Precor Experience Series 800 line EFX User manual

Service Manual
Experience™Series 800 line
EFX®
EFX800-16 Base
Fixed and Moving Arms

Contents
1Introduction 1
General Information 3
Orientation 3
Covers and Panels 3
System Component Overview 4
Tools 5
Specification Summary Table 5
Parts 7
Lubricants 7
Cleaning Solutions 7
Electrical Requirements 8
Safety Guidelines 9
Safety guideline you need to know and follow: 9
2Operation Verification 11
Operation Verification Tests 11
Operation Verification Checklist 12
3Standard Service and Diagnostics Menus 13
About 13
Service Access Codes 13
How to Access the Service and Diagnostics Menus 14
P10, P20, and P30 consoles 14
P80 consoles 14
P62 and P82 consoles 15
Navigating the Service Menus 16
P10 & P30 consoles 16
P80 and P82 consoles 16
P62 consoles 17
Hardware Validation Service Menu (51765761) 18
Experience Series 800 Line EFX ii

P10, P20, and P30 consoles 18
P62, P80, and P82 consoles 19
Club Settings Service Menu (5651565) 20
P10 & P30 consoles 20
P62, P80, and P82 Console 22
About menu 22
Equipment Usage menu 23
System Settings menu 24
Maintenance menu 27
Information Display (65) 28
P10, P20, and P30 consoles 29
P62, P80, and P82 consoles 29
4Adjustment Procedures 31
Available Adjustment Procedures 31
First Stage Drive Belt Tension Adjustment 32
About 32
Procedure 33
Second Stage Drive Tension Adjustment 36
About 36
Procedure 37
Lift Motor Calibration 40
About 40
Procedure 40
5Replacement Procedures 43
Available Replacement Procedures 43
Battery Replacement 44
About 44
Determining the battery condition 44
Battery Fuse 44
Covers and Panels Replacement 47
Experience Series 800 Line EFX iii

About 47
Cover Replacement Procedures 49
Front Lift Cover Replacement 49
Lift Interface Plate Cover Replacement 51
Accessory Tray Cover Replacement 53
Ramp-to-Drive Transition Cover Replacement 54
Ramp Cover Replacement 55
Drive Access Cover Replacement 56
Drive Disk Covers Replacement 57
Drive Housing Covers Replacement 59
First Stage Drive Belt Replacement 67
About 67
Procedure 68
Second Stage Drive Belt Replacement 72
About 72
Procedure 73
Generator and Eddy Brake Assembly Replacement 77
About 77
Procedure 77
Step-up Pulley and Tensioner Assembly Replacement 82
About 82
Step-upPulley and Tensioner Assembly Exploded View 83
Procedure 83
Drive Components Assembly Replacement 86
About 86
Procedure 86
Cranks and Input Bearing Assembly Replacement 93
About 93
Procedure 93
Lift Motor Replacement 99
Experience Series 800 Line EFX iv

About 99
Specifications 99
Lift motor power 99
Procedure 99
LPCA (Lower PCA) Board Replacement 105
About 105
LPCA System Block Diagram 105
LPCA Interface Connections 106
LPCAFuse Locations 107
Procedure 108
Fixed Arms Replacement 112
About 112
Procedure 112
Moving Arms Replacement 114
About 114
Procedure 114
Stairarm Replacement 117
About 117
Procedure 117
6Troubleshooting 123
About 123
Introduction To Troubleshooting 123
Basic Steps 123
Standard Error Codes 125
About 125
Viewing Logged Error Codes 126
Available Error Codes 127
Troubleshooting with Error Codes 127
Error Log & Event Log 128
About 128
Experience Series 800 Line EFX v

