Precor C354 User manual

•
•
•
C534. C534i Self Powered Elliptical Fitness Crosstrainerl
C534, C534i Elliptical Fitness Crosstrainer
Warning: This service manual is for use by Precor trained service providers only.
Ifyou are notaPrecorTrained Servicer, you must notattemptto serviceany PrecorProduct;
Call your dealer for service.
This document contains information required to perform the majority of troubleshooting, and
replacement procedures required to repair and maintain this product.
This document contains general product information, software diagnostic procedures (when
available), preventative maintenance procedures, inspection and adjustment procedures,
troubleshooting procedures, replacement procedures and electrical block and wiring diagrams.
To move directly to aprocedure. click the appropriate procedure in the bookmark section to the
left of this page. You may "drag" the separator bar between this page and the bookmark section
to change the size of the page being viewed.
©2004 Precor Incorporated
Unauthorized Reproduction and Distribution Prohibited
By Law
Page 1

C534, C534i Self Powered Elliptical Fitness Crosstrainer
•Section One -Things You Should Know
Right, Left, Front, and Back Conventions
In this manual, right, left, front, and back are from the perspective of auser standing on the EFX,
facing the display enclosure.
General System Information
•The generator performs three functions in the EFX. First, by controlling the amount of
electrical load applied to the generator, the user's pedalling resistance is controlled.
Second, the generator is used to charge the EFX's internal battery. Lastly, one of the
generators three phase output windings is monitored to determine when the unit is
in use
and when it is idle. This system also determines the stride rate by determining the operating
speed (output frequency) of the monitored generator winding.
Warning and Caution Statements and General Safety Guidelines
Warning statements indicate aparticularly dangerous activity. Warning statements you will find in
this manual include:
••If the EFX has been in recent use, the load resistors and load resistor mounting bracket may
be extremely hot.
•Because this is aself 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 while voltage
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.
•When the unit is used, stairarms are in motion, the generator will operate and produce
potentially hazardous voltages even when the battery
is disconnected.
•To remove power from the EFX, the optional external power supply (when equipped) must
be disconnected from the wall outlet and the red (positive) lead must be disconnected from
the battery. Always ensure that the EFX external power supply is unplugged from the wall
outlet and the red (positive) lead is removed from the battery when you inspect or adjust the
EFX,
or when you isolate, remove, or replace an EFX component.
•Removing the covers exposes high voltage components and potentially dangerous
machinery. Exercise extreme caution when you perform maintenance procedures with the
cover(s) removed.
••During service operations you will be very close to moving machinery and voltage bearing
components. When you perform maintenance procedures with the covers removed, remove
jewelry (especially from ears and neck), tie up long hair, remove neck ties, and do not wear
loose clothing.
Page 2

••
C534, C534i Self Powered Elliptical Fitness Crosstrainerl
Exercise caution when touching any wire or electrical component during EFX operation.
• A pinching hazard exists when the unit is operated by turning the crankarms by hand. It is
possible to seriously pinch afinger between the crankarm and stairarm. The stairarms
should be removed before operating the crankarms by hand.
Caution statements are intended to prevent damage to the EFX as aresult of the current activity.
Caution statements 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 know and follow include:
•Read the owner's manual and follow all operating instructions.
•Operate the EFX on asolid, level surface.
•Visually check the EFX before beginning service or maintenance operations. If it is not
completely assembled or is 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 shoes and remove any embedded stones. Tie long
hair back.
•
•Do not rock the unit. Do not stand or climb on the handlebars, display enclosure, or cover.
•Do not set anything on the handlebars, display enclosure, or cover. Never place liquids on
any part of the EFX, while performing service.
•To prevent electrical shock, keep all electrical components away from water and other
liquids.
•Do not use accessory attachments that are not recommended by the manufacturer-such
attachments might cause injuries.
Page 3

C534, C534i Self Powered Elliptical Fitness Crosstrainer
•General Information
For the latest exploded view, part number and part pricing information, visit the Precor dealer
website at "www.precor.comlconnection.
Tools Required
•
•
Multimeter
Anti-static kit
4" -6" gear puller
Precor part number 20030-108 belt gauge
US and metric end wrench set
US and metric socket wrench set
Torque wrench, 200 in.llbs.
Torque wrench, 200 ft./Ibs
Allen wrench set
Screwdriver set
7/16" allen key, socket wrench mounted
Straight edge
Page 4

