Precor C542i, Manual

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

Page 2: ...termining the operating speed output frequency of the monitored generator winding Warning and Caution Statements and General Safety Guidelines Warning statements indicate a particularly dangerous acti...

Page 3: ...s included in this manual are listed below When it is necessary to lift or move the EFX ensure that the EFX has adequate support and that you use proper lifting techniques Safety guidelines you should...

Page 4: ...Precor dealer website at www precor com connection Tools Required Multimeter Allen wrench set Anti static kit Screwdriver set 4 6 gear puller 7 16 allen key socket wrench mounted Precor part number 2...

Page 5: ...ms stairarm ramps and stairarm wheels using water or a 30 1 solution of Simple Green and water Wipe the surface of the electronic console with a damp sponge or soft cloth Dry with a clean towel A 30 1...

Page 6: ...ctivities Perform the software diagnostics Check LED and keypad function Record the odometer reading Check speed sensor function is the stride rate displayed when the unit is in operation If not see P...

Page 7: ...far left and key 7 on the far right The standard access codes use all sequential key presses The allowable delay between key presses is short If too much time is taken between key presses the access p...

Page 8: ...y is functioning Check each key in this manner including the numeric keyboard Press and hold the ENTER key for 2 seconds to advance to the heart rate test 6 The message HEART RATE TEST will be display...

Page 9: ...er Page 9 10 The message BRAKE TEST will be displayed followed the resistance level and brake level readings This test allows you to test the brake resistance at each resistance level Press the ENTER...

Page 10: ...he ENTER key to advance to software version 7 The message SOFTWARE VERSION will be displayed followed by the software versions of the upper and lower PCA s For example UPPER 1 01 LOWER 1 01 Press the...

Page 11: ...ement Use the and keys to select either U S Standard or METRIC measurements Press the ENTER key to advance to maximum workout time 6 The message SET MAX WORKOUT TIME will be displayed followed by the...

Page 12: ...o Precor When a problem occurs record the following information Model and serial number Software version number Note Look at the PROM mounted on the upper PCA A label on the PROM indicates the softwar...

Page 13: ...rate 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 8 Press the RESI...

Page 14: ...ix phase generator connector from the lower PCA refer to Diagram 5 1 below 4 With an ohmmeter read between terminals 1 2 terminals 1 3 terminals 1 5 terminals 1 6 and terminals 1 7 on the six phase ge...

Page 15: ...rosstrainer Page 15 6 Replace the generator per procedure 7 17 Reconnect the intermediate cable removed in step 5 to the replacement generator and the lower PCA 7 Reconnect the red battery lead to ter...

Page 16: ...mounting bracket may be extremely hot 2 Remove the three screws that fasten the load resistor assembly and shield to the frame upright Rotate the load resistor assembly 180 degrees and set it on the t...

Page 17: ...gnificantly high or low it may be adjusted using the adjustment bolt shown in Diagram 5 2 First loosen but do not remove the four generator mounting bolts and the jam nut Hold the adjustment bolt head...

Page 18: ...the lift motor drive screw until the measurement between the top of the lift nut and the end of the lift motor drive screw is 9 inches See Diagram 5 4 While rotating the lift motor yoke do not allow t...

Page 19: ...error 30 31 or 32 continue with step 3 otherwise see Procedure 6 3 10 Pry the end cap out of the front of the frame base tube See Diagram 6 1 11 Carefully withdraw both cables and mid point connector...

Page 20: ...r and continue with step 7 15 Remove the upper display housing per Procedure 7 1 steps 1 to 4 Disconnect the upper interconnect cable from the mid point connector Substitute a known good interconnect...

Page 21: ...lead of the wrist strap to the units frame 2 If the EFX powers up and functions normally until a particular key s is pressed skip to step 12 3 If an Error 5 key depressed message is immediately displ...

Page 22: ...he diagnostics program per procedure 3 2 If the key s necessary to access the diagnostic program is not functioning skip to step 14 12 Test the keypad per Procedure 3 2 step 4 13 If all of the keys te...

Page 23: ...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 inter...

Page 24: ...pper 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...

Page 25: ...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 Pr...

