Precor C554i, Manual

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

Page 2: ...ther be necessary to either equip the unit with the optional external power supply or have an assistant pedal on the unit while voltage measurements are being taken Because of the danger of working on...

Page 3: ...lude Read the owner s manual and follow all operating instructions Operate the EFX on a solid level surface Visually check the EFX before beginning service or maintenance operations If it is not compl...

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: ...stairarms stairarm ramps and stairarm wheels using water or 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: ...tive maintenance 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 oper...

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: ...cating that the 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 TE...

Page 9: ...number of hours that the EFX has been in use Press the ENTER key to advance to software version 7 The message SOFTWARE VERSION will be displayed followed by the software versions of the upper and low...

Page 10: ...ll 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 or no limit Pr...

Page 11: ...ip it to 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...

Page 12: ...ual rubbing hitting grinding or squeaking noises 5 If the EFX makes unusual noises or the electronic display does not change appropriately troubleshoot per Section 6 6 Press the RESISTANCE key until y...

Page 13: ...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 14: ...tness Crosstrainer Page 14 6 Replace the generator per Procedure 7 19 Reconnect the intermediate cable removed in step 5 to the replacement generator and the lower PCA 7 Reconnect the red battery lead...

Page 15: ...e Warning and Caution statements listed in Section 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 three...

Page 16: ...ng the tension of the input drive belt will also affect the tension of the generator belt If the input belt tension has been changed continue with step 7 6 Place a 20030 108 or equivalent belt gauge o...

Page 17: ...the belt tension should be set 20 lbs higher than the previous readings Therefore a new input pulley belt should be tensioned to 120 lbs and a new generator belt should be tensioned to 80 lbs Over ti...

Page 18: ...oting an error 30 31 or 32 continue with step 3 otherwise see Procedure 6 2 2 Pry the end cap out of the front of the frame base tube See Diagram 6 1 3 Carefully withdraw both cables and mid point con...

Page 19: ...onnector and continue with step 7 7 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 interco...

Page 20: ...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 Error 5 key depressed message is immediately...

Page 21: ...1 Access the 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 t...

Page 22: ...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 23: ...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 24: ...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 25: ...he Warning and Caution statements listed in 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 Rem...

Page 26: ...8 Reconnect the keyboard cable to the upper PCA 9 Reconnect the upper interconnect cable to the upper PCA 10 Remove the ground lead of the wrist strap from the EFX frame then remove the wrist strap fr...

Page 27: ...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 17 3 Attach the wrist strap to your arm then conn...

Page 28: ...om 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 th...

Page 29: ...aded screwdriver See Diagram 7 3 3 Carefully withdraw both cables and mid point connector Diagram 7 3 Interconnect Cables and Mid Point Connector 4 If you are replacing the upper interconnect cable sk...

Page 30: ...terconnect cable from the upper PCA See Diagram 7 2 Remove the four screws that fasten the display housing backplate to the main column Remove the display housing backplate 10 Securely tape one end of...

Page 31: ...of the rear cover 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 they must be positioned so t...

Page 32: ...the input pulley shaft Torque the nut to 300 in lbs 7 Replace the stairarm assembly as described in Procedure 7 11 steps 11 to 12 8 If you are replacing both crankarm assemblies repeat steps 6 and 7 f...

Page 33: ...lts 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 gener...

Page 34: ...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 35: ...rosstrainer Page 35 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 36: ...A 2 Remove the stairarm assemblies as described in Procedure 7 11 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 37: ...low 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 and torque to 500 in pounds 10 Replace th...

Page 38: ...described below 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...

Page 39: ...ment wheels are improved both the right 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 p...

Page 40: ...e bolts from the wheel Discard the 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...

Page 41: ...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 42: ...to which the handlebar linkage was mounted 4 Remove the two bolts that fasten the hook to the stairarm and remove the hook form the stairarm 5 Remove the retaining clip that fastens the stairarm to t...

Page 43: ...spacer Set the handlebar linkage at its mounting position and fasten it with the bolt removed in step 3 Torque the handlebar linkage bolt to 200 inch pounds Snap the plastic cap removed in step 3 into...

Page 44: ...that fasten the ramp end cap to the ramp assembly Slide the ramp end cap out of the ramp assembly and rotate the ramp assembly toward the rear of the unit 4 Remove four rear ramp mounting bolts 2 each...

Page 45: ...y at it s mounting position Hand start the rear mounting bolts and the two front bottom mounting bolts Torque the rear mounting bolts to 120 inch pounds Torque the two front bottom mounting bolts to 1...

Page 46: ...r to the upper pivot 4 Set the replacement handlebar in it s mounting position and hand start the three bolts and washers removed in step 3 that fasten the handlebar to the upper pivot 5 Hand start th...

Page 47: ...to the handlebar linkage There are two washers and a spacer in the handlebar linkage as shown in Diagram 7 9 3 Remove the handlebar linkage 4 Slide the spacer into the bushing in the rear of the handl...

Page 48: ...he upper pivot arm The bearing shaft will be very tight a long handled socket wrench with a 7 16 hex key will be necessary for removal See Diagram 7 11 Diagram 7 11 Upper Pivot Arm 3 Remove the upper...

Page 49: ...e upper PCA Remove the display housing front panel 5 Remove the four screws that fasten the display backplate to the upper main column Remove the display housing backplate 6 Pry the end cap out the fr...

Page 50: ...tep 12 and torque them to 240 in lbs 15 Replace the left and right frame tubes per Procedure 7 22 steps 5 7 16 Rotate the right hand handlebar with upper pivot into it s mounting position Thread the u...

Page 51: ...oving the top cover See Diagram 7 14 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 52: ...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 53: ...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 54: ...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 55: ...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 56: ...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 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: ...ing bracket 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 th...

Page 59: ...he 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 prov...

Page 60: ...n the upper 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 fram...

Page 61: ...ons per Procedure 7 17 2 Remove three bolts washers and single nut that fasten the right stairarm connector to the right stairarm Remove three bolts washers and single nut that fasten the left stairar...

Page 62: ...en the ramp and rear ramp bracket to 12 ft lbs Torque the two bolts between the ramp and the front ramp support to 20 ft lbs 13 Replace the ramp end cap with the screw removed in step 3 14 Rotate both...

Page 63: ...lts washers and single nut that fasten the right stairarm connector to the right stairarm Remove three bolts washers and single nut that fasten the left stairarm connector to the left stairarm 3 Rotat...

Page 64: ...the ramp and rear ramp bracket to 12 ft lbs Torque the two bolts between the ramp and the front ramp support to 20 ft lbs 13 Replace the ramp end cap with the screw removed in step 4 14 Rotate both s...

Page 65: ...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 66: ...8 J5 1 4 7 J2 1 4 7 R X T X RX TX J2 3 J2 6 J5 3 J5 6 Microprocessor System Micrprocessor System M1 J2 Mid Point Connector J1 20 Ohm 300W 20 Ohm 300W M2 Generator M6 M7 R BK Power Input Jack R BK J4 1...

Page 67: ...C554i Self Powered Elliptical Fitness Crosstrainer Page 67 Wiring Diagram 8 2 C554i Navy Self Powered J1 5 J1 6 J1 7 BK W R Y G BL Jack Battery...