Precor AMT12 base Service Manual

Service Manual

AMT12 Base

Open Stride and Fixed Stride

Contents

1 - Introduction ......................................................................................................................... 7

About this Document ...................................................................................................................... 7

General Information........................................................................................................................ 8

Right, Left, Front, and Back Conventions .......................................................................... 8

General System Information ................................................................................................ 8

General Information .............................................................................................................. 8

Tools Required ......................................................................................................................... 8

4 - 6 gear puller .............................................................................................................................. 8

Safety Guidelines ........................................................................................................................... 8

Operating Safety ............................................................................................................................ 9

2- Operation Verification....................................................................................................... 11

Verification Procedure ..................................................................................................................11

Verification Checklist ....................................................................................................................12

3- Standardized Service Access Codes ................................................................................. 13

Accessing the Service Software ...................................................................................................13

P20 Service Software Access ............................................................................................. 14

Entering the Service Software on a P80 console ........................................................... 15

Hardware Validation = Diagnostic Tests (51765761) ..................................................................16

Club Parameter = Settings (5651565) .........................................................................................17

Information Display (65) ...............................................................................................................18

4- Theory of Operation .......................................................................................................... 19

Console Models ............................................................................................................................19

Basic operation of a console ........................................................................................................20

AMT Base Operation ....................................................................................................................22

Power Generation ................................................................................................................ 22

Lower Electronics Module .................................................................................................. 22

DC Power Distribution: ......................................................................................................... 22

A regulated 14.5VDC power supply charges the 12V battery. .................................. 22

AMT Resistance Control: ..................................................................................................... 23

Vertical Resistance: ............................................................................................................. 23

Horizontal Resistance: .......................................................................................................... 24

AMT motion detection (RPM): ........................................................................................... 24

DC Lift System – Position Monitoring (If Equipped .......................................................... 27

5- Troubleshooting Procedures ............................................................................................. 28

Introduction ...................................................................................................................................28

Troubleshooting Generated Power ..............................................................................................29

Measuring the Resistance of a Generator ...................................................................................30

Upper Display does not illuminate ................................................................................................31

Standardized Error Codes ............................................................................................................33

Validating the Reported Failure ....................................................................................................34

Troubleshooting Control Error Codes ..........................................................................................35

Error 05 - Key Depressed at Power Up ........................................................................................35

Error 09 - Lower PCA Memory Test Errors ..................................................................................37

Error 12 - Watchdog (Lower PCA) ...............................................................................................37

Error 80, 81, 82, & 83 – P30 Machine Controls Not Working ......................................................38

Troubleshooting the Brake System ..............................................................................................39

Troubleshooting the Lift System ...................................................................................................40

Error 40 - No Lift Motion Detected ...............................................................................................41

Error 42 - Lift Position Value Out of Range ..................................................................................43

Error 44 - Un-commanded Lift Motion ..........................................................................................45

Error 45 - Lift Moving in Wrong Direction .....................................................................................46

Error 46 – Low Battery Voltage (Open Stride AMT12 only) .........................................................47

Troubleshooting Communications ................................................................................................48

Errors 30, 31, 32 and 33 - Communications Error .......................................................................48

Event 70 - 79 ................................................................................................................................49

Troubleshooting Heart Rate Issues: .............................................................................................50

Wireless Heart Rate Does Not Work ............................................................................................51

6- Replacement Procedures ................................................................................................... 53

Cover Replacement......................................................................................................................54

Replacing a Belt Guard ................................................................................................................65

Replacing the Upper Arm Grip .....................................................................................................69

Replacing a Flat Belt Terminal .....................................................................................................74

Replacing a Upper Arm Flat Belt Pulley .......................................................................................80

Replacing a Stairarm Pedal .........................................................................................................85

Replacing a Stairarm ....................................................................................................................87

Replacing the Flat Belts ...............................................................................................................93

Inside Flat Belt Replacement .......................................................................................................97

Outside Flat Belt Replacement ..................................................................................................106

Replacing the Front Arm Assemblies - With Flat Belts and Press Fit Cams (After 4/3/2013) ...122

Replacing the Lower Board ........................................................................................................163

Replacing the Lower PCA and Battery Bracket .........................................................................164

Replacing the Battery .................................................................................................................166

Replacing the Generator Belt .....................................................................................................167

Replacing the Generator ............................................................................................................169

Replacing the Drive Input Pulley Belt .........................................................................................171

Replacing the Step Up Pulley ....................................................................................................172

Replacing the Crank Arm ...........................................................................................................175

Replacing the Drive Input Pulley ................................................................................................178

Replacing the Lift Arm Housing ..................................................................................................185

Replacing the drive input housing ..............................................................................................202

Replacing a Tie Rod ...................................................................................................................222

Replacing the H-Brake Belt ........................................................................................................225

Replacing the H-Brake Drum Assembly.....................................................................................233

Replacing the Gas Shock ...........................................................................................................242

Replacing the Incline Motor ........................................................................................................245

7 – Adjustment Procedure ................................................................................................... 251

Measuring the Resistance of a Generator .................................................................................251

Inspecting and Adjusting the H-brake Belt Tension ...................................................................252

Inspecting and Adjusting the Generator Belt Tension ................................................................255

Inspecting and Adjusting the Drive Input Belt Tension ..............................................................257

Calibrating the Incline Motor ......................................................................................................263

Drive Belt Gauge Instructions ....................................................................................................265

8- Preventative Maintenance ............................................................................................... 267

9- Wiring & Block Diagrams............................................................................................... 269

P30 - AMT '11 835 Block Diagram .............................................................................................269

P20_P30_P80 AMT '11 Wiring Diagram ....................................................................................269

10 – Exploded View .............................................................................................................. 271

1 - Introduction

In This Section

About This Document .......................................................................

Right, Left, Front, and Back Conventions .......................................

General System Information .............................................................

General Information ..........................................................................

Tools Required ..................................................................................

Warning and Caution Statements and General Safety Guidelines

Safety .................................................................................................

About this Document

Warning: This service manual is for use by Precor trained service providers only.

If you are not a Precor Trained Servicer, you must not attempt to service any Precor Product; Call your dealer for service.

This document contains information required to perform the majority of troubleshooting, and replacement procedures required to repair and maintain this product.

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.

Manual Number: 20039-172 rev A02

General Information

Multimeter

US and metric end wrench set

Allen wrench set

US and metric socket wrench set

Anti-static kit

Torque wrench, 200 in./lbs.

Screwdriver set

Torque wrench, 200 ft./lbs

OTC 6673 Universal Belt Tension Gauge

4 - 6 gear puller

Right, Left, Front, and Back Conventions

In this manual, right, left, front, and back are from the perspective of a user standing on the AMT facing the console display.

FIGURE 1: FRONT, BACK, LEFT, RIGHT CONVENTIONS

General System Information

The generator performs three functions in the AMT. First, by controlling the amount of electrical current applied from the generator to a load circuit, the user’s pedaling resistance is controlled. Second, the

generator is used to charge the AMT’s internal battery. Lastly, one of the generators three phase output

windings is monitored to determine when the unit is in use and when it is idle. This system also determines the step rate by determining the operating speed (output frequency) of the monitored generator winding. A magnetic brake applies resistance to horizontal motion and a sensor that measures horizontal motion (stride length).

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

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.

 Caution statements are intended to prevent damage to the AMT as a result of the current activity.

Caution statements included in this manual are listed below:  When it is necessary to lift or move the AMT, ensure that the AMT has adequate support and that

you use proper lifting techniques. When the rear platform is removed, the AMT may be lifted from the rear and moved like a wheelbarrow.

 To remove power from the AMT, the optional external power supply (when equipped) must be

disconnected from the wall outlet and the red (positive) wire must be disconnected from the battery. Always ensure that the AMT external power supply is unplugged from the wall outlet and the red (positive) wire is removed from the battery when you inspect or adjust the AMT, or when you isolate, remove, or replace an AMT component.

 Removing the covers exposes high voltage components and potentially dangerous machinery.

Exercise extreme caution when you perform maintenance procedures with the cover(s) removed.

 During service operations you will be very close to moving machinery and voltage bearing

components. When you perform maintenance procedures with the covers removed, remove jewelry (especially from ears and neck), tie up long hair, remove neck ties, and do not wear loose clothing.

 Exercise caution when touching any wire or electrical component during AMT operation.  A pinching hazard exists when the unit is operated. It is possible to seriously pinch a finger. The

AMT can be mechanically locked by inserting a screwdriver through the primary sheave and frame. See the illustration below. Locking the AMT will prevent accidental pinching.

A pinching hazard exists when the unit is operated. It is possible to seriously pinch a finger. The AMT can be made immobile by lift the stairarm pedals and removing the tension from stairarm flat belts. Removing the tension from the flat belts will prevent accidental pinching.

Operating Safety

Safety guidelines you should know and follow include:

 Read the owner’s manual and follow all operating instructions.  Operate the AMT on a solid, level surface with the unit properly leveled. The AMT is properly leveled

when all five feet are in contact with the floor. Visually check the AMT before beginning service or maintenance operations. If it is not completely assembled or is damaged in any way, exercise extreme caution while operating and checking the AMT.

 When operating the AMT, do not wear loose clothing. Do not wear shoes with heels or leather soles.

Check the soles of your shoes and remove any embedded stones. Tie long hair back.

 Do not rock the unit. Do not stand or climb on the handlebars, display enclosure, or cover.  Do not set anything on the handlebars, display enclosure, or cover. Never place liquids on any part of

the AMT, while performing service.

 To prevent electrical shock, keep all electrical components away from water and other liquids.  Do not use accessory attachments that are not recommended by the manufacturer-such attachments

might cause injuries.

 AMT’s equipped with Cardio Theater PVS units will have external power supply and coaxial cable routed

through the bottom of the unit to the top of the display console. Cord management must be maintained.

2- Operation Verification

This section provides you with a quick method of checking the AMT operation. Check the AMT operation at the end of a maintenance procedure and when it is necessary to ensure that the AMT is operating properly.

Verification Procedure

1 Pedal the AMT to apply power, or use the optional external power supply. 2 Press and hold the reset key for at least 6 seconds, if errors are present the error log will be displayed.

Make note of all the errors in the error log and odometer reading for which the error occurred. The odometer in the error log can help you determine age and relevance of the error. Once the errors have been written down, the error log can be cleared.

3 Enter the Hardware Validation test by entering Diagnostic mode as follows:

 Press either the STOP, PAUSE or RESET buttons and then enter 5,1,7,6,5,7,6,1  Select and run the Display Test, then the Keypad Test, then the Heart Rate Test and verify

results. (LEDs light, Keys all function, Heart rate is acquired and displayed)

 Enter the Machine Tests (submenu) and run the Brake test and the Incline test and verify results.

(Resistance is smooth and is controlled from resistance level 1 to resistance level 20, Lift (if applicable) goes up and down and the A/D value changes smoothly throughout the range)

 Press the reset or back key to exit diagnostics.

4 Operate the AMT in the Manual program. Adjust the resistance to level 7. Operate the AMT for at least

1 minute while pedaling the unit. a) Concentrate on the feel of the motion and the sound of the input drive assembly. Be on the alert for

unusual noises or vibrations.

b) Observe the LED’s on the electronic console. Make sure that each LED lights as the information

corresponding to that LED is displayed on the electronic console.

