Precor Commercial Adaptive Motion Trainer C100i User manual

C100i Adaptive Motion Trainer
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C100i Adaptive Motion Trainer
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.
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.
Acrobat Reader Users:
To move directly to a procedure, 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.
© 2006 Precor Incorporated
Unauthorized Reproduction and Distribution Prohibited By Law
20039-154

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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 a user standing on the
C100i facing the display enclosure.
General System Information
• The generator performs three functions in the C100i. First, by controlling the amount of
electrical current applied from the generator to a load circuit, the user’s pedalling resistance
is controlled. Second, the generator is used to charge the C100i’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).
Warning and Caution Statements and General Safety Guidelines
Warning statements indicate a particularly dangerous activity. 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.
• To remove power from the C100i, 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 C100i 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
C100i, or when you isolate, remove, or replace an C100i 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 C100i operation.

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• A pinching hazard exists when the unit is operated. It is possible to seriously pinch a finger.
The C100i can be mechanically “locked” by inserting a screwdriver through the primary
sheave and frame. See the illustration below. Locking the AMX100i will prevent accidental
pinching.
• Caution statements are intended to prevent damage to the C100i 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 C100i, ensure that the C100i has adequate support
and that you use proper lifting techniques. When the rear platform is removed, the C100i
may be lifted from the rear and moved like a “wheelbarrow”.
Safety guidelines you should know and follow include:
• Read the owner’s manual and follow all operating instructions.
• Operate the C100i on a solid, level surface with the unit properly leveled. The C100i is
properly leveled when all five “feet” are in contact with the floor. Visually check the C100i
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 C100i.
• When operating the C100i, 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 C100i, while performing service.

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• 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.
• C100i’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.
General Information
For the latest exploded view, part number and part pricing information, visit the Precor dealer
website at “www.precor.com/connection”.
Tools Required
Multimeter Allen wrench set
Anti-static kit Screwdriver set
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./lbs.
Torque wrench, 200 ft./lbs

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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 a regular basis.
Regular Preventive Maintenance (Owner)
Cleanliness of the C100i and its operating environment will keep maintenance problems and
service calls to a minimum. Precor recommends that you perform the following preventive
maintenance schedule.
After Each Use
• Wipe down the covers, handlebars and stairarms with a damp cloth.
Daily Maintenance
Clean the C100i’s frame, covers, stairarms and foot pedals using water or a 30:1 solution of
Simple Green®and water. Wipe the surface of the electronic console with a damp sponge or soft
cloth. Dry with a clean towel. A 30:1 solution of Simple Green®and water or Contec Athletix®
wipes are the only cleaning products that have been tested and approved for use on the C100i.
The use of an acid (citric) based cleaner is not authorized by Precor.
Weekly Maintenance
• Vacuum underneath the C100i, following these steps:
1. Unplug the optional external power supply (when equipped) from the AC outlet
2. Remove the platform at the rear of the C100i.
3. Carefully lift the rear of the C100i and move it to a temporary location.
4. Vacuum the rug or damp mop the floor.
5. Make sure that the floor is dry before returning the C100i to its original position and
replacing the platform.
• Re-level the C1100i to ensure that all five “feet” are in contact with the floor.
• Thoroughly test all C100i per Section Four, including heart rate.
• Cardio Theater cord management must be observed.

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Quarterly Maintenance
1. Remove the side covers per Procedure 7.12.
2. Check the belt alignment and tension as in Procedure 5.2.
3. Clean the inside of the C100i.
4. Inspect fasteners for proper tightness and torque.
5. Check for excessive noise during vertical and horizontal operation.
6. Replace the side covers.
7. Re-level the C100i to ensure that all five “feet” are in contact with the floor.
On-Site Preventive Maintenance (Service Technician)
When you are called to service a C100i, perform these preventive maintenance activities:
• Perform the software diagnostics. Check LED and keypad function. Record the odometer
reading.
• Check stride rate and stride length sensor function (is the stride rate and stride length
displayed when the unit is in operation?).
• Visually inspect the drive belts for cracks, fraying or excessive wear.
• When furnished, inspect the optional power supply cords. If a power supply cord(s) is
damaged, install a new power supply.
• Visually examine all wires and check connectors and wire connections. Secure connections
and replace wiring as necessary.
• Cardio Theater cord management must be observed.

