Precor Precision 400 Series User manual

Service Manual
Precision™ Series 400 line
EFX400-14/18 Elipticalls

Contents
Introduction 1
Service manual contents 2
Additional Service Documentation and Videos 2
Service Safety Guidelines 4
Safety guideline you need to know and follow: 4
General Information 6
Features 6
Model and Serial Numbers 7
Model Numbers 7
Serial Numbers 8
About 8
Serial Number Label Location 9
Orientation 9
Tools and Supplies 10
Specification Summary 11
Fastener Torque Specification 11
Calibration Specification 12
BeltTension Specification 13
Bolt Grade Identification 13
Bolt Grade Markings Chart 13
Parts 14
Lubricants 14
Cleaning Procedure 15
Approved Cleaning Products 15
Cleaning Procedure 15
Power Requirements 16
Equipment Power Requirements 16
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Page ii

Equipment Spacing Requirement 17
Operation Verification 19
R40 Operation Verification Test 19
R20 Operation Verification Test 21
Standard Service Menus 25
About 25
Service Menu Access Codes 25
R40 Service Menu Access Codes 25
R20 Service Menu Access Codes 26
How to Access the Standard Service Menus 26
R40 How To Access Standard Service menus 26
R20 How To Access Standard Service menus 28
Standard Service Menus 29
R40 Standard Service Menus 29
Hardware Validation (51765761) 29
Information Display (65) 30
My Settings Menu (5671) 31
R20 Standard Service Menus 31
Hardware Validation (51765761) 31
Information Display (65) 32
My Settings Menu (5671) 33
DEMO Mode (R40) 34
Enter DEMO mode: 34
Disable DEMO mode 35
Standard Service Menus 36
About 36
Service Menu Access Codes 36
How to Access the Standard Service Menus 37
Standard Service Menus 40
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Page iii

R40 Standard Service Menus 40
R20 Standard Service Menus 42
Information Display (65) 43
My Settings Menu (5671) 44
DEMO Mode (R40) 45
Adjustment Procedures 47
Available Ajustment Procedures 47
Input Drive and Step-up Belt Tension Adjustment 48
About 48
Specialized Tools 49
Specifications 49
Procedure 49
Belt Tension and Alignment Verification 50
Belt Tension and Alignment Procedure 53
Lift Motor Calibration 63
About 63
Specifications 63
Videos 63
Lift Motor Calibration 63
Input Drive Assembly Adjustment 69
About 69
Procedure 69
Available Replacement Procedures 73
Available Replacement Procedures 73
Covers and Panels Replacement 75
Water Bottle Assy covers 75
Lift covers 77
Rear Drive covers 81
Console Replacement 93
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Page iv

Procedure 93
Power Entry Module Replacement 96
Procedure 96
Data Cable Replacement 100
Procedure 101
Replacing the Upper Data Cable 102
Replacing the Lower Data Cable 105
Lower PCA (LPCA) Replacement 111
Procedure 111
Input Drive Belt and Step-up Belt Replacement 118
Procedure 118
Input Drive Belt and Step-up Belt Replacement 124
Procedure 124
Step-up Pulley Assembly Replacement 130
Procedure 130
Input Drive Assembly Replacement 137
Procedure 137
Idler Pulley Replacement 141
Procedure 141
Eddy Current Magnet Assy Replacement 144
Procedure 144
Speed Sensor Assy Replacement 146
Service Videos 146
Procedure 146
Crankarm Assembly Replacement 151
Procedure 151
Pillow Block Bearing Replacement 155
Procedure 155
Specialized Tools 155
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Page v

Stairarm Assembly Replacement 163
Procedure 163
Stairarm Pivot Block Replacement 166
Procedure 166
Stairarm Wheel Assembly Replacement 170
Procedure 170
Stairarm Pedal Replacement 172
Procedure 172
Moving Arm Replacement 175
Procedure 175
Outrigger Side Tube Replacement 179
Procedure 179
Ramp Replacement 187
Procedure 187
Ramp Pivot Bracket 190
Lift Motor Replacement 194
Specifications 194
Videos 195
Procedure 195
Lift Yoke Assembly Replacement 204
Specifications 204
Videos 205
Procedure 205
Troubleshooting 211
About 211
Basic Troubleshooting Steps 211
Validate the customer reported issue 212
Verify Input Power 212
Verify (reproduce) the customer issue 213
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Page vi

