Service Manual, 5.17 EFX.fm

Transcription

5.17 Elliptical Fitness Crosstrainer
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.
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.
© 2003 Precor Incorporated
Unauthorized Reproduction and Distribution Prohibited By Law
20039-123
Page 1
5.17 Ellipitical Fitness Crosstrainer
Section One - Things You Should Know
System Information
The 5.17 disables lift (ramp) operation and changes in resistance levels when the unit is not in
use. In order for ramp and resistance levels to be selectable the unit must be in use, that is, the
system must be receiving a normal pulse from the reed switch speed sensor.
The 5.17 EFX operates from a 12 Vdc source. An AC to DC power adapter is provided with the
EFX. See Diagram 1.1.
Diagram 1.1 - Power Adapter
Right, Left, Front, and Back Conventions
In this manual, right, left, front, and back are from the perspective of a user standing on the EFX
5.17, facing the display enclosure.
Warning and Caution Statements and General Safety Guidelines
Warning statements indicate a particularly dangerous activity. Warning statements you will find in
Page 2
this manual include:
•
To remove power from the EFX 5.17, the power adapter’s power cord must be disconnected
from the wall outlet. Always ensure that the EFX 5.17 power adapter is unplugged from the
wall outlet when you inspect or adjust the EFX 5.17, or when you isolate, remove, or replace
a EFX 5.17 component.
•
Removing the covers exposes high voltage components and potentially dangerous
machinery. Exercise extreme caution when you perform maintenance procedures with the
hood removed.
•
During service operations you will be very close to moving machinery and high voltage
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 EFX 5.17
operation.
Caution statements are intended to prevent damage to the EFX 5.17 as a result of the current
activity. Caution statements included in this manual are listed below:
•
Notice the orientation notch on the PROM. These components must be positioned with the
same notch orientation.
Safety guidelines you should know and follow include:
•
Read the owner’s manual and follow all operating instructions.
•
Visually check the EFX 5.17 before beginning service or maintenance operations. If it is not
completely assembled or is damaged in any way, exercise extreme caution while operating
and checking the EFX 5.17.
•
When operating the EFX 5.17, do not wear loose clothing. Do not wear shoes with heels or
leather soles. Check the soles of your shoes and remove any embedded stones. Tie long
hair back.
•
Do not rock the unit. Do not stand or climb on the handlebars, display enclosure, or cover.
•
Do not set anything on the handlebars, display enclosure, or cover. Never place liquids on
any part of the EFX 5.17.
•
To prevent electrical shock, keep all electrical components, such as the power cord and
circuit breaker away from water and other liquids.
•
Do not use accessory attachments that are not recommended by the manufacturer-such
attachments might cause injuries.
Page 3
General Information
For the latest exploded view, part number and part pricing information, visit the Precor dealer
website at “www.precor.com/Dealer.
Required Tools and Equipment
The following list is a summary of the tools and equipment required when you service Precor’s
EFX 5.17.
TOOLS
phillips and flat-head screwdrivers
EQUIPMENT
anti-static wrist strap
digital multimeter
standard and metric allen wrench sets
open-end wrench set
Supplies
drive ratchet and ratchet set
blue loctite
cable ties
chip puller
Spares
rubber mallet
interconnect cables
snap ring pliers
torque wrench
belt gauge (part # 20030-117)
Page 4
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 EFX 5.17 and its operating environment will keep maintenance problems and
service calls to a minimum. Precor recommends that you perform the following preventive
maintenance schedule.
At the End of Each Day
Wipe down the stairarms, ramps, wheels and frame with a damp cloth.
Every Week
Wipe the surface of the electronic console with a slightly-damp sponge or soft cloth. Dry with a
clean towel.
CAUTION
Keep water away from electronic components to prevent shock.
On-Site Preventive Maintenance (Service Technician)
Perform the following preventive maintenance tasks each time you are called to service an EFX
5.17:
Examine the belts for wear, cracks or other signs of deterioration and replace if necessary.
Visually examine all wires and check connectors and wire connections. Secure connections and
replace wiring as necessary.
Page 5
Section Three - Checking EFX 5.17 Operation
This section provides you with a quick method of checking EFX operation. Check the operation
of the EFX at the end of most maintenance procedures.
Procedure
1.
Plug the power adapter’s power cord into the wall outlet, the power adapter’s jack into the
EFX 5.17 and set the on/off switch in the “on” position.
2.
Select Resistance Level 1.
3.
Operate the EFX for 4–5 minutes. As you operate the EFX, concentrate on the operating
sounds made by the unit. Be on the alert for unusual rubbing, hitting, grinding, or squeaking
noises.
4.
If the EFX makes unusual noises or the electronic display does not change appropriately,
troubleshoot per section 6.
5.
Press the RESISTANCE
another 2–3 minutes.
6.
If the EFX resistance does not change or the operation of the EFX feels inconsistent
compared with Resistance Level 1, troubleshoot per section 6.
7.
Press the RESISTANCE
another 2–3 minutes.
8.
If the resistance of the EFX 5.17 does not change or the EFX operation feels inconsistent
with Resistance Levels 1 and 5, troubleshoot per Procedure 6.5.
9.
Press the CROSSRAMP key while viewing the electronic console. Confirm that the foot
pads incline and the ramp display increments to 7 as the CROSSRAMP key is pressed.
key until you reach Resistance Level 5. Operate the EFX for
key until you reach Resistance Level 10. Operate the EFX for
10. Press the CROSSRAMP
key while viewing the electronic console. Confirm that the foot
pads return to the lowest position and the ramp display decrements to 1 as the
CROSSRAMP key is pressed.
11. If the ramp system of the EFX 5.17 does not operate properly, troubleshoot per Procedure
6.4.
12. Turn off the EFX with the circuit breaker, then unplug the power adapter’s power cord from
the wall outlet.
Page 6
Procedure 4.1 - Calibrating the Lift Motor
1.
In order to calibrate the lift motor, it is necessary to disconnect the lift motor from the ramp
assembly.
2.
Set the on/off switch in the “off” position. Remove the six screws that retain the front half of
the front cover to the rear half of the front cover and remove the front half cover.
3.
Remove the retaining clip from each lift nut mounting pin. Support the lift ramp assembly
and remove the lift mounting pins from the lift nut. Raise the ramp and support it from the
handlebars using a bungi cord (See Diagram 4.1).
Diagram 4.1 - Supporting the Ramp
4.
Connect a DC voltmeter between the blue and brown wires of the lift motor connector. Set
the on/off switch in the on position. Operate the ramp until the DC voltmeter reading is as
close to 1.1 VDC as possible. Set the on/off switch in the off position. Set the meter, while
still connected between the blue and brown wires, to read ohms. Grasp the lift motor drive
screw and rotate it until the ohmmeter reads 240Ω (See Diagram 4.2)
5.
Rotate the lift nut on the lift motor drive screw until the distance between the top surface of
the lift nut and the top of the lift motor drive screw is three inches. If the lift motor drive screw
is allowed to rotate while lift nut is being positioned, the ohmmeter will no longer read 240Ω.
The lift calibration number must be 240Ω. The distance measurement must be correct and
the ohmmeter must read 240Ω for the lift calibration to be correct.
Page 7
Diagram 4.2 - Lift Motor Mounting
3.00”
Lift Nut Pin
Lift Nut
Retaining Clip
Lift Nut
Lift Motor
Drive Screw
Lift Motor
6.
Remove the bungi cord from the ramp and set the ramp at it’s mounting position. Do not
rotate the lift nut any more than is necessary to align the holes in the lift nut with the holes in
the ramp. Replace both lift nut mounting pins. Replace both retaining clips on the lift nut
mounting pins.
7.
Set the on/off switch in the “on” position. Thoroughly test all lift related functions per Section
Three.
8.
Set the on/off switch in the “off” position, replace the front cover per Procedure 6.1.
Page 8
Procedure 4.2 - Inspecting and Adjusting Belt Alignment and
Tension
Procedure
1.
Set the on/off switch in the “off” position.
WARNING
Before continuing with this procedure, review the Warning and Caution statements listed in
Section One, Things You Should Know.
2.
Remove the rear cover as described in Procedure 6.1.