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Procedure 3.1 - Software Access Codes
The C100i uses the standard access codes to provide access to the various software features.
Use the RESET key and the numeric keypad to enter the access code. The access code must be
entered when the Precor banner is scrolling on the display. 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 and the display will return to the
idle state with the Precor banner displayed. If the access is aborted, it will be necessary to start
over from the beginning. Refer to Diagram 3.1.
Standard Access Codes
Diagnostics Keys RESET,5,1,7,6,5,7,6,1
Odometer Keys RESET,6,5
Club Settings Keys RESET,5,6,5,1,5,6,5
Diagram 3.1 - C100i Display

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Procedure 3.2 - Accessing the Diagnostic Software
The treadmill's diagnostic software consists of the following modes:
• Display Test
• Keyboard Test
• Heart Rate Test
• Brake Test
•RPMTest
• Battery Test
• Stride Position Test
Procedure
1. Start pedaling the C100i using a vertical motion.
2. Using the RESET key and the numeric keypad, press keys RESET,5,1,7,6,5,7,6,1,
sequentially.
3. Hardware Validation will scroll across the display followed by DISPLAY TEST.
4. Press the OK key, the upper most group of LED’s will illuminate on the display. Check
the display to ensure that all LED segments are illuminated.
5. Press the OK key six more times to display the remaining LED groups. Check each
display group to ensure that all LED segments are illuminated.
6. Press the CLEAR key then the Tkey, KEYBOARD TEST will scroll across the display.
7. Press the OK key, a representation of all of the keys on the console will be displayed.
Pressing a key on the console will cause the representation of that key to go off. Press
all of the keys on the console to ensure that all of the keys are functioning.
8. Press and hold the CLEAR key then the Tkey, HEART RATE will be displayed.
9. Grasp both of the heart rate grips on the handlebar, after a couple of seconds the heart
rate will be displayed in the heart rate display. The unfiltered an filtered heart rate will
be displayed in the lower display window.
10. Use chest strap transmitter or a test transmitter to test the wireless heart rate function,
after a couple of seconds the heart rate will be displayed in the heart rate display. The
unfiltered an filtered heart rate will be displayed in the lower display window.
11. Press the CLEAR key then the Tkey, BRAKE TEST will scroll across the display.
12. Press the OK key, BRAKE will be displayed.

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13. Press the OK key, PWRB will be displayed with the current power bit reading. Pressing
the resistance S,Twill change the power bit setting.
14. Press the CLEAR key then the Tkey, RPM TEST will scroll across the display.
15. Press the OK key, RPM will be displayed.
16. Press the OK key, PULSE will be displayed with the current speed pulse count.
17. Press the CLEAR key then the Tkey, BATTERY TEST will scroll across the display.
18. Press the OK key, the current battery voltage will be displayed.
19. Press the CLEAR key then the Tkey, STRIDE POSITION TEST will scroll across the
display.
20. Press the OK key, the low, high and actual stride positions will be displayed. The low
display shows the lowest position reading achieved during the test. The high display
shows the highest position reading achieved during the test. The actual display
changes with the current stride position. Stride on the AMT to the maximum horizontal
movement in both directions. At maximum stride length the low stride display should
read 0 and the high stride display should read 40.
21. Press the OK key, the low and stride positions will be displayed.
22. Press the RESET key to exit the hardware validation test.

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Procedure 3.3 - Information Display
Software version numbers are invaluable for tracking and identifying problems and staying aware
of changes to the operation and features of the product.
Procedure
The information display will access the following data;
• Odometer
• Hour Meter
• U-Boot Software
• U-Base Software
• Lower Base Software
• Metrics Board Software
• Stride Dial Software
• Serial Number
• Usage log
• Error Log
Procedure
1. Start pedaling the C100i using a vertical motion.
2. With the PRECOR banner scrolling, press the keys RESET,6,5, sequentially.
3. DIAGS-INFORMATION DISPLAY will scroll across the display.
4. Use the S,Tkeys to move to the desired display shown in the list above.
5. ODOMETER display. Press the OK key.
6. The horizontal distance will be displayed in miles or kilometers and the vertical
distance will be displayed in steps.
Note: The odometer data is stored in non-volatile memory on the upper PCA. If the upper PCA
is replaced the odometer data will be lost.
7. Press the CLEAR key to exit the odometer display.
8. HOUR METER display. Press the OK key.
9. The operating time of the unit will be displayed as 12345 HOURS. The operating time
is defined as total amount of time that the unit has operated in program modes. The
hour meter is also used to provide the “time stamp” for the error code log.
10. Press the CLEAR key to exit the hour meter display.