Verify My Settings parameter values 213
Verify service bulletin and software update incorporation 213
Verify console operation 214
Verify that there are no current active error codes 214
Verify hardware validation diagnostic tests 215
Verify that there are no new error codes 215
Error Log Display 216
About 216
Accessing the Error Log 216
Error Log Parameter Descriptions 216
Clearing the Error Log 217
Error Code Troubleshooting Guide 217
System Troubleshooting Procedures 218
Data Cable Troubleshooting 219
Console Does Not Illuminate Troubleshooting 221
Console Keypad and Upper PCA Troubleshooting 223
Console Keypad and Upper PCA Troubleshooting 224
Speed Sensor Troubleshooting 225
Eddy Current Magnetic Brake System Troubleshooting 227
Lift System Troubleshooting 231
Preventive Maintenance (PM) 233
About 233
PM Tasks and Schedule 233
Electrial System Information 235
System Wire Diagram Label 235
System Electrical Block Diagram 236
System Wire Diagram 237
Product Literature & Videos 238
Service & Maintenance Documentation 238
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Page vii

Precor Websites 238
Service Videos 239
Parts 240
About 240
Precor Connect Partner's website 240
Exploded View Diagrams and Parts List 243
Appendix A : Edition Information i
Edition i
Additional Documentation i
Copyright i
Appendix B : Notices and Safety ii
Trademarks ii
Intellectual Property ii
Warranty ii
Safety Notices iii
Service Safety Guidelines iii
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Page viii

Introduction
Only Precor certified technicians are authorized to service Precor equipment. If you are not
a Precor certified servicer, you must not attempt to service any Precor product. Call your
dealer for service information
WARNING: This service documentation is for use by Precor certified servicer pro-
viders only. Personal injury can result from electrical shock and/or mechanical mov-
ing parts.
This service manual applies to the EFX400-14/18 Precision™ Series 400 Line ellipticals.
Model Configuration
EFX423 R20 console, Fixed Arms with variable CrossRamp, 15-40 degs, Stride
Length 21-24" (53-61 cm), Resistance 20 levels.
EFX425 R20 console, Moving Arms with fixed ramp, Stride Length 21-24" (53-61
cm) , Resistance 20 levels.
EFX427 R20 Convertible Arms (moving or fixed) with CrossRamp, 15-40 degs,
Stride Length 21-24" (53-61 cm), Resistance 20 levels
EFX443 R40 console, Fixed Arms with variable CrossRamp, 15-40 degs, Stride
Length 21-24" (53-61 cm) , Resistance 20 levels.
EFX447 R40 Convertible Arms (moving or fixed) with CrossRamp, 15-40 degs,
Stride Length 21-24" (53-61 cm), Resistance 20 levels
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Page 1
1 Introduction

Service manual contents
The service manual contains information to service, repair, troubleshoot, and maintain the
machine base.
This manual does not include console service and repair information, for console service
and repair information, refer to the console service manual.
However, the service manual does include information about how to use the console stand-
ard service menus, diagnostic tests and error code log to help troubleshoot and repair
machine issues.
Additional Service Documentation and Videos
There are additional literature and video resources available that can help you to use, ser-
vice, troubleshoot, and repair the machine. Refer to Product Literature & Videos topic:
l"Product Literature & Videos" on page238
lOnline service manual , see "Edition Information" on pagei.
See Also
"General Information" on page6
"Operation Verification" on page19
"Standard Service Menus" on page36
"Adjustment Procedures" on page47
"Available Replacement Procedures" on page73
"Troubleshooting" on page211
"Preventive Maintenance (PM)" on page233
"Electrial System Information" on page235
"Product Literature & Videos" on page238
"Parts " on page240
"Edition Information" on pagei
"Service Safety Guidelines" on page4
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any questions.
Page 2
1 Introduction
Service manual contents

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any questions.
Page 3
1 Introduction
Additional Service Documentation and Videos