•
•
•
C534, C534i Self Powered Elliptical Fitness Crosstrainerl
Section Two -Preventive Maintenance
Preventive maintenance measures are either scheduled or unscheduled. Scheduled preventive
maintenance activities are included here so that you are aware of preventive measures
performed on aregular basis.
Regular Preventive Maintenance (Owner)
Cleanliness of the EFX and its operating environment will keep maintenance problems and
service calls to aminimum. Precor recommends that you perform the following preventive
maintenance schedule.
After Each Use
•Unplug the optional external power supply (when equipped) from the AC outlet.
•Wipe down the covers, handlebars, stairarm wheels and stairarm ramps with adamp cloth.
Daily Maintenance
Clean the EFX's frame, covers, stairarms, 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 aclean towel. A30:1solution of Simple Green® and water
is
the only cleaning solution that has been tested and approved for use on the C534 ramps. Use of
any other cleaner, may cause degradation of the ramp anodizing and void the ramp warranty.
The use of an acid (citric) based cleaner will cause ramp anodizing damage and
is not authorized
by Precor.
Weekly Maintenance
•Vacuum underneath the EFX, following these steps:
1.Unplug the optional external power supply (when equipped) from the AC outlet.
2. Place the EFX on its side.
Note:
Place adrop cloth under the EFX to protect the flooring and to ensure that the EFX handrail
is not scratched or damaged.
3. Vacuum the rug or damp mop the floor.
4. Make sure that the floor is dry before returning the EFX to an upright position.
Page 5

C534, C534i Self Powered Elliptical Fitness Crosstrainer
•Quarterly Maintenance
1. Remove the rear covers.
2. Check the step up and input belt alignment and tension as in Procedure 5.3.
3. Replace the rear cover.
On-Site Preventive Maintenance (Service Technician)
When you are called to service aEFX, perform these preventive 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 operation?). If
not, see Procedure 6.3 (C534) or Procedure 6.4 (C534i).
•Visually inspect the drive belts for cracks, fraying or excessive wear.
•When furnished, inspect the optional power supply cords. If apower supply cord(s)
is
damaged, install anew power supply.
•
•
•Visually examine all wires and check connectors and wire connections. Secure connections
and replace wiring as necessary.
Page 6

•C534, C534i Self Powered Elliptical Fitness Crosstrainerl
Procedure 3.1 -Software Access Codes
The C534 and C534i use the standard access codes to provide access to the various software
features.
In using the standardized access codes the keys are hypothetically numbered left to
right with key
#1 on the 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 procedure will be aborted. If the access is aborted, it will
be necessary to start over from the beginning. See Diagram 3.1. The C534 display does not
utilize key positions #2 and #3, however, they must be counted to correctly locate keys #4
through #6. On the display, key
#1 is the RESET key and key #4 is the QUICK START key.
Standard Access Codes
•
•
Diagnostics
Odometer
Club Settings
Diagram 3.1 -C534 Display Panel
Keys RESET ,5,1 ,7,6,5,7,6,1
Keys RESET,6,5
Keys RESET,5,6,5,1 ,5,6,5
Page?

C534. C534i Self Powered Elliptical Fitness Crosstrainer
•Procedure 3.2 -Accessing the Diagnostic Program
The EFX diagnostic software cycles through the following tests:
•Display Test
•Keyboard Test
•Heart Rate Test
•Battery Test
•
RPM Test
•Brake Test
Procedure
Start pedalling and continue to pedal as you perform step 2.
With the PRECOR banner scrolling, press keys RESET,5,1,7,6,5,7,6,1., sequentially.
The message HARDWARE VALIDATION will be displayed for afew seconds.
The message DISPLAY TEST will be displayed followed by every LED on the display being
illuminated. Check each LED segment to ensure that all of the segments are illuminated.
Press the ENTER key to advance to the keyboard test.
The message KEYBOARD TEST will be displayed followed by agraphical representation of
each key position on the display housing. As each key
on the display is pressed the key
representation is turned "off', indicating that the key
is functioning. Check each key in this
manner, including the numeric keyboard. Press and hold the ENTER key for 2seconds to
advance to the heart rate test.
1.
2.
3.
4.
e5.
6. The message HEART RATE TEST will be displayed followed by the unfiltered (U), filtered
(F) and polar (P) heart rate readings if the heart rate option
is installed in the C534 and a
chest strap transmitter or atest transmitter is being used. If the heart rate option
is not
installed
in the C534, the message NO HEART RATE RECEIVER will be displayed instead
of the heart rate readings. Press the ENTER key to advance to the brake test.
7. The message BATTERY TEST will be displayed followed by the battery voltage. Press the
ENTER key to advance to the RPM test.
8. The message RPM TEST will be displayed followed by the pulse (power bit) reading and the
RPM reading. Press the ENTER key to advance to the brake test.
9. 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 key to exit the diagnostics program.
•Page 8

