Precor AMT12 base User manual

© 2012 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law Page 1of 214
Service Manual
AMT12 Base
AMT800-16/18 Base
AMT700-16/18 Base
Open Stride and Fixed Stride

© 2012 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law Page 2of 214
Table of Contents
FIGURE 174
TABLE OF CONTENTS ....................................................................................................................................... 2
ABOUT THIS DOCUMENT ................................................................................................................................. 6
THINGS YOU SHOULD KNOW........................................................................................................................... 7
Right, Left, Front, and Back Conventions ................................................................................................................................. 7
System Operation Overview .................................................................................................................................................... 7
Tools Required......................................................................................................................................................................... 7
Parts and Exploded View Diagrams .......................................................................................................................................... 8
Drive Belt Gauge Instructions .................................................................................................................................................. 9
How to the Drive Belt Gauge ............................................................................................................................................... 9
Procedure ............................................................................................................................................................................ 9
WARNING AND CAUTION STATEMENTS AND GENERAL SAFETY GUIDELINES ................................................. 11
Warning and Caution Statements.......................................................................................................................................... 11
Safety .................................................................................................................................................................................... 11
CHECKING THE AMT OPERATION................................................................................................................... 13
Procedure ........................................................................................................................................................................... 13
ADJUSTMENT PROCEDURES .......................................................................................................................... 14
H-brake Belt Tension Adjustment .......................................................................................................................................... 14
Procedure ........................................................................................................................................................................... 14
Generator Belt Tension Adjustment ...................................................................................................................................... 16
Procedure ........................................................................................................................................................................... 16
Drive Input Belt Tension Adjustment..................................................................................................................................... 18
Procedure ........................................................................................................................................................................... 18
Lift Motor Calibration Adjustment......................................................................................................................................... 21
Issues/symptoms............................................................................................................................................................... 21
Tools required ................................................................................................................................................................... 21
Procedure .......................................................................................................................................................................... 21

© 2012 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law Page 3of 214
REPLACEMENT PROCEDURES......................................................................................................................... 28
Cover Replacement ............................................................................................................................................................... 28
Top Cover Removal ........................................................................................................................................................... 28
Front Cover Removal ......................................................................................................................................................... 30
Center Beam Cover Removal............................................................................................................................................. 31
Back Cover Removal............................................................................................................................................................. 32
Left and Right Side Cover Removal.................................................................................................................................... 33
Left and Right Side Bottom Cover Removal ........................................................................................................................... 33
Left and Right Bottom Cover Assembly ............................................................................................................................. 34
Left and Right Side Cover Assembly .................................................................................................................................. 34
Back Cover Assembly ........................................................................................................................................................... 35
Center Beam Cover Assembly ........................................................................................................................................... 36
Front Cover Assembly .......................................................................................................................................................... 36
Upper Arm Cover Replacement ............................................................................................................................................ 36
Rear Flat Belt Terminal Cover Replacement............................................................................................................................ 38
Upper Arm Cam Cover Replacement ................................................................................................................................ 39
Top Cover Assembly ............................................................................................................................................................ 39
Replacing the Belt Guard ....................................................................................................................................................... 40
Finger Guard Replacement Procedure .............................................................................................................................. 40
Replacing the Upper Arm Grip ............................................................................................................................................... 43
Upper Arm Grip Replacement Procedure ......................................................................................................................... 43
Replacing a Flat Belt Terminal................................................................................................................................................ 49
Flat Belt Terminal Replacement Procedure....................................................................................................................... 49
Rear ................................................................................................................................................................................... 49
Replacing a Upper Arm Flat Belt Pulley.................................................................................................................................. 53
Replacing a Stairarm .............................................................................................................................................................. 60
Stairarm ReplacementProcedure......................................................................................................................................... 61
Replacing the Flat Belts.......................................................................................................................................................... 66
Belt Replacement & Odometer Tracking Codes .................................................................................................................... 68
Flat Belt Installation - Front Clamp .................................................................................................................................... 74
Outside Flat Belt Replacement.......................................................................................................................................... 76
Replacing the Front Arm Assemblies - With Flat Belts and Press Fit Cams (After 4/3/2013).................................................... 91
Replacing a Front Arm Assembly –Without Flat Belts and Non-Press Fit Cams (Prior to 4/3/2013)..................................... 114
Replacing the Lower Board .................................................................................................................................................. 127
Replacing the Lower PCA and Battery Bracket...................................................................................................................... 128
Replacing the Battery .......................................................................................................................................................... 130
Replacing the Generator Belt ............................................................................................................................................... 131
Replacing the Generator ...................................................................................................................................................... 132
Replacing the Drive Input Pulley Belt ................................................................................................................................... 133