3.
Operate the unit by rapidly rotating a crankarm by hand. As the unit operates watch the
drive belts for proper alignment. The belts should operate parallel to each other and the
belts should maintain even spacing.
4.
If the belts are not correctly aligned...
THEN...
Continue with the next step.
OTHERWISE...
Skip to step 13
5.
Refer to Diagram 4.3 for the following belt alignment steps.The right and left tension bolts
have locking tabs. If necessary, use pliers to bend the locking tabs out of the way so that the
bolts can be turned.
6.
If the step up pulley belt is out of alignment to the right, continue with step 8.
7.
If the step up pulley belt is out of alignment to the left, continue with step 10.
8.
Turn the left tension bolt 1/4 turn clockwise, then repeat step 3. If turning the left adjustment
bolt 1/4 of a turn was not sufficient, turn the right tension bolt 1/4 of a turn counterclockwise.
9.
Repeat step 8, alternating between the left and right tension bolts until the alignment is
correct. Continue with step 13.
10. Turn the right tension bolt 1/4 of a turn clockwise, then repeat step 3. If turning the right
adjustment bolt 1/4 of a turn was not sufficient, turn the left tension bolt 1/4 turn
counterclockwise.
11. Repeat step 10, alternating between the right and left tension bolts until the alignment is
correct.
12. Belt tension must now be checked and if necessary corrected. Remember, if it is necessary
to change the belt tension, the belt alignment must be maintained.
Page 9
Diagram 4.3 - Drive Unit
Step up
Belt
Input
Belt
Brake
13. Place a belt gauge (McMaster-Carr 6160K12 or Grainger 3HX33) in the middle of the step
up belt and the center of the belt span (see Diagram 4.4). Lay a straight edge along the
length of the belt and beside the belt gauge. Slide one of the o-rings up against the shoulder
of the belt gauge. Press downward on the belt gauge, causing the belt to deflect. Read the
deflection on the belt gauge at the edge of the straight edge. Deflect the belt 1/2”. Read the
tension across the top edge of the o-ring. If the belt is correctly tensioned the gauge will
read between 14 and 16 pounds.
14. If the tension in step 13 is correct skip to step 18. Otherwise continue with the next step.
Page 10
Diagram 4.4 - Measuring Belt tension
15 lbs
1/2”
15. If the locking tabs on the right and left tension bolts have not been straightened, use pliers to
bend the locking tabs out of the way so that the bolts can be turned.
IF...
The belt tensioning gauge reads
less than 14 pounds
THEN...
Turn both tension bolts
clockwise, in equal quarter-turn
increments, until the belt tensioning
gauge reads 14 - 16 pounds @1/2” deflection.
The belt tensioning gauge reads
more than 16 pounds
Turn both tension bolts
counterclockwise, in equal
quarter-turn increments, until the belt
tensioning gauge reads 14 - 16 pounds @ 1/2”
deflection.
16. Verify that the belt alignment is still correct by performing the procedure in step 3.
17. When both the step pulley tension and alignment are correct, use pliers to bend the tension
bolt locking tabs into the “locking” position.
18. The input pulley tension must now be checked and corrected, if necessary. There is not
sufficient room to use the belt tension gauge to set the input pulley belt tension. The Input
Page 11
belt tension will be checked by measuring the position of the stub tensioner within it’s
adjustment slot (See Diagram 4.5)
Diagram 4.5 - Stub Tensioner Adjustment
1-1/2”
Stub Tensioner
Axle Nut
Step Up Pulley
Adjustment Bolt
19. The distance from the end of the stub tensioner adjustment slot to the edge of the stub
tensioner axle should be 1-1/2 inches. Loosen the stub tensioner axle nut slightly. If
necessary, insert a lever, such as a large flat bladed screwdriver, into the sub tensioner
adjustment slot and carefully move the stub tensioner until the distance measurement is
1-1/2 inches. Tighten the stub tensioner axle nut.
20. When the input belt tension is correct, torque the stub tensioner nut to 200 in/lbs.
21. Check the operation of the unit as described in Section Three, then re-install the rear cover
as described in Procedure 6.1
Page 12
Procedure 4.3 - Display Diagnostics
Note:
This section is applicable only for units with software versions 1.02 (both lower and upper
software) only. Software version lower than 1.02 to not support display diagnostics.
1.
Since it is necessary to depress a key on the display as the unit is being powered up, it will
be necessary to have an assistant power the unit up while you press the display key (unless
you have very long arms).
2.
Press and hold the RESET key as the on/off switch is set in the on position. Do not release
the RESET key.
3.
Four eights will be displayed. Check to ensure that all of the display segments are
illuminated.
4.
While continuing to depress the RESET key, press each of the remaining keys one at a
time. As each key is depressed a corresponding L.E.D. segment will go out, indicated that
the key being pressed is functioning normally.
5.
While continuing to depress the RESET key, depress both “↑” keys. When both “↑” keys are
depressed, release the RESET key, while continuing to depress both “↑” keys. The upper
software version will be displayed.
6.
While continuing to depress both “↑” keys, press both “↓”. When both “↓” are depressed,
release both “↑”, the lower software version will be displayed.
7.
Release both “↓”to exit the display diagnostics.
Page 13
Procedure 5.1 - Troubleshooting the Lower and Upper
Interconnect Cables
Anti-static kits can be ordered from Precor (part number 20024-101).
Troubleshooting the Upper Interconnect Cable
1.
WARNING
2.
Attach the anti-static wrist strap to your arm, then connect the ground lead of the wrist strap
to the units frame.
3.
Remove the four bolts that fasten the front half of the frame to the rear half of the frame. The
upper interconnect cable connects to the lower interconnect cable where the two frame
halves are joined. Carefully, slide the front half of the frame away from the rear half of the
frame.
4.
Remove the rear cover. For convenience, the upper interconnect cable is the cable that
attaches to the upper PCA and the lower interconnect cable is the cable that connects to the
lower PCA.
5.
Disconnect the upper interconnect cable from the upper PCA and the lower interconnect
cable.
6.
Connect a known good upper interconnect cable from the lower interconnect cable to the
upper PCA. Route the cable outside of the unit at this time.
7.
Check operation as described in Section Three.
8.
If the unit operated correctly when the new interconnect cable was installed...
THEN...
The original upper interconnect cable
is bad; install a new cable as described
in Procedure 6.5.
9.
OTHERWISE...
The original upper interconnect cable
is not bad; continue with the next step.
Reconnect the original upper interconnect cable to the upper PCA.
Page 14
Troubleshooting the Lower Interconnect Cable
10. Remove the shield from the lower PCA.
11. Remove the interconnect cable from the lower PCA.
12. Connect a known good lower interconnect cable between the lower PCA and the upper
interconnect cable.
13. Check operation as described in Section Four.
14. If the unit operated correctly when the spare lower interconnect cable was installed...
THEN...
The original interconnect cable is bad,
OTHERWISE...
The original interconnect cable is good,
install a new interconnect cable as
continue with the next step
described in Procedure 6.5, skip to step 19
15. Reconnect the original lower interconnect cable to the lower PCA.
16. Reconnect the lower interconnect cable to the upper interconnect cable.
17. Replace the lower PCA shield.
18. Replace the rear cover.
19. Carefully, slide the two frame halves together. Replace and tighten the four frame bolts.
20. Check operation as described in Section Three.
Page 15
Procedure 5.2 - Troubleshooting the Keypad and Upper PCA
If the function keys on the electronic console are unresponsive, the problem may be either the
upper PCA or keypad. This troubleshooting procedure gives you the information you need to
determine which of these components is malfunctioning.
Procedure
1.
Set the circuit breaker in the “off” position.
WARNING
Section One of the Residential Treadmill Service Manual.
2.
Remove the screws that secure the upper display assembly to the upper handrail. Carefully,
pull some excess interconnect cable out from the targa upright. Rotate the display housing,
so that the rear of the upper PCA is facing upward, and set the display housing on the upper
handrail.
3.
Attach the wrist strap to your arm, then connect the ground lead of the wrist strap to the
treadmill frame.
Diagram 5.1 -5.17 Upper PCA, Rear View
Interconnect Cable
Connector (J1)
Keypad Connector
Pin #1
4.