•
•
•
C534. C534i Self Powered Elliptical Fitness Crosstrainerl
Procedure 3.3 -Displaying the Odometer
Procedure
1. Start pedalling and continue to pedal as you perform step 2.
2. With the PRECOR banner scrolling, press keys RESET,6,5, sequentially.
3. The message INFORMATION DISPLAY will be displayed for afew seconds.
4. The message ODOMETER will be displayed followed by the total number of strides
accumulated. The total number of strides can be converted to miles by dividing by
2241 or
to kilometers by dividing by 1392.5. Press the ENTER key to advance to total strides.
5. The message TOTAL STRIDES will be displayed followed by the total number of strides
logged on the EFX. Press the ENTER key to advance to hour meter.
6. The message HOUR METER will be displayed followed by the total number of hours that
the C534 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 upperand lower PCA's. For example, UPPER 1.01 LOWER 1.01. Press the ENTER key
to advance to error log.
8. The message ERROR LOG will be displayed followed by the error in log position 1. Each
log entry shows the log position, the stride count when the error occurred and the hour
meter when the error occurred. For example; 1ER21 123456 STR 45678 HRS. The error
log can record up to ten error conditions. The error code in position one will be the most
recent error and the error in position ten will be the oldest error. If more than ten errors have
been logged. only the ten most recent will be displayed. When anew error is logged. each
existing error
is pushed down one position and the error in position 10, if any, is lost. Use the
T and£. keys to move through the log. Pressing and holding the QUICK START key for
four seconds will clear the log. Press the ENTER key to exit the odometer program.
Page 9

C534, C534i Self Powered Elliptical Fitness Crosstrainer
•Procedure 3.4 -Club Settings
1. Start pedalling and continue to pedal as you perform step 2.
2. With the PRECOR banner scrolling, press keys RESET,5,6,5,1,5,6,5, sequentially.
3. The message SET CLUB PARAMETERS will be displayed for afew seconds.
4. The message SELECT LANGUAGE will be displayed followed by the currently selected
language. Use
the" and... keys to select the language preference. Press the ENTER
key to advance to units of measurement.
5. The message SELECT UNITS will be displayed followed by the currently selected unit of
measurement. 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 currently
selected maximum workout time. Use
the" and ... keys to select the maximum workout
time. The maximum workout time may be set between 1and 240 minutes or no limit. Press
ENTER to advance to maximum pause time.
7. The message SET MAX PAUSE TIME will be displayed followed by the currently selected
maximum pause time. Use
the.. and ... keys to select the maximum pause time. The
maximum pause time
is the that will elapse after the pause key has been pressed until the
unit resets. The maximum pause time may be set between 1and 120 seconds. Press
ENTER to exit the club settings program.
Page 10

•
•
•
C534, C534i Self Powered Elliptical Fitness Crosstrainerl
Procedure 3.5 -Documenting Software Problems
When aproblem is found with either the software or upperor lower PCA's, record the information
listed below. If you isolated the problem to either the PROM, upper PCA, or lower PCA, include
the information you recorded with the malfunctioning PROM or PCA when you ship it to Precor.
When aproblem occurs, record the following information:
•Model and serial number
•Software version number
Note:
Look at the PROM mounted on the upper PCA. Alabel on the PROM indicates the software
version number.
•User and program number running when the problem occurred
• A description of:
aWhat happened or failed to happen.
bThe action taken by the user just before the problem occurred.
cProblem-related information (such as how far into the program the problem occurred,
the work level being used when the problem occurred, etc.).
•The frequency of occurrence.
Page 11