5 If the unit is equipped with a variable step height (Open Stride), press the INCLINE key while viewing

the electronic console. Pedal the unit and confirm that the step height increases and the incline display increments to level 5 as the INCLINE key is continually being pressed.

6 If the unit is equipped with a variable step height (Open Stride), press the INCLINE key while viewing

the electronic console. Pedal the unit and confirm that the step height increases and the incline display decrements to level 1 as the INCLINE  key is pressed.

7 Press and hold the reset key for at least 6 seconds, to look at the error log again. This time look for any

NEW errors displayed resulting from the verification test indicating that the unit needs attention.

Verification Checklist

Operation Verification Checklist

If errors are present in the error log, make note of those errors and clear the error log.

All LEDs function properly during the “Hardware Validation” Tests.

All keys on the keypad function properly during the “Hardware Validation” Tests.

Heart rate functions normally and displays a valid heart rate.

Input drive system functions properly throughout the minimum to maximum resistance range. All drive system components (belts, pulleys, lower control module) free of excessive noise, vibrations, or smells

Incline (if equipped) A/D value increments and decrements smoothly throughout the incline range.

Incline operates within the complete range of lift when the “UP” or “DOWN” keys are pressed, and are free of excessive noise or vibrations.

No new errors were logged in the error log.

3- Standardized Service Access Codes

Access Code

Heading Name

Function

51765761

Hardware Validation

Running Diagnostic Tests

5651565

Club Parameters (Commercial)

Changing Machine and/or Workout Parameters

65

Information Display

Acquiring Information

These standardized service access codes that are followed by all consoles (Standard, P10, P20, P30) are split into 3 functional modes, “Hardware Validation”, “Club Parameters”, and “Information Display”.

 “Hardware Validation” is a set of functional diagnostic tests that are useful in

troubleshooting problems as well as verifying proper operation.

 “Club Parameters” are sometimes referred to as “Club Settings”, and are used to manage

usage of the machine.

 “Information Display” is used to access information such as the odometer, software

versions, and error logs.

Accessing the Service Software

Accessing these 3 areas are accomplished the same on all consoles (Standard, P10, P20, P30) except

P80. You must first press either “STOP”, “PAUSE”, or “RESET” key (whichever is available on your

specific console) followed by a numeric code for the area of service software you wish to access. The standard access codes use sequential key presses, not simultaneous key hold downs. The allowable delay between key presses is short. If too much time is taken between key presses or the wrong key is pressed the access procedure will be aborted. If the access is aborted, it will be necessary to start over from the beginning.

The codes are as follows;

On the “Standard”, “P10”, and “P30” consoles these codes are entered via a direct access 10-key pad. The “P20” has a slightly more challenging method of entry.

P20 Service Software Access

The P20 will start with stop, pause, or reset, numeric values have been assigned to the function keys in the absence of the 10-key pad.

Entering the Service Software on a P80 console

Procedure:

1. The Welcome screen will be the first screen you see when you approach the P80 console. Press the Pause button and continue holding it down while you double press (prior to version 1.1 software release) or single press (version 1.1 or after software release) in sequential order an X configuration on the Volume and Channel key pad ( Channel Up, Volume Down, Volume Up, Channel Down). See Diagram 8. Release the Pause button when done pressing the arrows.

Note: The keypad X configuration sequence should not be faster than 1 second between each key stroke. Any speed faster than 1 second may result in an unsuccessful access to the

sign-in screen.

Diagram 8

2. The sign-in screen will be displayed. Type in the technician access code (5,1,7,6,5,7,6,1) and press OK.

Hardware Validation = Diagnostic Tests (51765761)

Diagnostic Test

Performed

Console Function or

Base Function

Test Description

Display Test

Console Function Test

While in this test, each time the “OK” key is

pressed a different group of LEDs will illuminate. Press the back button to exit this test.

Keypad Test

Console Function Test

While in this test, a map of the keys will be displayed. When a key is pressed, the corresponding LED will extinguish. When finished, press and hold the “BACK” button to exit the test.

Heart Rate Test

Console Function Test

While in this test, unfiltered, filtered, and pulse values will be displayed. Use a Polar heart rate simulator to test the wireless heart rate. Grasp the grips to test the hand held heart rate. Press the back button to exit this test.

Brake Test

Base Function Test

Brake power bits information will be displayed. Use this test to determine resistance related problems. Press the back button to exit this test.

RPM Test

Base Function Test

Pulse is displayed, showing a count of zero crossings from the generator. RPM shows a

software averaged version of “Pulse”, and is

displayed in user mode as stride count. Use this test to determine stride count related problems. Press the back button to exit this test.

Battery Test

Base Function Test

Displays battery voltage. Use this test to determine the cause of low battery warnings. Press the back button to exit this test.

Stride Position Test

Base Function Test

Displays the output of the stride position sensor. Press the back button to exit this test.

Vertical Position Test

Base Function Test

Displays the output of the vertical position sensor. Press the back button to exit this test.

Stride Count Reset

Base Function Test

This is not a test, it resets the belt usage counter after a belt replacement. Press the back button to exit.

Crossramp Test

Base Function Test

Tests the lift motor functions of the adjustable step height feature. Press the back button to exit this test.

Club Parameter

Setting

Parameter Description

Select Language

Sets the default language for ALL workouts on this machine. Factory default is English. Language for single use workouts can still be set by the user from the workout options.

Select Units

Sets units of measure (US standard or Metric). Factory default is US standard.

Set Max Workout Time

Sets the maximum allowable workout time for each user. Factory default is 60 minutes.

Set Max Pause Time

Sets the maximum time that the workout can be paused for. Factory default is 120 seconds.

Set Max Cool Down Time

Sets the amount of time that a cool down period will occur at the end of every workout. Factory default is 5 minutes.

Set Metrics Default

Sets a metric that may be of specific importance to the specific facility or fitness trainer. The selected metric will scroll across the screen at regular intervals during the workout. Factory default is “NONE”

Club Parameter = Settings (5651565)

Information Display (65)

Information

Displayed

Information Description

Belt Usage

Displays the total number of strides counted since the last stride count reset. Also displays the total number of stride count resets performed on this machine.

Odometer

Displays the total number of accumulated strides on the unit. This value is stored on both the upper PCA in the console and on the lower PCA. Odometer information is transferred between the upper and lower boards when either of the boards has been changed or replaced.

Hours of Use

Displays the total number of hours that the unit took to accumulate those miles unit. This value is stored in the upper PCA in the console, so if that PCA is replaced the hours of use would start again from “0”

Upper Boot Software

Displays the current version of software that handles flash upgrades of upper PCA (console) software.

Upper Base Software

Displays the current version of operating software loaded in the upper PCA (console). This is the unit specific console software.

Lower Software

Displays the current version of software loaded in the lower control module.

Metrics Board Software

Displays the current version of software loaded in the Metrics board.

Stride Dial Software

Displays the current version of software loaded in the Stride Dial board.

Serial Number

The base serial number can be set here using the WinCSAFE computer software. Factory default is NONE.

Usage Log

Displays the Statistics of the workout programs used, the number of times accessed, and duration of use.

Error Log

Displays a running log of errors encountered on the unit.

4- Theory of Operation

Console Models

Consoles that could appear on the AMT12 Base

Basic operation of a console

The purpose of this section is to describe the operation and maintenance of the AMT base, however it would be difficult to talk about the base without referring to console controls. Basic console functions that apply to all models of consoles are discussed. For specific details about a particular model of console (P10, P20, P30, P80), please refer to that console manual.

All basic consoles provide user input (keypad functions), user display (LED display / user feedback), automated control (heart rate program, interval program) and service software routines (tests, settings, and information).

The keypad functions can vary between different console models, however the basic functions that all consoles have are Quickstart, Incline (up or down) and Resistance (up or down).

The display features can vary between different console models, however the information conveyed by those displays are very similar.

Service software routines are handled exactly the same for all console models. Entering into

“Hardware Validation” tests, “Club Parameter” settings, or “Information Display” is also the same and are called “Standardized Service Access Codes”.

The service software and standard access codes are described in detail in the “Standardized

Service Access Codes”, section 5 of this manual.

There are also “Standard Error Codes” which all console models follow. For a full listing of

“Standard Error Codes” used for this model see “troubleshooting”, section 7 of this manual.

The processor in the console provides user input, user display, and automated control to the system, while the processor in the lower electronics module performs the actual machine function. The two processors communicate via a serial data stream.

When the user makes a request of machine function to take place via the keypad (user input), the console processor communicates that request to the processor in the lower electronics module via the serial data stream.

Once the lower processor receives the request the lower control module performs the machine tasks associated with the request. The console processor goes about its business of monitoring keypad entry and providing display feedback.

The lower processor also provides status back to the console processor (via the serial data stream) to report if everything occurred properly, or if an error code needs to be written to the error log.

AMT Base Operation

Power Generation

The Commercial AMT base is powered by a 3-phase generator that spins when the user is pedaling the stairarms. There are 3 wires in the cable coming from the windings of the generator, connected to the lower control module via 3 individual spade style connectors. The frequency of the AC sine waves is determined by how fast the user is pedaling, and the voltage level of each AC sine wave is approximately 100VAC.

The generator performs three functions in the AMT. First, by providing power to the lower control module. Second, the generator is used to charge the EFX’s internal battery. Lastly, one of the generators six phase output windings is monitored to determine when the unit is in use and when it is idle. This system also determines the stride rate by determining the operating speed (output frequency) of the monitored generator winding.

Lower Electronics Module

The lower control module consists of an AC to DC conversion of the generator output, a distribution of DC power supplies, a DC lift motor controller (only on open stride models), and control of workout resistance.

DC Power Distribution:

Once the generator’s AC outputs are converted to DC, there are a number of regulated DC supplies

that power the various functions of the AMT. The first regulated DC power supply in the distribution chain is an 18VDC supply, but only supplies this 18VDC if the user is pedaling the AMT. If the customer wishes to add the external power option to the AMT, an external 18VDC supply replaces the 18VDC supplied by generator power, allowing the unit to stay powered up (whether pedaling or not).

A regulated 14.5VDC power supply charges the 12V battery.

A regulated 7.5VDC power supply is sent to the console via the data cable. The electronic circuits in the console operate on +5V DC, however the lower control module sends +7.5V DC due to the optional external equipment such as Fitlinxx, which may be connected to the CSAFE (Communication Standard for All Fitness Equipment) port. By sending a higher voltage (+7.5V) and regulating down to +5V DC, we insure that we can supply enough power to both the console and the optional external equipment. To insure that this 7.5VDC regulated power supply is stable enough to run all console related functions, the lower control module switches this 7.5VDC power “ON” only after a rate of greater than 20RPM at the crankarms is detected.

A regulated 5VDC power supply and a regulated 3.3VDC power supply are used to power all the digital logic functions of the lower control module.

Lift Motor

J3-2

J3-3 J3-4 J3-5

J3-6

R

BK

BR

1K

Intermediate Connector

R

BK

W

F1

6.3 amp

LIFT (If so equipped)

AMT Resistance Control:

Vertical Resistance:

The Experience Line AMTs use a three phase AC generator, and all current being drawn throughout the unit comes from this generator. The only other power supply in the unit is a variable power supply, used to provide variable control of mechanical resistance, in this case (Magnetic Force). The user selects the desired level of resistance at the console, and the console passes that request along to the lower control module via the serial communication through the data cable. The processor on the lower control module then adjusts the output of the variable supply to an

appropriate value to facilitate the user’s requested resistance level. That voltage is applied to an

eddy current magnet pointed at the flywheel of the generator, which then determines the amount of braking force that is placed on the generator. The more voltage sent to the eddy current magnet

the larger the magnetic braking force placed on the flywheel of the generator, thus providing mechanical resistance.