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11. U-BOOT SW display. This display the installed version of upper boot software. The
boot software is used to upload new software into the upper display PCA.
12. Press the OK key. The software part number will be displayed as XXXXX-XXX.
13. Press the CLEAR key to exit the U-Boot SW display.
14. U-BASE SW display. This display the installed version of upper PCA software.
15. Press the OK key. The software part number will be displayed as XXXXX-XXX.
16. Press the CLEAR key to exit the U-Base SW display.
17. LOWER BASE SW display. This display the installed version of lower PCA software.
18. Press the OK key. The software part number will be displayed as XXXXX-XXX.
19. Press the CLEAR key to exit the lower SW display.
20. METRICS BOARD SW display. This display the installed version of lower PCA
software.
21. Press the OK key. The software part number will be displayed as XXXXX-XXX.
22. Press the CLEAR key to exit the lower SW display.
23. STRIDE DIAL SW display. This display the installed version of lower PCA software.
24. Press the OK key. The software part number will be displayed as XXXXX-XXX.
25. Press the CLEAR key to exit the lower SW display.
26. SER. NUMBER display. Press the OK key.
27. The C100i’s serial number will be displayed. The serial number may be incorrect or not
displayed if the upper PCA has been replaced.
28. Press the CLEAR key to exit the serial number display.
29. USAGE LOG display. Press the OK key.
30. Use the S,Tkeys to move through the list of programs. A message will scroll
describing the program, the number of times and the number of minutes the program
was used.
31. Press the CLEAR key to exit the usage log display.
32. ERROR LOG display. Press the OK key, the quantity of errors in the log will be
displayed.

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33. Press the OK key, the most recent error will be displayed first.
34. Use the S,Tkeys to move through the list of errors. The error messages will list the
error name, the odometer reading when the error occurred, the hour meter when the
error occurred and the drive motor current reading when the error occurred.
35. If you wish to clear the error log, press and hold the QUICK START key. The message
HOLD TO CLEAR ERRORS will be displayed. The error log will be cleared when the
message NO ERRORS is displayed.
36. Press the RESET key to exit the information display.
37. Please note that the ERROR LOG may also be accessed at any time by pressing and
holding the RESET key for four seconds. If the error log does not contain any errors,
the message STUCK KEY will be displayed.

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Procedure 3.4 - Selecting Club Settings
Procedure
This procedure allows you to change the following club settings:
• Select Language
• Select Units
• Set Max Workout Time
• Set Max Pause Time
• Set Cool Down Time
Procedure
1. Start pedaling the C100i using a vertical motion.
2. With the banner scrolling, press keys RESET,5,6,5,1,5,6,5, sequentially.
3. Use the S,Tkeys to move to the desired display shown in the list above.
4. DIAGS-SET CLUB PARAMETERS will scroll across the display.
5. When SELECT LANGUAGE is displayed. Press the OK key.
6. Use the S,Tkeys to toggle between the available languages.
7. Press the BACK key to exit the select language display.
8. SELECT UNITS display. Press the OK key.
9. Use the S,Tkeys to toggle between U.S and METRIC measurements.
10. Press the BACK key to exit the set units display.
11. SET MAX WORKOUT TIME display. Press the OK key.
12. Use the S,Tkeys to select the maximum time a user can remain in a program.
13. Press the BACK key to exit the set max. workout time display.
14. SET MAX PAUSE TIME display. Press the OK key.
15. Use the S,Tkeys to select the maximum time a program will remain in the pause
mode.
16. Press the BACK key to exit the set max. pause time display.

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17. SET COOL DOWN TIME display. Press the OK key.
18. Use the S,Tkeys to select the cool down time from 0 to 5 minutes.
19. Press the BACK key to exit the set cool down time display.
20. Press the RESET key to exit the club settings program.

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Procedure 3.5 - Documenting Software Problems
When a problem is found with either the upper software or lower PCA’s, record the information
listed below. Refer to Procedure 3.6 to install new upper software. Please note, installing new
upper software is only appropriate if a later software version containing a correction for the
problem experienced is available. If an appropriate software version is not available the
information below must be forwarded to Precor customer support. This information will be used
to correct and create new software, whenever it is appropriate.
When a problem occurs, record the following information:
• Model and serial number
• Software part numbers, Procedures 3.3.11 to 3.3.25.
• User and program number running when the problem occurred
• A description of:
a What happened or failed to happen.
b The action taken by the user just before the problem occurred.
c Problem-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.