,----------------------------------------- ---_._------
C534, C534i Self Powered Elliptical Fitness Crosstrainer
•Section Four -Checking EFX Operation
This section provides you with aquick method of checking EFX operation. Check the operation
of the EFX at the end of most maintenance procedures.
Procedure
1. Start striding on the EFX or plug the optional external power supply (when available) into the
EFX and the AC outlet.
2. When the PRECOR banner scrolling, press QUICK START.
3. Select Resistance Level 1and press ENTER.
4. Operate the EFX for 4-5 minutes. As you operate the EFX, concentrate on the operating
sounds made by the unit.
Be on the alert for unusual 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 Akey 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.
8. Press the RESISTANCE Akey until you reach Resistance Level 20. Operate the EFX for
another
2-3 minutes.
9. If the resistance of the EFX does not change or the EFX operation feels inconsistent with
Resistance Levels 1and 10, troubleshoot per Section
6.
10. Check the LED's mounted on the upper PCA and the function keys displayed on the
electronic console by performing Procedure 3.2.
Page 12

•
•
C534, C534i Self Powered Elliptical Fitness Crosstrainerl
Procedure 5.1 -Measuring the Resistance of aGenerator
(C534, only)
Caution
Remove power from the EFX before you measure generator resistance.
Procedure
1. Remove the rear cover and disconnect the red battery lead from terminal M6 of the lower
PCA.
WARNING
Before continuing with this procedure, review the Warning and Caution statements listed in
Section One, Things You Should Know.
2. Set the ohmmeter to arange that will conveniently read up to
50 Q.
3. Remove the three generatoroutput leads from the lower PCA, brown from terminal M3, blue
from terminal M4 and violet from terminal M5.
4. With an ohmmeter, read between the brown and blue leads, blue and violet leads and the
brown and violet leads removed in step
3. Each of the three readings should be between
26 Qand 27
Q. If any of the readings are significantly high or significantly low, replace the
generator.
Diagram 5.1 - Lower peA
M3
M4
M5
Lift
Connector
•
5. Reconnect the generator leads to the lower PCA as follows: violet to M5, blue to M4 and
brown to M3.
6. Reconnect the red battery lead to terminal M6 of the lower PCA.
Page 13

C534, C534i Self Powered Elliptical Fitness Crosstrainer
•Procedure 5.2 -Measuring the Resistance of aGenerator
(C534i, only)
Caution
Remove power from the EFX before you measure magnet resistance.
Procedure
1. Remove the rear cover and disconnect the red battery lead from terminal M6 of the lower
PCA.
WARNING
Before continuing with this procedure, review the Warning and Caution statements listed in
Section One, Things You Should Know.
2. Set the ohmmeter to arange that will conveniently read up to 50 .0.
•
3. Remove the six phase generator connector from the lower PCA, refer to Diagram 5.2,
below.
4. With an ohmmeter, read between terminals 1&2, terminals 1&3, terminals 1& 5, terminals
1&
6, and terminals 1&7on the six phase generator connector (J1). Each of the six
readings should be between 36 nand 39 .0.
5. 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 4on the
generator connector. If the reading are now correct check and or replace the intermediate
cable.refer to Diagram 5.4. If the readings are still incorrect, remove the six phase
generator.
•
Six Phase
Generator
Prom
Battery
AC Adapter
Page 14

•
•
•
C534. C534i Self Powered Elliptical Fitness Crosstrainerl
6. Replace the generator per Procedure 7.17. Reconnect the intermediate cable removed in
step 5to the replacement generator and the lower PCA.
7. Reconnect the red battery lead to terminal M6 of the lower PCA.
Page 15