The reason that Precor uses a 3-phase generator on a self-powered AMT while self-powered EFXs use a 6-phase generator is centered in its use of Magnetic force as a resistance method.

Horizontal Resistance:

The AMT’s horizontal braking force is achieved through the use of a drum style eddy current brake assembly. The inner drum of the assembly has a number of fixed magnets glued to outer circumference of the drum. These fixed magnets are considered the primary magnetic field. The outer drum of the assembly has a copper sleeve bonded to the inner circumference of the drum. When the outer drum moves relative to the position of the inner drum, the fixed magnets induce a current into the copper sleeve. The current now flowing in the copper sleeve will produce a secondary field, which will in turn repel against the magnetic field of the fixed magnets.

AMT motion detection (RPM):

This diagram shows the 3 sine waves from the generator, which the LPCA uses to supply and

distribute power throughout the system. The LPCA also utilizes a “zero crossing detector” to

determine a stride count by counting the zero crossings from 1 of the 3 sine waves coming from

the generator. The zero crossing counts the speed of the generator and the LPCA processor divides out the step-up in the pulleys will determine the RPM at the cranks.

When the user begins to pedal the unit, The LPCA powers up right away. To insure that all regulated supplies are up and stable, the unit holds power off of the UPCA until a minimum of 20 RPMs at the crank is detected. Once this minimum speed is detected, the processor will turn on a relay, which in turn switches power onto the UPCA. When the user presses “Quickstart” or goes into a program, the UPCA is going to want to use the actual stride count for its user display functions. The stride is counted by the LPCA processor, and transferred to the UPCA processor via the communication cable.

DC Lift System – Motion Control (If Equipped)

The motor used in the lift system of a self-powered unit is a DC motor. It is powered by 12VDC from the battery, and utilizes a 7 amp self-resetting fuse on the lower control module to protect the switching circuitry on the lower control module. Motion can be driven in 2 different directions by switching the polarity of the battery voltage applied to the windings of the motor. Since the lift motor is only expected to travel at one speed, the voltage is NOT varied. A single voltage is switched to the lift motor to initiate motion, and the polarity is switched to control direction.

When the user presses the “UP” button on the console and the console passes that request along

to the lower control module via the serial communication through the data cable. The processor on the lower control module then switches the 12VDC battery voltage to the lift motor windings as a POSITIVE 12VDC.

When the user presses the “DOWN” button on the console and the console passes that request along to the lower control module via the serial communication through the data cable. The processor on the lower control module then switches the 12VDC battery voltage to the lift motor windings as a NEGATIVE 12VDC.

DC Lift System – Position Monitoring (If Equipped)

The unit also requires an absolute measurement of lift position. This is achieved through the use of a potentiometer. The potentiometer is turned by being geared to the motor, which changes the wiper resistance.

With +3.3V DC applied across the potentiometer, the center wiper connection will be a variable voltage (between 0 and +3.3V DC), dependent on the position of the lift. This variable voltage is applied to the input of an 8-bit A/D converter, which converts the analog voltage into an 8-bit binary numeric representation that the processor can understand.

As the voltage returned by the potentiometer changes between 0 and 3.3V DC, the corresponding A/D values change between 0 and 255. In this way, the processor can keep track of where in the lift range the lift is truly positioned.

It is important to note that since the potentiometer is mechanically connected to the gearing of the motor, it would be highly unlikely (if not, impossible) for a lift motor to go out of calibration without having some damage that needs to be repaired. See the section on troubleshooting the lift system if this occurs.

5- Troubleshooting Procedures

In This Section

 Introduction  Troubleshooting Generated Power  Troubleshooting No Power To The Console  Standardized Error Codes  Validating The Reported Failure  Troubleshooting Control Error Codes  Troubleshooting the Brake System  Troubleshooting the Lift System  Troubleshooting Communications Errors  Odometer Tracking & Flat Belt Replacement Event Codes  Troubleshooting Heart Rate Issues

This section contains troubleshooting procedures and presents a methodology for identifying and isolating system issues. Not all system issues will create an error code condition so the approach is to identify and verify the stated problem and then use the systems own self tests to help isolate the problem. In many cases, that will include the use of error codes, but not always.

Introduction

The customer has reported a failed condition. The failure that is reported may differ from your observations as a trained technician. That is why it is important to validate the reported failure. The first step in this investigative troubleshooting methodology is to first identify the current overall operating condition of the treadmill. Is it operational or not.

If the AMT does not turn on or the console will not illuminate:

Follow the appropriate procedure for “Troubleshooting Generated Power” or “Troubleshooting No Power to the Console”.

If the system powers up and can be at least partially operated: Follow the procedure below – “Validating the Reported Failure”.

Troubleshooting Generated Power

The generator performs three functions in the AMT. First, by controlling the amount of electrical load applied

to the generator, the user’s pedaling resistance is controlled. Second, the generator is used to charge the

AMT’s internal battery. Lastly, one of the generators three phase output windings is monitored to determine when the unit is in use and when it is idle. This system also determines the stride rate by determining the operating speed (output frequency) of the monitored generator winding.

WARNING:

Before continuing with this procedure, review the Warning and Caution statements listed in the Warning and

Caution Statements and General Safety Guidelines Section, Things You Should Know.

Because this is a self-powered unit, it will be necessary to equip the unit with the optional external power supply

or have an assistant pedal 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.

Perform the generator resistance test per Procedure XX. If any of the resistance measurements are significantly high or significantly low, replace the generator.

The following voltage reading must be taken while the unit is in motion. Extreme care must be taken to keep meter leads, hands, etc. clear of all moving parts. Using an AC voltmeter, measure the voltage between 1 & 2, 2 & 3, and 1 & 3 on J1 of the lower PCA. All AC voltage readings will vary depending on the unit’s stride rate at the time the measurement is taken. At a stride rate of 100 strides per minute, all three voltage readings will be approximately 100 VAC -110 VAC.

If any of the three readings in step 2 are significantly low, replace the generator. If you have performed all of the above tests and are unable to resolve the problem, contact Precor customer

support.

Measuring the Resistance of a Generator

Caution

If an external power supply is connected to the EFX, disconnect the external power supply from the EFX before continuing with this procedure. Before continuing with this procedure, review the Warning and Caution statements listed in Section One, Things You Should Know.

Procedure

Remove the red battery lead from the lower PCA. See Diagram 10.3.1 Set the ohmmeter to a range that will conveniently read up to 50 . Remove the three-phase generator connector from the lower PCA; refer to Diagram 8.1.1, below. With an ohmmeter, read between terminals 1 & 2, terminals 2 & 3, and terminals 1 & 3 on the six phase

generator connector (J1). Each of the readings should be between 26  and 30 . 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 is now correct check and or replace the intermediate cable. Refer to Diagram 8.1.1. If the readings are still incorrect, remove and replace the generator per Procedure XX.

Reconnect the intermediate cable removed in step 5 to the replacement generator and the lower PCA. Reconnect the red battery lead to terminal M6 of the lower PCA.

Diagram 8.1.1 Lower Control Module Connector Layout

Troubleshooting No Power to the Console

This troubleshooting is for P10, P20, or P30 consoles only. P80's use their own power source.

Upper Display does not illuminate

1. Because this is self-powered unit, the display will not illuminate until it is used or the optional external power supply is equipped. If the optional external power supply is equipped, the display should be constantly illuminated. If the optional external power supply is not equipped, the unit must be used at a stride rate of 20 strides per minute or higher for the display to illuminate.

2. If the optional external power supply is not equipped, skip to step 5.

3. Disconnect the optional external power supply from the EFX and measure between the inner

and outer sleeves of the power supply’s output jack with a DC voltmeter. You should measure

approximately 18 VDC.

4. If the voltage measured in step 3 was significantly low, replace the optional external power supply. If the voltage measured in step 3 was 0 Vdc, disconnect external power supply from its AC outlet and measure the voltage at the AC outlet. If the AC outlet voltage is normal replace the optional external power supply. If the AC outlet voltage is significantly low or 0 Vdc, the AC system must be inspected by an electrician.

5. Troubleshoot the generator per Procedure 9.2.

6. If the generator was found to be good, the problem will be in either the lower PCA, upper PCA or the upper to lower PCA interconnect cables.

Warning

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.

7. Remove the rear cover and disconnect the interconnect cable from the J2 connector of the lower PCA.

8. The following voltage reading must be taken while the unit is in motion. Extreme care must be taken to keep meter leads, hands, etc. clear of all moving parts. Using a DC voltmeter, measure the voltage between TP13 (+5D) and TP4 (DGND). Refer to Diagram 5.13.1. The voltage measured should be approximately 5 Vdc. If the voltage is significantly low, replace the lower PCA. Additionally, the DS1 LED should illuminate.

9. Reconnect the interconnect cable to the J2 connector of the lower PCA and repeat the voltage

DGND, TP4

PROM

+5D, TP13

DS1 LED

J2 Connector

measurement in step 8. The voltage measured should be approximately 5 Vdc. If the voltage is significantly low, the problem is in the upper PCA or the upper to lower PCA interconnect cables.

Diagram 5.13.1 - Partial View of Lower PCA

10. Troubleshoot the upper to lower PCA interconnect cables per Procedure 9.1.

11. If the upper to lower interconnect cables are found to be good, replace the upper PCA.

12. If you have performed all of the above tests and are unable to resolve the problem, contact Precor customer support.

CAUTION: Swapping a lower control module from a good unit into a bad unit could easily damage the lower control module from the good unit, since there could be something in the bad unit that causes the lower to fail. This could potentially produce two bad units instead of one.

Standardized Error Codes

Control

Errors

Com

munic

Lift System

Errors

The system generates error codes and stores those codes in a block of memory known as the ERROR LOG, and does so when it detects conditions that are defined in the error reporting software. The error log has 10 locations in a first in-first out configuration. In other words it will display the 10 MOST RESENT errors, with error location 1 being the most recent. While not all system issues will generate an error code, those that do are shown here. These codes are useful in isolating certain system issues.

To view errors in the error log, press and hold the reset key for at least 6 seconds. If there are errors logged, this action will take you into the error log. The error log can also be accessed through the “Information Display” by pressing either pause or reset, then the numbers 6, 5.