Accessing the Error Log & Event Log 128
Using the Error Log & Event Log 129
Error Log & Event Log 131
About 131
Accessing the Error Log & Event Log 131
Using the Error Log & Event Log 132
Active Status Light (ASL) 133
About 133
ASL Overview 134
ASL States 135
ASL Functions 136
System Troubleshooting Procedures 139
Available Troubleshooting Procedures 139
Blown Battery FuseTroubleshooting 140
8Preventive Maintenance 142
About 142
Maintenance Schedule 142
9Theory of Operation 145
About 145
What's New 145
Operating Summary Information 145
Power-up Initialization State 145
Banner Default State 145
System Component Overview 146
System Wiring Diagram 149
10Exploded View Diagram & Parts List 150
About 150
Exploded View Diagrams and Parts LIst 150
Exploded View Diagrams 151
Exploded View Diagram - Fixed ArmModels 152
Experience Series 800 Line EFX vi

Page 2 of 5 153
Page 3 of 5 154
Page 4 of 5 155
Page 5 of 5 156
Exploded View - Moving Arms Option 157
Page 2 of 5 158
Page 3 of 5 159
Page 4 of 5 160
Page 5 of 5 161
Parts LIst 163
Parts List - Fixed Arm Models 163
Parts List - Moving Arm Models 167
Appendix A : Edition Information i
Edition i
Copyright i
Appendix B : Notices and Safety ii
Trademarks ii
Intellectual Property ii
Warranty ii
Safety Instruction ii
Safety Notices ii
Experience Series 800 Line EFX vii

1Introduction
If you are not a Precor certified servicer, you must not attempt to service any Precor Product.
Call your dealer for service.
WARNING: This service documentation is for use by Precor certified servicer pro-
viders only. Personal injury can result from electrical shock and/or mechanical moving
parts.
This service manual applies to the Experience™ Series 800 Line EFX®models with the
EFX800-16 Base.
Model EFX800-16 Base Configuration
EFX833 Fixed Arms, Moving CrossRamp, and P30 console
EFX883 Fixed Arms, Moving CrossRamp, with P82 console
EFX835 Moving Arms, Moving CrossRamp, and P30 console
EFX885 Moving Arms, Moving CrossRamp, and P82 console
This document provides information to service the equipment base independent of the
installed console. For console service documentation, refer to the particular console service
manual.
This document contains information required to perform Troubleshooting and replacement pro-
cedures required to repair and maintain this equipment including: general product information,
software diagnostic procedures, preventative maintenance procedures, inspection and adjust-
ment procedures, Troubleshooting procedures, replacement procedures and system block
and wiring diagrams.
Experience Series 800 Line EFX 1
1 Introduction

Additional Documentation
There is also an online web version if you have internet access at: Online Service Manuall
See Also
"General Information" on the facing page
"Safety Guidelines" on page9
"Operation Verification" on page11
Standard Service Software
"Preventive Maintenance" on page142
"Adjustment Procedures" on page31
"Replacement Procedures" on page43
Troubleshooting
Experience Series 800 Line EFX 2
1 Introduction

General Information
The following information provides general equipment and service information that will help
you to use this manual to properly repair and maintain the elliptical .
Orientation
The equipment orientation (front, right, left, back) used in manual is referenced to a user stand-
ing on the equipment facing the console.
Covers and Panels
Covers and Panels
Equipment cover and access panel locations.
Experience Series 800 Line EFX 3
1 Introduction
General Information

For cover removal and installation, see "Covers and Panels Replacement" on page47.
System Component Overview
Basic electrical system component locations.
Experience Series 800 Line EFX 4
1 Introduction
General Information

Tools
General set of service and repair tools.
lUS and Metric Hex Key set lStandard and Phillips screw driver set
lUS SAE and Metric Wrench setlDVM Multimeter
lTorque wrench lExternal Retaining Ring Pliers
lUS SAE and Metric socket set lBelt Tension Gauge (recommended Kent-Moore BT-33-73-F)
Specification Summary Table
This table provides a summary of system component torque and belt rating specifications.
System Component Specification
RF coax connector 2.4 in-lbs (0.271 Nm)
Display fasteners 180 in-lbs (20 Nm
Set screws 300 in-lbs (34 Nm)
Experience Series 800 Line EFX 5
1 Introduction
General Information

