the CANCEL key...

Page 9: ...CK C556i Navy key to proceed to the hour meter display 5 The display name HOUR METER will be displayed press the OK key the hour meter will be displayed as the total number of hours of use Fractional parts of an hour are stored internally the display will be truncated to the nearest full hour 6 Press the CANCEL C532i or the BACK C556i Navy key to proceed to the U Boot SW display 7 The display name...

Page 10: ...croll you through the list of programs that have been used 20 Press the CANCEL C532i or the BACK C556i Navy key to proceed to the error log display 21 The display name ERROR LOG will be displayed press the OK key 22 The first error log entry will be displayed 1 ERXX XX STRIDES XX HRS 23 Pressing the keys will move you through the log entries Press the OK key to view the selected error Entry 1 will...

Page 11: ...age and exit the select language display 4 Press the CANCEL C532i or the BACK C556i Navy key to proceed to the select units display 5 The display name SELECT UNITS will be displayed press the OK key to proceed to the select units display or an key to proceed to a different display 6 One of two measurement standards will be displayed U S Standard or Metric 7 If U S Standard is selected weights will...

Page 12: ...ime display 16 The display name SET COOL DOWN TIME will be displayed press the OK key to proceed to the set cool down time display or an key to proceed to a different display 17 The current cool down time will be displayed Pressing any key will increase or decrease the cool down time between 0 and 5 minutes 18 Press the BACK key C556i Navy to proceed to the set custom courses display or the Cancel...

Page 13: ...ou ship it to Precor When a problem occurs record the following information Model and serial number Software version numbers for upper and lower PCA s User and 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 before the problem occurred c Problem related information such as how far into the program the problem...

Page 14: ...ts Like the COM port settings the program may or may not remember your directory preference between runs There are 3 directories that were created for you during installation of the software They are underneath the same directory in which you installed the program You ll find one each for consumer commercial and experience line machines The commercial folder is the default Uploading software and s...

Page 15: ...ill indicate that upload is in progress The Progress bar will show the progress of the upload which may take as much as 5 minutes depending on the download speed of the computer When the upload is complete disconnect the cable between the computer and the unit and power the unit down allowing the lower board to completely discharge Power up the unit and verify the software version from the display...

Page 16: ...ipe down the stairarms ramps wheels and frame with a damp cloth Every Week Wipe the surface of the electronic console with a slightly damp sponge or soft cloth Dry with a clean towel CAUTION Keep water away from electronic components to prevent shock On Site Preventive Maintenance Service Technician Perform the following preventive maintenance tasks each time you are called to service a EFX Examin...

Page 17: ...f the EFX makes unusual noises or the electronic display does not change appropriately troubleshoot per section 6 4 6 Press the RESISTANCE key until you reach Resistance Level 10 Operate the EFX for another 2 3 minutes 7 If the EFX resistance does not change or the operation of the EFX feels inconsistent compared with Resistance Level 1 troubleshoot per section 6 4 8 Press the RESISTANCE key until...

Page 18: ...eter read between terminals 1 2 terminals 1 3 terminals 1 5 terminals 1 6 and terminals 1 7 on the six phase generator connector J1 Each of the readings should be between 36 Ω and 40 Ω 7 If any of the readings are significantly high or significantly low remove the intermediate cable from the generator and perform the same measurements as in step 4 on the generator connector If the readings are now...

Page 19: ...C532i C556i Navy Elliptical Fitness Crosstrainer Page 19 Diagram 5 1 Lower PCA Red Battery Connection Generator Connector Load Resistor Connections Cable Lower Interconnect ...

Page 20: ...d Caution statements listed in Sec tion One Things You Should Know WARNING If the EFX has been in recent use the load resistors and mounting bracket may be extremely hot 2 Remove the two screws that retain the black plastic shield on the left side of the EFX Remove the black plastic shield from the EFX 3 Place a automotive or equivalent belt tension gauge on the input belt as shown in Diagram 5 2 ...

Page 21: ...ator belt as shown in Diagram 5 3 Diagram 5 3 Generator Belt Tension Measurement 7 The belt gauge should approximately 110 lbs If the generator belt tension is significantly high or low it may be adjusted using the adjustment bolt shown in Diagram 5 3 First loosen but do not remove the four generator mounting nuts Thread the adjustment bolt into or out of the generator to change the belt tension W...