Page 26: ...t movement is being displayed continue with step 2 If an Error 42 is being displayed lift out of range skip to step 12 2 If the lift moves briefly and then displays an Error 40 skip to step 12 If the...

Page 27: ...r per Procedure 5 3 and re test lift functions in a normal operating mode 14 If the A D reading was erratic and did not smoothly follow lift motion visually check the connections between the lift inte...

Page 28: ...n One Things You Should Know 2 Attach the anti static wrist strap to your arm then connect the ground lead of the wrist strap to the units frame 3 Remove the four screws that secure the display housin...

Page 29: ...nect the keyboard cable to the upper PCA 10 Reconnect the upper interconnect cable to the upper PCA 11 Remove the ground lead of the wrist strap from the EFX frame then remove the wrist strap from you...

Page 30: ...h this procedure review the Warning and Caution statements listed in Section One Things You Should Know 2 Remove the rear cover per Procedure 7 17 3 Attach the wrist strap to your arm then connect the...

Page 31: ...input power jack to the J4 connector The 6 conductor cable from the generator as to connector J1 From the battery connect the red wire to M6 and the black wire to M7 of the lower PCA Connect the two...

Page 32: ...CA 2 Pry the end cap out the front of the frame base tube with a thin bladed screwdriver See Diagram 7 4 3 Carefully withdraw both cables and mid point connector Diagram 7 4 Interconnect Cables and Mi...

Page 33: ...e Disconnect the interconnect cable from the upper PCA Remove the four screws that fasten the display housing backplate to the main column Remove the display housing backplate 10 Securely tape one end...

Page 34: ...ttery lead from terminal M6 of the lower PCA 2 Remove the stairarm assembly as described in Procedure 7 11 steps 2 to 4 Note Notice the position of the two crank arms When the crankarms are replaced t...

Page 35: ...ace the stairarm assembly as described in Procedure 7 10 steps 11 to 12 8 If you are replacing both crankarm assemblies repeat steps 6 and 7 for the second crankarm assembly 9 Set the unit at it s hig...

Page 36: ...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...

Page 37: ...rator and remove its drive belt 9 Slide the step up pulley assembly with both the generator and input belts out of the drive unit 10 Remove and discard the generator belt Set the replacement generator...

Page 38: ...iner Page 38 17 Tension both belts per Procedure 5 2 Note the differences between tensioning a new belt and a existing used belt 18 Replace the red battery lead removed in step 1 and check unit operat...

Page 39: ...e stairarm assemblies as described in Procedure 7 10 steps 2 to 4 3 Remove the crankarm assemblies as described in Procedure 7 4 steps 2 to 5 4 Remove the input pulley assembly mounting nuts 2 per pil...

Page 40: ...ntil the edge of the pillow block bearing is parallel with the edge of the frame upright Replace the nuts in the other pillow block bearing and torque to 500 in pounds 10 Replace the crankarms per Pro...

Page 41: ...low a Straighten the locking tabs and turn the left and right tension bolts counterclockwise until tension is removed from both belts See Diagram 5 2 b Remove both tension bolts and slide the input be...

Page 42: ...and left wheel should be replaced Additionally two new wheel covers 43702 504 will be required accommodate larger wheel mounting bolts 3 The wheel assembly is provided as an assembly that includes bo...

Page 43: ...bolts and the wheel Replacement wheel mounting bolts are furnished with the replacement wheel 8 Install the replacement wheel assembly in the wheel cover Install and hand tighten the two wheel axle bo...

Page 44: ...bolts that fasten the stairarm pedal onto the stairarm 2 Remove the stairarm pedal from the stairarm 3 Set the replacement stairarm pedal at it s mounting position on the stairarm 4 Install and hand t...

Page 45: ...onto the stairarm 4 Remove the stairarm pedal from the stairarm 5 Set the stairarm pedal at it s mounting position on the replacement stairarm 6 Install and hand tighten the stairarm pedal mounting ha...

Page 46: ...rear of the unit 3 Remove the two bolts that fasten the lower rear portion of the ramp to the frame See Diagram 7 8 Diagram 7 8 Lower Ramp Mounting 4 Remove the four bolts two on top and two on the b...