C534, C534i Self Powered Elliptical Fitness Crosstrainer
•Procedure 5.3 -Inspecting and Adjusting Belt Tension
Procedure
1. Remove the rear cover and disconnect the red battery lead from terminal M6 of the lower
PCA. If you are only inspecting the generator belt tension, skip to step 7.
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 load resistors 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 the top of the frame
upright.
•
•
3. Place a20030-108 or equivalent belt gauge on the input belt as shown in Diagram 5.3.
Diagram 5.3 -Input Belt Tension Measurement
Step Up Adjustment
Pulley Belt Gauge
Bolt-l--------~
4. The belt gauge should read 100 Ibs. If the belt tension is significantly high or low the belt
tension may be adjusted using the adjustment bolts shown in Diagram 5.2. To adjust the
belt tension first straighten the locking tabs on both bolts. When adjusting the tension, turn
Page 16

•5.
6.
C534, C534i Self Powered Elliptical Rtness Crosstrainerl
both bolts equal amounts. When the adjustment is complete the step up pulley shaft must
remain perpendicular to the frame and drive belt. Turning the adjustment bolts clockwise will
increase belt tension, turning the adjustment bolts counter-clockwise will decrease belt
tension.
Changing 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.
Place a20030-108
or equivalent belt gauge on the generator belt as shown in Diagram 5.4.
•
•
Diagram 5.4 -Generator Belt Tension Measurement
Adjustment Nut
Jam Nut
7. The belt gauge should read 60 Ibs. 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 bolts and the jam nut. Hold the adjustment bolt head
with one wrench and turn the adjustment nutto change the belt tension. When the tension is
correct, tighten the jam nut. Tighten and torque the four generator mounting bolts to 150
inch pounds.
Page 17

•
----------------------------
C534. C534i Self Powered Elliptical Fitness Crosstrainer
8. If either the input pUlley belt or the generator belt is being replaced with anew belt, the belt
tension should be set 20 Ibs. higher than the previous readings. Therefore anew input
pulley belt should be tensioned to 120 Ibs. and anew generator belt should be tensioned to
80 Ibs. Over time and use the belts will "relax" and the tensions will be as stated in steps 4
and
7.
9. Reconnect the red battery lead to terminal M6 of the lower peA.
Page 18

•C534, C534i Self Powered Elliptical Fitness Crosstrainerl
Procedure 6.1 -Troubleshooting the Lower and Upper
Interconnect Cable
Typical symptoms associated with adefective interconnect cable is either an error 30 or no
power to the upper PCA. This procedure requires that you have aknown good upper
interconnect cable, lower interconnect cable and mid-point connector.
1. If you are troubleshooting an error 30,31 or 32 continue with step 3, otherwise see
Procedure 6.3 (C534) or Procedure 6.4 (C534i).
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 connector.
•
Diagram 6.1 - Interconnect Cables and Mid-Point Connector
.'
Lower
Intercon nect:--iPt----:--=~'-'-----r--_I~./
Cable
End Cap
-:'--'-f--~
Upper
Interconnect
Cable
•
4. Disconnect both cables from the mid-point connector and replace the mid-point connector
with aknown good mid-point connector. If the mid-point connector does not correct the
problem, replace the original mid-point connector and continue with step
5.
Page 19

•
•
•
C534, C534i Self Powered Elliptical Fitness Crosstrainer
5. Remove the rear cover. Disconnect the lower interconnect cable from the lower PCA and
the mid-point connector. Substitute aknown good interconnect cable from the lower PCA to
the mid-point connector. It
is not necessary to route the test interconnect cable through the
frame tube, for convenience route it externally.
6. If the lower interconnect cable corrects the problem, replace the cable per Procedure 7.3. If
the lower interconnect cable does not correct the problem, re-connect the original lower
interconnect cable to the lower PCA and mid-point connector and continue with step
7.
7. Remove the upper display housing per Procedure 7.1, steps 1to 4. Disconnect the upper
interconnect cable from the mid-point connector. Substitute aknown good interconnect
cable from the upper PCA to the mid-point connector. It
is not necessary to route the test
interconnect cable through the frame tube, for convenience route it externally.
8. If the upper interconnect cable corrects the problem, replace the cable per Procedure 7.3. If
the upper interconnect cable does not correct the problem, re-connect the original upper
interconnect cable to the mid-point connector and continue with step
9.
9.
Replace the upper PCA per Procedure 7.1, steps 9to 11.
10. If you have performed all of the procedures above and have been unable to correct the
problem, call Precor customer service.
Page 20