Set the voltmeter to a range that will conveniently read +6 Vdc.
5.
Set the circuit breaker in the “on” position.
Page 16
6.
Use a DVM, set for DC volts, and read between pin 6 of J2 and the each of the pins in Table
5.1 (no keys pressed) and Table 5.2 (with the appropriate key pressed)...
Table 5.1. Voltage Test Points (Function Keys Not Pressed)
Place the positive lead of the
voltmeter on...
The voltmeter should
read...
Pin 3 of J2
5 Vdc ± 500 mVdc
Pin 4 of J2
5 Vdc ± 500 mVdc
Pin 5 of J2
5 Vdc ± 500 mVdc
Pin 7 of J2
5 Vdc ± 500 mVdc
Pin 8 of J2
5 Vdc ± 500 mVdc
Pin 9 of J2
5 Vdc ± 500 mVdc
Table 5.2. Voltage Test Points (Function Keys Pressed)
Place the positive
voltmeter lead on...
Pin 3 of J2
Pin 4 of J2
Pin 5 of J2
Pin 7 of J2
Pin 8 of J 2
Pin 9 of J2
At the electronic
console, press...
SELECT/ENTER
CROSSRAMP
CROSSRAMP
PAUSE/RESET
RESISTANCE
RESISTANCE
The voltmeter should
read between...
0 Vdc and 500 mVdc
0 Vdc and 500 mVdc
0 Vdc and 500 mVdc
0 Vdc and 500 mVdc
0 Vdc and 500 mVdc
0 Vdc and 500 mVdc
7.
If the voltage readings match those listed in Tables 5.1 and 5.2 and one or more keys do not
function, replace the upper PCA.
8.
If the voltage readings in Table 5.1 are incorrect, disconnect the keypad cable from the key
pad connector and repeat the voltage measurements in Table 5.1. If the voltage readings
are now correct, replace the display housing (keypad). If the voltage readings are still
incorrect, replace the upper PCA.
9.
Set the circuit breaker in the “off” position.
10. If necessary, carefully re-connect the keypad cable to the keypad connector.
Page 17
11. Remove the ground lead of the wrist strap from the treadmill frame, then remove the wrist
strap from your arm.
12. Position the display enclosure on the display plate. Install the screws that secure the display
enclosure to the display plate.
13. Check the operation of the treadmill as described in Section Three.
Page 18
Procedure 5.3 - Troubleshooting the Speed Sensor
Circuit Description
The speed sensor is a reed switch. A magnet is mounted on the step up pulley. The magnet
passes the speed sensor once per revolution. The output from the speed sensor is a 5 Vdc
square wave, the frequency of which indicates the operating speed. When a square wave output
is not being generated from the speed sensor the system assumes the unit is not in use and
disables lift (ramp) operation and resistance level changes.
WARNING
Procedure
1.
Remove the rear covers. Set the on/off switch in the “on” position. Operate the unit. If the
system timer has not started and a stride rate is not displayed, the speed sensor is not
operative. We shall use the presence of a stride rate to determine when the speed sensor is
functioning normally.
2.
A magnet must be installed in the step up pulley. If the stride rate is not being displayed in
step 1, verify that a magnet is installed in the step up pulley and that the space between the
end of the reed switch and the step up pulley is approximately 1/8 inch (See Diagram 5.2).
Diagram 5.2 - Speed Sensor
Step Up Pulley
Magnet
S
Step
Reed Switch
3.
Rotate the step up pulley so that the speed sensor magnet is not near the reed switch.
Using a DC voltmeter, measure the voltage between terminal 1 and terminal 2 of J2 on the
Page 19
lower PCA. The measurement should be approximately 5 Vdc. If the measurement is
correct, skip to step 4. If the voltage is missing or significantly low, disconnect the speed
sensor and repeat the measurement on the J2 connector. If the measurement is now correct
(5 Vdc), replace the speed sensor. If the voltage is still missing or significantly low, replace
the lower PCA. Skip to step 5.
4.
Rotate the step up pulley so that the speed sensor magnet is next to the reed switch. Using
a DC voltmeter, measure the voltage between terminal 1 and terminal 2 of J2 on the lower
PCA. The measurement should be approximately 0 Vdc. If the voltage is 5 Vdc or
significantly high, replace the speed sensor.
5.
With the DC voltmeter connected to terminals 1 and 2 of J2 on the lower PCA, rock the step
up disk forward and backward so that the magnet is passing in front of and away from the
reed switch. The DC voltmeter should alternate between 0 Vdc and 5 Vdc. If the voltage
measurement does not alternate between 0 Vdc and 5 Vdc, repeat steps 2 through 4. If the
voltage does alternate between 0 Vdc and 5 Vdc, continue with step 6.
6.
If you have performed all of the above tests and the stride rate is not displayed when the unit
is operated, there are three parts that could cause the problem. There are not any good
tests to check these parts other than substituting a known good part. They are lower PCA,
interconnect cable and upper PCA. Replace only one part at a time. If the new part does not
correct the problem, replace the original part.
7.
If you have performed all of the above tests and the speed sensor is still not functioning, call
Precor Technical Support.
Page 20
Procedure 5.4 - Troubleshooting the Lift System
Note:
The lift motor is disabled when the EFX is not being used. The speed sensor must detect motion
in order for lift operation to be enabled. In the following procedures, when lift motor movement is
being tested the stairarms must be in motion. Before performing this procedure, ensure that the
speed sensor is operating normally per Procedure 5.3. The lift motor is connected to the lower
PCA via two cables. The lift motor connects to a cable that goes to the mid point of the frame
where it connects to another cable that completes the path to the lower PCA. The cables will be
referred to the forward and rear lift motor cables, respectively.
1.
If the lift motor will not move skip to step 10. If the lift motor moves and an error occurs
continue with step 2.
2.
Set the on/off switch in the “off” position. Disconnect the lift motor cable from J6 of the lower
PCA.
3.
The following measurements will be measured on the connector that was removed from J6
of the lower PCA in step 2. Using an ohmmeter, measure between terminal 4 (brown) and
terminal 6 (orange wire). The measurement should be approximately 1KΩ. Measure
between terminals 4 and 5 (blue wire) and measure between 5 and 6. The two
measurements should total approximately 1 KΩ. If any of the measurement are open (∞) or
significantly high or low, continue with step 4. If all three measurements are correct, skip to
step 8.
4.
Remove the four bolts that fasten the rear and forward halves of the frame together and
carefully separate the two frame halves. Disconnect the rear lift motor cable from the
forward lift motor cable.
5.
The following measurements will be measured on the forward lift motor cable connector.
Using an ohmmeter, measure between terminal 4 (brown) and terminal 6 (orange wire). The
measurement should be approximately 1KΩ. Measure between terminals 4 and 5 and
measure between 5 (blue wire) and 6. The two measurements should total approximately 1
KΩ. If any of the measurement are open (∞) or significantly high or low, continue with step 6.
If all three measurements are correct, replace the rear lift cable
6.
Remove the six screws that fasten the front cover halves together. Remove the front half of
the front cover. Disconnect the forward lift motor cable from the lift motor cable.
7.
The following measurements will be measured on the lift motor cable connector. Using an
ohmmeter, measure between terminal 4 (brown) and terminal 6 (orange wire). The
measurement should be approximately 1KΩ. Measure between terminals 4 and 5 and
measure between 5 (blue wire) and 6. The two measurements should total approximately 1
KΩ. If any of the measurement are open (∞) or significantly high or low, replace the lift
motor. If all three measurements are correct continue with step 8.
8.
If you have performed all of the above tests and an error still occurs when the lift motor
Page 21
operates, there are three parts that could cause the problem. There are not any good tests
to check these parts other than substituting a known good part. They are lower PCA,
interconnect cable and upper PCA. Replace only one part at a time. If the new part does not
correct the problem, replace the original part.
9.
If you have performed all of the above tests and the lift system is still not functioning, call
10. Set the circuit breaker in the “off” position. Remove the F1 (6.3 amp) fuse from the lower
PCA. Measure the fuse with an ohmmeter. The measurement should be 1Ω or less. If the
fuse is good, re-insert the fuse and skip to step 12. If the fuse is open (∞) or significantly
high, replace the fuse. Before operating the lift motor, it is necessary to perform a continuity
test on the lift motor.
