Precor C576i, 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: ...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: ...damaged in any way exercise extreme caution while operating and checking the EFX When operating the EFX do not wear loose clothing Do not wear shoes with heels or leather soles Check the soles of your...

Page 4: ...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 5: ...e 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 not re...

Page 6: ...The allowable 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...

Page 7: ...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 TEST will be...

Page 8: ...strainer Page 8 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 9: ...software 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...

Page 10: ...d keys to select the maximum workout time The maximum workout time may be set between 1 and 240 minutes or no limit Press ENTER to advance to maximum pause time 7 The message SET MAX PAUSE TIME will b...

Page 11: ...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 12: ...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 13: ...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 t...

Page 14: ...PCA refer to Diagram 5 1 below 6 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 generator connector J1 Each of the readings sh...

Page 15: ...C576i Self Powered Elliptical Fitness Crosstrainer Page 15 Diagram 5 1 Lower PCA Red Battery Connection Generator Connector Load Resistor Connections Cable Lower Interconnect...

Page 16: ...fer to procedure 7 1 WARNING Before continuing with this procedure review the Warning and Caution statements listed in Section One Things You Should Know WARNING If the EFX has been in recent use the...

Page 17: ...uge on the generator 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 lo...

Page 18: ...mounting position and rotate it clockwise Ensure that the cover is fully engaged and fasten it with the screw removed in step 1 Set the left side of the rear cover in it s mounting position and rotate...

Page 19: ...lift it to unsnap it from the ramp Remove the cover 3 Remove the two bolts that retain the incline motor yoke assembly in the ramp 4 Carefully slide the incline motor yoke out of the ramp and lower t...

Page 20: ...change The A D number must be 127 and the physical measurement must be 9 1 2 inches for the calibration to be correct 8 Lift the ramp off of the frame and slide the incline motor yoke into the ramp D...

Page 21: ...ector Refer to Diagram 6 1 Diagram 6 1 Data Cable Mid Point Connector 3 External of the upper column connect a replacement upper interconnect cable to the mid point connector and the upper PCA 4 Check...

Page 22: ...on as described in Section 4 If the unit works properly replace the lower interconnect cable as described in Procedure 7 4 10 If the symptoms are unchanged remove the external lower interconnect cable...

Page 23: ...n 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 stuck key message is immediatel...

Page 24: ...m 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 12 If all of the keys test good the problem may be u...

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: ...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 a...

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: ...s present replace 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 hear...

Page 31: ...rror 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 2 If the incline moves briefly and then displays an Error 40...

Page 32: ...ent smoothly without skips calibrate the incline 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...

Page 33: ...e covers Replace the screws removed in step 1 to fasten the left and right side covers Replacing the Top Section of the Rear Cover 5 Remove the left and right side covers as described above 6 Loosen d...

Page 34: ...upply input jack at its mounting location and fasten it with the nut removed in step 10 17 Replace the left and right side covers as described above Replacing the Front Section of the Rear Cover 18 Re...

Page 35: ...n the replacement cover 26 Set the replacement cover in its mounting position Fasten the cover with the two screws removed in step 25 Slide the small cover removed in step 24 onto the front section of...

Page 36: ...sert a narrow flat bladed screw driver in the slot in the front of the cover clip See Diagram 7 4 Diagram 7 4 Lift Cover Clip 3 Carefully pry the cover clip away from the pivot cover There are latchin...

Page 37: ...om the lower incline motor mount Lift the incline motor out of its mounting position and set it on the floor in front of the EFX Refer to Diagram 754 12 Remove the two screws that fasten the battery b...

Page 38: ...Crosstrainer Page 38 17 Set the incline motor in its mounting position and slide the clevis pin into the incline motor s lower mount Fasten the clevis pin with the hitch pin 18 Replace the front and u...

Page 39: ...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 40: ...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 41: ...ould Know 2 Remove the right side rear cover per Procedure 7 1 3 Attach the wrist strap to your arm then connect the ground lead of the wrist strap to the EFX frame 4 Disconnect the all of cables and...

Page 42: ...6 conductor cable from the incline motor to connector J5 From the battery connect the red wire to M6 and the black wire to M7 of the lower PCA Connect the two leads from the load resistors to M1 and M...

Page 43: ...arefully pull the old interconnect cable out of the mid point access hole while feeding the new interconnect cable into the unit When the new cable is fully into the unit remove the tape and discard t...

Page 44: ...e new interconnect cable into the unit When the new cable is fully into the unit remove the tape and discard the old interconnect cable Connect the lower interconnect cable to the mid point connector...