The following is a list of the error codes currently assigned to the AMT12:

Error 05 Key depressed at power up Error 09 Memory error (Lower PCA) Error 12 Watchdog (Lower PCA)

Error 30 Upper PCA not receiving data from lower PCA Error 31 Faulty data received from lower PCA Error 32 Lower PCA not receiving data from upper PCA Error 33 Faulty data received from upper PCA Error 37 ESTOP Not Working

Error 40 No lift motion detected Error 42 Lift position value out of range Error 44 Un-commanded lift movement

Error 45 Lift moving in incorrect direction

P30 Machine Control Errors

AMT Odometer

Tracking & Flat

Belt Replacement

Event Codes

Error 46 Low Battery Voltage (AMT12 only)

Error 50 Too much brake current

Error 62 Vertical Stride Error

Event 71 Virgin Lower Board Detected Event 72 Write Error – Bad “version” byte Event 73 Write Error – Bad “size” byte Event 74 Upper or Lower Board Has Been Replaced Event 75 Upper or Lower Board Has Been Replaced Event 76 Upper or Lower Board Has Been Replaced Event 77 Upper or Lower Board Has Been Replaced Event 78 Display “Replace Belts Soon” (90 million strides) Event 79 Display “Replace Belts Now” (100 million strides)

Error 80 P30 Lift Up Not Working Error 81 P30 Lift Down Not Working Error 82 P30 Speed Up Not Working Error 83 P30 Speed Down Not Working

The subsequent pages list the details of each of the error codes that exist within the Precor software hierarchy. Each page will include a description of the error code being displayed and the systems associated with the error code.

Potential causes for the error codes will be listed with the most likely cause first and the least likely cause listed last. It must be understood that this document can not anticipate every possible cause for a particular error code. However, it should list the causes encountered in the majority of cases.

The document will then list the suggested remedies associated with each of the possible causes. The possible remedy listing will numerically coincide with the possible cause listing.

Validating the Reported Failure

1. Look to see if there is an error in the error log. This is often the source of vital information to point your troubleshooting in the right direction. Write down the errors and the odometer readings that are reported in the log and then clear the error log by pressing and holding the “Quick Start” key.

2. Run the unit in normal user mode and verify that the reported failure occurs. Make note of any other observations of things that occur at the time of the failure.

3. Run the unit in the service access software per the procedure in section 5 (5-1-7-6-5-7-6-1, Hardware Validation Tests), and verify that the console (display, keypad, and heart rate) functions are working normally.

NOTE: Keep in mind that if a key on the keypad doesn’t function, the lower control module will not be aware of any request for action that the user has initiated. In this case the cause for the failure would not be in the lower portion of the unit, and no errors will be logged.

4. Run the unit in the service access software per the procedure in section 5 (5-1-7-6-5-7-6-1, Hardware Validation Tests) and verify that the machine (incline) functions are working normally.

IMPORTANT NOTE: If a failure is observed in user mode but works perfectly in the hardware validation tests, this could be an indication that a setting in the club parameters may be creating a limit. It is also important to keep in mind that some problems could be intermittent and will require a fair amount of vibration to recreate, and some problems are weight (load) related and you may need to recreate that condition as well.

5. Look at the error log again to see what errors have returned. This will validate that they are real and current errors. Do not disregard the previous errors that were cleared, but understand that the odometer reading when compared to the total unit odometer reading will determine how recent the error message occurred.

NOTE: If no error codes are present but the system is not operating normally, follow the troubleshooting steps for the most directly related troubleshooting topic. For instance, heart rate issues will not generate error codes but can be troubleshot using its procedure. Similarly, the same can be said of the lift motor issues.

6. Look up the current service bulletins for this unit. This step will determine if this is previously identified issue that already has a solution. If so, following the service bulletin will avoid unnecessary troubleshooting steps. If no such service bulletin exists, continue with the troubleshooting steps for the system that is failing (Control, Brake System, Cross ramp

System, Communication, or Heart Rate).

Troubleshooting Control Error Codes

Errors in this section cover console controls (error 5 & 80-83), or processor/memory (error 9 & 11) conditions. These are errors that although they are valid to the proper function of the machine, are not part of a specific base system (lift system, etc…). Follow the steps for error code 5, 9, 12, 80 and 81 on the following pages.

Error 05 - Key Depressed at Power Up

Description

The power up test sequence has detected a key in the operated condition (Stuck Key). The power up test sequence is performed every time the unit is turned on (powered up). This test is performed because a permanently stuck key will inhibit the correct operation of the unit.

Possible Causes

1 A key on the display housing is permanently stuck in the operated condition. 2 One of the upper PCA’s keypad interface chips has failed. 3 Liquid (perhaps perspiration) is present on the surface of the display overlay.

Possible Remedies

1 Remove the keypad connector cable from the upper PCA. Restart the power up sequence; if the

ERROR 5 (Stuck Key) is no longer present, the keypad is the cause. The keypad is typically part of the display housing. Replace the display housing to correct the problem.

2 Remove the keypad connector cable from the upper PCA. Restart the power up sequence; if the

ERROR 5 (Stuck Key) is still present, the upper PCA is the cause. Replace the upper PCA to correct this problem.

3 Wipe the surface of the display overlay clean of all liquid. Restart the power up sequence; if the

ERROR 5 (Stuck Key) is no longer present, the liquid was the cause.

Error 09 - Lower PCA Memory Test Errors

Description

Error 09 checks lower PCA memory locations during the power up test sequence. If a fault is found during the power up test sequence, error 09 will be displayed. This error code is only used on products utilizing the dual microprocessor system.

Possible Cause

This error message almost always indicates a lower PCA problem when it is consistently displayed. Failures causing this error message to be displayed are rare.

Possible Remedy

If the error message is consistently displayed when the unit is powered up, the lower control module should be replaced. It is possible to see this error message displayed intermittently due to external causes.

Error 12 - Watchdog (Lower PCA)

Description

The error 12 watchdog monitors the lower control module low voltage power. If the low voltage power drops below a preset level, the error 12 will be displayed.

Possible Causes

1 A failure in the lower control module overloads the low voltage power supply and causes it to drop

below the preset limit.

2 A fault is in the interconnect cable (lower control module to upper PCA) causing the lower control

module low voltage power supply be too low.

3 A failure in the upper PCA that overloads the lower control module low voltage power supply causing it

to be too low.

Possible Remedies

1 If the error message is consistently displayed when the unit is powered up, the lower control module

should be replaced. It is possible to see this message displayed intermittently due to external causes. If the unit's AC input significantly dips during the power up test sequence the test could fail resulting in this message being displayed. Treadmills operating on non-dedicated AC circuits may see this message displayed on an intermittent basis.

2 Substitute a known good interconnect cable in place of the existing cable to determine if the

interconnect cable is the cause. For the purpose of the test, the substitute cable should be connected directly between the upper PCA and lower control module.

3 Substitute a known good upper PCA for the existing PCA to determine if the upper PCA is the cause.

Error 80, 81, 82, & 83 – P30 Machine Controls Not Working

Description

This error monitors the incline (up and down) controls of a P30 console. These switches are not traditional mechanical switches, they are optical switches.

Error 80 P30 Lift Up Not Working Error 81 P30 Lift Down Not Working Error 82 P30 Speed Up Not Working Error 83 P30 Speed Down Not Working

Possible Causes

1 Machine control interconnect cable has come unplugged from the upper PCA. 2 Bad machine control cable. 3 Bad machine control assembly.

Possible Remedies

1 Open the P30 console to expose the circuit boards, and verify that the machine control cable has not

become unplugged from the upper PCA. 2 Substitute a known good machine control cable. Substitute a known good machine control assembly.

Troubleshooting the Brake System

Brake System Description:

The brake system consists of a variable power supply with an output voltage based on the resistance level selected by the user. The voltage is applied to an electromagnet that is mounted to the generator frame, and produces an eddy current breaking force applied to the flywheel of the generator.

1. Connect a DC voltmeter to the wired terminals of the electromagnet using clip leads, and dress the leads out the back of the unit so as not to interfere with the motion of the crankarms.

2. Pedal the unit (to supply power) and place the unit in the “Hardware Validation” service mode (Reset 5,1,7,6,5,7,6,1). Run the “Brake Test” and press resistance “UP” ▲ until the unit is at resistance level 7.

3. The voltmeter should read between 10 and 20 VDC depending on how fast you are pedaling.

4. If no voltage is present, either the variable power supply on the lower control module is bad (no output from the lower control module) or there is an open in the electromagnet.

Troubleshooting the Lift System

Lift System Description:

The Lift system consists of a DC voltage driven lift motor, and an internal 1 K  (Ohms) potentiometer for lift position monitoring. Because the incline motor is a DC motor, direction is controlled by the polarity applied to the incline motor. When a positive voltage is applied to the motor, the motor will move upward. When a negative voltage is applied to the motor, the motor will move downward. As the motor moves, the 1 K (Ohms) potentiometer is rotated via an internal gear drive system. The potentiometer’s changing resistance is fed to the incline control system and converted to an A/D (analog to digital) number that is used in the to indicate ramp position. The operating system has a battery monitoring system. If the battery voltage falls below 11 VDC when stride height movement is initiated or the battery voltage falls below 10 VDC after the ramp movement has been initiated, ramp movement will be stopped and the message ERROR 46 will be displayed. Stride Height motion will not be enabled until such time as the battery voltage exceeds the above limits. The battery voltage must be raised to correct this condition either by battery charging or battery replacement. This is strictly a battery problem and not a incline system or incline motor problem. It is important when you start to troubleshoot the lift system to determine if the problem is due to an inability to move the lift, or an inability to monitor the lift position. This will determine whether you need to troubleshoot the DC voltages going to the motor windings, or if you need to troubleshoot the DC voltages and/or ohm readings from the potentiometer. The error log will help determine which is causing the issue. Press and hold the reset key for at least 6 seconds, if there are errors present this action will display the error log. If there is an error code for a lift system error (Error 40 through 45) logged in the error log, go to the appropriate error code troubleshooting page and follow the steps for that error.

Note: All resistance measurements must be performed with power removed from the AMT. Performing resistance measurements with voltage applied may damage your ohmmeter.

 Operation of lift motor for testing:

Most Precor AMTs require the unit to be pedaled for power to be present in order to operate the lift. For this reason the use of the external power option (if available) is recommended so that power can be provided without pedaling. It is also advisable that the servicer use the Machine Tests within the “Hardware Validation” mode (accessible through Pause-5-1-7-6-5-7-6-1) to check lift operation.

Error 40 - No Lift Motion Detected

Description

Error 40 indicates that the lift system has been instructed to start moving and no lift motion has been

NEED NEW PICTURE

detected by the lift position monitoring system.

Possible Causes

1. The lower control module lift fuse open.

2. The lift motor is physically jammed and unable to move.

3. The lower control module is bad.

4. The battery is bad.

5. A lift motor cable is bad.

Possible Remedies

1. Remove power from the unit and remove the cover to expose the lower control module. Remove the 6.3amp fuse (it looks like a pencil eraser) and with an ohmmeter, check the resistance. The ohm value of the fuse should be less than 1 . If the fuse is higher than 1 ohm, replace it. If

the fuse is 1 ohm or less, plug it back into its socket and re-install the cover. If the fuse is good and the lift still will not move, continue to the next possible cause. Newer LPCAs are equipped with a 7amp self-resetting circuit breaker.

2. The lower control module can fail in one of two modes.  The lift switch could fail in an operated (shorted) condition. If this happens the lift will move

(either up or down) as soon as the unit is powered up. The typical result is that the lift will be physically jammed as described above, and it will also probably cause the lift fuse to open (Newer LPCAs are equipped with a 7amp self-resetting circuit breaker).

 The lift switch may also fail in an open condition. If this happens the lift will not operate in one

direction. Perform the following steps to determine if the switch is open. If the lift moves in one direction but not the other, replace the lower control module.

3. If the lift does not move in either direction or fails to move in the “UP” direction (more torque is needed to move the lift in the “UP” direction), the battery could be at fault. Measure the voltage on the battery, and if it is 11 VDC or lower replace it.