Page 22: ...1 and proceed to the crossramp test 4 Operate the CROSSRAMP or CROSSRAMP keys as required to set the lift A D number to 182 5 Rotate the lift yoke on the lift motor drive screw until the distance from the upper surface of the plastic nut in the lift yoke to the end of the drive screw is 1 38 If the lift motor drive screw rotates the lift calibration number will no longer be 182 The lift calibratio...

Page 23: ...ken when removing the outrigger tube to avoid damaging the data cable Carefully remove the left outrigger tube from the shaft at its center point 5 Slide the upper data cable the cable in the outrigger tube out of the main frame tube to expose the mid point connector and the lower data cable 6 Disconnect both cables from the mid point connector and replace the mid point connector with a known good...

Page 24: ... is not necessary to route the test data cable through the frame tube for convenience route it externally Diagram 6 2 Upper Display Cable 11 If the upper data cable corrects the problem replace the cable per Procedure 7 4 If the upper data cable does not correct the problem re connect the original upper data cable to the mid point connector and the upper PCA and continue with step 10 12 Carefully ...

Page 25: ...tinue with the next step 2 This condition may be caused by either one of the keypads or upper PCA Power the EFX on by pedaling or with the external power supply Remove the display bracket cover from the rear of the display Disconnect heart rate cables Disconnect the data cable from the Upper PCA See Diagram 6 2 3 Remove the four screws that fasten the rear cover to the display Release the six disp...

Page 26: ...ble to correct the problem call Precor customer service 9 Access the diagnostics program per procedure 2 1 10 Test the keypad per Procedure 2 1 11 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 12 If one or more keys do not function correctly either the keypad display housing or upper PCA could be defective Re...

Page 27: ...m must be inspected by an electrician 5 Troubleshoot the generator per Procedure 6 4 6 If the generator was found to be good the problem will be in either the lower PCA upper PCA or the upper to lower PCA interconnect cables Warning Because this is a self powered unit it will either be necessary to either equip the unit with the optional external power supply or have an assistant pedal on the unit...

Page 28: ...t the upper to lower PCA interconnect cables per Procedure 6 1 11 If the upper to lower interconnect cables are found to be good replace the upper PCA 12 If you have performed all of the above tests and are unable to resolve the problem contact Precor customer support DGND TP4 PROM 5D TP13 DS1 LED J2 Connector ...

Page 29: ...measure ments are being taken Because of the danger of working on the unit while it is in motion using the optional external power supply is strongly recommended 1 Perform the generator resistance test per Procedure 5 1 If any of the resistance measurements are significantly high or significantly low replace the generator 2 The following voltage readings must be taken while the unit is in motion E...

Page 30: ...eadings when neither hand held or chest strap are in use Diagram 6 5 Hand held chest strap heart rate PCA Normal hand held reading No chest strap reading 1 Access the diagnostic program Procedure 2 1 Advance to the heart rate display portion of the diagnostic program Verify that a chest strap signal is not being accepted with either a Polar heart rate test transmitter or a known good chest strap t...

Page 31: ...te contact on the handlebar The reading should be 1 Ω or less Measure between pin 3 of the input connector and the upper right hand held heart rate contact on the handlebar The reading should be 1 Ω or less Measure between pin 2 of the input connector and the upper left hand held heart rate contact on the handlebar The reading should be 1 Ω or less Measure between pin 1 of the input connector and ...

Page 32: ... that is being received by the chest strap portion of the heart rate PCA 12 Grip the hand held heart rate contacts if the hand held signal is now being accepted something in the near vicinity is radiating RF energy that is being received by the chest strap portion of the heart rate PCA 13 The source of the radiated energy must be determined and relocated so that it no longer affects the heart rate...

Page 33: ... battery replacement This is strictly a battery problem and not a incline system or incline motor problem 1 If an Error 40 no incline movement is being displayed continue with step 2 If an Error 42 is being displayed incline out of range skip to step 12 No Incline Movement 2 If the incline moves briefly and then displays an Error 40 skip to step 12 If the incline does not move prior to displaying ...

Page 34: ... motor per Procedure 5 3 and re test incline functions in a normal operating mode 14 If the A D reading was erratic and did not smoothly follow incline motion visually check the connections between the intermediate cable and the J3 connector on the lower PCA and between the intermediate cable 15 Exit the hardware validation program and leave the unit idle long enough for it to shut off Disconnect ...