© 2012 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law Page 4of 214
Replacing the Step-Up pulley ............................................................................................................................................... 135
Replacing the Crank Arm...................................................................................................................................................... 136
Replacing the Drive Input Pulley .......................................................................................................................................... 141
Replacing the Lift Arm Housing ............................................................................................................................................ 147
Replacing the drive input housing ........................................................................................................................................ 161
Replacing a Tie Rod .............................................................................................................................................................. 176
Replacing the Stride Dial Sensor........................................................................................................................................... 177
Replacing the H-Brake Belt .................................................................................................................................................. 179
Replacing the H-Brake Cam Assembly .................................................................................................................................. 182
Replacing the H-Brake Drum Assembly ................................................................................................................................ 187
Replacing the Gas Spring ..................................................................................................................................................... 196
Replacing the lift motor....................................................................................................................................................... 199
TROUBLESHOOTING .................................................................................................................................... 205
Troubleshooting the Generator ........................................................................................................................................... 205
Generator Operation Verification Test............................................................................................................................ 205
Procedure ......................................................................................................................................................................... 205
Troubleshootingthe Incline System ..................................................................................................................................... 207
Troubleshootingthe COMM Data Cable................................................................................................................................ 210
PREVENTIVE MAINTENANCE........................................................................................................................ 211
Regular Preventive Maintenance (Owner) ........................................................................................................................... 211
After Each Use ..................................................................................................................................................................... 211
Daily Maintenance............................................................................................................................................................... 211
Weekly Maintenance........................................................................................................................................................... 211
Quarterly Maintenance ....................................................................................................................................................... 211
On-Site Preventive Maintenance (Service Technician).......................................................................................................... 212
SYSTEM BLOCK DIAGRAM ............................................................................................................................ 213
WIRING DIAGRAM ....................................................................................................................................... 214

© 2012 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law Page 5of 214
AMT 12 Wiring Diagram....................................................................................................................................................... 214

© 2012 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law Page 6of 214
About This Document
Warning: This service manual is for use by Precor trained service providers only.
If you are not a Precor Trained Servicer, you must not attempt to service any Precor Product; 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.
Document PN: 20039-172 Rev A17

© 2012 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law Page 7of 214
Things you should know
Right, Left, Front, and Back Conventions
In this manual, right, left, front, and back are from the perspective of a user standing on the AMT facing
the console display.
Figure 1: Front, Back, Left, Right Conventions
System Operation Overview
The generator performs three functions in the AMT. First, by controlling the amount of electrical
current applied from the generator to a load circuit, the user’s pedaling resistance is controlled.
Second, the generator is used to charge the AMT’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 step rate by determining the operating speed (output frequency) of the
monitored generator winding. There is also a magnetic brake that applies resistance to horizontal
motion and a sensor that measures horizontal motion (stride length).
Tools Required
Multimeter
US and metric end wrench set
Allen wrench set
US and metric socket wrench set
Anti-static kit
Torque wrench, 200 in./lbs.
Screwdriver set
Torque wrench, 200 ft./lbs
OTC 6673 Universal Belt
Tension Gauge
4 - 6 gear puller

© 2012 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law Page 8of 214
Parts and Exploded View Diagrams
For the latest exploded view, part number and part pricing information, visit the Precor Partner
Website at http://www.precorconnect.com/ .

© 2012 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law Page 9of 214
Drive Belt Gauge Instructions
How to the Drive Belt Gauge
The following instructions will describe how to use the SP6673 belt tension gauge. Deviating from the
instructions may result in inaccurate readings and may potentially cause premature failure to the drive
belt or damage to the machine.
Procedure
1 Fully depress the ball so the hook engages the belt.
2 Hold the gauge square to the edge of the belt, and release the ball using a quick, snapping motion.
a)Gear belt tension gauge position: Tension gauge finger must land on top peak of gear belt tooth, not
in valley between.
b)Tension gauge should be in the middle 1/3 of the free span of belt, not too near to either fixed point.
c)Tension gauge must be pressed up against edge of belt.
d)Tension gauge has some internal friction and can show incorrect results. To overcome this- once the
gauge is in place on the belt, tap on the back of the gauge with a small hand tool (screwdriver, wrench,
etc) 5-8 times before reading.
3 Read tension on the dial face, across from the indicator on the gauge body.
4 If the belt tension is within manufacture's specifications, seat the belt. Run the machine for
approximately 1-2 minutes and then re- check the tension. This will allow the belt to seat itself in the
grooves of the pulley, and ensure tension is set correctly.