System Component Specification
Plastite screw fasteners 20 in-lbs (2.3 Nm)
Flathead screws 25 in-lbs (2.8 Nm)
Drive Assembly fastener 180 in-lbs (20.3 Nm)
Step-up Pulley and Tension Assy fasteners 180 in-lbs +/- 54 (20.3 +/_ 4.5 Nm)
Generator and Eddy Brake Assy fasteners 180 in-lbs +/- 54 (20.3 +/_ 4.5 Nm)
Linkarm fasteners 300 +/- 90 in-lbs (34 +/- 10 Nm)
Crankarm Retention Plate Fastener 30 +/- 9 in-lbs (3.4 +/- 1 Nm)
Yoke Ramp bolts 320 in-lbs (236.2 Nm)
First Stage Drive Belt Tension - New Belt 140-150 lbs (63.5 - 68 kgs)
First Stage Drive Belt Tension - Used Belt 125 - 135 lbs (56.7 - 61 Kgs)
Second Stage Drive Belt Tension - New Belt 110-120 lbs (50- 54.4 kgs)
Second Stage Drive Belt Tension - Used Belt 92 - 105 lbs (43 - 47.6 kgs)
.
Experience Series 800 Line EFX 6
1 Introduction
General Information

Parts
IMPORTANT: Always purchase OEM replacement parts and hardware from Precor.
If you use parts not approved by Precor, you could void the Precor Limited Warranty.
Use of parts not approved by Precor may cause injury.
Exploded View Diagram and Parts List
There is a copy of the parts Exploded View Diagram and Parts Identification List included in
the "Exploded View Diagram & Parts List" on page150 chapter that you can use as a quick ref-
erence. It is recommended that you go to the servicer partners Precor Connect (or Precor
Connection) website to view the most current parts information including the Exploded View
Diagram and Parts Identification List .
lPrecor Connect Partner website
Exploded View Diagram and Parts LIst, see "Exploded View Diagram & Parts List" on
page150.
.
Lubricants
Use only synthetic lubricants such as Mobil 1® synthetic or SuperLube® with Teflon® grease.
Use of unapproved lubricants, cleaners, or solvents may void the EFX warranty.
CAUTION: Do not apply any lubricants or wax to the deck and belt. Do not use Wax
Blast, silicon sprays, or other applied lubricants. The use of these lubricants will quickly
degrade the low-friction surface of the deck.
CAUTION: Do not use petroleum based lubricants on mechanical components such
as the lift, as this may result in degradation of nylon gearing mechanisms. Use only syn-
thetic lubricants such as "Super Lube with Teflon" or "Mobile One Synthetic" grease
(RED).
Cleaning Solutions
Wipe down equipment with recommended cleaning solution. Use dry cloth to remove residue
solution.
Experience Series 800 Line EFX 7
1 Introduction
General Information

lGeneral:
o1 oz mild soap (Simple Green) to 30 oz. water.
oAthletix equipment cleaner, 9x7 pre-saturated wipes (ATHLETIX PRODUCTS).
oEnivir Safe oxygen enhanced cleaner or Envir Safe glass and multi-task cleaner
concentrate.
lConsole and PVS: a diluted solution of one part 91% Isopropyl alcohol to one part
water.
CAUTION: Do not use acidic cleaners and do not spray directly onto the equipment
surfaces.
Electrical Requirements
The EFX is a self-powered unit that does not require external power to operate. Pedaling will
turn an internal generator which generates the power required to supply the internal elec-
tronics, lift motor, P10/P30 consoles, and battery charging functions.
Experience Series 800 Line EFX 8
1 Introduction
General Information