11. Remove the J6 connector from the lower board. Using an ohmmeter, measure between
terminals 2 (red wire) and 3 (black wire) of rear lift motor cable. The measurements should
be approximately 1Ω. If the measurement is significantly low, replace the lift motor. If any of
the readings are open (∞) or significantly high, check the lift motor cables (rear and forward
lift motor cables) and connectors. Repair any wires or connections that are bad. If the cable
and connectors are good, replace the lift motor.
12. Re-insert the J6 connector in the lower PCA. Set the on/off switch in the “on” position. Using
an DC voltmeter, connect the positive meter lead to terminal 2 of J6 and the negative meter
lead to terminal 3 of J6.In the following measurements the voltage polarity is important. Be
sure to note if the DC voltmeter is reading a positive or negative voltage. Operate the EFX
and press the CROSSRAMP s key. The measurement should be approximately +12 Vdc. If
the voltage is present and the lift motor moves normally, skip to step 13. The voltage will
only be present until such time as an error occurs. If +12 Vdc is not present skip to step 14.
If the voltage is measured but the motor does not move, replace the lift motor.
13. Press the CROSSRAMP t key. The measurement should be approximately -12 Vdc. If the
voltage is present and the lift motor moves normally skip to step 14. The voltage will only be
present until such time as an error occurs. If -12 Vdc is measured but the motor does not
move, replace the lift motor.
14. If one or more of the voltages in steps 12 or 13 were incorrect the problem is either the lower
PCA, one of the interconnect cables or the upper PCA. If the display does not indicate that
the ramp is moving in both directions when the appropriate CROSSRAMP key is pressed
the problem is either the Upper PCA or the keypad (display housing). Use Procedures 5.1 &
5.2 to determine if the problem is an interconnect cable, keypad or upper PCA.
15.
If you have performed all of the above tests and the lift system is still not functioning, call
Page 22
Procedure 5.5 - Troubleshooting the Magnetic Resistance
System
Note:
If the control circuit does not see an output from the speed sensor, the mechanism that changes
the resistance level is disabled. Therefore, the speed sensor must be operative and the unit must
be in use, before the resistance level can be changed. The resistance level is changed by
varying the proximity of the pairs of permanent magnets relative to an eddy current disk.The
magnet assembly’s position (relative to the eddy current disk) is varied by a gear motor and a
motor position controller. When the EFX is powered up (turned on), the magnet assembly
retracts until it operates the home switch. Once the home switch is activated the magnet
assembly moves to the resistance level 1 position. An infrared photo optic sensor is used to
determine the magnet assembly position during any subsequent resistance levels changes. The
target consists of alternate silver (reflecting) and black (non-reflecting) surfaces. The target is
attached to the gear motor and is rotated in front of the infrared sensor. The gear motor and
subsequent magnet assembly position is determined by counting the pulses from the infrared
sensor (See Diagram 5.3). Error codes 53, 54 and 55 are associated with the magnetic
resistance system. Error 53 will occur if the system does not receive pulses from the target at
start up or the system can not find the home switch at start up. Error 54 occurs when pulses from
the target are lost during operation. Error 55 occurs if the home switch is actuated at an
unexpected time.
Diagram 5.3 - Magnetic Resistance System
Magnet
Assembly
Eddy Current
Disk
Home
Switch
Gear Motor
1.
There is only one common failure mode of the magnetic resistance system, the resistance
Page 23
level will not change when requested.
2.
Set the on/off switch in the on position. Operate the EFX and check to see if a stride rate is
displayed. If a stride rate is not displayed, troubleshoot the speed sensor per Procedure 5.3.
3.
Set the on/off switch in the off position. Remove the rear covers.
4.
Set the on/off switch in the on position. As the EFX powers up the magnet assembly should
move toward the home switch. After the home switch has been activated the magnet
assembly will reverse direction and move to the resistance level 1 position. If the preceding
sequence was performed correctly, skip to step 20.
5.
If the magnet assembly did not move when it was powered up in step 4, continue with step
6. If the magnet assembly moves but does not complete the process described in step 4 and
an error message occurs, skip to step 9. If the magnet assembly correctly completes the
process described in step 4 and an error message occurs during subsequent resistance
level changes, skip to step 14.
6.
Set the on/off switch in the off position. Remove the F2 (1 amp) fuse from the lower PCA.
Using an ohmmeter, check the resistance of the fuse. The reading should be approximately
1Ω or less. If the fuse is open (∞) or the resistance is significantly high, replace the fuse
(See Diagram 5.4).
7.
Remove the black wire from the gear motor. Measure the resistance of the gear motor
winding, measure between the terminal with the red lead on it and the terminal that the black
wire was removed from. The resistance should be approximately 9Ω. If the reading is
significantly low, replace the gear motor.
8.
If you have performed the above tests in step 6 and 7 and the magnetic resistance system
still does not move when powered up, call Precor Technical Support.
9.
In order for the power up procedure (step 4) to be successfully completed, the magnetic
resistance system must receive pulses from the infrared photo optic sensor and receive a
signal from the home switch.
10. Set the on/off switch in the off position. Connect a DC voltmeter across resistor R14 on the
lower PCA (See Diagram 5.4).
11. Set the on/off switch in the on position. Initially the DC voltmeter will read either a voltage
near 0 Vdc or a voltage near 5 Vdc depending on whether the target is presenting a
reflective or non-reflective surface to the infrared photo optic sensor. When the gear motor
starts to turn the reading should drop to approximately 2.5 Vdc. If the voltage remains at
either 0 Vdc or 5 Vdc as the gear motor operates, the photo optic sensor is not functioning.
12. If the readings in step 11 are correct skip to step 15. Otherwise continue with step 13.
13. Set the on/off switch in the off position. Remove the lower PCA mounting screws and swing
the lower PCA away from it’s mounting bracket.
14. Check the photo optic target to ensure that the target label is in good condition and that the
Page 24
target is free to rotate as the gear motor operates (See Diagram 5.5). If the photo optic
target is in good condition and free to rotate, continue with step 15. Otherwise, replace the
target.
Diagram 5.4 - Lower PCA.
J8 Connector
R14 Resistor
F1 Fuse
D5 Diode
F2 Fuse
15. If necessary, move the magnet assembly so that it is not in contact with the home switch.
Set the on/off switch in the off position. Remove both wires from the home switch. Connect
an ohmmeter across the home switch. The ohmmeter should read approximately 0Ω.
Manually activate the home switch. The ohmmeter should read open (∞).
Page 25
Diagram 5.5 - Photo Optic Target
Photo Optic Target
16. If the readings in step 15 are not correct, replace the home switch.
17. If the readings in step 15 are correct, carefully check the wiring from the home switch to the
J8 connector on the lower PCA. Ensure that the wiring and connector are intact and that the
wiring is not nicked or cut. Replace or repair the wiring if necessary.
18. If the home switch wiring is good, replace the lower PCA.
19. If you have performed all of the above tests and the magnetic resistance system still does
not function properly, call Precor Technical Support.
20. If necessary set the on/off switch in the on position. Operate the EFX, when the timer starts
to count press the RESISTANCE s key. If the display does not indicate that the resistance
level has been changed, test the key pad per procedure 5.2.
21. If the display indicates that the resistance level has been changed, but the resistance
assembly did not move and/or an error 54 occurred, skip to step 14.
Page 26
Procedure 5.6 - Upper Display does not Illuminate
1.
Set the on/off switch in the “off” position and unplug the power adapter from the 5.17 EFX.
Remove the rear covers.
2.
Remove the F1 (6.3 amp) fuse and the F2 (1 amp) from the lower PCA (See Diagram 5.4).
3.
Check the fuses with an ohmmeter. They should read approximately 1Ω or less. Replace
either fuse if it reads open (∞) or significantly high.
4.
With the power adapter still unplugged from the EFX, set the on/off switch in the “on”
position. Check between the inner and outer sheaths of the input power jack with an
ohmmeter. The ohmmeter reading should be 2 megohms or greater.