Page 35: ...essary to perform the portion of this procedure that is required to access the particular section or sections that you are servicing Removal 2 Reach inside one of the stairarm slots in the front portion of the rear cover and locate one of the release points shown in Diagram 7 1 Gently press upwards on the release point to unsnap the access panel from the rear cover Grasp the raised edge of the acc...

Page 36: ...to the frame and remove the wedge cover See Diagram 7 3 Diagram 7 3 Wedge Cover 6 Remove the screws that fasten the lower PCA to the front cover section Do not remove any of the wires or cables from the lower PCA 7 Remove the three screws one front and two rear that fasten the front cover section to the frame See Diagram 7 4 Snap Mounting Screw Wedge Cover Mounting Screw ...

Page 37: ...on and fasten it with the screws removed in step 7 torque the screws to 6 9 inch pounds Re install the cover on the lower PCA 11 Set the wedge cover in its mounting position and fasten it with the screws removed in step 6 torque the screws to 6 9 inch pounds 12 Set the left and right cover sections in their mounting positions making sure that all of the tabs on the left and right cover are correct...

Page 38: ...data cable from the rear of the upper PCA See Diagram 6 2 5 Release the six snaps that fasten the display face to the display see Diagram 6 2 Lift the display face off of the display Removing and Replacing the Upper PCA 6 Disconnect the metrics PCA cable the keypad cable and the D pad cable from the upper PCA See Diagram 6 3 7 Remove the upper PCA by carefully unsnapping it from its mounts on the ...

Page 39: ...s cable from the metrics PCA See Diagram 6 3 20 Remove the metrics PCA by carefully unsnapping it from its mounts on the display front panel 21 Position the replacement metrics PCA at its mounting location on the display housing front panel and press it into place in its mounts on the display front panel 22 Reconnect the metrics cable to the metrics PCA 23 Position the display front panel on the d...

Page 40: ...r arm then connect the ground lead of the wrist strap to the EFX frame ground or unpainted surface 3 Disconnect the data cable red and black battery wires the load resistor wires and the generator cable from the lower PCA 4 Remove the screws that secure the lower PCA to the front cover section Remove the lower PCA 5 Position the replacement lower PCA at its mounting position on the front cover sec...

Page 41: ...e the data cable 3 Disconnect the data cable from the outrigger tube from the mid point connector module Disconnect the other end of the data cable from the upper PCA 4 Tape one end of the replacement data cable to the display end of the existing data cable Carefully pull the existing upper data cable out of the hole in the frame near the rear of the ramp as you feed the replacement data cable int...

Page 42: ...ent data cable into the frame Stop when the replacement data cable appears out of the hole in the frame 14 Remove the tape fastening the two data cables and discard the old data cable 15 Reconnect the data cable to the lower PCA 16 Connect the data cable to the mid point connector place the cables and mid point connector in the frame 17 Carefully set the outrigger tube in its mounting position and...

Page 43: ...e access panel top left and right cover sections as described in Procedure 7 1 2 Remove the left and or right stairarm assembly as described in Procedure 7 14 Note Notice the position of the two crank arms When the crankarms are replaced they must be posi tioned so that they are 180 degrees opposing 3 Remove the bolt that secures the crankarm to the input pulley shaft It will be necessary to use a...

Page 44: ...rque the bolt to 300 inch pounds 25 foot pounds 7 Replace the stairarm assembly as described in Procedure 7 14 8 If you are replacing both crankarm assemblies repeat steps 6 7 and 8 for the second crankarm assembly 9 Set the unit at it s highest resistance setting and use the EFX for a minimum of 3 minutes Stride in a forward direction for half of the time and in a backward direction for half of t...

Page 45: ...erator and input pulley belts out of the drive unit 7 Remove the input pulley belt Set the replacement input pulley belt in it s mounting position on the step up pulley assembly 8 Set the step up pulley assembly with the generator and input belt at its mounting position in the drive unit Replace the tensioning bolts locking tabs and brackets removed in step 6 Thread but do not tighten the left and...

Page 46: ... and input belts out of the drive unit 10 Remove the generator belt Set the replacement generator belt in its mounting position on the step up pulley assembly 11 Set the step up pulley assembly with the generator and input belt at its mounting position in the drive unit Replace the tensioning bolts locking tabs and bracket removed in step 6 Thread but do not tighten the left and right tension bolt...