If the battery needs to be replaced, make sure that the 14.5 VDC battery charging supply is putting out 14.5 VDC. If the 14.5 VDC charger voltage is not present on the lower control module, replace the lower control module.

If the lift moves “DOWN” but will not move “UP” (or has trouble moving up), monitor the battery

voltage while commanding the lift to move “UP”. If the battery starts out at 12VDC, but drops to a significantly lower voltage when commanded to move “UP”, replace the battery.

4. If the lift will not move in either direction, ohm out the cable that goes from the lower control module to the lift motor. If there are opens in the cable, repair or replace the cable.

Error 42 - Lift Position Value Out of Range

Description

This error code monitors the physical lift position via a lift position potentiometer that mechanically tracks the lift's physical position and sends a DC voltage back to the control system. The voltage is converted to an 8-bit digital number. This number is then used to represent the lifts physical position. Software sets upper and lower numerical limits. If the lift position number is found to be outside of the set limits, error 42 will be displayed. When troubleshooting an error 42 it is important to be aware of the actual physical position of the lift when the error occurs. If the lift is physically out of range or jammed you must first determine why the lift is physically out of range. When the lift is out of range the error 42 is a secondary symptom and the problem should treated as an error 40 instead of an error 42. The A/D value for the home position (Level-2) is approximately 83.

Possible Cause

1 Bad or intermittent connection in the lift motor connector. 2 The lift motor requires re-calibration. ***If the lift had been calibrated correctly at the time of

installation and working for some period of time it would be highly unlikely (if not impossible) for it to just go out of calibration on its own. It would be more likely that something has broken causing the A/D value to be wrong.

3 The lift motor potentiometer is bad.

Possible Remedies

1 Intermittent connections can be difficult to locate. If the error 42 condition is intermittent a

connection is almost certainly the problem. This is especially true if the error 42 occurs while the lift is within its normal physical range.

Carefully inspect the lift potentiometer connector, repair the poor connection, if possible. If the intermittent connection cannot be found or repaired, replace the lift motor.

A lift calibration number of 0 or 255 indicates an open or shorted potentiometer connection. This problem could be anywhere between the lift motor and the upper PCA. It can typically be found and traced with an ohmmeter.

 Remove the lift motor’s connector from the INCLINE connector on the lower control module.

Visually inspect the lift motor’s wiring and connector for any broken or improperly crimped connections. With an ohmmeter, read between the red & black wires, the black & white wires, and the red & white wires of the lift motor connector. The reading between the red & black wires should read approximately 1K  (Ohms). The sum of the readings between the black & white wires and red & white wires should total approximately 1K  (Ohms). If either reading is significantly high or open, replace the lift motor.

2 Refer to the lift calibration procedure. If the lift position number and physical lift position

measurement does not correspond with the service manual, calibrate the lift motor.

Note: There must be a reason for the lift motor to be out of calibration, therefore simply re-calibrating the lift motor will often not fix the problem.

3 If the lift calibration number (A/D value) is not 0 or 255 and does not increment when the lift motor

moves, replace the lift motor.

If you have performed all of the procedures above and have been unable to correct the problem, search for solutions in the service bulletins or call Precor customer service.

Error 44 - Un-commanded Lift Motion

Description

The lift control system has detected that the lift is in motion without a lift command having been issued. This can happen in one of two ways: either the lift drive circuit has failed in a turned on condition or the lift position sensor (lift position potentiometer or revolution sensor) is sending an erroneous signal to the lift control circuit.

Possible Causes

1 Poor or intermittent connection in the lift position sensor (potentiometer). 2 Bad lift position sensor 3 Bad lower control module.

Possible Remedies

1 This is the most common cause of an error 44. Verify all wiring and connections associated with

the lift position potentiometer. Repair or replace wiring or connections as appropriate. Because of the nature of the revolution sensor an error 44 is rarely associated with it.

2 Operate the lift in the diagnostics while monitoring the lift position number being displayed. If the

reading is erratic and makes large changes in readings the lift position potentiometer is probably bad. Replace the lift motor.

3 If there is actual lift motion without a manual or program control lift command having been issued,

replace the lower control module.

Error 45 - Lift Moving in Wrong Direction

Description

The lift control system has detected that the lift is moving in the opposite direction of the issued lift command.

Possible Causes

1 Lift Motor hysteresis.

2 Bad lower control module

Possible Remedies

1 This error would typically happen when the lift was already in motion (typically downward) when a

lift command in the opposite direction (lift up) was issued.

2 Some motors exhibited a very long turnaround time and the lift motor would still be moving in the

original direction (downward) while the control system was attempting to move the lift in the opposite direction.

3 If the error 45 condition is persistent, replace the lift motor. 4 This is a very rare condition, if the lift moves in the opposite direction of the issued lift command,

replace the lower control module.

Error 46 – Low Battery Voltage (Open Stride AMT12 only)

Description:

The operating system has a battery monitoring system. If the battery voltage falls below 11 VDC when stride height movement is initiated or the battery voltage falls below 10 VDC after the ramp movement has been initiated, ramp movement will be stopped and the message ERROR 46 will be displayed. Stride Height motion will not be enabled until such time as the battery voltage exceeds the above limits. The battery voltage must be raised to correct this condition either by battery charging or battery replacement. This is strictly a battery problem and not an incline system or incline motor problem.

Possible Causes:

1. Open fuse in fuse on the positive battery wire (Open Stride AMT12 only).

2. Faulty or poor connection on the battery or LPCA.

3. Low or no voltage output from battery.

Possible Remedies:

1. Remove power from the unit and remove the lift fuse from the in line fuse holder on the positive battery cable. Measure the fuse with an ohmmeter, the fuse should read approximately 1 ohm or less. If the ohmmeter reading is significantly high, replace the fuse. If the fuse is open, please refer to #2 below before you continue.

2. Check battery cable connector for shorts or poor connections.

3. Enter the diagnostic program per procedure, P80 Settings or Accessing the P30 Diagnostic Software. Using the diagnostic program allows you to test the incline system without continuously

pedaling the unit if you have an external power supply. Otherwise, you will need to continue to pedal the unit. Connect a DC volt meter to the J3 connector on the lower PCA as follows: voltmeter common lead to terminal 3 (black wire) and voltmeter "hot" lead to terminal 2 (red wire). Using the STRIDE HEIGHT ▲ or ▼ keys operate the incline. The voltmeter should read +12 VDC approximately when the incline is instructed to move upward and -12 VDC approximately when the incline is instructed to move downward. If the either voltage measurement is significantly low, replace the battery.

Troubleshooting Communications Errors 30, 31, 32 and 33 - Communications Error

Description

Errors 30 through 33 all indicate the loss of communications or erratic communications between the microprocessors in the upper PCA and the lower PCA. The trouble shooting procedures for all of the communication errors are essentially the same.

Error 30 is defined as upper PCA not receiving data from lower PCA. Error 31 is defined as faulty data received from lower PCA. Error 32 is defined as lower PCA not receiving data from upper PCA. Error 33 is defined as faulty data received from upper PCA

Possible Causes

1 An upper PCA to lower PCA interconnect cable (or modular coupler) is bad. 2 The interconnect cable at the upper PCA was mistakenly plugged into the CSAFE connector. 3 +5 VDC power supply is being overloaded by another component that is plugged onto the lower

PCA.

4 A defective lower control module. 5 A defective upper PCA.

Possible Remedies

1 Substitute a known good interconnect cable between the upper and lower PCAs to determine if

the interconnect cable is defective.

2 Remove the interconnect cable from the CSAFE connector and insert it in the correct upper PCA

connector.

3 Unplug all the components from the upper PCA and lower control module except, data cable, and

the AC power going to the lower control module. If the unit shows an error other than a communication error, plug in components one at a time, cycling power after each new component is plugged in. If a communication error is displayed, the last component plugged in is the cause of the error.

4 Substitute a known good lower control module to determine if the lower control module is

defective.

5 Substitute a known good upper PCA to determine if the upper PCAs defective.

Troubleshooting the Interconnect Cable

1 Remove the Consoles access cover. 2 Remove the right side cover as per procedure, Cover Replacement (on page XX). 3 Disconnect the interconnect cable from the upper PCA and the lower PCA. 4 External of the upper column, connect a replacement interconnect cable to the lower PCA and the upper

PCA.

5 Check operation as described in the Operation verification section. If the unit works properly, replace

the interconnect cable.

6 If you have performed all of the procedures above and have been unable to correct the problem, call

Precor customer suppor

Event 70 - 79

Odometer Tracking & Flat Belt Replacement Event Codes:

Description

The flat belts require replacement every 100 million strides. The system keeps track of the accumulated strides since the last belt replacement, and alerts the user that 100 million strides have elapsed and that it is time to replace the belts. Prior units have always lost odometer information whenever the upper board was replaced, so a new feature was engineered to maintain the current odometer information after a board replacement.

Event codes 70 through 79 are logged in the Error Log, but are really events and not errors. Event codes 70 through 77 are used to alert the unit that an upper or lower board has been replaced. The software determines which board has been replaced and makes the odometer reading of the replacement board

match that of the board that has not been replaced. Event codes 78 and 79 are used to display warnings to the user screen concerning belt replacement.

Event 71:

This event is used to report that a virgin lower board has been installed and that the upper board’s odometer

information should be written to the virgin lower board. The write operation occurs at the start of a workout.

Event 72 & 73:

This event is used to report that an odometer write operation had failed. The unit responds by re-writing the odometer record.

Events 74 – 77:

These events are used to report that an upper or a lower board has been replaced. Through the use of complex software algorithms the system determines which board is the replacement and makes the odometer reading of the replacement board match that of the board that has not been replaced. The write operation for these events will occur during the workout summary, and the workout summary will always occur 20 seconds after the pedals stop moving.

WARNING: If you are troubleshooting by swapping boards, you must remember to unplug the data cable from one board within that 20 second window before the workout summary, or the odometer will be overwritten. This could potentially cause all the units at the club to have incorrect odometer information, and all accurate belt replacement tracking would be lost.

Event 78:

This event is used to report that the odometer has reached 90 million strides since the last belt replacement. The system will display “Replace Belts Soon” at the banner screen.

Event 79:

This event is used to report that the odometer has reached 100 million strides since the last belt replacement. The system will display “Replace Belts now” at the banner screen and lock out all user controls.

Troubleshooting Heart Rate Issues:

Hand Held Heart Rate Does Not Work

1. Place your hands on the HHHR (Hand Held Heart Rate) contacts, making full contact with both top and bottom contacts for at least 15 seconds.

If the unit displays a heart rate, no problem exists. If the unit does not display a heart rate value within this time, continue to step 2.

2. Set the on/off switch to the off position, wait 10 seconds, then set the on/off switch to the on position and repeat step 1.

a. If the HHHR functions correctly, then the processor on the HR board was in a “latched-up”

condition, and cycling the power cleared the condition.

b. If the HHHR does not function correctly, continue with step 3.

3. Verify that the HHHR board has the correct operating voltage. Connect a voltmeter to VCC and Ground on the Power/Signal connector. The voltage should read between 4.5 and 5.5VDC.