5.
If the reading in step 4 is good skip to step 8, otherwise continue with the next step.
6.
If the reading in step 4 is significantly low, check the wiring between the lower PCA and the
on/off switch, between the on/off switch and the input power jack. Replace any cut or nicked
wiring.
7.
If you have performed all of the above tests and are unable to resolve the problem, contact
Precor customer support.
8.
Replace the F1 and F2 fuses in the lower PCA, perform the resistance measurement in step
4. The reading should be approximately 2 megohms or greater
9.
If reading in step 8 is significantly low, replace the lower PCA.
10. Plug power adapter into the EFX and set the on/off switch in the “on” position.
11. Measure across the D5 diode on the lower PCA with a DC voltmeter (See Diagram 5.4). The
reading should be approximately 5.0 Vdc.
12. If the reading in step 11 is good, skip to step 14. If the reading in step 11 is significantly low,
set the on/off switch in the “off” position. Disconnect the lift cable (J6), the gear motor cable
(J8) and the interconnect cable (J1) from the lower PCA.
13. Set the on/off switch in the “on” position. Repeat step 11. If the reading is still significantly
low, replace the lower PCA. If the reading is now good, the problem is either the
interconnect cable or the upper PCA.
14. Substitute a known good upper PCA. If the upper PCA does not correct the problem,
troubleshoot the upper and lower interconnect cables per Procedure 5.1
15. If you have performed all of the above tests and are unable to resolve the problem, contact
Precor customer support.
Page 27
Procedure 6.1 - Replacing the Front or Rear Covers
Procedure
1.
Set the on/off switch in the “off” position, then unplug the power adapter from the EFX.
WARNING
Removing and Replacing the Rear Cover
2.
Remove the 7 screws that secure the rear cover halves. Remove the 6 screws that secure
the rear covers to the frame.
3.
Remove both of the rear cover halves.
4.
When maintenance operations are complete, position the rear covers at their mounting
positions. Replace the 6 screws that secure the rear cover to the frame. Replace the 7
screws that secure the rear cover halves.
Removing and Replacing the Front Cover
5.
Remove the 6 screws that secure the front cover halves. Remove the front half of the front
cover.
6.
If the cover was removed to access the lift motor, it is not necessary to remove the rear half
of the front cover. If the rear half of the front cover must be replaced, continue with step 7.
Otherwise, skip to step 16.
7.
and remove the lift nut mounting pins from the lift nut. Raise the ramp and support it from the
handlebars using a bungi cord (See Diagrams 6.1 and 6.2).
Page 28
Diagram 6.1 - Supporting the Ramp
Cover Support Bracket
Retaining Clips
Lift Nut Mounting Pin
Lift Nut
Lift Motor Cable
Lift Motor
Clevis Pin
8.
Remove the screws that secure the cover support bracket and remove the cover support
bracket.
9.
Disconnect the lift motor cable from the lift motor interconnect cable.
10. Grasp the ring on the clevis pin and pull the clevis pin out of the lift motor. Remove the lift
motor. Do not allow the lift motor nut to rotate on the lift motor. If the lift motor nut rotates the
lift motor must be re-calibrated per Procedure 4.1, steps 4 and 5.
11. Remove and replace the rear cover.
12. Set the lift motor at it’s mounting position and insert the clevis pin.
13. Remove the bungi cord from the ramp and set the ramp at it’s mounting position. Do not
Page 29
mounting pins.
14. Set the cover support bracket at it’s mounting position and replace and tighten both cover
support bracket mounting screws.
15. Reconnect the lift motor cable to lift motor interconnect cable.
16. Set the front half of the cover at it’s mounting position. Replace and tighten the six front
cover mounting screws.
17. Check EFX operation as described in Section Three.
Page 30
Procedure 6.2 - Replacing the Display Enclosure or Upper PCA
Anti-static kits (part number 20024-101) can be ordered from Precor.
Removing the Display Enclosure
1.
Set the on/off switch in the “off” position, then unplug the power adapter from the EFX.
WARNING
2.
Remove the screws that secure the display housing to the display backplate.
3.
Attach an anti-static wrist strap to your arm, then connect the ground lead of the wrist strap
to the EFX frame.
4.
Disconnect the interconnect cable from the upper PCA.
5.
If you are going to re-install the display enclosure without replacing the upper PCA...
THEN...
Skip to Step 14.
OTHERWISE...
Continue with the next step.
Removing and Replacing the Upper PCA or Display Enclosure
6.
Carefully disconnect the keypad cable from the upper PCA.
7.
Remove the screws that secure the upper PCA to the display enclosure (See Diagram 6.3).
8.
Note the orientation of the Prom in the upper PCA. Using a chip puller, remove the Prom
from the defective upper PCA (see Diagram 6.4).
9.
Orient the Prom as in step 8 and carefully insert the Prom in the chip socket on the new
upper PCA. Take care not to bend the legs of the PROM.
10. Reposition the upper PCA at its mounting location on the display enclosure (refer to
Diagram 6.3). Replace and tighten the upper PCA mounting screws.
11. Reconnect the keypad cable to the upper PCA.
12. Reconnect the interconnect cable to the upper PCA.
13. Remove the ground lead of the wrist strap from the EFX frame, then remove the wrist strap
from your arm.
Page 31
Diagram 6.3 - Display Enclosure Mounting
Display Enclosure
Upper PCA
Display Backplate
Diagram 6.4 - Upper PCA
Orientation Notch
Prom
14. Position the display enclosure on the display backplate. Replace and tighten the display
mounting screws.
15. Check EFX operation as described in Section Three.
Page 32
Procedure 6.3 - Replacing the PROM
Anti-static kits (part number 20024-101) can be ordered from Precor.
1.
The PROM and the associated printed circuit assembly (PCA) are static sensitive. Antistatic devices must be used and all anti-static precautions must be followed during this
procedure.
2.
Remove the printed circuit assembly per its associated procedure.
3.
Currently we are using two styles of IC software packages. they are a 28 pin dual in line
package (DIP28) and a forty-four pin square package (PLCC44). Each of these packages
should be removed with a proper IC removal tool (see the illustrations below)
PLCC44 removal tool
DIP28 removal tool
4.
The IC’s may inserted into their socket by hand by carefully aligning the notch on the IC with
the notch on the IC socket and carefully pressing the IC into its socket. See the illustrations
below for the alignment notches. Care must be taken that the IC legs on a DIP28 are all
aligned in the socket to prevent the legs from bending when inserted. The PLCC44 IC must
be carefully aligned squarely in its socket or it will not insert. Do not force the IC into its,
socket. If it does not insert easily, remove the it and re-align it in its socket.
DIP28
Notch
Notch
Notch
PLCC44
Notch
Page 33
Procedure 6.4 - Replacing the Lower PCA
Removing the Lower PCA
1.
WARNING
2.
3.
to the EFX frame.
4.
Remove the shield from the lower PCA.
5.
Disconnect the cables from the lower PCA (See Diagram 6.5).
6.
Remove the screws that secure the lower PCA.
Diagram 6.5 - Lower PCA.
J2 Connector
Speed Sensor Cable
J8 Connector
Motor Cable
J1 Connector
Interconnect Cable
J4 Connector
+ DC Input
J5 Connector
- DC Input
J6 Connector
Lift Motor Cable
Replacing the Lower PCA
7.
Position the replacement lower PCA at its mounting position.
Page 34
8.
Install the screws that secure the lower PCA.
9.
Connect the cables disconnected in Step 5 (See Diagram 6.5).
10. Install the lower PCA shield.
11. Remove the ground lead of the wrist strap from the EFX frame, then remove the wrist strap
from your arm.
12. Re-install the rear cover as described in Procedure 6.1, then check the operation of the EFX
as described in Section Three.
Page 35
Procedure 6.5 - Replacing the Lower and/or Upper Interconnect
Cables
Before you install a new interconnect cable, test the existing interconnect cable as described in
Procedure 5.1.
Procedure
1.
WARNING
2.
For convenience, the upper interconnect cable is the cable that attaches to the upper PCA
and the lower interconnect cable is the cable that connects to the lower PCA.
Replacing the Upper Interconnect Cable
3.
to the EFX frame.