Safety Guidelines
WARNING: Only Precor certified servicers and technicians are permitted to service
Precor products. Personal injury can result from electrical shock and/or mechanical
moving parts.
Safety guideline you need to know and follow:
lRead and follow all Warning notices to protect yourself from personal injury.
lRead and follow all Caution notices to prevent damage to the equipment.
lRead the owner’s manual and follow all operating instructions.
lOperate the equipment on a solid, level surface.
lVisually check the equipment before beginning service or maintenance operations. If it
is not completely assembled or is damaged in anyway, do not attempt to operate the
equipment.
lNever place liquids on any part of the equipment while performing service.
lTo prevent electrical shock, keep all electrical components away from water and other
liquids.
lDo not use accessory attachments that are not recommended by the manufacturer.
non-DEM accessories can cause injuries.
lDo not stand or climb on the handlebars, display enclosure or cover.
lOn a self-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.
lOn ATM units when the stairarms are in motion; the generator will operate and produce
potentially hazardous voltages even when the battery is disconnected.
lOn AMT units with Cardio Theater PVS units will have external power supply and
coaxial cable routed through the bottom of the unit to the top of the display console.
Cord management must be maintained
lOn ATM units, a pinching hazard exists when the unit is operated. It is possible to ser-
iously pinch a finger. The AMT can be mechanically locked by inserting a screwdriver
through the primary sheave and frame.
lOn treadmills, removing the hood exposes high voltage components and potentially dan-
gerous machinery. Exercise extreme caution when you perform maintenance pro-
cedures with the hood removed.
When servicing the equipment:
lDuring service operations you will be very close to moving machinery and voltage bear-
ing components:
oRemove jewelry (especially from ears and neck),
oTie up long hair,
Experience Series 800 Line EFX 9
1 Introduction
Safety Guidelines

oRemove neck ties, and
oDo not wear loose clothing
See Also
"Safety Instruction" on pageii
"Safety Notices" on pageii
Experience Series 800 Line EFX 10
1 Introduction
Safety Guidelines

2Operation Verification
This section provides a method of verifying that the machine is operating correctly and can be
returned to service. Do this operation verification at the end of a maintenance procedure or
whenever it is necessary to ensure that the machine is operating properly.
Operation Verification Tests
Perform this procedure and tests to verify proper operation of the unit (use the "Operation Veri-
fication Checklist" on the next page to track results):
1. Error Code Verification
Verify that there are no current error codes or issues with the unit.
a. Go to the Error Log (or Event Log) to review any logged error codes. Resolve any
relevant active error codes, see"Error Log & Event Log" on page131.
b. P10, P30 consoles: Clear the error log; select a logged error and then hold down
the QUICK START key until the "NO ERRORS" message shows. Repeat pro-
cess until all error codes are deleted.
TIP: Error Log Delete Short Cut:
Press and hold the PAUSE/RESET key for a minimum of 6 seconds to open the Error
Log and view all logged error codes. If there are no logged error codes, the "Stuck
Key" message will show. To remove error codes, select the error code and press/hold
the QUICK START key until the "NO ERRORS" message shows.
Note:P62, P80, P82 consoles: Error codes are stored in the Event Log (Access
Hardware Validation (5,1,7,6,5,7,6,1) > select Settings >About >Event Log).
Unlike earlier model consoles, the error codes cannot be manually removed.
1. Hardware ValidationTests:
Access the diagnostics Hardware ValidationTests (access code 5,1,7,6,5,7,6,1) and
run the following tests:
a. DISPLAY TEST (select DISPLAY TEST): Follow prompts to run test.
b. KEYPAD TEST (select KEYPAD TEST): Follow prompts to run test.
c. HEART RATE TEST (select HEART RATE TEST): Follow to and run test.
d. CROSSRAMP TEST (select MACHINE TEST > CROSSRAMP TEST ):
i. Use the incline control to verify the incline level 1 and level 20 A/D values,
level 1 = [[[Undefined variable EFX800-16Base.spec-LifMotorAD1]]] and
level 20 = [[[Undefined variable EFX800-16Base.spec-LiftMotorAD20]]].
ii. Use the incline control to set the incline level to 20 and verify the A/D value
is [[[Undefined variable EFX800-16Base.spec-LiftMotorAD20]]].
lExit: Press the RESET key to exit diagnostics. On P82 consoles, press Back to
exit diagnostic and return to the Home page.
2. Operational Check:
Select the Manual program and operate the elliptical for at least 5 minutes. While
Experience Series 800 Line EFX 11
2 Operation Verification
Operation Verification Tests