© 2012 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law Page 10 of 214
If the tension is not set to the manufactures specifications, remove
the tension gauge and adjust the belt tension. Repeat steps 1 through 4
until specifications are met.

© 2012 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law Page 11 of 214
Warning and Caution Statements
and General Safety Guidelines
Warning and Caution Statements
Warning statements indicate a particularly dangerous activity that could cause personal injury. Warning
statements you will find in this manual include:
Because this is 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.
When the unit is used, stairarms are in motion; the generator will operate and produce potentially
hazardous voltages even when the battery is disconnected.
Caution statements are intended to prevent damage to the AMT as a result of the current activity.
Caution statements included in this manual are listed below:
• When it is necessary to lift or move the AMT, ensure that the AMT has adequate support
and that you use proper lifting techniques. When the rear platform is removed, the AMT
may be lifted from the rear and moved like a wheelbarrow.
• To remove power from the AMT, the optional external power supply (when equipped)
must be disconnected from the wall outlet and the red (positive) wire must be
disconnected from the battery. Always ensure that the AMT external power supply is
unplugged from the wall outlet and the red (positive) wire is removed from the battery
when you inspect or adjust the AMT, or when you isolate, remove, or replace an AMT
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.
• Exercise caution when touching any wire or electrical component during AMT operation.
• A pinching hazard exists when the unit is operated. It is possible to seriously pinch a finger. The AMT
can be mechanically locked by inserting a screwdriver through the primary sheave and frame. See the
illustration below. Locking the AMT will prevent accidental pinching.
A pinching hazard exists when the unit is operated. It is possible to seriously pinch a finger. The AMT
can be made immobile by lift the stairarm pedals and removing the tension from stairarm flat belts.
Removing the tension from the flat belts will prevent accidental pinching.
Safety

© 2012 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law Page 12 of 214
Safety guidelines you should know and follow include:
Read the owner’s manual and follow all operating instructions.
Operate the AMT on a solid, level surface with the unit properly leveled. The AMT is properly leveled
when all five feet are in contact with the floor. Visually check the AMT 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 AMT.
When operating the AMT, 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 AMT, 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.
AMT’s equipped 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.

© 2012 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law Page 13 of 214
Checking the AMT Operation
This section provides you with a quick method of checking AMT operation. Check the operation of the
AMT at the end of most maintenance procedures.
Procedure
1 Start striding on the AMT or plug the optional external power supply (when available) into the AMT
and the AC outlet.
2 When the PRECOR banner displayed, press QUICK START.
3 Select Resistance Level 1 and press ENTER.
4 Operate the AMT for 4–5 minutes. As you operate the AMT, concentrate on the operating sounds
made by the unit. Be on the alert for unusual rubbing, hitting, grinding, or squeaking noises.
5 Ensure that the AMT is properly leveled, that the two "feet" are in contact with the floor and there is
no side to side rocking.
6 If the AMT makes unusual noises or the electronic display does not change appropriately,
troubleshoot per Section, AMT Base Troubleshooting Procedures. 147).
7 Press the RESISTANCE key until you reach Resistance Level 10. Operate the AMT for another 2–3
minutes.
8 If the AMT resistance does not change or the operation of the AMT feels inconsistent compared with
Resistance Level 1, troubleshoot per Section, AMT Base Troubleshooting Procedures. 147).
9 Press the RESISTANCE key until you reach Resistance Level 20. Operate the AMT for another 2–3
minutes.
10 If the resistance of the AMT does not change or the AMT operation feels inconsistent with
Resistance Levels 1 and 10, troubleshoot per AMT Base Troubleshooting Procedures. 147).
11 Check the LED’s mounted on the upper PCA and the function keys displayed on the electronic
console by performing Procedure, Accessing the P30 Diagnostic Software. and P80
System Settings (on page 58).
12 Check stride indicator for proper operation.
13 Check wireless and hand held heart rate functions.