4.
Remove the hardware that secures the display to the display backplate. Disconnect the
interconnect cable from the upper PCA.
5.
Remove the four bolts that fasten the front half of the frame to the rear half of the frame.
Carefully separate the two frame halves. Disconnect the upper interconnect cable from the
lower interconnect cable.
6.
Tape the replacement upper interconnect cable to the lower end (between the frame halves)
of the existing upper interconnect cable. Carefully pull the existing interconnect cable out of
the display access hole. When the replacement cable appears out of the display access
hole, untape and discard the old upper interconnect cable.
7.
Connect the upper interconnect cable to the upper PCA. Set the display assembly at it’s
mounting location and replace the display mounting screws.
8.
Connect the upper interconnect cable to the lower interconnect cable. Carefully slide the
front frame half into the rear frame half. Replace and securely tighten the four frame bolts
removed in step 5.
9.
Check the operation of the EFX as described in Section Three.
Replacing the Lower Interconnect Cable
10. Remove the rear covers per Procedure 6.1.
Page 36
11. Disconnect the lower interconnect cable from the lower PCA.
12. Remove the four bolts that fasten the front half of the frame to the rear half of the frame.
Carefully separate the two frame halves. Disconnect the lower interconnect cable from the
upper interconnect cable.
13. Tape the replacement lower interconnect cable to the lower end (between the frame halves)
of the existing lower interconnect cable. Carefully pull the existing interconnect cable out of
the lower PCA access hole. When the replacement cable appears out of the lower PCA
access hole, untape and discard the old upper interconnect cable.
14. Connect the lower interconnect cable to the lower PCA.
15. Connect the lower interconnect cable to the upper interconnect cable. Carefully slide the
front frame half into the rear frame half. Replace and securely tighten the four frame bolts
removed in step 5.
16. Replace the rear covers per Procedure 6.1.
17. Check the operation of the EFX as described in Section Three.
Page 37
Procedure 6.6 - Replacing the Input Power Jack
Removing the Power Entry Module
1.
Set the on/off switch in the “off” position and disconnect the power adapter from the EFX.
WARNING
2.
Remove the rear covers per Procedure 6.1.
3.
Remove the mounting nut from the input power jack.
Diagram 6.6 - Input Power Jack
Input Power Jack
4.
Remove the input power jack from the input panel.
5.
Disconnect both red wires from on/off switch and the red and black wires from the capacitor.
Disconnect the red wire from J4 of the lower PCA and the black wire from J5 of the lower
PCA. Remove and discard the input power jack and the associated wiring.
6.
Set the replacement input power jack at it’s mounting and secure it with the furnished nut.
7.
Reconnect the wiring removed in step 5. The red wires at the on/off switch can be replaced
in any order. At the capacitor, the black wire must connect to the (-) negative terminal and
the red wire must connect to the (+) positive terminal. At the lower PCA the black wire must
connect to J5 and the red wire must connect to J4. Verify that the wiring is connected
correctly before applying power to the EFX.
Page 38
8.
Plug the power adapter into an AC outlet and to the EFX.
9.
Set the on/off switch in the on position and check the operation of the EFX as described in
Section Three.
Page 39
Procedure 6.7 - Replacing the Input Capacitor
1.
WARNING
2.
3.
Disconnect the red and black wires from the capacitor.
Diagram 6.7 - Input Capacitor
Capacitor
Bracket
Capacitor
4.
Note the orientation of the negative and positive terminals of the capacitor. Loosen the
clamping screw on the capacitor bracket and slide the capacitor out of the capacitor bracket.
5.
Slide the replacement capacitor into the capacitor bracket and orient the capacitor as noted
in step 4.
6.
Tighten the capacitor bracket clamping screw until the capacitor will not rotate in the
capacitor bracket.
7.
Connect the red wire to the (+) positive terminal and the black wire to the (-) negative
terminal of the capacitor.
8.
Replace the rear covers per Procedure 6.1.
9.
Check the operation of the EFX as described in Section Three.
Page 40
Procedure 6.8 - Replacing the ON/OFF Switch
Removing the ON/OFF Switch
1.
WARNING
2.
Remove the rear covers as described in Procedure 6.1.
3.
Disconnect the wiring from the on/off switch.
4.
Depress the mounting tabs that secure the switch to its mounting bracket. Remove the
switch from its mounting position.
Replacing the ON/OFF Switch
5.
Make sure that the new on/off switch is set to the “off” position. Snap the switch assembly
into the mounting bracket.
6.
Reconnect the switch wiring removed in step 3.
7.
Re-install the rear cover as described in Procedure 6.1, then check the operation of the EFX
as described in Section Three.
Page 41
Procedure 6.9 - Replacing the Lift Motor
Removing the Lift Motor
1.
Set the on/off switch in the “off” position. Remove the six screws that retain the front half
front cover to the rear half of the front cover and remove the front half cover.
2.
handlebars using a bungi cord (See Diagram 4.1).
Lift Nut Pin
Lift Nut
Retaining Clip
Lift Nut
Lift Motor
Drive Screw
Lift Motor
Clevis Pin
3.
Disconnect the lift motor cable from the lift motor interconnect cable.
4.
Grasp the ring on the clevis pin and pull the clevis pin out of the lift motor.
5.
Remove the lift motor from the EFX.
Replacing the LIft Motor
6.
Set the replacement lift motor at it’s mounting position and replace the clevis pin.
7.
Connect the lift motor cable to the lift motor interconnect cable.
Page 42
8.
Calibrate the lift motor per Procedure 4.1, steps 4 and 5.
9.
mounting pins.
10. Set the on/off switch in the “on” position. Thoroughly test all lift related functions per Section
Three.
11. Set the on/off switch in the “off” position, replace the front cover per Procedure 6.1.
Page 43
Procedure 6.10 - Replacing a Crankarm Assembly
Removing a Crankarm Assembly
1.
WARNING
2.
3.
Remove the stairarm assembly as described in Procedure 6.22.
Note:
Notice the position of the two crank arms. When the crankarms are replaced, they must be
positioned so that they are 180 degrees opposing.
4.
Remove the 14 mm. bolt that secures the crankarm to the input pulley shaft. It will be
necessary to use a Pitman arm puller or 4” to 6” gear puller to remove the crankarm. Do not
use a hammer or mallet to remove the crankarm.
5.
If you are removing both crank arm assemblies, repeat Steps 3 and 4 for the second
crankarm assembly.
Diagram 6.9 -Replacing a Crank Arm Assembly
14 mm Bolt
Pivot Block
Crankarm
Crankarm
Page 44
6.
Clean the crankarm mounting bolt threads and the input pulley shaft threads with an alcohol
swab. Allow them to dry and apply blue loctite to the crankarm mounting bolt threads.
7.
Position the crankarm on the input pulley shaft. Thread and hand tighten the 14 mm. bolt
into the input pulley shaft. Torque the nut to 300 in/lbs.
8.
Replace the stairarm assembly as described in Procedure 6.22.
9.
If you are replacing both crankarm assemblies, repeat steps 6 and 7 for the second
crankarm assembly.
10. Set the unit at it’s highest resistance setting and use the EFX for a minimum of 3 minutes.
Stride in a forward direction for half of the time and in a backward direction for half of the
time. Set the on/off switch in the “off” position and re-torque both of the 14 mm. crankarm
mounting bolts to 300in/lbs.
11. Replace the rear cover per Procedure 6.1.
Page 45
Procedure 6.11 - Replacing a Pillow Block Bearing
1.
WARNING
Section One, Things You Should Know
2.
3.
Remove both stairarm assemblies per Procedure 6.22.
4.
Remove the crankarm from the same side as the pillow block bearing that you are replacing
or both crankarms if you are replacing both pillow block bearings. See Procedure 6.10.
5.
Remove tension from the input pulley and step-up pulley belts as described below:
a.
Loosen the stub tensioner axle nut and remove the tension from the input belt (See
Diagram 4.5).
b.
Straighten the locking tabs and turn the left and right tension bolts counterclockwise until
tension is removed from the step up belt. (See Diagram 4.5)
c.
Slide the input and step up belts off of their pulleys.
4.