Page 47: ...nput pulley assembly mounting nuts 2 per pillow block bearing 5 Straighten the locking tabs and turn the left and right tension bolts counterclockwise until tension is removed from the both belts Refer to Diagram 5 2 Diagram 7 6 Input Pulley Assembly 6 Remove the input pulley assembly Slide input pulley belt off of the input pulley assembly 7 Hold the replacement input pulley assembly at it s moun...

Page 48: ...e frame uprights Refer to Diagram 7 9 If necessary loosen the four drive unit mounting bolts align the drive unit and torque the drive unit mounting bolts to 400 inch pounds 10 Tension both belts per Procedure 5 2 Note the differences between tensioning a new belt and a existing used belt 11 Replace the left and right side rear covers ...

Page 49: ...ten the locking tabs and turn the left and right tension bolts counterclockwise until tension is removed from the both belts Refer to Diagram 5 2 b Remove both tension bolts and slide the input belt off of the step up pulley assembly 5 Place the input belt and step up belt in place on the replacement step up pulley Set other end of the generator belt on the generator pulley 6 Replace the tension b...

Page 50: ...emove tension from the generator s drive belt 3 Remove the three generator mounting screws shown in Diagram 7 7 4 Remove the three bearing clamp screws shown in Diagram 7 8 5 Slide the generator toward the side of the EFX and lift the generator and remove its drive belt 6 Remove the four generator mounting nuts Disconnect the generator s cable connector from the intermediate cable and remove the g...

Page 51: ...hten the three generator mounting screws removed in step 9 Set the bearing clamp in its mounting position replace and tighten the three bearing clamp mounting screws removed in step 9 11 Hand start but do not tighten the four mounting nuts removed in step 6 The generator must be able to move in order to adjust the belt tension 12 Adjust the generator drive belt tension per Procedure 5 3 13 Reconne...

Page 52: ...s the battery bracket tab and remove the battery bracket tab See Diagram 7 9 Diagram 7 9 Battery Mounting 4 Slide the old battery out of its mounting bracket 5 Slide the replacement battery into the battery mounting bracket 6 Replace the battery bracket tab and fasten it with the nut removed in step 3 7 Connect the black wire removed in step 2 to the negative battery terminal Connect the red wire ...

Page 53: ...the access top left and right cover sections as described in Procedure 7 1 2 If the moveable arm s connecting link is attached to the stairarm remove it from the stairarm 3 Remove the stairarm pivot block retaining ring flat washer and wave washer from the crankarm pin See Diagram 7 10 4 Remove the stairarm from the crankarm and roll the stairarm off of the rear of the ramp Diagram 7 10 Wheel Asse...

Page 54: ...e stairarm into the ramp channel from the rear of the ramp Slide the stairarm pivot block onto the crankarm pin and replace the wave washer flat washer and retaining ring removed in step 3 8 Replace the left right top and access panel cover sections per Procedure 7 1 ...

Page 55: ...al from the stairarm There are two strips of double sided tape between the pedal and the stairarm so there will be some resistance when you remove the pedal 2 Remove the two strips of double sided tape and replace them with two new strips of double sided foam tape Precor part number 39874 101 Diagram 7 11 Stairarm Pedal Viewed from the Bottom of the Stairarm 3 Set the pedal in its mounting positio...

Page 56: ...m to the crankarm Slide the stairarm off of the crankarm and leave the wave washer on the crankarm 4 Roll the stairarm out of the rear of the ramp 5 Remove the stairarm pedal from the existing stairarm and install it on the replacement stairarm per Procedure 7 13 6 Remove the stairarm wheel from the existing stairarm and install it on the replacement stairarm per Procedure 7 12 7 Roll the stairarm...

Page 57: ...r Procedure 7 1 3 Remove both stairarms per Procedure 7 14 4 Remove the two bolts that fasten the lower rear portion of the ramp to the frame See Diagram 7 11 Diagram 7 11 Lower Ramp Mounting 5 Remove the two bolts that fasten the upper end of the ramp to the lift motor yoke See Diagram 7 12 6 Carefully lift the ramp and slide it off of the lift motor yoke 7 Slide the replacement ramp onto the lif...

Page 58: ...lliptical Fitness Crosstrainer Page 58 Diagram 7 12 Upper Ramp Mounting 8 Replace both stairarms per Procedure 7 11 9 Replace the left right top and access panel cover sections per Procedure 7 1 Upper Ramp Mounting Bolts ...