Service Safety Guidelines
WARNING: Only Precor certified servicers and technicians are permitted to ser-
vice Precor products. Personal injury can result from electrical shock and/or mech-
anical moving parts.
Review the following safety information prior to servicing the equipment. This safety inform-
ation will help to prevent personal injury or damage to the equipment while servicing the
equipment.
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-OEM 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 AMT1units when the stairarms are in motion; the generator will operate and pro-
duce potentially hazardous voltages even when the battery is disconnected.
lOn AMT units with Cardio Theater PVS2units 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 AMT 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.
1Adaptive Motion Trainer
2Personal Viewing System display.
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Page 4
1 Introduction
Service Safety Guidelines

lOn ellipticals, removing the hood exposes high voltage components and potentially
dangerous 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
bearing components:
oRemove jewelry (especially from ears and neck).
oTie up long hair.
oRemove neck ties.
oDo not wear loose clothing.
See Also
"Notices and Safety" on pageii
"Safety Notices" on pageiii
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Page 5
1 Introduction
Service Safety Guidelines

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.
Features
The equipment operating specifications.
Feature Specification
Consoles R20 and R40 consoles
*R40 supports smart phone charging.
CrossRamp Incline 15-40 degs, 20 levels
Stride Length Stride Length 21-24" (53-61 cm)
Resistance 625 Watts, 20 levels
Lift Motor Actuator
115 Vac (range: 90-132 Vac), 50/60 Hz1nominal
Internal Thermal Protection, auto reset
Stroke: 2"-23" (5-60 cm)
External Load: max 1.300 lb (590 Kgs
Linear Speed: 19 in/min (48 cm/min
Position Potentiometer: Wiper, Linear taper, Total Reistance
1,000 ohms
Heart Rate
Two Heart Rate sensor types:
lTouch Handheld Handlebar Heart Rate sensors (HHHR2).
lTelemetry equipped for wireless chest strap heart rate mon-
itoring.
Power 120V, 60Hz, dedicated 15A circuit
Max User Weight Maximum exerciser weight: 350 lbs (159 kgs)
Dimension/Weight
Weight: 240 lb / 109 kg
Dimensions:
L 84 in X W 31 in X H 67 in
L 213 cm X W 79 cm X H 171 cm
1The hertz (symbol: Hz) is the derived unit of frequency in the International System of Units
(SI) and is defined as one cycle per second.
2Handheld Handlebar Heart Rate
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2 General Information
Features

Model and Serial Numbers
Model and Serial Numbers
Model Numbers
The product model number is a six digit alphanumeric code "AAAXXX" containing the
product type, product line, console type, and feature level designator:
l"AAA" - three alpha character PRODUCT TYPE designator
l"X" – 1 digit numeric PRODUCT LINE designator
l"X" – one digit numeric CONSOLE type designator
l"X" – one digit numeric FEATURE LEVEL designator
Example
Product model number: TRM1833
lTRM – Treadmill
l8 – Experience Line
l3 – P30 console
l3 – Fixed ramp
Product Model Number Designator Definitions
PRODUCT TYPE PRODUCT LINE CONSOLE FEATURE LEVEL
TRM: elliptical
EFX2: elliptical
AMT3: AMT
UBK4: Upright
RBK5: Recumbent
SCL6StairClimber
8-Experience
Premium
7-Experience Stand-
ard
6-Experience Good
6-Assurance Stand-
ard
4-Precision, Con-
sumer
8-P80, P82
6-P62
4-R40
3-P30, P31
2-P20/R20
1-P10
7EFX: Mov Ramp/Cnvrt
Arms
1Treadmill
2Elliptical Fitness Crosstrainer
3Adaptive Motion Trainer
4Upright Bike
5Recumbent Bike
6StairClimber
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Page 7
2 General Information
Model and Serial Numbers

PRODUCT TYPE PRODUCT LINE CONSOLE FEATURE LEVEL
2-Energy, Consumer 5TRM: High Speed/De-
cline
AMT: Moving Step Height
EFX: Mov Ramp/Mov
Arms
RBK: Standard features
UBK: Standard features
SBK1Standard features
3TRM: Fixed Ramp
AMT: Fixed Step Height
EFX: Moving Ramp/Fixed
Arms
2EFX: Man Ramp/Mov
Arms
1EFX: Fixed Ramp/Moving
Arms
Serial Numbers
About
The serial number uniquely identifies each machine. The serial number is an alphanumeric
code comprised of a four character model designator, a 1 letter build month code, a 2 digit
day built, a 2 digit year built and a four digit consecutive daily build number.
1Spinner Indoor Cycle
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Page 8
2 General Information
Serial Numbers