Remove the nuts that secure both pillow block bearings to the mounting studs on the drive
weldment uprights. (See diagram 6.10)
5.
Lift the pillow block assembly(s) off of the mounting studs and slide the pillow block
assembly(s) off of the input pulley shaft.
6.
Slide the replacement bearings onto the input pulley shaft and onto the mounting studs.
Page 46
Diagram 6.10 - Pillow Block Bearings
Input Pulley
Mounting Nut
Pillow Block
Bearing
7.
Thread and hand tighten the pillow block mounting nuts onto the mounting studs. Torque
the pillow block mounting nuts to 200 in/lbs.
8.
Align and tension the step up and input belts per Procedure 4.2.
9.
Replace the crankarm(s) per Procedure 6.10. If both crankarms have been removed, the
crankarm with the magnet must be reinstalled on the right hand side.
10. Replace the stairarms per Procedure 6.22.
11. Replace the rear covers per Procedure 6.1.
Page 47
Procedure 6.12 - Replacing the Eddy Current Disk Assembly
1.
WARNING
2.
3.
Remove the stairarm assemblies as described in Procedure 6.22.
4.
Remove the crankarm assemblies as described in Procedure 6.10.
5.
Remove tension from the drive belts and remove the pillow block bearings per Procedure
6.11, steps 4 to 7.
6.
Slide the step up and input belts off of the input pulley shaft and remove the input pulley and
eddy current disc assembly from the drive unit. (See Diagram 6.10)
7.
Slide the eddy current disk off of the input pulley shaft (See Diagram 6.11).
Diagram 6.11- Eddy Current Disk
Eddy Current
Disk
Pillow Block
Bearing
Crankarm
8.
Slide the replacement eddy current disk onto the input pulley shaft.
Page 48
9.
Slide the step up and input belts onto the input pulley shaft as you set the input pulley shaft
in it’s mounting position in the drive unit.
10. Slide the pillow block bearings onto the input pulley shaft.
11. Complete the installation, alignment and tensioning per Procedure 6.11, steps 8 to 13.
Page 49
Procedure 6.13 - Replacing the Input Pulley Belt
1.
WARNING
2.
3.
4.
5.
6.11, steps 4 to 7.
6.
7.
Carefully, lay the EFX on it’s side. Remove the bolts that retain mounting plate for the input
module and on/off switch. Swing the mounting plate away from the drive unit.
8.
Remove the left and right tension bolts, locking tabs and brackets. Slide the step up pulley
assembly with both the step up and input belts out of the drive unit.
9.
Remove the input pulley belt and place the replacement input pulley belt in it’s place on the
step up pulley assembly.
10. Set the step up pulley assembly with the step up and input belt at it’s mounting position in
the drive unit. Replace the tensioning bolts, locking tabs and brackets removed in step 8.
Thread the left and right tension bolts into the step up pulley shaft. (See Diagram 6.12 &
6.13)
Page 50
Diagram 6.12 - Input Pulley Belt
Input Pulley
Belt
Input Pulley
11. Slide the step up and input belts onto the input pulley shaft as you set the input pulley shaft
Page 51
Procedure 6.14 - Replacing the Step-Up Pulley Belt
1.
WARNING
2.
3.
4.
5.
6.11, steps 4 to 7.
6.
7.
Remove the left and right tension bolts, locking tabs and brackets. Slide the step up pulley
assembly with both the step up and input belts out of the drive unit.
8.
Remove the step up pulley belt and place the replacement step up pulley belt in it’s place on
the step up pulley assembly.
9.
Set the step up pulley assembly with the step up and input belt at it’s mounting position in
the drive unit. Replace the tensioning bolts, locking tabs and brackets removed in step 8.
Thread the left and right tension bolts into the step up pulley shaft.
Page 52
Diagram 6.13 - Step Up Pulley Belt
Step Up
Pulley
Step Up
Pulley Belt
Page 53
Procedure 6.15 - Replacing the Input Pulley Assembly
1.
WARNING
2.
3.
4.
5.
6.11, steps 4 to 7.
6.
7.
eddy current disc assembly from the drive unit. (See Diagram 6.10, 6.12 & 6.13)
8.
Slide the eddy current disk off of the input shaft assembly.
9.
Slide the eddy current disk onto the replacement input shaft assembly.
Page 54
Procedure 6.16 - Replacing the Step-Up Pulley Assembly
1.
WARNING
2.
3.
4.
5.
6.11, steps 4 to 7.
6.
eddy current disc assembly from the drive unit. (See Diagram 6.10, 6.12 & 6.13)
7.
Remove the left and right tension bolts, locking tabs and brackets.
8.
9.
Slide the step up pulley assembly with both the step up and input belts out of the drive unit.
10. Place the step up and input belts on the replacement step up pulley.
11. Set the replacement step up pulley assembly with the step up and input belt at it’s mounting
position in the drive unit. Replace the tensioning bolts, locking tabs and brackets removed in
step 8. Thread the left and right tension bolts into the step up pulley shaft.
Page 55
Procedure 6.17 - Replacing the Speed Sensor Assembly
Removing the Speed Sensor Assembly
1.
WARNING
2.
3.
Disconnect the speed sensor cable from the lower PCA. (See Diagram 6.5)
4.
Remove the hardware that secures the speed sensor assembly to the drive unit.
Diagram 6.14- Speed Sensor
Step Up Pulley
Magnet
S
Step
Speed Sensor
Replacing the Speed Sensor Assembly
5.
Position the speed sensor at its mounting position and set the gap between the end of the
speed sensor and the step up pulley at approximately 1/8 inch.
6.
Replace the hardware that secures the speed sensor to the drive unit.
7.
Reconnect the speed sensor cable to the lower PCA.
Page 56
8.
Re-install the rear covers as described in Procedure 6.1, then check the operation of the
EFX as described in Section Three.
Page 57
Procedure 6.18 - Replacing the Eddy Current Magnet
Assembly
Removing the Magnet Assembly
1.
The resistance level must be at level 0 when this procedure is performed. If necessary
operate the unit and set the resistance level at 0 and then proceed with step 2.
2.
WARNING
3.
4.
to the EFX frame.
5.
Remove the shield from the lower PCA.
6.
Disconnect the cables from the lower PCA (See Diagram 6.5).
7.
Remove the screws that secure the lower PCA, remove the lower PCA.
8.
Grasp the target disk and carefully pull it off of the gear motor extension shaft.
9.
Remove the screws that secure the lower PCA mounting bracket, remove the lower PCA
mounting bracket. (See Diagram 6.15).
Page 58
Diagram 6.15 - Eddy Current Magnet Assembly
Shield
Magnet Assembly
Extension Shaft Follower
Home Switch
Target Disk
Lower PCA
Lower PCA
Mounting Bracket
Gear Motor Extension Shaft
Gear Motor
10. Remove the two screws that retain the magnet assembly. Slide the magnet assembly off of
the extension shaft follower.
11. If necessary, adjust the position of the extension shaft follower on the extension shaft so
that the distance from the edge of the follower to the end of the shaft is 1-5/16 inches (See
Diagram 6.16).
Diagram 6.16 - Follower Positioning
Extension Shaft Follower
Extension Shaft
1-5/16”
12. Slide the replacement magnet assembly onto the extension shaft follower and set the
magnet assembly in it’s mounting position. Replace the magnet assembly mounting screws
removed in step 10.
Page 59
13. Set the lower PCA mounting bracket in it’s mounting position and replace the mounting
screws removed in step 9.
14. Carefully press the target disk onto the gear motor extension shaft.
15. Set the lower PCA in it’s mounting position and replace the mounting screws removed in
step 7. Reconnect the lower PCA cables as shown in Diagram 6.5.
16. Replace the lower PCA shield.
17. Re-install the rear covers as described in Procedure 6.1, then check the operation of the
Page 60
Procedure 6.19 - Replacing a Stairarm Pivot Block
Removing the Stairarm Pivot Block
1.
WARNING
2.
3.
Remove the mounting bolt and nut that fastens the stairarm pivot block to the stairarm. (See
Diagram 6.17)
4.
Slide the stairarm off of the stairarm pivot block.
5.