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Procedure 3.6 - Software Uploading Procedure
This unit utilizes an upper PCA software system that is capable of on site upper PCA software
uploading (re-programming). The software upload may be accomplished with the use of a pocket
PC or a laptop computer. Contact Precor Technical Support for details.
Upload Procedure
1. The C100i must be “powered down” before the upload procedure can be initiated.
Ensure that the C100i has not be used for a sufficient time to allow the lower PCA to
completely discharge. The light emitting diode on the lower PCA will go out when the
power supply is discharged, approximately 45 seconds.
2. If the CSAFE Full port is in use, temporarily disconnect the RJ-45 cable from the
CSAFE Full port. If the CSAFE Full port is not in use, temporarily remove the plastic
plug from the CSAFE Full port.
Console, Rear View, with Rear Cover Removed,
3. Connect the computer interface cable to the CSAFE Full port.
4. Select the software file to be uploaded on the computer.
5. Start pedaling the C100i or power up using the external power supply. When the C100i
“powers up” the upload will commence. Upload status is displayed on the PC, when
100% is reached the upload is complete. You must continue to pedal until the upload is
complete, approximately 2 minutes.
CSAFE
Power
CSAFE
Full

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6. Stop pedaling or disconnect the external power supply when the upload is complete,
and allow the lower PCA to completely discharge. The light emitting diode on the lower
PCA will go out when the power supply is discharged.
7. Start pedaling the C100i, after it has been allowed to power down, the C100i will now
be operating on the newly uploaded software.
8. Verify software version per Procedure 3.3.
9. Thoroughly, check the C100i’s function per Section Four.

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Section Four - Checking C100i Operation
This section provides you with a quick method of checking C100i operation. Check the operation
of the C100i at the end of most maintenance procedures.
Procedure
1. Start striding on the C100i or plug the optional external power supply (when available)
into the C100i and the AC outlet.
2. When the PRECOR banner displayed, press QUICK START.
3. Select Resistance Level 1 and press ENTER.
4. Operate the C100i for 4–5 minutes. As you operate the C100i, 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 C100i is properly leveled, that all five “feet” are in contact with the floor
and there is no side to side rocking.
6. If the C100i makes unusual noises or the electronic display does not change
appropriately, troubleshoot per Section 6.
7. Press the RESISTANCE Skey until you reach Resistance Level 10. Operate the
C100i for another 2–3 minutes.
8. If the C100i resistance does not change or the operation of the C100i feels inconsistent
compared with Resistance Level 1, troubleshoot per Section 6.
9. Press the RESISTANCE Skey until you reach Resistance Level 20. Operate the
C100i for another 2–3 minutes.
10. If the resistance of the C100i does not change or the C100i operation feels inconsistent
with Resistance Levels 1 and 10, troubleshoot per Procedure 6.4.
11. Check the LED’s mounted on the upper PCA and the function keys displayed on the
electronic console by performing Procedure 3.2.
12. Check stride indicator for proper operation.
13. Check wireless and hand held heart rate functions.

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Procedure 5.1 - Measuring the Resistance of a Generator
Caution
If a external power supply is connected to the C100i, disconnect the external power supply from
the C100i before continuing with this procedure.
Procedure
1. Remove the right side cover per Procedure 7.12.
2. Remove the red battery wire from the lower PCA. See Diagram 5.1.
WARNING
Before continuing with this procedure, review the Warning and Caution statements listed in
Section One, Things You Should Know.
3. Set the ohmmeter to a range that will conveniently read up to 50:.
4. Remove the two wires from the LOAD terminals of the lower PCA.
5. With an ohmmeter, read between the wires removed in step 5. The reading should be
approximately 10:Replace the two wires removed in step 5.
6. Remove the three wires from the 3 PHASE GEN IN terminals of the lower PCA.
7. With an ohmmeter, read between the red & white, red & black and white & black wires.
Each reading should be approximately 25: Reconnect the wires removed in step 7
8. 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 4 on the
generator connector. If the reading are now correct check and or replace the
intermediate cable.refer to Diagram 5.1. If the readings are still incorrect, remove the
three phase generator.
9. Reconnect the red battery wire removed in step 3.
10. Replace the right side cover.

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Diagram 5.1 - Lower PCA
LOAD
3 PHASE
GEN IN
BATTERY