Serial Number Label Location
The serial number label is located on the left side of the hood and on the left side of the front
frame weldment underneath the hood.
Note:Always use the frame serial number label to verify the machine serial num-
ber. Do not use a label attached to a plastic cover, the cover may have been
replaced from a different machine.
Orientation
The equipment orientation (front, right, left, & back) is referenced to an exerciser standing
on the machine facing the console.
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Page 9
2 General Information
Orientation

Tools and Supplies
Tools and supplies required to complete the machine service and repair.
Tools
• US and Metric Hex Key set • Standard straight slot tip screw drive set
• US and Metric socket set • Philips tip screw driver set
• Us and Metric wrench set • US & metric Allen wrench set
• Cutters • 7/16” Allen key, socket mounted
• Rubber mallet • Pliers
• Tape measure /Straight edge ruler • Inner and outer snap ring pliers
•DVM1meter • Torque2Wrenches: 9 in lbs to 100 in - lbs
(83 ft-lbs)
1digital volt meter
2Torque is a measure of the force that can cause an object to rotate about an axis. Bolt/nut
example: 5 NM torque is equivalent to 5 newton's of force applied one meter from the center
of the bolt, 6 ft-lb is equivalent to 6 lbs of force applied 1 foot away from the center of the
bolt.
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2 General Information
Tools and Supplies

•AC1Clamp-on averting current meter • DVM Multimeter
•ESD2wrist strap and pad • Compatible HR3chest strap or Polar HRM
simulator xmitter (Precor PN:
PPP000000020045101)
• 12 " wonder bar • Vacuum cleaner (recommend ESD safe
model)
• Gates Carbon Drive Belt Tension APP • Drive Belt tension Gauge (Kent-Moore BT-
33-73-F
Supplies
• Super Lube Gel with Teflon by Permatex
(1)
• Cleaning rags
• Loctite 243 Blue Medium Strength Thread-
locker
• Cleaner Degreaser (see "" on page15)
• Cable tie assortment (1 3/4", 3", 4"
lengths)
(1)or equivalent synthetic teflon based grease (Mobil 1, NLGI 2 Teflon Synthetic Grease).
Specification Summary
Fastener Torque Specification
System component fastener torque specification:
System Component Specification
RF4coax connector 2.4 in-lbs (0.271 Nm)
Display mounting fasteners 180 in-lbs (20 Nm
1Alternating Current: electric current which periodically reverses direction between positive
and negative polarity.
2Electrostatic Discharge or Electrostatic Sensitive Device.
3Heart Rate
4Radio Frequency: Identifies electromagnetic signals with frequency spectrum between the
3 kHz (3,000 hertz) to 300 GHz (300 billion hertz) range.
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2 General Information
Specification Summary

System Component Specification
Set screws 300 in-lbs (34 Nm)
Plastite screw fasteners 20 in-lbs (2.3 Nm)
Flathead screws 25 in-lbs (2.8 Nm)
Idler Pulley Bolt 120in-lbs (13.6 Nm)
Input Belt Tension Bolt 200 in-lbs (17 ft-lbs, 22.6 Nm)
Lift Yoke Mounting Bolts 240 in-lbs (20 ft-lbs, 27 Nm)
Pillow Block Mounting Bolts 120 in-lbs (10 ft-lbs, 13.6 Nm)
Eddy Current Magnet Mounting Bolts 66 in-lbs (7.5 Nm)
Crank Arm Mouinting Bolt 300 in-lbs (25 ft-lbs, 34 Nm)
Step-up Pulley Axle Nut 480 in-lbs (40 ft-lbs, 54.2 Nm)
Stairarm Pivot Block Mounting Bolt 180 in-lbs (15 ft-lbs, 20.3 Nm)
Stairarm Wheel Assembly Screws 60 in-lbs (6.8 Nm)
Ramp Bracket To Frame Bolts 480 in-lbs (40 ft-lbs, 54.2 Nm)
Ramp Bracket To Ramp Screws 144 in-lbs (12 ft-lbs, 16.3 Nm)
Lift Motor Lower Mounting Bolt 60 in-lbs (6.8 Nm)
Calibration Specification
System calibration specification:
System Component Specification
Lift Motor Jackscrew Calibration Distance 1 in (2.54 cm)
Incline Level A/D1Calibration Incline angle A/D values:
lNominal value: 13 ±5 @ -2%
incline
lNominal value: 37 ±5 @0%
incline
lNominal value: 242 ±5 @ 15%
incline
1analog to digital converter
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Page 12
2 General Information
Specification Summary