4. Using an ohmmeter, measure between the grip contacts and the cable connector end. Verify the wiring of the HHHR contacts (top left, bottom left, top right, bottom right) go to the proper pin on the Grip/Contact connector, and that none of the lines are shorted.

a. If the cable is miswired, Correct the wiring error. b. If the cable is shorted, replace the cable. c. If the cable checks out OK, Continue.

5. Verify that the grip connections are free of corrosion.

a. If NO, Replace the corroded HHHR grips. b. If Yes, Continue.

6. Verify that there is a ferrite bead around the cable from the HHHR board to the upper PCA. (GEN06 treadmill only)

7. If the above procedures do not correct the problem, replace the heart rate board.

8. Verify that the unit does not display a heart rate with only one hand on a grip. This would indicate static damage, and require replacement of the heart rate board.

Wireless Heart Rate Does Not Work

1. Verify wireless heart rate with a known good chest strap transmitter or test transmitter. If the heart rate reading is erratic, incorrect, or absent, continue with step 2. NOTE: It may be necessary to lean in closer to the console at first to allow receiver to begin to acquire a heart rate signal.

2. Verify that the HHHR board has the correct operating voltage. Connect a voltmeter to VCC and Ground on the Power/Signal connector. The voltage should read between 4.5 and 5.5VDC.

3. Identify other sources of wireless interference signals in close proximity to the unit (such as Wi-Fi networks, cordless phones, etc.). NOTE: This is not to say that something like a Wi-Fi network cannot be present at all, but if it is transmitting in close proximity the heart rate system MAY pick it up. These interference sources can

be very difficult to track down and locate, and may require that you ask the customer if such devices are present. Some common sources of interference signals are listed below.

4. Using an ohmmeter, verify that upper and lower PCAs have a good electrical path to chassis ground.

5. If the above procedures do not correct the problem, replace the heart rate board.

Possible sources of interference signals include, BUT NOT LIMITED TO:

Wi-Fi Network Routers Cordless Telephones Cell Phones Electronic Dog Fences Garage Door Remotes Noisy AC feeds Florescent light ballasts

6- Replacement Procedures

In This Section

Cover Replacement ...................................................................................................................................

Replacing a Belt Guard .............................................................................................................................

Replacing the Upper Arm Grip ..................................................................................................................

Replacing a Flat Belt Terminal ..................................................................................................................

Replacing a Upper Arm Flat Belt Pulley ....................................................................................................

Replacing a Stair arm Pedal ......................................................................................................................

Replacing a Stair arm ................................................................................................................................

Replacing the Flat Belts ............................................................................................................................

Replacing the Front Arm Assemblies - With Flat Belts and Press Fit Cams (After 4/3/2013) ..................

Replacing a Front Arm Assembly - Without Flat Belts and Non-Press Fit Cams. (Prior to 4/3/2013) ......

Replacing the Lower Board .......................................................................................................................

Replacing the Lower PCA and Battery Bracket ........................................................................................

Replacing the Battery ................................................................................................................................

Replacing th

Generator Belt ..........................................................................................................................................

Replacing the Generator ...........................................................................................................................

Replacing the Drive Input Pulley Belt ........................................................................................................

Replacing the Step Up Pulley ....................................................................................................................

Replacing the Crank Arm ..........................................................................................................................

Replacing the Drive Input Pulley ...............................................................................................................

Replacing the Lift Arm Housing .................................................................................................................

Replacing the drive input housing .............................................................................................................

Replacing a Tie Rod ..................................................................................................................................

Replacing the Stride Dial Sensor ..............................................................................................................

Replacing the H-Brake Belt .......................................................................................................................

Replacing the H-Brake Cam Assembly .....................................................................................................

Replacing the H-Brake Drum Assembly ....................................................................................................

Replacing the Gas Shock ..........................................................................................................................

Replacing the Incline Motor .......................................................................................................................

Cover Replacement

When replacing the covers, right, left, front, and back are from the perspective of a user standing on the AMT facing the consoles display.

FIGURE 2: FRONT, BACK, LEFT, RIGHT CONVENTIONS

Top Cover Removal

1 Standing at the front of the AMT, push in and then downward on the cover gasket with your thumbs until

the gasket locking tabs are free of the top cover, grasp the gasket and remove. The gasket is split at the back to facilitate removal.

FIGURE 3: COVER GASKET

2 Grasp the top cover at the gasket opening and pull upward to apply pressure to the locking tabs. While

pressure is applied to the top cover gently tap the front cover just below the top cover with the heel of your hand. See figure below.

FIGURE 4: FRONT TOP COVER RELEASE

3 Standing at the side of the AMT, pull the loose end of the top cover up to apply slight pressure on the

locking tabs. With the heel of your hand, gently tap the back cover just below the top cover, see figure below. The top cover should release from the back cover, remove the top cover and set aside.

FIGURE 5: TOP COVER

Front Cover Removal

1 Remove the two #10 x ¾ inch screws located at the bottom corners of front cover.

FIGURE 6: FRONT COVER - SCREW LOCATIONS

2 There are two triangle markers embossed into the left and right side covers, the markers indicate locking

joints. Place the heels of your hands just above the left and right side triangle markers. Gently tap the triangle markers with the palm of your hand, the locking tabs will release and the front can be removed.

FIGURE 7: SIDE COVER MARKERS AND FRONT COVER

Center Beam Cover Removal

1 Remove the platform.

2 Apply forward pressure at the base of center beam cover, lift the cover up slightly until the locking tab

is clear of the frame.

3 Pull the center beam cover back toward you until the cover is free from the frame.

Note: Do not lift the cover up right after the front cover tab releases, lifting up the cover too quickly may not allow the middle center beam tabs to clear the frame slots, damaging the tabs.

FIGURE 8: CENTER BEAM COVER REMOVAL

Back Cover Removal

1 Grasp the top of the rear cover and pull back, the back cover will release from the locking tab and then

the cover can be lifted out of the slots in the bottom covers.

FIGURE 9: BACK COVER REMOVAL

Left and Right Side Cover Removal

1 Grasp each side of the left side cover, near the bottom, lift up and then pull the bottom of the cover out

and away from the frame. The cover will release from the locking tabs. 2 Rotate the bottom of the side cover towards the back of the AMT to remove. 3 Repeat steps 1 and 2 to remove the right side cover.

FIGURE 10: SIDE COVER REMOVAL

Left and Right Side Bottom Cover Removal

1 Remove the eight #10 x ¾ inch screws that fasten the bottom covers to the frame.

FIGURE 11: LEFT AND RIGHT SIDE COVER SCREW LOCATIONS

2 The left and right side bottom covers can now be removed by lifting them up and out.

FIGURE 12: BOTTOM COVERS REMOVED

Left and Right Bottom Cover Assembly

1 Set the left and right bottom covers in place, align the cover mounting holes. 2 Fasten the two covers together with the 8 #10 x ¾ inch screws.

Left and Right Side Cover Assembly

1 Grasp the side cover near the bottom, rotate the side cover so that the top of the side cover points

toward the front of the AMT and the round notch in the cover points up. 2 Thread the top of the side cover under the upper arm weldment and toward the front of the AMT. 3 Rotate the top of the side cover up until the round notch of the side cover meets the upper arm. 4 Push the bottom of the side cover in until the tabs of the side cover rest in the notches on the bottom

cover. 5 Repeat the side cover assembly procedure for the right side cover.

FIGURE 13: SIDE COVER ASSEMBLY

Back Cover Assembly

1 Hold the back cover up against the frame of the AMT in the approximate final position.

2 Slide the bottom of the back cover in until the tabs of the back cover rest in the notches of the bottom

covers.

FIGURE 14: BACK AND BOTTOM COVER ASSEMBLY

3 Rotate the back cover forward until the locking tab of the back cover is aligned with cover mounting slot

of the frame, push against the top of the back cover until the locking tab and slot are engaged.

FIGURE 15: BACK COVER LOCKING TAB

Center Beam Cover Assembly

1 Set the center beam cover over the frame beam so that the front of the center beam cover is about 3

inches away from the bottom of the back cover. 2 Slide the center beam cover forward until the front of the center beam cover has engaged into the back

cover. 3 Push down on the back of the center beam cover until the locking tab of the cover has engaged with

mounting slot of the frame beam. 4 Replace the platform.

Front Cover Assembly

1 Guide the arm openings in the front cover around the arms of the AMT, taking care that the tabs at the

bottom corners of both openings are inside the two side covers. Then guide the front cover into place

until the latches on the side covers click into place. 2 Fasten the two #10 x ¾ inch screws at the bottom corners of the front cover. Tighten the screws

completely.

Upper Arm Cover Replacement

FIGURE 16: UPPER ARM COVERS

Procedure: 1 Remove the four screws that fasten the inside upper arm covers to the upper arm. 2 Remove the screws that fasten the outside upper arm covers to the upper arm. 3 Remove the inside and outside covers from the upper arm. 4 Secure the replacement cover to the arm using the five screws removed in step 1. Finger Tighten screws

in all locations before fully tightening screws.

FIGURE 17: UPPER ARM COVER SCREW LOCATIONS

Rear Flat Belt Terminal Cover Replacement

1 Remove the two screws that secure the flat belt covers to the flat belt terminal, remove the outside

terminal cover. 2 Rotate the inside terminal cover down until it is below the stairarm pedal, pull to remove. 3 Align the top of the replacement inside cover so that it is pointing toward the floor. Place the bottom of

the cover in between the flat belt terminal and the stairarm pedal. Rotate the top of the cover up and in

to place. 4 Fasten the outside and inside terminal cover to the flat belt terminal using the two #10-24 X 1.25 screws.

FIGURE 18: FLAT BELT TERMINAL COVERS

Upper Arm Cam Cover Replacement

1 Slide the vertical handlebar boot cover up the handlebar to gain access to the upper arm cam cover

screws. 2 Remove the two screws that secure the upper arm cam covers to the upper arm, remove the covers. 3 Secure the replacement upper arm cam covers to the upper arm using the two screws removed in step

2.

FIGURE 19: UPPER ARM CAM COVERS

Top Cover Assembly

Important: In the following steps, do not apply excessive force to seat the cover. 1 Position the rear edge of the top cover so that the clips on the top and back covers are engaged securely.

2 Gently snap the front edge of the top cover into place, using the heel of your hand if necessary. 3 Wrap the gasket around the center fame column below the heart rate sensor grips and then fit it into the

top cover. Make sure that the surfaces and edges of the gasket are flush with those on the top cover.

Replacing a Belt Guard

Finger Guard Replacement Procedure Upper Arm Cover Removal

FIGURE 20: UPPER ARM COVERS

1 Remove the four screws that fasten the inside upper arm covers to the upper arm. 2 Remove the screw that fasten the outside upper arm covers to the upper arm. 3 Remove the inside and outside covers from the upper arm. 4 Repeat the process for the remaining upper arm covers.

FIGURE 21: UPPER ARM COVER SCREW LOCATIONS

Belt Guard Removal

5 Grasp the belt guard mounting rings located on each side of the upper arm. Gently pull out and away

from the grip connection ring's just enough to extend past the mounting bolt.

FIGURE 22: BELT GUARD AND UPPER ARM

6 The belt guard assembly is two interlocking pieces and needs to be separated before it can be removed

from flat the belt:

a) Lower the belt guard down just below the upper arm.

b) Squeeze the belt guard near the base to release locking tabs and rotate two halves down.

c) Taking care to not lose the rollers inside the belt guard, pull the two belt guard halves away from

each other to separate.

