Precor C546i, Service Manual

Page 1: ...required to repair and maintain this product This document contains general product information software diagnostic procedures when available preventative maintenance procedures inspection and adjust...

Page 2: ...e by determining the operating speed output frequency of the monitored generator winding Warning and Caution Statements and General Safety Guidelines Warning statements indicate a particularly dangero...

Page 3: ...tements 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...

Page 4: ...it the 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 nu...

Page 5: ...tairarms 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...

Page 6: ...nance activities 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 no...

Page 7: ...ble delay between key presses is short If too much time is taken between key presses the access procedure will be aborted If the access is aborted it will be necessary to start over from the beginning...

Page 8: ...e key 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 dis...

Page 9: ...strainer 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...

Page 10: ...ware part number UPPER APP XXXX XXX Use the and keys to display the boot software part number UPPER BOOT XXXXX XXX and lower software part number LOWER XXXXX XXX Press the ENTER key to advance to erro...

Page 11: ...WORKOUT TIME will be displayed followed by the currently selected maximum workout time Use the and keys to select the maximum workout time The maximum workout time may be set between 1 and 240 minutes...

Page 12: ...be forwarded to Precor customer support This information will be used to correct and create new software whenever it is appropriate Lower software is firmware The PROM in the lower PCA must be replace...

Page 13: ...1 The EFX must be powered down before the upload procedure can be initiated Ensure that the EFX has not be used for a sufficient time to allow the lower PCA to completely discharge The light emitting...

Page 14: ...el 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 8 Press...

Page 15: ...hase 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 genera...

Page 16: ...tness Crosstrainer Page 16 6 Replace the generator per Procedure 7 18 Reconnect the intermediate cable removed in step 5 to the replacement generator and the lower PCA 7 Reconnect the red battery lead...

Page 17: ...s and 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...

Page 18: ...with step 7 6 Place a 20030 108 or equivalent belt gauge on the generator belt as shown in Diagram 5 3 Diagram 5 3 Generator Belt Tension Measurement 7 The belt gauge should read 110 lbs If the gener...

Page 19: ...the belt tension should be set 20 lbs higher than the previous readings Therefore a new input pulley belt should be tensioned to 180 lbs and a new generator belt should be tensioned to 130 lbs Over ti...

Page 20: ...ke on 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 a...

Page 21: ...he Warning and Caution statements listed in Section One Things You Should Know 9 Attach the anti static wrist strap to your arm then connect the ground lead of the wrist strap to the units frame 10 Re...

Page 22: ...the four mounting screws removed in step 4 Trouble shoot the lower interconnect cable starting with step 9 Troubleshooting the Lower Interconnect Cable 16 Disconnect the lower interconnect cable from...

Page 23: ...en connect the ground 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 a key depressed message is immed...

Page 24: ...am per procedure 3 2 If the key s necessary to access the diagnostic program is not functioning skip to step 14 11 Test the keypad per Procedure 3 2 step 4 12 If all of the keys test good the problem...

Page 25: ...ust 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 PC...

Page 26: ...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 an...

Page 27: ...measurements 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...

Page 28: ...chest strap signal is not being received the system will accept the hand held signal Note There are four typical failure modes for the hand held chest strap heart rate system They are 1 hand held is n...

Page 29: ...be determined and relocated so that it no longer affects the heart rate PCA Televisions cell phones Cardio theatre receivers etc are possible sources of radiated energy 12 Remove the temporary jumper...

Page 30: ...the heart rate PCA 19 If 5 Vdc is not present remove the connector from J4 of the heart rate PCA Measure between the ground and 5 Vdc pins of the connector just removed from the heart rate PCA for 5...

Page 31: ...o lift 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...

Page 32: ...ift motor 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 l...

Page 33: ...upper mid point cover Remove two screws that fasten the lower mid point cover Remove both halves of the cover and the split gasket See Diagram 7 1 Diagram 7 1 Mid Point Cover 21 Fit the two replaceme...

Page 34: ...Section 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...