© 2012 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law Page 14 of 214
Adjustment Procedures
H-brake Belt Tension Adjustment
WARNING: Before continuing with this procedure, review the Warning and Caution statements
listed in the Warning and Caution Statements and General Safety Guidelines Section, Things You
Should Know.
Procedure
1 Remove the gasket, top, front, rear, left and right side covers per, Cover Replacement Procedure.
2 Place a belt gauge on the H-brake belt.
Figure 50: H-Brake Belt Tension Gauge
3 The belt gauge should read approximately 130-140 lbs. If the belt tension is significantly high or low
the belt tension may be adjusted by loosening or tightening the H-Brake adjustment bolt.
Figure 51: H-Brake Belt and H-Brake Cam

© 2012 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law Page 15 of 214

© 2012 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law Page 16 of 214
Generator Belt Tension Adjustment
WARNING: Before continuing with this procedure, review the Warning and Caution statements
listed in the Warning and Caution Statements and General Safety Guidelines Section, Things You
Should Know..
Procedure
1 Remove the gasket, top, front, rear, left and right side covers per procedure, Cover Replacement.
2 Place a belt gauge on the generator belt.
3 Check the generator belt tension, if not within specification continue with the following adjustment
steps. See Drive Belt Gauge Instructions.
Generator Belt Tension Specification
Generat
or Belt
Tension
new
85 +/- 5 lbs (38.6 +/- 2.3 kgs)
used*
60 - 75 lbs (27.2 - 34 kgs)

© 2012 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law Page 17 of 214
Note: * More than 1 hour of use.
a. Loosen or tighten the generator adjustment nut and bolt until the belt gauge reading is within
specification.
b. Tighten the two bolts that secure the generator mounting bracket to the frame. Torque to 160
inch pounds.
4 Select the QUICKSTART program and adjust the resistance key until resistance level 10 is
displayed. Pedal the AMT for approximately one minute.
9 Recheck the drive input belt and the generator belt tension, readjust if out-of-spec. See Drive Belt
Gauge Instructions.
10 Replace the covers per procedure, Cover Replacement.

© 2012 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law Page 18 of 214
Drive Input Belt Tension Adjustment
WARNING: Before continuing with this procedure, review the Warning and Caution statements
listed in the Warning and Caution Statements and General Safety Guidelines Section, Things You
Should Know.
Procedure
1 Remove the gasket, top, front, rear, left and right side covers per procedure, Cover Replacement.
2 Place a belt gauge on the drive input belt as shown below.
3 Check the drive input belt tension, if not within specification continue with the following adjustment
steps. See Drive Belt Gauge Instructions.
Drive Belt Tension Specification
Drive
Belt
Tension
new
135 +/- 5 lbs (61.2 +/- 2.3 kgs)
used*
100 - 125 lbs (45.4 - 56.7 kgs)

© 2012 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law Page 19 of 214
Note: * More than 1 hour of use.
a Loosen the generator mounting bolts.
b Loosen the generator adjustment bolt.
c Loosen or tighten the Step-Up pulley adjustment bolt until the drive belt tension is within
specification. See Drive Belt Gauge Instructions).
dTighten the two Step-Up pulley mounting bolts. Torque to 160 inch pounds.
e Select the QUICKSTART program
displayed. Pedal the AMT for approximately one minute.
f Recheck the drive belt tension, readjust if needed.
4 Place the belt gauge on the generator belt.

© 2012 Precor Incorporated, Unauthorized Reproduction and Distribution Prohibited by Law Page 20 of 214
5 Check the generator belt tension, if not within specification continue with the following adjustment
steps. See Drive Belt Gauge Instructions.
Generator Belt Tension Specification
Generat
or Belt
Tension
new
85 +/- 5 lbs (38.6 +/- 2.3 kgs)
used*
60 - 75 lbs (27.2 - 34 kgs)
Note: * More than 1 hour of use.
a Loosen or tighten the generator adjustment nut and bolt until the belt gauge reading is within
specification.
b Tighten the two bolts that secure thegenerator mounting bracket to the frame. Torque to 160
inch pounds.
c Select the QUICKSTART program
displayed. Pedal the AMT for approximately one minute.
f Recheck the generator belt tension, readjust if out-of-spec.
10 Replace the covers as per procedure, Cover Replacement.