Page 47: ...47 Diagram 7 9 Upper Ramp Mounting 7 Rotate both stairarms forward and place them on the ramp tracks 8 Replace the left and right rear covers per Procedure 7 14 and check unit operation as described...

Page 48: ...dlebar clamp 5 Set the replacement handlebar in its mounting position and slide the handlebar into the handlebar clamp 6 Align the lower end handlebar with its mounting holes Hand start the lower hand...

Page 49: ...ctor J1 and upper interconnect cable connector J5 from the upper PCA Remove the display housing front panel 5 Remove the four screws that fasten the display backplate to the upper main column Remove t...

Page 50: ...with upper pivot into it s mounting position Thread the upper pivot into the main column and torque it to 100 ft lbs 15 Repeat the procedure in step 16 with the left hand handlebar and upper pivot 16...

Page 51: ...he top cover See Diagram 7 13 remove the two phillip screws that fasten the top cover section to the frame upright Remove three screws that fasten the top cover section to the rear cover support Remov...

Page 52: ...over section to the frame 8 Set the top cover section in it s mounting position replace and tighten the two phillips screws that fasten the top cover section to the frame upright See Diagram 7 13 Repl...

Page 53: ...resistors 4 Remove the screw that fastens one of the load resistor clips to the mounting bracket Remove the resistor s being replaced 5 Slide the replacement resistor into its mounting position so tha...

Page 54: ...esistor wires into the slots at the top of the frame upright This will keep the wires away from all moving parts such as the stairarms 9 Reconnect the red battery lead removed in step 1 and replace th...

Page 55: ...the generator s adjustment bolt and thread the adjustment bolt into tab to remove tension from the generator s drive belt Remove the drive belt from the generators pulley 6 Remove the four generator m...

Page 56: ...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 Adju...

Page 57: ...he lower PCA 4 Use an antistatic wrist connect to a grounding point when performing steps 5 6 11 and 12 5 Remove the four screws fastening the lower PCA to the battery bracket and remove the lower PCA...

Page 58: ...and fasten it with its mounting nut 10 Remove the electrical tape from the battery terminals and reconnect the battery wires as follows the red wire to the positive battery terminal and the black wire...

Page 59: ...power input jack to the power input jack mounting plate Remove the power input jack from the power input jack mounting plate 6 Fasten the replacement power input jack to the power input mounting with...

Page 60: ...C542i Elliptical Fitness Crosstrainer Page 60 11 Replace the red battery lead removed in step 1 and check unit operation as described in Section Four...

Page 61: ...ten the lower end of the lift motor to the frame and remove the lift motor assembly from the EFX 6 Remove the nut and bolt from the end of the lift motor drive screw Thread the lift motor yoke assembl...

Page 62: ...end of the frame tube to the main column Remove the frame tube 4 Set the replacement frame tube at it s mounting position and hand start the bolts with washers at the upper end of the frame tube Hand...

Page 63: ...er sections per Procedure 7 14 2 Rotate both stairarms to the rear so that they are resting on the floor to the rear of the EFX Diagram 7 21 Ramp Mounting Bracket 3 Remove the four bolts that fasten t...

Page 64: ...the ramp onto the lift yoke and set it at its mounting position on the ramp mounting bracket 9 Replace and torque the four bolts that fasten the ramp to the rear ramp bracket to 12 ft lbs 10 Apply a c...

Page 65: ...package PLCC44 Each of these packages should be removed with a proper IC removal tool see the illustrators below 4 The IC s may inserted into their socket by hand by carefully aligning the notch on th...

Page 66: ...Elliptical Fitness Crosstrainer Page 66 Wiring Diagram 8 1 C542i Self Powered J1 5 J1 6 J1 7 BK R W Y G BL Lift Motor Intermediate Connector R BK BR BL O R BK W G BR J3 2 J3 3 J3 4 J3 5 J3 6 Battery...

Page 67: ...J2 2 5 8 J5 1 4 7 J2 1 4 7 R X T X RX T X J2 3 J2 6 J5 3 J5 6 Microprocessor System Micrprocessor System M1 BR J2 Mid Point Connector J1 20 Ohm 300W 20 Ohm 300W BL M2 M3 M4 M5 Generator V BL BR M6 M7...