FIGURE 23: BELT GUARD REMOVAL

7 Place the two sections of the replacement belt guard so they are positioned around the flat belt just

below the upper arm. The front belt guard should be positioned so that the interlocking tabs are pointing

toward the front of the machine, and the guard toward the back. The rear belt guard should be positioned

with the guard toward the front. Align the interlocking tabs of the front belt guard with the slots of the

rear belt guard; rotate the halves together around the flat belt until the locking tabs are locked.

FIGURE 24: BELT GUARD INTERLOCKING TABS AND SLOTS

8 Grasp each belt guard mounting ring, lift the belt guard into position over the upper arm mounting bolts,

and then secure each mounting ring to the connection ring.

FIGURE 25: BELT GUARD MOUNTING

9 Replace the upper arm covers as per procedure, Upper Arm Cover Replacement (on page 61).

Replacing the Upper Arm Grip

Upper Arm Grip Replacement Procedure Upper Arm Cover Removal

FIGURE 26: UPPER ARM COVERS

1 Remove the four screws that fasten the inside upper arm covers to the upper arm. 2 Remove the screw that fasten the outside upper arm covers to the upper arm. 3 Remove the inside and outside covers from the upper arm. 4 Repeat the process for the remaining upper arm covers.

FIGURE 27: UPPER ARM COVER SCREW LOCATIONS

Belt Guard Removal

5 Grasp the belt guard mounting rings located on each side of the upper arm. Gently pull out and away

from the grip connection ring's just enough to extend past the mounting bolt.

FIGURE 28: BELT GUARD AND UPPER ARM

6 The belt guard assembly is two interlocking halves and needs to be separated before it can be removed

from flat belt:

a) Lower the belt guard down just below the upper arm.

b) Squeeze the belt guard near the base to release locking tabs and rotate the two halves down.

c) Taking care to not lose the rollers inside the belt guard, pull the two belt guard halves away from

each other to separate.

7 Repeat the process for the remaining belt guard.

FIGURE 29: BELT GUARD REMOVAL

Upper Arm Grip Removal

8 Remove the two #10-24X.75 screws that secure the grip to the upper arm, there is one screw on each

side of the upper arm.

FIGURE 30: UPPER ARM GRIP SCREW LOCATIONS

9 Grasp the grip connecting ring located on each side of the upper arm, pull up and over the flat belt pulley

mounting bolt to remove the grip.

FIGURE 31: UPPER ARM GRIP REMOVAL

Upper Arm Grip Installation

10 Grasp the grip connecting ring located on each side of the upper arm grip, pull out and place the grip

over the flat belt pulley mounting bolt. 11 Secure the upper arm grip to the upper arm using the two #10-24X.75 screws. Repeat the process for the remaining upper arm grip.

Belt Guard Installation

12 Place the two halves of the belt guard so they are positioned around the flat belt just below the upper

arm. The smaller half should be positioned so that the interlocking tabs are pointing toward the front of

the machine, and the guard toward the back. The larger half should be positioned with the guard toward

the front. Align the interlocking tabs of the smaller half with the slots of the larger half; rotate the halves

together around the flat belt until the locking tabs are locked.

FIGURE 32: BELT GUARD INTERLOCKING TABS AND SLOTS

13 Grasp each belt guard mounting ring, lift the belt guard into position over the upper arm mounting bolts,

and then secure each mounting ring to the connection ring. 14 Replace the upper arm covers as per procedure, Upper Arm Cover Replacement (on page 61).

Replacing a Flat Belt Terminal

Flat Belt Terminal Replacement Procedure Rear Flat Belt Terminal Cover Removal

1 Remove the two #10-24 X 1.25 screws that secure the flat belt terminal covers to the flat belt terminal,

remove the outside terminal cover. 2 Rotate the top of the inside terminal cover down until it is below the stairarm pedal, pull to remove. 3 Repeat the process for the remaining rear flat belt terminal cover.

FIGURE 33: FLAT BELT TERMINAL COVERS

4 Remove the tension from the inner flat belt pulleys by lifting up on the stairarms, pulling the flat belts off

the flat belt pulleys, and then gently setting the stairarm down. 5 Remove the flat belt terminal stop bolt and washer. 6 Remove the flat belt terminal adjustment bolt and washer.

FIGURE 34: FLAT BELT CLAMP AND FLAT BELT TERMINAL

7 Remove the mounting bolt and washer that secure the flat belt terminal to the stairarm, remove the flat

belt terminal and anti-rotation disc.

FIGURE 35: FLAT BELT TERMINAL REMOVAL

Flat Belt Terminal Installation

8 Apply a thin layer of AMSOIL GPOR1 synthetic polymeric grease to the flat belt terminal shaft. 9 Carefully slide on the anti-rotation disc and flat belt terminal. Do not use excessive force. Fasten the

anti-rotation disc and replacement flat belt terminal onto the stairarm using the washer and mounting

bolt removed in step 5, torque to 300 inch pounds or 25 foot pounds. 10 Fasten the stop bolt and washer to the flat belt clamp, but do not fully tighten at this time. 11 Thread the adjustment bolt through the washer, flat belt clamp and into the flat belt terminal.

12 Lift the stairarms and then thread the flat belts over the flat belt pulleys.

Adjusting the Stairarm Pedal Height

13 Loosen, but do not remove the stairarm adjustment stop bolt. 14 Push one of the stairarm pedal's down to its lowest level. Measure the distance from the bottom of the

stairarm tube to the top of the center beam frame, the distance between the stairarm tube and the center

beam frame should be 3-7/8 inches.

FIGURE 36: STAIRARM HEIGHT MEASUREMENT

15 If the measurement is too low or too high, tighten or loosen the adjustment bolt until the 3-7/8 inch

measurement is achieved.

FIGURE 37: FLAT BELT TERMINAL ADJUSTMENT

16 Repeat the process for the remaining stairarm. 17 Fully tighten the stop bolt, torque to 300 inch pounds or 25 foot pounds.

Rear Flat Belt Terminal Cover Installation

1 Align the top of the replacement inside cover so that it is pointing toward the floor. Place the bottom of

the cover in between the flat belt terminal and the stairarm pedal. Rotate the top of the cover up and in

to place. 2 Fasten the outside and inside terminal cover to the flat belt terminal using the two #10-24 X 1.25 screws.

FIGURE 38: FLAT BELT TERMINAL COVERS

Replacing a Upper Arm Flat Belt Pulley

Upper Arm Flat Belt Pulley Replacement Procedure

1 Remove the main body covers as per procedure, Cover Replacement (on page 53). 2 Remove the tension from the inner flat belt pulleys by lifting up on the stairarms, pulling the flat belts off

the flat belt pulleys, and then gently setting the stairarm down.

Upper Arm Cover Removal

FIGURE 39: UPPER ARM COVERS

3 Remove the four screws that fasten the inside upper arm covers to the upper arm. 4 Remove the screw that fasten the outside upper arm covers to the upper arm. 5 Remove the inside and outside covers from the upper arm. 6 Repeat the process for the remaining upper arm covers.

FIGURE 40: UPPER ARM COVER SCREW LOCATIONS

Belt Guard Removal

7 Grasp the belt guard mounting rings located on each side of the upper arm. Gently pull out and away

from the grip connection ring's just enough to extend past the mounting bolt.

FIGURE 41: BELT GUARD AND UPPER ARM

8 The belt guard assembly is two interlocking halves and needs to be separated before it can be removed

from flat belt:

a) Lower the belt guard down just below the upper arm.

b) Squeeze the belt guard near the base to release locking tabs and rotate the two halves down.

c) Taking care to not lose the rollers inside the belt guard, pull the two belt guard halves away from

each other to separate.

9 Repeat the process for the remaining belt guard.

FIGURE 42: BELT GUARD REMOVAL

10 Remove the 3/8-16 X 3 mounting bolt, the two washers and the 3/8-16 lock nut that secure the upper

arm pulley to the upper arm.

FIGURE 43: UPPER ARM FLAT BELT PULLEY MOUNTING

11 Slide out the upper arm pulley, the two spacers, and the pulley shaft from the upper arm.

FIGURE 44: UPPER ARM FLAT BELT PULLEY REMOVED

12 Slide the pulley shaft into the flat belt pulley, place one spacer on each side of the flat belt pulley. Ensure

the belt goes over the top of the pulley. Insert the assembly into the upper arm. 13 Secure the flat pulley assembly to the upper arm using the mounting bolt, washers and lock nut. Thread

the mounting bolt from the inside of the upper arm towards the outside of the upper arm, torque to 300

inch pounds or 25 foot pounds.

Note: Lock nut should be on the outside of the upper arm.

Upper Arm Grip Installation

14 Grasp the grip connecting ring located on each side of the upper arm grip, pull out and place the grip

over the flat belt pulley mounting bolt. 15 Secure the upper arm grip to the upper arm using the two #10-24X.75 screws.

Repeat the process for the remaining upper arm grip.

Belt Guard Installation

16 Place the two halves of the belt guard so they are positioned around the flat belt just below the upper

arm. The smaller half should be positioned so that the interlocking tabs are pointing toward the front of

the machine, and the guard toward the back. The larger half should be positioned with the guard toward

the front. Align the interlocking tabs of the smaller half with the slots of the larger half; rotate the halves

together around the flat belt until the locking tabs are locked.

FIGURE 45: BELT GUARD INTERLOCKING TABS AND SLOTS

17 Grasp each belt guard mounting ring, lift the belt guard into position over the upper arm mounting bolts,

and then secure each mounting ring to the connection ring.

Upper Arm Cover Installation

18 Secure the upper arm covers to the arm weldment using the five #10-24X1.25 screws.

FIGURE 46: UPPER ARM COVER SCREW LOCATIONS

19 Lift the stairarms and then thread the flat belts over the flat belt pulleys. 20 Replace the main body covers asp per procedure, Cover Replacement (on page 53).

Replacing a Stairarm Pedal

FIGURE 47: STAIRARM AND STAIRARM PEDAL

Stairarm Pedal Replacement Procedure

1 Pivot the stairarm up into a vertical position. Note: The following procedure will be much more efficient

if an assistant holds the stairarm up. 2 Remove the four screws, washers and washer plate that secure the stairarm pedal to the stairarm,

remove the stairarm pedal. 3 Fasten the replacement stairarm pedal to the stairarm using the four screws, washers and washer plate

removed in step 2. 4 Torque the screws to 15 inch pounds, starting from the single screw at the end of the stairarm, than

screw mounted in the middle, finally the two rear pedal screws.

FIGURE 48: STAIRARM AND STAIRARM PEDAL SCREW LOCATIONS

Replacing a Stairarm

FIGURE 49: STAIRARM AND FRONT ARM

Stairarm Replacement Procedure

Rear Flat Belt Terminal Cover Removal

1 Remove the two #10-24 X 1.25 screws that secure the flat belt terminal covers to the flat belt terminal,

remove the outside terminal cover. 2 Rotate the top of the inside terminal cover down until it is below the stairarm pedal, pull to remove. 3 Repeat the process for the remaining rear flat belt terminal cover.

FIGURE 50: FLAT BELT TERMINAL COVERS

Flat Belt Terminal Removal

4 Remove the mounting bolt and washer that secure the flat belt terminal to the stairarm, remove the flat

belt terminal and anti-rotation disc.