Remove the stairarm pivot block retaining ring from the crankarm pin. Slide the stairarm
pivot block off of the crankarm pin. If the stairarm pivot block is being replaced because of
excessive wear, check the condition of the crank arm pin, it may be necessary to replace the
crankarm.
Page 61
Diagram 6.17 - Stairarm Mounting.
Mounting Bolt
Retaining Ring
Stairarm
Pivot Block
Crankarm
Replacing the Stairarm Pivot Block
6.
Slide the stairarm pivot block onto the crankarm pin and replace the retaining ring removed
in step 5.
7.
Slide the stairarm onto the stairarm pivot block. Install and hand tighten the stairarm pivot
block mounting hardware. Torque the stairarm pivot block mounting bolt to 15 ft./lbs.
8.
Replace the rear cover per Procedure 6.1.
Page 62
Procedure 6.20 - Replacing a Wheel, Wheel Axle or Wheel Bearings
Procedure
1.
WARNING
2.
Remove the screws from the wheel axle. If when removing the second wheel axle screw,
the axle rotates and the screw does not unthread, insert a 5/32” allen wrench into the end of
the axle from which the screw has been removed. The allen wrench will hold the axle while
you remove the remaining screw. Remove the wheel assembly from the stairarm.
Diagram 6.18- Wheel Assembly
Axle Screw
Wheel
Stairarm
Axle Screw
3.
Thread one of the axles screws a few turns into one end of the axle. Hold the wheel
assembly, with the axle screw downward, over a solid surface. Press the axle screw firmly
against the solid surface until the opposite bearing is pressed out of the wheel assembly.
Remove the axle screw from the axle and then remove the axle from the wheel. Insert a
blunt object, such as a screwdriver handle, into the wheel and press the remaining bearing
out of the wheel (See Diagram 6.19).
Page 63
Diagram 6.19 - Wheel Assembly
Wheel
Bearing
Axle Screw
Bearing
Axle
4.
Reassemble the wheel assembly using such replacement parts as required. Firmly press
one of the bearings into the wheel by hand. Insert the axle through the wheel and into the
bearing that is pressed into the wheel. Slide the remaining bearing over the axle and press
the bearing into the wheel by hand. Be sure that both bearing are fully pressed into the
wheel bearing pockets.
5.
Place the wheel into the stairarm and insert and hand tighten the wheel axle screws. Torque
the wheel axle screws to 25 in/lbs.
Page 64
Procedure 6.21 - Replacing a Stairarm Pedal
1.
2.
Loosen and remove the two bolts that fasten the stairarm pedal onto the stairarm.
3.
Remove the stairarm pedal from the stairarm.
4.
Set the replacement stairarm pedal at it’s mounting position on the stairarm.
5.
Install and hand tighten the stairarm pedal mounting hardware removed in step 2. Torque
the stairarm pedal mounting bolts to 60 in/lbs.
Diagram 6.20 - Stairarm Pedal
Stairarm
Mounting Bolt
Pedal
Page 65
Procedure 6.22 - Replacing a Stairarm
1.
2.
3.
Remove the mounting bolt and nut that fastens the stairarm pivot block to the stairarm. (See
Diagram 6.17)
4.
Slide the stairarm off of the stairarm pivot block.
5.
Loosen and remove the two bolts that fasten the stairarm pedal onto the stairarm.
6.
Remove the stairarm pedal from the stairarm.
7.
Set the stairarm pedal at it’s mounting position on the replacement stairarm.
8.
Install and hand tighten the stairarm pedal mounting hardware removed in step 5. Torque
the stairarm pedal mounting bolts to 60 in/lbs.
9.
Remove the screws from the wheel axle. If when removing the second wheel axle screw,
the axle rotates and the screw does not unthread, insert a 5/32” allen wrench into the end of
the axle from which the screw has been removed. The allen wrench will hold the axle while
you remove the remaining screw. Remove the wheel assembly from the stairarm.
10. Insert and hand tighten the wheel axle screws. Torque the wheel axle screws to 25 in/lbs.
11. Slide the replacement stairarm assembly onto the stairarm pivot block. Install and hand
tighten the stairarm pivot block mounting hardware. Torque the stairarm pivot block
mounting hardware until no axial play can be felt between the stairarm pivot block and
stairarm. The stairarm tube must be fully collapsed against the stairarm pivot block. If there
is a gap between the upper or lower wall of the stairarm tube, re-torque the stairarm to
stairarm pivot block mounting bolts. The stairarm should still easily pivot on the stairarm
pivot block.
12. Replace the rear cover per Procedure 6.1.
Page 66
Procedure 6.23 - Replacing the Ramp Assembly
Procedure
1.
2.
Remove the rear cover per Procedure 6.1 and pivot both stairarms to the rear of the unit.
1.
Remove the six screws that retain the front half front cover to the rear half of the front cover
and remove the front half cover.
2.
handlebars using a bungi cord (See Diagram 4.1). Do not allow the lift motor nut to rotate. If
the lift motor nut is allowed to rotate, the lift must be re-calibrated per Procedure 5.2.
3.
Remove the nuts and bolts that fasten the lower ends of the ramp to the frame (See
Diagram 6.21).
Diagram 6.21 - Ramp Mounting
Ramp
Mounting Bolt
4.
Support the ramp and remove the bungi cord, lift the ramp off of the frame.
5.
Set the replacement ramp at it’s mounting position and support it from the handlebars with a
bungi cord.
6.
Replace and tighten the ramp mounting bolts removed in step 3. Do not overtighten the
ramp mounting bolts, the ramp must pivot freely.
Page 67
7.
mounting pins.
8.
Set the on/off switch in the “on” position. Thoroughly test all lift related functions per Section
Three.
9.
Set the on/off switch in the “off” position, replace the front cover per Procedure 6.1
Page 68
Procedure 6.24 - Replacing a Handlebar
Removing a Handlebar
1.
2.
Remove the screws from the lower end of the handlebar to be replaced.
3.
Loosen, but do not remove, the upper handlebar clamp mounting bolts.
Diagram 6.22 - Handlebar Mounting
Upper Handlebar Clamp
Left
Handlebar
Right
Handlebar
Lower Mounting
Screw
4.
Slide the lower end of the handlebar off of the frame and then slide the upper end of the
handlebar out of the upper handlebar clamp.
Replacing a Handlebar
5.
Slide the replacement handlebar into the upper handrail clamp and then slide the lower end
of the handlebar onto the frame.
6.
Tighten the upper handlebar clamps loosened in step 3.
7.
Replace and tighten the lower handlebar screws removed in step 2.
Page 69
Procedure 6.25 - Replacing the Stub Tensioner
1.
WARNING
2.
3.
Remove the stub tensioner mounting bolt, remove the stub tensioner.
4.
Set the replacement stub tensioner and replace but do not tighten the stub tensioner
mounting bolt.
5.
Tension the input pulley belt per Procedure 4.2, steps 19 -22.
6.
Re-install the rear covers as described in Procedure 6.1, then check the operation of the
Page 70
Procedure 6.26 - Replacing the Gear Motor
1.
WARNING
2.
3.
Remove the lower PCA, and magnet assembly per Procedure 6.18, steps 4-10.
4.
Remove the red and black wires from the gear motor.
5.
Remove the set screw from the gear motor extension shaft (See Diagram 6.23).
Diagram 6.23 - Gear Motor Mounting
Set Screw
Extension Shaft
Gear Motor
Gear Motor Mounting Nut
6.
Remove the nuts that fasten the gear motor to it’s mounting bracket, remove the gear motor.
7.
Set the replacement gear motor at it’s mounting position and replace and tighten the
mounting nuts removed in step 5.
8.
Replace and tighten the extension shaft set screw.
9.
Connect the red wire to the positive (+) terminal and the black wire to the negative (-)
terminal of the gear motor.
Page 71
10. Replace the magnet assembly and lower PCA per Procedure 6.18, steps 11-17.
11. Re-install the rear covers as described in Procedure 6.1, then check the operation of the
Page 72
Wiring Diagram 7.1 - 5.17
Page 73
Block Diagram 7.2 - 5.17
Page 74

Service Manual, 5.17 EFX.fm

Transcription

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