Page 59: ... Diagram 7 14 Diagram 7 14 Moveable Handlebar Lower End 2 Removing the connecting link prevents it from resting on the outrigger tube and will prevent the painted surfaces of the outrigger tube and connecting link from damage Remove the connecting link mounting bolt and set the connecting link aside Diagram 7 15 Handlebar Connecting Link Connecting Link Moveable Handlebar Mounting Bolt Connecting ...

Page 60: ... Diagram 7 16 Diagram 7 16 Moveable Handlebar 5 Set the replacement moveable handlebar in its mounting position Carefully start hand threading the moveable handlebar to avoid cross threading and then tighten 6 Replace the outrigger tube per Procedure 7 18 7 Fasten the connecting link to the stairarm with the hardware removed on step 3 torque the bolt to 40 foot pounds 480 inch pounds Moveable Hand...

Page 61: ... is required to access the cover being replaced 2 Grasp the upper front cover section and lift upwards to remove it See Diagram 7 17 Diagram 7 17 Front Covers 3 Remove the four screws that fasten the top cover section See Diagram 7 18 Diagram 7 18 Top Cover with Upper Front Cover Removed Upper Front Cover Lower Front Cover Upper Mounting Screws Lower Mounting Screws ...

Page 62: ...the upper rear cover in its mounting position and fasten it with the two screws removed in step 7 8 Raise the incline to its highest position and set the lower rear cover in its mounting position and fasten it with the screws removed in step 6 torque the screws to 6 9 inch pounds 9 Set the lower front cover in its mounting position ensuring that the tabs in the lower front cover align with the poc...

Page 63: ...he outrigger tube Before proceeding with procedure be sure that the EFX is in a solid stable position and will not tip or fall off of the temporary support 3 Remove the three bolts from the upper end of the outrigger tube and four bolts from the lower end of the outrigger tube See Diagram 7 21 Diagram 7 21 Outrigger Tube Mounting 4 Loosen but do not remove the two clamp bolts at the handlebar pivo...

Page 64: ...onnected to the mid point connector and the lower end of the outrigger tube 8 Disconnect the data cable from the mid point connector 9 Remove the data cable from the old outrigger tube and feed it into the replacement outrigger tube 10 Connect the data cable to the upper PCA and the mid point connector 11 Set the outrigger tube at its mounting position and fasten it with the seven bolts removed in...

Page 65: ...g bracket is removed The support will also facilitate the mounting and alignment of the replacement ramp mounting bracket 3 Remove the four screws that fasten the ramp mounting bracket to the ramp Diagram 7 23 Ramp Mounting Bracket 4 Remove the two large bolts that fasten the ramp mounting bracket to the frame 5 Set the ramp mounting bracket at it mounting position and fasten it to the frame with ...

Page 66: ...am 7 24 Diagram 7 24 Lift Motor Mounting 5 Disconnect the lift motor cable connector 6 Remove the nut and bolt that fasten the lower end of the lift motor to the frame 7 Thread the lift motor yoke onto the replacement lift motor 8 Set the replacement lift motor in its mounting position and secure it with the nut and bolt removed in step 7 torque the bolt to 60 inch pounds 9 Reconnect the lift moto...

Page 67: ...cal Fitness Crosstrainer Page 67 11 Raise the ramp and slide the lift yoke into the ramp and fasten it with the hardware removed in step 3 12 Replace the lower and upper front covers 13 Thoroughly test the EFX per Section Four ...

Page 68: ... proper IC removal tool see the illustration below 4 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 T...

Page 69: ...C532i C556i Navy Elliptical Fitness Crosstrainer Page 69 Wiring Diagram 8 1 C532i C556i Navy EFX J3 2 J3 3 J3 6 J3 4 J3 5 Incline Motor R BK BR BL O ...

Page 70: ... System Micrprocessor System M1 J10 Mid Point Connector J4 20 Ohm 300W 20 Ohm 300W M2 Generator M6 M7 R BK Power Input Jack R BK J4 1 J4 2 Lift Motor J3 2 J3 3 J3 4 J3 5 J3 6 R BK BR BL 1K 5V DS1 Green Intermediate Connector O R BK G W BR F1 6 3 amp Heart Rate PCA J4 J1 1 J1 2 J1 3 J1 4 L e f t B o t t o m G r i p L e f t T o p G r i p R i g j t To p G r i p Ri g h t B o t t o m G r i p R R BK BK ...