operating the unit, you will verify basic resistance and incline control functionality and
that the various console metric indicators and user interface displays are showing the
correct values and user information:
a. Operate the RESISTANCE control from level 1 through 20. Concentrate on the
feel of the pedaling motion verifying increased resistance. Be on the alert for any
unusual noises, odors, or vibrations.
b. Press and hold the INCLINE UP control to raise the crossramp from level 1 until
the maximum incline level is reached while viewing the incline indicator. Confirm
that the indicators maximum crossramp level reads 20 and that there are no
unusual noises or vibration.
c. Press and hold the INCLINE DOWN control to lower the crossramp from level
20 until the lowest level is reached while viewing the incline indicator. Confirm
that the ramp returns to level 1 (lowest level) and that there are no unusual noises
or vibrations.
3. Final Error Code Check:
Verify that there were no new relevant logged error codes caused the operation veri-
fication tests.
a. Go to the Error Log (or Event Log) and make sure that there are no new relevant
logged error codes. If there are any new relevant error codes, resolve the error
code and repeat the operation verification procedure.
b. On P10, P30 consoles, clear the Error Log of all logged error codes.
4. Return to service:
On successful completion of these tests, return unit to service.
Operation Verification Checklist
Use this checklist to track that each "Operation Verification Tests" on the previous page was
successfully completed. When each test was successfully completed, return the unit to ser-
vice.
Error Log Verification Check, record, and then clear any errors in the error log.
Display Test: Verify the console metric display LEDs function properly.
Keypad Test: Verify console hardkeys and keypad keys function properly.
Heart Rate Test: Verify the heart rate functions properly.
CrossRamp Test; Verify the cross ramp operates through the full incline range.
Operational Check: Verify the unit performance while operating the unit in
Manual program mode.
Error Log Check: Final check for any new error codes that may have been
logged during the verification tests.
.
Experience Series 800 Line EFX 12
2 Operation Verification
Operation Verification Checklist

3Standard Service and Diagnostics Menus
About
There are three Standardized Service and Diagnostics menus used across Precor cardio
product lines providing equipment usage information, club settings, and machine service dia-
gnostic tests:
lHardware Validation (5,1,7,6,5,7,6,1) is a set of automated diagnostic tests and hard-
ware calibration routines used to troubleshoot and verify machine operation.
lClub Settings (5,6,5,1,5,6,5) also referred to as Club Parameters used to manage and
customize user machine workout limit parameters. On touchscreen consoles, machine
usage information and error event code data is included.
lInformation Display (6,5) provides software information, machine usage information,
and error event codes. Only supported on P10, P20, and P30 consoles.
The service and diagnostics menus are accessed by entering the standardized service access
code. The user interface and service menu capabilities will vary based on the console model
and type of exercise equipment. consoles that currently support standardized service modes
include:
Non-touchscreen consoles: P10, P20, and P30
Touchscreen consoles: P62, P80, and P82
Service Access Codes
The following table lists the available standardized service menus and access codes:.
SERVICE
ACCESS CODE SERVICE MENU FUNCTION
5,1,7,6,5,7,6,1 Hardware Validation Diagnostic tests.
5,6,5,1,5,6,5 Club Settings Configure machine and workout
parameter limits(1).
6,5 ‡Information Display View usage stats, HW/SW con-
nectivity, and error code inform-
ation(2).
1) On P62, P80, and P82 consoles, the Information Display (6,5) data is also included in Club Set-
tings (5,6,5,1,5,6,5).
2) The Information Display (65) is not supported on the P62, P80, and P82 consoles, access Club
Setting (5,1,7,6,5,7,6,1) to access similar data.
Experience Series 800 Line EFX 13
3 Standard Service and Diagnostics Menus
About