FIGURE 51: FLAT BELT TERMINAL REMOVAL

Stairarm Removal

5 Place the shaft of a Philips screw driver into the drain hole on the bottom of the front arm. Rotate the

front arm bearing by turning the outside mounting bolt that secures the front arm to the stairarm, until

the screw driver engages into the bearing and locks it. You may have to rotate the bearing one full turn

to align the bearing lock hole with drain hole. 6 Once the screwdriver has locked the bearing preventing further rotation, fully remove the inside and

outside mounting bolts. Remove the stairarm.

FIGURE 52: STAIRARM AND FRONT ARM SCREW LOCATIONS

Stairarm Pedal Removal

7 Pivot the stairarm up into a vertical position. Note: The following procedure will be much more efficient

if an assistant holds the stairarm up. 8 Remove the four screws and washers that secure the stairarm pedal to the stairarm, remove the stairarm

pedal.

FIGURE 53: STAIRARM AND STAIRARM PEDAL SCREW LOCATIONS

Stairarm Knuckle Cover Removal

9 Remove the two #10-24 X .75 screws that secure the stairarm knuckle cover to the stairarm and set

aside the knuckle cover.

FIGURE 54: STAIRARM KNUCKLE COVER SCREW LOCATIONS

Stairarm Knuckle Cover Installation

10 Secure the knuckle cover to the replacement stairarm using the two #10-24 X .75.

Stairarm Pedal Installation

11 Fasten the replacement stairarm pedal to the stairarm using the four screws and washers removed in

step 2. 12 Torque the screws to 25 inch pounds, starting from the single screw at the end of the stairarm, then the

two camp screws, finally the two rear pedal screws.

FIGURE 55: STAIRARM AND STAIRARM PEDAL SCREW LOCATIONS

13 Position the stairarm in the front arm. 14 Place the shaft of a Philips screw driver into the drain hole on the bottom of the front arm and thread

one of the two 1/2-13X1 screws into stairarm. Using the installed screw, rotate the front arm bearing

until the screw driver engages into the bearing, locking the bearing. You may have to rotate the bearing

one full turn to align the bearing lock hole with drain hole. 15 Once the screwdriver has locked the bearing preventing further rotation, fully tighten the inside and

outside mounting bolts, torque to 83 foot pounds or 1000 inch pounds. 16 Remove the screwdriver from the drain hole.

Rear Flat Belt Terminal Installation

17 Carefully slide on the anti-rotation disc and flat belt terminal. Do not use excessive force. Fasten the

anti-rotation disc and flat belt terminal onto the stairarm using the washer and mounting bolt, torque to

300 inch pounds or 25 foot pounds.

FIGURE 56: FLAT BELT TERMINAL REMOVAL

Rear Flat Belt Terminal Cover Installation

18 Align the top of the replacement inside cover so that it is pointing toward the floor. Place the bottom of

the cover in between the flat belt terminal and the stairarm pedal. Rotate the top of the cover up and in

to place. 19 Fasten the outside and inside terminal cover to the flat belt terminal using the two #10-24 X 1.25 screws.

FIGURE 57: FLAT BELT TERMINAL COVERS

Lift the stairarms and then thread the flat belts over the flat belt pulleys.

Replacing the Flat Belts

WARNING: Before continuing with this procedure, review the Warning and Caution statements listed in the Warning and Caution Statements and General Safety Guidelines Section, Things You Should Know.

The AMT utilizes a four flat belt system that provides support to the stairarms and allows fluid movement. There are two outside flat belts and two inside flat belts. The two outside flat belts are routed from the stairarm terminals, up over a flat belt pulley and through the upper arm, terminating at the upper arm cams. The inside flat belts are routed from the platform through a series of pulleys, terminating at the upper arm cams. The flat belt system has a predetermined life span of 100,000,000 strides, which will be monitored through the AMT's software. When the stride count reaches 90,000,000, a message will be displayed on the console, warning that the flat belts will need to be replaced. If the belts have not been replaced by the time the stride count has reached 100,000,000 and a stride count reset has not been issued through software diagnostics, the AMT will lock out the display with an out of service, replace flat belts message. The stride count odometer is now stored on both the upper PCA and Lower PCA. The dual memory locations allow the stride count to be transferred in the event that an upper PCA or lower PCA is replaced. If the upper PCA is replaced, the stride count stored on the lower PCA will be written to the new upper PCA. If the lower PCA is replaced, the stride count stored on the upper PCA will be written to the new lower PCA.

Note: When the belts are replaced, it is required that all 4 flat belts be replaced at the same time.

FIGURE 58: FLAT BELTS

Precor recommends not swapping lower and upper PCA boards to troubleshoot, but if swapping is the only option to isolate a problem, swap only one PCA board at a time. If you are swapping a PCA board to perform troubleshooting, note the process below to prevent the stride count odometer from being prematurely overwritten.

 When you stop pedaling the AMT, the AMT will pause for 20 seconds, and then give a 10 second

workout summary (which is when the records are written). After the PCA board is replaced and testing

the AMT is complete you will need to unplug the data cable within the 20 second pause period to prevent

the summary from happening. If the AMT is prevented from going into the summary, the stride count

will not be overwritten.  When testing is complete make sure that each PCA board is replaced in the original unit from which it

was removed. The only exception to this would be if you find a bad board that needs to be replaced.  All of these functions will place a code (70-79) in the error log, and they should be cleared before

returning the unit to use. The following table shows the possible belt and PCA board swapping event codes.

Belt Replacement & Odometer Tracking Codes

Tracking And Writing the Stride Count

When the write occurs

Event Code

Event Description

Direction Of Write Operation

At start up

71

Virgin Lower Board Detected

The UPCA stride count record is written to the LPCA

72

Bad "version" byte

The UPCA stride count record is written to the LPCA

73

Bad "size" byte

The UPCA stride count record is written to the LPCA

During the workout summary

74

LPCA stride count is less than that of the UPCA, and the UPCA is less than 30,000 strides.

The LPCA stride count record is written to the UPCA

75

LPCA stride count is less than 30,000 strides, and is lower than that of the UPCA.

The UPCA stride count record is written to the LPCA

76

LPCA stride count is greater than that of the UPCA, and UPCA stride count is greater than 30,000.

The UPCA stride count record is written to the LPCA

77

UPCA stride count is greater than that of the LPCA, and LPCA stride count is greater than 30,000.

The LPCA stride count record is written to the UPCA

Tracking Belt Replacements

When

Event Code

Event Description

What Happens

At the banner

78

Stride count greater than 90 million strides

Display "Belts Must Be Replaced Soon"

79

Stride count greater than 100 million strides

Display "Belts Change Required"

Inside Flat Belt Replacement

1 Remove the main body covers as per procedure, Cover Replacement (on page 53). 2 Remove the screw that secures the belt keeper to the frame and remove the belt keeper. 3 Remove the tension from the inner flat belt pulleys by lifting up on the stairarms, pulling the flat belts off

the flat belt pulleys, and then gently setting the stairarm down.

Flat Belt Removal - Front Clamp

4 Remove the two mounting bolts and washers that secure the front flat belt clamp to the platform.

FIGURE 59: FRONT BELT CLAMPS

Note: Any time the flat belt terminal screws are removed from the flat belt clamp or cams, the screws must be discarded and replaced with new screws.

5 Temporarily reinstall the two belt clamp mounting bolts without the washers. Having the belt clamp

installed without the washers will help ease the removal and installation of the flat belts. 6 Remove and discard the two 1/4-20X1 flat belt clamp screws and shims that secure the flat belt to the

clamp.

FIGURE 60: FRONT BELT CLAMP SCREW REMOVAL

7 Using a screwdriver tip, push out the pin from the flat belt loop and clamp and then slide the flat belt out

of the clamp.

Upper Arm Cam Cover Removal

8 Remove the two #10-24X1.25 screws that secure the upper arm cam covers to the upper arm, then

remove the covers. It may be necessary to adjust the position of the vertical handlebar to gain access

to the upper arm cam cover screws.

FIGURE 61: UPPER ARM CAM COVERS

Flat Belt Removal - Upper Arm Cam

Note: Any time the flat belt terminal screws are removed from the flat belt clamp or cams, the screws must be discarded and replaced with new screws.

9 Remove and discard the two 1/4-20X1 flat belt cam clamp screws and shims that secure the flat belt to

the clamp.

FIGURE 62: UPPER INSIDE CAM SCREW REMOVAL

10 Using a screw driver tip, push out the pin from the flat belt loop and cam clamp and then slide the flat

belt out of the cam clamp. Remove the flat belt.

FIGURE 63: UPPER INSIDE CAM PIN REMOVAL

Flat Belt Installation - Upper Arm Cam

11 Lay the replacement flat belt on a flat surface with the flat belt segments facing up. Measure the distance

in from the end of the flat belt 10 inches. Using a straight edge and permanent marker draw a line across

the flat belt at 10 inches. Repeat this process for the other end of the flat belt.

FIGURE 64: FLAT BELT END MEASUREMENT

12 Place the inside flat belt on the cam so the length of the flat belt is draped towards the back of the AMT.

Make sure the smooth side of the flat belt contacts the cam and the segmented side is facing up. 13 Install a replacement 1/4-20X1 screw and shim in one of the cam clamp screw holes, do not fully tighten

at this time.

FIGURE 65: UPPER INSIDE CAM FLAT BELT ROUTING

Precor AMT12 base Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1 - Introduction

About this Document

General Information

Right, Left, Front, and Back Conventions

General System Information

General Information

Tools Required

Safety Guidelines

Operating Safety

2- Operation Verification

Verification Procedure

Verification Checklist

3- Standardized Service Access Codes

Accessing the Service Software

P20 Service Software Access

Entering the Service Software on a P80 console

Hardware Validation = Diagnostic Tests (51765761)

Club Parameter = Settings (5651565)

Information Display (65)

4- Theory of Operation

Console Models

Basic operation of a console

AMT Base Operation

Power Generation

Lower Electronics Module

DC Power Distribution:

A regulated 14.5VDC power supply charges the 12V battery.

AMT Resistance Control:

Vertical Resistance:

Horizontal Resistance:

AMT motion detection (RPM):

5- Troubleshooting Procedures

Introduction

Troubleshooting Generated Power

Measuring the Resistance of a Generator

Upper Display does not illuminate

Standardized Error Codes

Validating the Reported Failure

Troubleshooting Control Error Codes

Error 05 - Key Depressed at Power Up

Error 09 - Lower PCA Memory Test Errors

Error 12 - Watchdog (Lower PCA)

Error 80, 81, 82, & 83 – P30 Machine Controls Not Working

Troubleshooting the Brake System

Troubleshooting the Lift System

Error 40 - No Lift Motion Detected

Error 42 - Lift Position Value Out of Range

Error 44 - Un-commanded Lift Motion

Error 45 - Lift Moving in Wrong Direction

Error 46 – Low Battery Voltage (Open Stride AMT12 only)

Event 70 - 79

Troubleshooting Heart Rate Issues:

Wireless Heart Rate Does Not Work

6- Replacement Procedures

Cover Replacement

Replacing a Belt Guard

Replacing the Upper Arm Grip

Replacing a Flat Belt Terminal

Replacing a Upper Arm Flat Belt Pulley

Replacing a Stairarm Pedal

Replacing a Stairarm

Replacing the Flat Belts

Inside Flat Belt Replacement