Page 45: ...2 Remove the 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 positioned so that they are 180 degrees oppos...

Page 46: ...ds 6 Position the crankarm on the input pulley shaft Thread and hand tighten the axle bolt into the input pulley shaft Torque the axle bolt to 200 in lbs 7 Replace the pinch bolt and locknut torque th...

Page 47: ...n front of the EFX Refer to Diagram 7 9 Diagram 7 9 Incline Motor 4 Disconnect the intermediate cable from the incline motor cable 5 Remove the two bolts that fasten the incline motor yoke into the ra...

Page 48: ...s cable to the intermediate cable 10 Mount the incline motor to the EFX frame with the clevis and hitch pins removed in step 2 11 Calibrate the incline motor per Procedure 5 3 12 Replace front and upp...

Page 49: ...ey 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...

Page 50: ...assembly with both the generator and input belts out of the drive unit 10 Remove the generator belt Set the replacement generator belt in it s mounting position on the step up pulley assembly 11 Set t...

Page 51: ...C576i Self Powered Elliptical Fitness Crosstrainer Page 51 18 Check the operation of the EFX as described in Section Four...

Page 52: ...put 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...

Page 53: ...e frame uprights Refer to Diagram 7 10 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...

Page 54: ...r 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 Refer to Diagram 5 2 b Remove both tens...

Page 55: ...d set it aside 3 Remove the two screws that fasten the ramp end cap to the ramp Remove the ramp end cap Refer to Diagram 7 11 Diagram 7 11 Ramp Assembly 4 The left side and or right side ramp trim wil...

Page 56: ...e channel in the bottom front of the ramp Slide the trim onto the ramp while feeding each T nut into the ramp channel Do not tighten the trim fastening screws at this time Repeat this procedure with t...

Page 57: ...fasten the stairarm pedal onto the stairarm Refer to Diagram 7 13 2 Remove the stairarm pedal from the stairarm 3 Set the replacement stairarm pedal at it s mounting position on the stairarm 4 Instal...

Page 58: ...r from the EFX and set it aside 5 Remove the two screws that fasten the ramp end cap to the ramp Remove the ramp end cap Refer to Diagram 7 11 6 The left side and or right side ramp trim will need to...

Page 59: ...o the end of the stairarm connector Fasten the stairarm connector to the stairarm with the bolt removed in step 6 and a washer on each side of the steel spacer in the end of the stairarm connector 14...

Page 60: ...ts that fasten the incline yoke into the ramp Refer to Diagram 7 16 Carefully slide the incline out of the ramp and lower the ramp to the frame Take care to not allow the incline yoke to rotate on the...

Page 61: ...crankarm with the retaining ring removed in step 7 11 Slide the large black spacer onto its mounting position on the stairarm Slide the steel spacer into the end of the stairarm connector Fasten the s...

Page 62: ...andlebar to the stairarm connector There are two washers and a steel spacer in the stairarm connector Diagram 7 17 Lower Handlebar Mounting 2 Remove the stairarm connector from the handlebar 3 Remove...

Page 63: ...ot tighten them at this time 5 Slide the spacer into the stairarm connector and place a washer on each side of the spacer Position the handlebar and the stairarm connector at their mounting positions...

Page 64: ...bar to the stairarm connector There are two washers and a spacer in the stairarm connector 3 Remove the stairarm connector 4 Slide the spacer into the bushing in the rear of the stairarm connector and...

Page 65: ...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 66: ...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 67: ...otor out of its mounting position and set it on the floor in front of the EFX Refer to Diagram 7 22 Diagram 7 22 Replacing a Battery 4 Remove the two screws that fasten the battery bracket to the rear...

Page 68: ...fasten it with the screws removed in step 8 9 Set the incline motor in its mounting position and slide the clevis pin into the incline motor s lower mount Fasten the clevis pin with the hitch pin 10 s...

Page 69: ...er support Refer to Diagram 7 23 4 Remove the power jack s wiring from the wire clips and discard the power jack and wiring 5 Fasten the replacement external power input jack into the cover with the m...

Page 70: ...package PLCC44 Each of these packages should be removed with a proper IC removal tool Refer to the illustrations below 4 The IC s may inserted into their socket by hand by carefully aligning the notc...

Page 71: ...Powered Elliptical Fitness Crosstrainer Page 71 Wiring Diagram 8 1 C576i 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 72: ...C576i Self Powered Elliptical Fitness Crosstrainer Page 72 Block Diagram 8 2 C576i Self Powered...