Page 35: ...rews 9 Reconnect 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 st...

Page 36: ...ing with this procedure review the Warning and Caution statements listed in Section One Things You Should Know 2 Remove the rear cover per Procedure 7 19 3 Attach the wrist strap to your arm then conn...

Page 37: ...m the 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...

Page 38: ...per and lower interconnect cables are connected at the mid point of the main column Remove the mid point column cover per Procedure 7 1 6 Disconnect the upper interconnect cable from the mid point con...

Page 39: ...2 Tape the replacement interconnect cable to the old interconnect cable at the lower PCA end of the old interconnect cable 14 Carefully pull the old interconnect cable out of the mid point access hol...

Page 40: ...rear cover 2 Remove the stairarm assembly as described in Procedure 7 12 steps 2 to 4 Note Notice the position of the two crank arms When the crankarms are replaced they must be positioned so that the...

Page 41: ...00 in lbs 7 Replace the stairarm assembly as described in Procedure 7 12 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...

Page 42: ...t 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 a...

Page 43: ...he generator 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 ge...

Page 44: ...rosstrainer Page 44 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...

Page 45: ...es as described in Procedure 7 12 steps 2 to 4 3 Remove the crankarm assemblies as described in Procedure 7 5 steps 2 to 5 4 Remove the input pulley assembly mounting nuts 2 per pillow block bearing 5...

Page 46: ...t or dead blow hammer tap the other pillow block bearing until 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 an...

Page 47: ...generator belts as described below a Straighten the locking tabs and turn the left and right tension bolts counterclockwise until tension is removed from the both belts See Diagram 5 2 b Remove both t...

Page 48: ...ne Things You Should Know 3 Because the replacement wheels are improved both the right and left wheel should be replaced Additionally two new wheel covers 43702 504 will be required accommodate larger...

Page 49: ...bolts from the wheel Discard the bolts and the wheel Replacement wheel mounting bolts are furnished with the replacement wheel 9 Install the replacement wheel assembly in the wheel cover Install and...

Page 50: ...he two 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...

Page 51: ...ng position on the replacement stairarm 6 Install and hand tighten the stairarm pedal mounting hardware removed in step 5 Torque the stairarm pedal mounting bolts to 60 in lbs 7 Remove the four screws...

Page 52: ...rd the rear of the unit 4 Remove four rear ramp mounting bolts 2 each side See Diagram 7 8 Diagram 7 8 Rear Ramp Mounting 5 Remove the ramp from the EFX 6 Set the ramp assembly at its mounting positio...

Page 53: ...screws that fasten the lower end of the handrail into the frame tube 4 Slide the upper end of the handrail out of the upper handrail clamp and then slide the lower end of the handrail off of the fram...

Page 54: ...e in the lower front of the upper main column and extract the interconnect cables 4 Disconnect the upper interconnect cable from the mid point connector See Diagram 7 10 Diagram 7 10 Upper Main Column...

Page 55: ...aw the upper interconnect cable out of the access hole at the bottom of the upper main column 9 Set the upper main column at it s mounting position hand start the four mounting bolts removed in step 5...

Page 56: ...oving the top cover See Diagram 7 12 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 suppor...

Page 57: ...ront cover 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 1...

Page 58: ...of the 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...

Page 59: ...n step 2 8 Route the load resistor 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 remov...

Page 60: ...ut on 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 gener...

Page 61: ...two 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...

Page 62: ...from the 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 lo...

Page 63: ...ket 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...

Page 64: ...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 the mounting nut provide...

Page 65: ...at fasten 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 a...

Page 66: ...quare package PLCC44 Each of these packages should be removed with a proper IC removal tool see the illustrations below 4 The IC s may inserted into their socket by hand by carefully aligning the notc...

Page 67: ...Powered Elliptical Fitness Crosstrainer Page 67 Wiring Diagram 8 1 C546i 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 J...

Page 68: ...C546i Self Powered Elliptical Fitness Crosstrainer Page 68 Block Diagram 8 2 C546i Self Powered...